Order of the Federal Environmental, Industrial and Nuclear Supervision Service (Rostechnadzor) No. 500 of 7 December 2020
Unofficial translation. Only the Russian original published in the official sources of the Russian Federation has legal force. This translation is provided for reference and does not replace the official document.
1. These Federal Norms and Rules in the field of industrial safety, "Safety Rules for Chemically Hazardous Production Facilities" (hereinafter - the Rules), establish requirements aimed at ensuring industrial safety and preventing accidents and cases of industrial injury at chemically hazardous production facilities (hereinafter - CHPF) at which, in accordance with sub-clauses "b", "e", "f", "g" of paragraph 1 of Appendix 1 to Federal Law No. 116-FZ of 21 July 1997 "On Industrial Safety of Hazardous Production Facilities" (Collection of Legislation of the Russian Federation, 1997, No. 30, Article 3588; 2018, No. 31, Article 4860) (hereinafter - Federal Law No. 116-FZ), hazardous substances (hereinafter - chemically hazardous substances) are obtained, used, processed, formed, stored, transported and destroyed.
2. The Rules have been developed to implement the provisions of paragraph 3 of Article 4 of Federal Law No. 116-FZ as regards the establishment of mandatory requirements for: activities in the field of industrial safety, including the workers of hazardous production facilities; the safety of processes at hazardous production facilities, including the procedure for actions in the event of an accident or incident at a hazardous production facility; the safety justification of a hazardous production facility.
3. The Rules are intended for application: (a) in the development of processes, the development of documentation, the operation, technical re-equipment, major repair, mothballing and liquidation of CHPF; (b) in the manufacture, installation, commissioning, maintenance, diagnostics and repair of technical devices used at CHPF; (c) in carrying out the industrial safety expert review of: documentation for the mothballing and liquidation of CHPF; documentation for the technical re-equipment of CHPF where such documentation does not form part of the design documentation of such a facility that is subject to expert review in accordance with the legislation on town-planning activities; technical devices, buildings and structures, and industrial safety declarations used at CHPF; the safety justification of CHPF, as well as amendments made to the safety justification of CHPF.
4. The Rules establish industrial safety requirements for organisations carrying out their activities in the field of industrial safety.
5. To bring CHPF into conformity with the requirements of the Rules, the organisation operating a CHPF shall, after the Rules enter into force, carry out on a one-off basis a comprehensive survey of the actual condition of the CHPF, and, where deviations are identified, develop a set of compensatory measures for the further safe operation of such facilities and arrange for amendments to be made to the design documentation, the documentation for the technical re-equipment, mothballing and liquidation of the CHPF, or for such documentation to be developed anew.
6. Explosion and fire safety requirements for CHPF are applied in accordance with the federal norms and rules in the field of industrial safety that establish general explosion safety rules for explosion- and fire-hazardous production operations and facilities. When carrying out welding work and metal cutting, the requirements shall be observed of Federal Law No. 123-FZ of 22 July 2008 "Technical Regulations on Fire Safety Requirements" (Collection of Legislation of the Russian Federation, 2008, No. 30, Article 3579; 2018, No. 53 (Part I), Article 8464) (hereinafter - Federal Law No. 123-FZ), of the federal norms and rules in the field of industrial safety that establish requirements for welding work, and of the rules for the safe conduct of gas-hazardous, hot and repair work at hazardous production facilities.
7. Processes (production processes during which the chemical composition of the product being processed is changed to obtain a substance with different properties, and processes for the storage and loading and unloading of chemically hazardous substances) shall be developed on the basis of the initial data for the development of CHPF documentation, taking into account the quantity of chemically hazardous substances provided for in paragraph 1 of Appendix 1 to Federal Law No. 116-FZ that are simultaneously present or may be present at a CHPF, in accordance with Tables 1 and 2 of Appendix 2 to Federal Law No. 116-FZ, and also an analysis of the hazards arising during the conduct of the process and of the conditions for the occurrence and development of possible emergency situations.
8. In the design documentation, the documentation for the technical re-equipment, mothballing and liquidation of a hazardous production facility (hereinafter - the design) of each process of a CHPF, including the processes for the storage and loading and unloading of chemically hazardous substances, the critical values of the parameters or a set thereof for the chemically hazardous substances involved in the process shall be defined. The permissible range of parameter variation is established taking into account the characteristics of the process. The technical characteristics of the control and emergency protection (EP) system shall correspond to the rate of change of the process parameter values within the required range (the accuracy class of the measuring instruments, the inertia of the measuring systems, the measurement range). The regulated parameter values for the conduct of the process are established in the initial data for the development of CHPF documentation and specified in the process regulations as the optimum standards for the conduct of the process regime (hereinafter - the regulated process parameters).
9. The methods and means that prevent the parameters from exceeding the established limits are established in the initial data for the development of CHPF documentation and specified in the process regulations. The initial data for the development of CHPF documentation are developed by research organisations or organisations specialising in the relevant field.
10. The conditions of chemical safety for carrying out an individual process or its stages are ensured by: the rational selection of the interacting components on the basis of the condition of maximum reduction or exclusion of the formation of chemically hazardous mixtures or products; the selection of rational modes for dosing the components, the prevention of the possibility of their ratios deviating from the regulated values and of the formation of chemically hazardous concentrations in the system; the introduction into the process medium, on the basis of the physico-chemical conditions of the process, of additional substances - inert diluents-phlegmatisers, substances leading to the formation of inert diluents or preventing the formation of chemically hazardous mixtures; the rational selection of the hydrodynamic characteristics of the process (the methods and mode of movement of the medium and mixing of the components, the head and flow velocity) and of the heat-exchange characteristics (the thermal head, the heat-transfer coefficient, the heat-exchange surface), as well as of the geometric parameters of the apparatus; the use of components in a phase state that impedes or excludes the formation of a chemically hazardous mixture; the selection of the values of the state parameters of the process medium (composition, pressure, temperature) that reduce its chemical hazard; reliable power supply (established in the initial data).
11. Chemical process systems (a combination of technical devices and the material, thermal and energy flows (links) between them, functioning as a single whole and intended for the processing of starting substances into products), including the equipment of the stages of storage and loading and unloading of starting substances and products, shall be equipped with means for monitoring the parameters that determine the chemical hazard of the process, with the recording of readings and pre-emergency (and, where necessary, warning) alarm signalling of their values, as well as with means of automatic control and EP. The requirements for the monitoring, control, alarm and EP systems that ensure the safe conduct of CHPF processes are defined in Chapter VI of the Rules.
12. For chemically hazardous processes, including the processes for the storage and loading and unloading of chemically hazardous substances, EP systems shall be provided that prevent the occurrence of an accident upon deviation from the maximum permissible values of the process parameters stipulated by the process regulations in all operating modes and that ensure the safe shutdown of the process or its transfer to a safe state in accordance with a predetermined programme.
13. EP systems are incorporated into the general automated process control system (hereinafter - APCS). The generation of the signals for its actuation shall be based on the regulated maximum permissible values of the parameters, which are determined by the properties of the substances handled and the characteristic features of the process.
14. The power stability of the chemical process system of a CHPF is ensured by the selection of a rational power supply scheme, by the number of power sources (main and standby) and by their reliability, and shall ensure the accident-free shutdown of the CHPF process in the event of failures or accidents in the power supply system. The parameters that characterise the power stability of the process, and the means and methods of ensuring this stability, are determined during the development of CHPF documentation and are established in the process regulations. The means of ensuring the power stability of the chemical process system shall ensure the capability of the EP means to function for a period sufficient to exclude a hazardous situation.
15. Chemical process systems in which toxic products (gaseous, liquid, solid) are handled shall be sealed and shall prevent the creation of hazardous concentrations of these substances in the environment in all operating modes and stages.
16. For CHPF associated with the obtaining, use, storage, transportation and destruction of chemically hazardous substances, measures and means shall be provided that reduce to the maximum extent the ingress of chemically hazardous substances into the atmosphere of the production premises (the working area), as well as the monitoring of the content of chemically hazardous substances in the air.
17. To reduce to the maximum extent the emissions of chemically hazardous substances of a CHPF into the environment in the event of an emergency depressurisation of the chemical process system, the following measures shall be provided: at facilities of hazard classes I and II - the installation of automatic quick-acting shut-off and/or cut-off devices with an actuation time of no more than 12 s; at facilities of hazard class III - the installation of shut-off and/or cut-off devices with remote control and an actuation time of no more than 120 s; at facilities of hazard class IV - the installation of shut-off devices with a manual drive, whereby the minimum time for putting them into action shall be provided by means of rational placement (the maximum permissible proximity to the operator's workplace), but no more than 300 s. In this case, conditions for the safe cut-off of the flows shall be ensured and hydraulic shocks shall be excluded.
18. For the emergency discharge of chemical process systems of the chemically hazardous products handled, the equipment of the process installations or special emergency discharge systems is used. Special emergency discharge systems shall: be in a state of constant readiness; prevent the formation of chemically hazardous mixtures both within the systems themselves and in the surrounding atmosphere, as well as the development of accidents; ensure the minimum possible discharge time; be equipped with means of monitoring and control. The use of special emergency discharge systems for other purposes shall be prohibited.
19. The capacity of the emergency discharge system (a special one or one in the form of process installation equipment intended for the emergency discharge of chemical process systems) is calculated for the reception of products in quantities determined by the conditions for the safe shutdown of the process.
20. The chemically hazardous substances discharged shall be directed into closed systems for further utilisation.
21. The combining of emissions of chemically hazardous substances containing substances capable, when mixed, of forming chemical compounds that are more hazardous in their effects shall not be permitted.
22. Where a liquid phase is present in the gas flow, devices that prevent its entrainment shall be provided on the gas discharge lines.
23. In processes in which, upon deviation from the specified process modes, the ingress of chemically hazardous products into the inert media supply line (helium, nitrogen and other media) is possible, a non-return valve or another device that prevents the transfer of chemically hazardous substances into the inert media supply line is installed on the latter.
24. Where chemically hazardous substances are present in the process equipment or where their formation is possible, the operating organisation develops and adopts the necessary organisational and technical measures that ensure, taking into account the technical means provided for in the CHPF documentation, the protection of personnel from the effects of these substances in the event of chemical injury.
25. For CHPF of hazard classes I, II and III, taking into account the chemical process features, the organisation develops and approves an action plan for the localisation and elimination of the consequences of accidents (hereinafter - the action plans), in which it provides for the actions of the workers for the prevention of accidents and, in the event of their occurrence, for the localisation and maximum reduction of the severity of the consequences, as well as the technical systems and means used for this purpose.
26. The workers of organisations carrying out activities at CHPF shall be certified in the field of industrial safety in accordance with the procedure established by Government Resolution of the Russian Federation No. 1365 of 25 October 2019 "On Training and Certification in the Field of Industrial Safety, on Matters of the Safety of Hydraulic Structures and Safety in the Electric Power Industry" (Collection of Legislation of the Russian Federation, 2019, No. 44, Article 6204). All workers shall be trained in the rules for the use and the methods of checking the serviceability of personal protective equipment and shall undergo training in its application.
27. The organisation of the work for maintaining a reliable and safe level of operation and repair of the process and auxiliary equipment, pipelines and fittings, monitoring and emergency protection systems, means of communication and warning, and power supply, as well as of buildings and structures; the distribution of duties and the limits of responsibility among the technical services (the process, mechanical, power, and instrumentation and automation services) for ensuring the industrial safety requirements; and also the list and volume of operational, repair and other technical documentation shall be defined in the internal administrative documents of the organisation that establish the requirements for the safe conduct of work at CHPF, taking into account the requirements of paragraph 90 of the Rules.
28. In production operations that include a CHPF, measures for the prevention of the entry of unauthorised persons onto the hazardous production facility are developed in the design.
29. Processes are carried out in accordance with the process regulations approved by the organisation operating the CHPF. The process regulations are the principal technical document that defines the optimum process regime and the procedure for carrying out the operations of the process, and that ensures the output of products of the required quality and safe conditions for the operation of the production. The process regulations are developed on the basis of the CHPF documentation. Amendments to the process flow diagram, the equipment arrangement, and the monitoring, communication, warning and EP systems are made after amendments have been made to the design documentation, the documentation for the technical re-equipment, mothballing and liquidation of the CHPF. The amendments made shall not adversely affect the operability and safety of the entire process system as a whole.
30. Process regulations shall be developed for the process of producing types of products (or intermediate products) of a specified quality. An intermediate product shall be considered to be a substance obtained at one or several process stages of production and which is a raw material for subsequent process stages.
31. Depending on the degree of assimilation of the production operations and the purposes of the work carried out, the following types of process regulations are provided for: permanent, temporary (start-up), one-off (experimental) and laboratory (start-up notes, production procedures). The basic requirements for process regulations are provided in Chapter IV of the Rules.
32. When developing process regulations, organisations take into account the features and specific characteristics of CHPF provided for in the design and/or administrative documentation of the operating organisation.
33. The regulated parameter values for the conduct of the process, which are established in the initial data for the development of the documentation of hazardous production facilities, are specified in the process regulations.
34. The information and data provided in the process regulations may be used in the development of documentation for the conduct by the operating organisation of production control, in the development of the action plan for the localisation and elimination of the consequences of accidents at hazardous production facilities, as well as of industrial safety declarations.
35. Depending on the degree of assimilation of the production operations and the purposes of the work carried out, the following types of process regulations are provided for: permanent; temporary (start-up); one-off (experimental); laboratory (start-up notes, production procedures).
36. Permanent process regulations are developed for assimilated chemical process production operations that ensure the required quality of the products manufactured.
37. Temporary (start-up) process regulations are developed for: production operations that are new to the given organisation; operating chemical process production operations to whose technology fundamental changes have been made; production operations with a new technology.
38. One-off (experimental) process regulations are developed for the output of commercial products at experimental and pilot-industrial installations (shops), as well as for experimental and pilot-industrial work carried out at operating production operations, in accordance with the requirements of the federal norms and rules in the field of industrial safety that establish general explosion safety rules for explosion- and fire-hazardous production operations and facilities.
39. Laboratory regulations (start-up notes, production procedures) are developed for laboratory, bench and model installations that do not produce commercial products. Commercial products may be produced in a volume of up to 1000 kg/year under laboratory regulations (start-up notes, production procedures).
40. The systematisation of installations by kind and type is provided in Appendix No. 1 to the Rules.
41. All types of process regulations shall be developed taking into account the requirements of Federal Law No. 102-FZ of 26 June 2008 "On Ensuring the Uniformity of Measurements" (Collection of Legislation of the Russian Federation, 2008, No. 26, Article 3021; 2019, No. 52 (Part I), Article 7814).
42. Permanent, temporary and one-off process regulations connected with the need to ensure the industrial safety of processes shall consist of the following sections: general characteristics of the production; characteristics of the products manufactured; characteristics of the raw materials, materials, intermediate products and energy resources; description of the chemical process and diagram; material balance; consumption standards for the main types of raw materials, materials and energy resources; production control and process management; possible incidents in operation and methods for their elimination; safe operation of the production; list of mandatory instructions; process flow diagrams of the production; specification of the main process equipment (technical devices), including equipment for environmental protection purposes.
43. Laboratory regulations (start-up notes, production procedures) connected with the need to ensure the industrial safety of processes shall, in general form, contain the following data: the purpose of the installation; a brief characterisation of the raw materials, intermediate products, finished product, waste, waste water and emissions of harmful substances, with an indication of their toxic, fire- and explosion-hazardous properties; a description of the process flow diagram and the arrangement of the apparatus; a description of the diagram of the instrumentation and automation, interlocks and safety devices; a description of the power supply diagram; requirements for safe operation; requirements for ensuring environmental safety; drawings of the process flow diagram. Depending on the purpose of the installation, the composition of the laboratory regulations (start-up notes, production procedures) may be reduced or expanded.
44. The section "General characteristics of the production" shall contain: the full name of the production; the year of commissioning; the capacity of the production (the design capacity and the capacity achieved at the time of drawing up the regulations); the number of process lines (streams) and stages and their names; the production method; the organisations that produced the design documentation; the organisation that performed the functions of the general designer; the organisation that developed the technological part of the design documentation; the organisation that developed the process; information on reconstruction (whether reconstruction of the production was carried out, in what year, the name of the design documentation, by which organisation the design documentation for the reconstruction was produced and according to the developments of which organisation).
45. In the section "Characteristics of the products manufactured" the following are provided: the technical name of the product in accordance with the normative and technical documentation; the name of the national standard, technical specifications, organisation standard or production specification in accordance with the requirements of which the products are manufactured, with a list of the technical requirements; the main properties and quality of the products manufactured, the physico-chemical properties and constants: appearance, density, solubility, solidification or melting temperatures, boiling temperature, vapour pressure, viscosity, electrical conductivity, dielectric constant and other indicators; the field of application (the main one); information on the registration of the information cards of potentially hazardous chemical and biological substances; information on the safety data sheets of the substances (materials). All the data on the characteristics of the products manufactured shall correspond to the data adopted in the interstate and national standards, technical specifications and organisation standards, or to the data provided in the normative documentation, with a mandatory reference to them. Where several products are obtained under one and the same regulations, the characteristics are provided for each product obtained. The properties characterising the fire and explosion hazard and the toxicity of the finished product, raw materials, intermediate products and production waste are provided in the section "Safe operation of the production", to which reference shall be made in the relevant sections of the process regulations.
46. The section of the process regulations "Characteristics of the raw materials, materials, intermediate products and energy resources" includes all types of raw materials, materials, intermediate products and energy resources used in the production process. All the indicators are provided with permissible deviations. The section "Characteristics of the raw materials, materials, intermediate products and energy resources" provides data characterising the starting raw materials, materials, intermediate products and energy resources, systematised in the form of a table (Table No. 1).
47. Special requirements (where they exist) for the raw materials, materials, intermediate products and energy resources used in the production are specifically stipulated.
48. In the section of the process regulations "Description of the process and diagram", the essence of the process is provided, with an indication of the main and side reactions, thermal effects, temperatures, pressure, volumetric velocities, types of catalysts, formulations and other indicators.
49. The description of the process flow diagram is carried out by stages of the process, beginning with the receipt and preparation of the raw materials and ending with the dispatch of the finished product. The description specifies: the process parameters (standards) that affect the conditions of explosion and/or chemical safety, the values of which have been established by the process developer and/or by the design decisions. The process parameters (standards) that affect the quality of the products, the energy efficiency of the process and the environmental standards are provided in the description at the discretion of the developer of the regulations. The method of grouping the parameters (by apparatus, by units) is established by the developer of the regulations; the main equipment used; the systems for the control, alarm and interlocking of the process parameters, and the emergency protection systems; references to the drawing of the process flow diagram included in the regulations. Where a special regulation (formulation) exists for the preparation of the raw materials, reference is made to it in the description of the process flow diagram. The names of the equipment, pipelines and process stages are provided in accordance with the name in the equipment data sheet or the technical documentation and remain unchanged throughout the text of the regulations.
50. In the description of the processes for the separation of chemical products (combustible ones or their mixtures with non-combustible ones), the degree of separation of the media and the explosion safety measures that prevent the formation of explosive mixtures at all stages of the process shall be specified.
51. Where non-combustible liquids with combustible gases dissolved in them, which are subject to discharge into the sewerage system, are handled in the processes, the measures for the extraction of combustible gases from them and their residual content, the means for monitoring the content of combustible gases and the frequency of such monitoring shall be specified. The information on these measures shall also be provided in the sections of the process regulations "Production control and process management" and "Safe operation of the production".
52. For aerosol separation apparatus, the measures for the prevention of the formation of solid-phase deposits on the internal surfaces of such apparatus, or the safe methods and frequency of carrying out operations for the removal of such deposits, shall be specified.
53. If, in drying processes, there is direct contact of the product being dried with the drying agent, the methods for cleaning the spent drying agent of the dust of the product being dried and the means for monitoring the cleaning, as well as the frequency of such monitoring, shall be specified.
54. In the description of reaction processes proceeding with the possible formation of intermediate peroxide compounds, side explosive products of resinification and condensation (polymerisation, polycondensation) and other unstable substances with their probable deposition in the apparatus and pipelines, the following shall be specified: the methods and frequency of monitoring the content in the starting raw materials of impurities that promote the formation of explosive substances; the methods and frequency of monitoring the presence of unstable compounds in the intermediate products; the methods and frequency of the introduction of inhibitors that prevent the formation in the apparatus of hazardous concentrations of unstable substances; the need for the continuous circulation of products and raw materials in the tank apparatus for the prevention or reduction of the possibility of the deposition of solid explosive unstable products; the methods and frequency of the removal from the apparatus of the reaction mass enriched with hazardous components; the mode and time of storage of products capable of polymerising or resinifying, including the periods of their transportation.
55. When catalysts are used, including organometallic ones, which upon interaction with atmospheric oxygen and/or water may spontaneously ignite and/or explode, the measures that prevent the possibility of supplying to the system raw materials, materials and inert gas containing oxygen and/or moisture in quantities exceeding the maximum permissible values shall be specified. The permissible concentrations of oxygen and moisture, and the methods and frequency of monitoring their content in the starting products, taking into account the physico-chemical properties of the catalysts used, shall be specified.
56. When describing the processes for the storage and loading and unloading of liquefied gases and highly flammable and combustible liquids, the following shall be specified: the procedure for carrying out the process operations for the storage and movement of combustible liquid substances, the filling and emptying of mobile and stationary storage tanks, the principles for selecting the process parameters the values of which determine the explosion safety of carrying out these operations (pressure, movement velocities, maximum permissible maximum and minimum levels, methods of releasing the vacuum and other parameters affecting explosion safety); the measures that prevent the possibility of accidental mixing of products at all stages of carrying out the loading and unloading operations; the procedure for preparing the tanks for the current (next) filling (freeing them of the residues of products previously contained in them, washing, cleaning, the neutralisation of the tanks, other types of preparatory work) and for carrying out the work on switching (connecting) pipelines and fittings; the procedure for preparing storage tanks for filling after installation or repair; the measures that prevent the possibility of an explosion in this equipment (monitoring of the oxygen concentration in the equipment, as well as other parameters determining the explosion hazard). When describing the procedures under this paragraph, references to the relevant operational documents may be provided.
57. In the section, the emergency devices and the systems for the supply of inert and inhibiting substances, as well as the frequency of monitoring their serviceability, shall be described.
58. In the section, the characteristics of the equipment used for the cleaning of the waste gases and the discharged waste water of polluting harmful substances, and for the collection and utilisation of production waste, shall be provided.
59. Where several similar process lines are present, the description of the process diagram may be made for one process line, with an indication of this at the beginning of the section.
60. In the section of the process regulations "Material balance", the material balance is drawn up per unit of time (hour), per unit of product manufactured, per production stream or for the capacity of the production as a whole.
61. To prepare the material balance, a diagram is provided showing all incoming and outgoing streams, with all main stages and processing operations that change the qualitative and quantitative indicators of the process streams marked on it. After the diagram, a material balance table is provided characterising the qualitative and quantitative indicators of all streams. For processes with few stages, the balance may be prepared only in the form of a table.
62. The material balance for new production facilities is prepared on the basis of the design documentation. For existing ones, it is prepared on the basis of the performance indicators achieved by the production facilities during the last year before the technological regulations were drawn up. The material balance is revised where additional operations or stages are included in the technological process or excluded from it.
63. The consumption rates for the main types of raw materials, materials and energy resources shall be presented in the form of a table (Table No. 2).
64. In the section of the technological regulations entitled "Production Control and Management of the Technological Process", the monitoring systems, the automatic and remote control systems (control systems) and the emergency alarm systems associated with the need to ensure the industrial safety of technological processes shall ensure the accuracy of maintaining the process parameters and the reliability and safety of carrying out the technological processes.
65. The section provides the setpoint values of the protection systems for hazardous parameters, and also indicates the limits of the critical parameter values.
66. The production control and management data for all stages of the technological process ensuring compliance with the regulatory indicators, the indicators of the finished products and the emissions into the environment shall be presented in the form of a table (Table No. 3).
67. The names of measuring instruments installed "on site" are included in the table only where there is a technological need.
68. The setpoints of the alarm and interlock systems are indicated in column 4 of Table No. 3: "Alarm and Interlock Setpoints". For facilities with process units of all explosion-hazard categories, the limits of the critical parameter values are indicated in this column.
69. For complex diagrams, instead of a list of interlock systems, a block structure diagram of the automatic protection system of the production facility may be attached to Table No. 3.
70. The name of the measuring instruments, indicating the measurement ranges or scales, is provided in column 5 of Table No. 3: "Test Method and Control Instrument".
71. The section shall also specify the methods and means that prevent the parameters from exceeding the established limits.
72. A list shall be drawn up of the parameters of the process stages whose control in manual mode shall be prohibited.
73. For explosion-hazardous technological processes, the automatic emergency protection systems shall be specified which prevent the occurrence of an emergency situation upon deviation from the maximum permissible values of the process parameters provided for by the regulations in all operating modes, and which ensure the safe shutdown of the process or its transfer to a safe state in accordance with a predetermined programme.
74. The automation equipment used under the action plan for the localisation and elimination of the consequences of accidents at hazardous production facilities shall be identified separately (for example, by highlighting the shut-off devices on the process streams (in bold type, in a different colour, with a circle), and also by text in the upper right corner of the process flow diagram).
75. The frequency of testing of the shut-off and control valves and the actuators, and the frequency of checking of the instruments and testing of the other technical means involved in the monitoring, control and emergency protection systems of the technological processes, shall be mutually coordinated.
76. The list of alarm and interlock systems and/or the list of analytical monitoring may be separated into individual tables.
77. Information on possible incidents, their causes and the methods for eliminating them shall be presented in the form of a table (Table No. 4).
In the section of the technological regulations, the main possible incidents in the technological process of production affecting its explosion and/or chemical safety are listed, such as: deviations from the technological regime standards in respect of pressure, temperature, the feed rate of reagents and the product output, the switching-off of monitoring instruments, local overheating, and also the failure or damage of technical devices. The possible causes of the incidents and the actions of the workers to eliminate them are indicated. The developer also provides in the section data on the limit values of the deviations of the technological process parameters that directly affect the quality of the products manufactured.
78. The section "Safe Operation of Production" of the technological regulations for the production of products (hereinafter - the Section) is developed for production facilities being designed, in operation and being reconstructed.
79. When developing the technological regulations, enterprises and organisations may, where necessary and taking into account the features and specifics of the production facilities, and subject to compliance with the requirements set out in paragraph 80 of the Rules, specify in more detail or include additional requirements ensuring safety in the conduct of the technological process. At the same time, such requirements may not be lower than the requirements established by the legislation of the Russian Federation in the field of industrial safety.
80. The Section shall specify the technological data necessary for the development and implementation of measures to ensure safety and optimal sanitary and hygienic working conditions for the workers, including: the characteristics of the hazards of the production facility; possible incidents and emergency situations and the methods for preventing and containing them; the protection of technological processes and equipment against accidents and of the workers against injury; the safety measures that shall be observed during the operation of the production facility.
81. The subsection "Characteristics of the Hazards of the Production Facility" shall present: data on the characteristics of the fire-hazardous and toxic properties of the raw materials, intermediates, finished products and production waste in accordance with Table No. 1 set out in Appendix No. 2 to the Rules; information on the explosion and fire hazards and the sanitary characteristics of the production buildings, premises, zones and outdoor installations in accordance with Table No. 2 set out in Appendix No. 2 to the Rules; the main hazards of the production facility arising from the features of the technological process or the performance of individual production operations, from the features of the equipment used and the conditions of its operation, and caused by breaches of the safety rules by the workers.
82. The subsection "Possible Incidents and Emergency Situations and the Methods for Preventing and Containing Them" provides information on possible incidents and emergency situations arising from failure to comply with the requirements for conducting the technological process and performing production operations, in the course of operating the equipment and communications, which may cause a fire, an explosion, injury to or poisoning of the workers, or environmental pollution. The information is presented in accordance with Table No. 3 set out in Appendix No. 2 to the Rules. Column 1 of Table No. 3 set out in Appendix No. 2 to the Rules shall specify the monitoring, control and protection instruments whose failure to operate requires an emergency shutdown or transfer to another mode (circulation, manual control). The safe mode of the technological process shall be set out in the section "Description of the Technological Process and Diagram" of the technological regulations.
83. The subsection "Protection of Technological Processes and Equipment against Accidents and of the Workers against Injury" indicates the measures applied to prevent the formation in the technological systems of explosive mixtures and the spontaneous thermal decomposition or polymerisation of reaction masses and process media, and also the measures for suppressing explosions and uncontrolled chemical reactions in the process equipment, extinguishing fires and limiting the zones of development of emergency situations. In accordance with Table No. 4 set out in Appendix No. 2 to the Rules, this subsection lists the interlocks, the control and alarm means, the devices for the emergency shutdown of equipment, and the safety, relief and shut-off valves, with the mandatory indication of their functional purpose and the actions performed.
84. The subsection "Safety Measures during the Operation of Production" shall contain the following information: safety requirements for the start-up and shutdown of technological systems and individual types of equipment, their placing on standby, their being on standby and their return from standby into operation; safety measures in conducting the technological process and performing the routine production operations; requirements for ensuring the explosion safety of technological processes: the adopted boundaries of the process units, the values of the energy indicators and the explosion-hazard categories of the units, the limits of possible destruction in the event of explosions, and the safety and emergency protection measures provided for. The assessment of the explosion hazard of the process units shall be carried out in accordance with the requirements of the federal norms and rules on industrial safety establishing the general rules of explosion safety for explosion-and-fire-hazardous production facilities and installations; safe methods of handling thermopolymers, pyrophoric deposits and products, organometallic and other solid and liquid chemically unstable compounds (peroxide compounds, acetylides, nitro compounds of various classes, resinification products, nitrogen trichloride and other compounds) capable of decomposing with an explosion; methods for rendering harmless and neutralising the production products in the event of spills and accidents; the probability of the accumulation of static electricity charges, its hazard and the methods for its neutralisation. The information is presented in accordance with Table No. 5 set out in Appendix No. 2 to the Rules; a description of the safe method for removing production products from the technological systems and individual types of equipment; measures to prevent the emergency depressurisation of the technological systems, the equipment used and the pipelines and their critical assemblies; safety measures for the warehousing and storage of raw materials, semi-finished products and finished products and the handling of them, and also for the carriage (transportation) of the finished products; a list of the personal protective equipment for the workers in accordance with Table No. 6 of Appendix No. 2 to the Rules.
85. Organisations operating hazardous production facilities of hazard classes I, II and III shall develop action plans for the localisation and elimination of the consequences of accidents at hazardous production facilities in accordance with Resolution of the Government of the Russian Federation No. 1437 of 15 September 2020 "On Approval of the Regulation on the Development of Action Plans for the Localisation and Elimination of the Consequences of Accidents at Hazardous Production Facilities" (Collected Legislation of the Russian Federation, 2020, No. 38, Article 5904).
86. The section provides a list of the instructions that are mandatory for guidance in conducting the technological process and ensuring safety, including: start-up instructions (upon the start-up of new production facilities); general production (general workshop) instructions; technological instructions on the industrial safety of production facilities (workshops) or other production subdivisions, if they differ substantially from the general characteristics of the production facility (workshop); instructions on preparing equipment for repair and accepting equipment from repair; instructions on shutdown for major overhaul and start-up of production after major overhaul; instructions on carrying out equipment repairs; instructions for all workplaces in accordance with the staffing schedule, including the workplaces of cross-cutting occupations (the instructions for the technological personnel shall include a description of the technological process and the automatic emergency protection (PAZ) systems, the technological regime standards and the rules for start-up, shutdown and other work operations).
87. The list of instructions in the technological regulations is provided as at the time of drawing up the technological regulations.
88. All mandatory instructions are developed by the enterprise on the basis of the approved technological regulations and the standard instructions.
89. The process flow diagram of the production facility is drawn up for one technological line for the equipment common to the department (workshop, production facility). Separate process flow diagrams may be drawn up by stages (processing operations). The apparatus, communications, the control and regulation system, the points of monitoring and regulation of the production process parameters, and also the alarm and interlock points, are placed on the process flow diagram.
90. The process flow diagram shall contain the symbols and a legend indicating the item numbers and the names of the apparatus.
91. The recommended form of the specification for the main technological equipment and technical means is given in Appendix No. 3 to the Rules.
92. All types of technological regulations (permanent, temporary, one-off, laboratory) are developed by the organisation operating the chemical process production, with the exception of one-off (pilot) regulations for pilot installations and pilot work carried out at existing production facilities, which shall be developed by the process-developer organisation and agreed with the organisation operating the chemical process production.
93. Responsibility for the completeness and quality of the development of the sections of the technological regulations for the production of products, and for the control over ensuring its implementation, is assigned to the technological service of the organisation, production facility, department or installation.
94. All types of technological regulations (permanent, temporary, one-off, laboratory) are approved by the head (or the deputy head) of the organisation operating the chemical process production, with the exception of one-off (pilot) regulations for pilot installations and pilot work carried out at existing production facilities that have been developed by the process-developer organisation.
95. The title pages of the various types of technological regulations shall be drawn up in accordance with Appendix No. 4 to the Rules. In accordance with recommended form 1, the permanent technological regulations of established production facilities ensuring the required quality of the products manufactured are drawn up. In accordance with recommended form 2, the following are drawn up: the first permanent technological regulations developed after temporary (start-up) regulations; the temporary (start-up) technological regulations of a production facility new to the organisation and of existing production facilities to whose technology fundamental changes have been made; one-off (pilot) and laboratory technological regulations (start-up notes, production methods) based on the developments of the central plant laboratories and the design bureaux of organisations. In accordance with recommended form 3, the following are drawn up: technological regulations based on the developments of one's own organisation; one-off (pilot) regulations of pilot installations and pilot work carried out at existing production facilities; laboratory regulations (start-up notes, production methods) of the laboratory, bench and model installations created within the organisation.
96. The title page of all technological regulations is signed by the officials specified therein.
97. The recommended form of the "Contents" pages of the technological regulations is set out in Appendix No. 5 to the Rules.
98. After the last section of the technological regulations, the "Signature Sheet of the Permanent (Temporary, One-off, Laboratory) Technological Regulations" is placed. The "Signature Sheet" contains the title and number of the regulations and the signatures of the developers of the regulations. The last sheet of the regulations is the "Sheet for Registration of Amendments and Additions".
99. The signature sheet of the technological regulations is executed with the signatures of: the chief engineer of the organisation (the technical director, the production director); the head of the production and technical (technical) department of the organisation; the head of production; the head of the workshop; the head of the technical control department.
100. Under the heading "Agreed", the following sign: the head of the service for managing the industrial safety system at hazardous production facilities of hazard classes I and II, or the head of the production control service for compliance with industrial safety requirements at hazardous production facilities of hazard classes III and IV; the deputy head of the organisation for environmental protection; the chief mechanic and the chief power engineer of the organisation; the chief metrologist of the organisation; the head of the central laboratory of the organisation.
101. The number of copies of the technological regulations is determined by the organisation operating the chemical process production.
102. The compilation of the materials of the regulations shall be carried out in accordance with the sequence set out in paragraphs 42 and 43 of the Rules.
103. After the agreement, signing and approval of the original of the regulations, the seal of the organisation (organisations) is affixed to the title page and the necessary number of copies is made. The original and the copies are then bound. The ends of the binding threads are sealed with a label on which the following are placed: the number of pages in the document, the surname, first name and patronymic (if any) of the person responsible for the binding, the signature of the responsible person and the seal of the organisation (if any).
104. The originals of the approved technological regulations are kept in the responsible service of the organisation, which provides the heads of production facilities, workshops, departments and other production subdivisions with registered copies.
105. Erasures and corrections in the text of the technological regulations shall not be permitted. Corrections are entered in the sheet for registration of amendments and additions.
106. The text and graphic materials of the technological regulations are drawn up in accordance with the requirements of the unified system of design documentation.
107. The period of validity of the permanent technological regulations is established at no more than 10 years. The approval, reissue, cancellation and extension of the validity of the technological regulations is formalised by an order of the head of the organisation.
108. For all temporary technological regulations, the periods are established in accordance with the production ramp-up rate standards laid down by the plans and taking into account the time necessary for drawing up the permanent technological regulations. Where the production ramp-up period is less than one year, the period of validity of the temporary (start-up) technological regulations may be established at up to one year. In the absence of production ramp-up standards laid down by the plans, the period of validity of the temporary technological regulations is determined by the person approving it. Upon expiry of the period of validity of the temporary technological regulations, permanent technological regulations shall be approved.
109. If, by the end of the period of validity of the temporary technological regulations, the production facility has not reached the design technical and economic indicators, or if refinements have been made to the production technology by the developer organisation relating to a change in capacity, in the volumes of raw material consumption, in the improvement of product quality or in process safety, the period of validity of the temporary technological regulations shall be extended, or temporary technological regulations shall be drawn up for a new period. The period of extension of the validity of the temporary technological regulations is established and formalised by an order of the head of the organisation.
110. For one-off (pilot) technological regulations, their periods of validity are established in accordance with the periods for carrying out the pilot work or the periods for the output of a specified volume of products.
111. For one-off (pilot) technological regulations under which the production of pilot output is carried out over several years, the period of validity of the technological regulations is established at no more than 5 years.
112. The period of validity of the laboratory technological regulations (the start-up note, the production method) is established by the person approving the technological regulations.
113. The period of validity of the technological regulations is calculated from the day of its approval.
114. The output of products and the conduct of pilot work under unapproved technological regulations, or under technological regulations whose period of validity has expired, shall be prohibited.
115. Where the technological regulations do not ensure the proper quality of products, the environmental protection requirements or other mandatory requirements, or where there are significant amendments and additions that greatly hamper the use of the regulations, a decision on their early cancellation, revision or reissue shall be taken by the head of the organisation.
116. Amendments and additions may be made to the technological regulations.
117. The amendments made shall not adversely affect the operability and safety of the entire technological system as a whole.
118. The development, agreement and approval of amendments and additions to the technological regulations are carried out in accordance with the procedure established for the development, agreement and making of amendments and additions to the technological regulations.
119. The procedure for formalising amendments and additions is set out in Appendix No. 6 to the Rules.
120. All approved amendments shall be registered in the "Sheet for Registration of Amendments and Additions" by the person responsible for the regulatory and technical documentation of the structural subdivision where the original or the copies are kept. On the title page of the technological regulations to which amendments (additions) have been made, below the title of the regulations, the responsible person makes the inscription "With Amendment and Addition No. ____", indicating the numbers and dates of the order putting the amendment (addition) into effect, and certifying it with his signature. On the sheets of the technological regulations, in the text next to the amended (supplemented) paragraphs, the sign "*izm.1" (first amendment), "*izm.2" (second amendment) and so on is placed, without indicating the date of approval of the amendment or affixing a signature.
121. "Cumulative statements" may be maintained in accordance with Appendix No. 8 to the Rules, into which, for the purpose of the prompt implementation of technological activities, amendments not related to industrial safety matters are entered, for the purpose of their accumulation and subsequent processing in the form of amendments.
122. The last sheet with the signatures of the officials is completed in accordance with the form established by the Rules.
123. When amendments are made to the piping of the apparatus, diagrams of the new piping are attached to the text on the amendments. The part of the diagram containing the amendments shall contain information on the name of the process flow diagram, its number, the numbers and dates of approval of the amendment, and the signatures of the developer of the amendment to the diagram and of the head of the organisation approving the amendment to the technological regulations.
124. Amendments and additions to the technological regulations are put into effect by an order or other document approved by the head of the organisation.
125. The selection of the equipment of a chemically hazardous production facility shall be carried out in accordance with the technological initial data for the development of the documentation of the chemically hazardous production facility, the requirements of the regulatory legal acts of the legislation of the Russian Federation in the field of industrial safety, and the Rules.
126. For technological equipment, machinery and pipeline valves, an assigned service life is established, taking into account the specific operating conditions. The data on the service life shall be indicated by the manufacturer organisation in the data sheets of the equipment, machinery and pipeline valves. For technological pipelines, the developer of the documentation for the chemically hazardous production facility establishes the assigned service life, which shall be reflected in the documentation and entered in the data sheets of the pipelines. The maintenance, operation and inspection (examination) of pipelines, shut-off valves and safety valves are carried out in accordance with the design. The procedure and frequency of inspection (examination) of pipelines, shut-off valves and safety valves are indicated in the technical documentation by the manufacturer. The extension of the period of safe operation of technological equipment, machinery, pipelines and pipeline valves that have exhausted their assigned service life is carried out in accordance with the procedure established by the industrial safety requirements.
127. Machinery and equipment, vessels and other components of chemically hazardous production facilities that are subject to the technical regulations shall comply with the requirements of those technical regulations.
128. The installation of technological equipment and pipelines shall be carried out in accordance with the requirements of the regulatory legal acts in the field of industrial safety, the technical regulations, and the design and working documentation and the instructions for the installation and operation of the equipment. Equipment and pipelines, materials and component products may not be permitted for installation in the absence of documents confirming the quality of their manufacture and their compliance with the requirements of the technical regulations and the regulatory technical documents.
129. The data sheets of equipment, machinery, pipeline valves, protective means and instrumentation shall indicate the reliability indicators provided for by the technical regulations and other regulatory documents.
130. At a chemically hazardous production facility, the volume of non-destructive testing of the welded joints of technological pipelines transporting toxic and highly toxic substances shall be no less than 100 per cent of the weld length of each welded joint. The selection of the non-destructive testing methods and the volume of testing of other categories of pipelines, sufficient to ensure their safe operation, shall be determined by the documentation for the chemically hazardous production facility and by the regulatory documentation in the field of industrial safety.
131. The wall thickness of pipelines shall be determined by the non-destructive testing method. The wall thickness may be determined by other methods in places where the use of non-destructive testing is difficult or impossible.
132. Chemical process systems shall be leak-tight.
133. For carrying out the periodic cleaning of technological equipment established by the regulations, means of hydraulic, mechanical or chemical cleaning are provided which preclude the presence of people inside the equipment during the period of the work.
134. Apparatus containing chemically hazardous substances shall be equipped with devices for purging and for connecting water, steam and inert gas lines, provided for during the development of the documentation for this type of equipment.
135. The placement of technological equipment and pipeline valves in production buildings and on open areas shall ensure the convenience and safety of their operation and the possibility of carrying out repair work and taking prompt measures to prevent emergency situations or to contain accidents.
136. The placement of technological equipment and pipelines shall ensure safety in the performance of work on the maintenance, repair and replacement of the apparatus and its elements.
137. The placement of technological equipment and pipelines in premises and on outdoor installations, and of pipelines on trestles, shall be carried out taking into account the possibility of carrying out visual monitoring of their condition and performing work on their maintenance, technical diagnostics, repair and replacement.
138. The equipment of a chemically hazardous production facility of hazard classes I and II that has been withdrawn from an operating chemical process system shall be dismantled if it is located in the same premises as chemical process systems in which chemically hazardous substances are obtained, used, processed or formed. In all other cases, it shall be isolated from the operating chemical process systems.
139. During the operation at a chemically hazardous production facility of technological equipment and pipelines in which corrosive substances are handled, methods for their protection shall be provided, taking into account the rate of corrosive wear of the structural materials used, in accordance with the recommendations of research organisations specialising in the field of anti-corrosion protection.
140. Technological equipment and pipelines in contact with corrosive substances shall be manufactured from materials resistant in the working media, in accordance with the instructions of the manufacturing enterprises or in accordance with the recommendations of research organisations specialising in the field of anti-corrosion protection. In cases of the protection of equipment and pipelines with corrosion-resistant non-metallic coatings, their use shall be justified. Equipment and pipelines made of corrosion-resistant non-metallic materials, including polymer and composite materials (glass, porcelain, fluoroplastic, polyethylene, polyvinyl chloride, chlorinated polyvinyl chloride, polypropylene, acrylonitrile butadiene styrene), may be used where there is an appropriate justification confirmed by the results of research and where safety measures are developed.
141. The procedure for monitoring the degree of corrosive wear of equipment and pipelines using non-destructive testing methods, and the methods, frequency and locations for taking the control measurements, shall be determined in the operating documentation of the manufacturer organisation, taking into account the specific operating conditions (for new technological processes - based on the results of special research).
142. When selecting pumps and compressors for a chemically hazardous production facility, the technical requirements for the safety of equipment for operation in chemically hazardous media and the Rules shall be taken into account. Pumps and compressors used for moving chemically hazardous substances are selected, in terms of their reliability and design features, taking into account the critical parameters of the technological process and the physico-chemical properties of the products being moved. At the same time, the number of pumps and compressors is determined on the basis of the condition of ensuring the continuity of the technological process, and in justified cases (confirmed by a reliability calculation) their redundancy is provided for. When selecting pumps and compressors for a chemically hazardous production facility, the technical requirements for the safety of equipment for operation in chemically hazardous media and the Rules shall be taken into account.
143. The sequence of actuation of the interlock systems of the pumps and compressors shall be determined by the actuation programme (algorithm) of the automatic emergency protection (PAZ) system of the process installation.
144. The shut-off isolation valves installed on the discharge and suction pipelines of a pump or compressor shall be positioned as close to it as possible and shall be located in an area convenient for maintenance.
145. A check valve shall be installed on the discharge pipeline, unless there is another device preventing the reverse movement of the substances being conveyed.
146. The operation of compressor units shall not be permitted where the means of automation, monitoring and the interlock system are absent or in a faulty condition.
147. Periodic or continuous instrument monitoring of the vibration level shall be established to the extent specified by the equipment manufacturer.
148. The manufacture, installation and operation of pipelines and fittings for chemically hazardous substances shall be carried out taking into account the physico-chemical properties and process parameters of the conveyed media, as well as the technical safety requirements for pipelines and fittings intended for service in chemically hazardous media, and these Rules.
149. The routing of pipelines shall ensure the shortest length of the lines and shall preclude sagging and the formation of stagnant zones.
150. Where pipelines are routed through the structural elements of buildings and other obstacles, measures shall be taken to preclude the possibility of transmitting additional loads to the pipes. Where pipelines for conveying chemically hazardous substances are routed along overpasses, ease of maintenance and protection against mechanical damage shall be provided.
151. Pipelines shall not have flanged or other detachable joints. Flanged joints may be permitted only at the locations where fittings are installed or where pipelines are connected to apparatus, as well as in those sections where the process conditions require periodic dismantling for the cleaning and repair of the pipelines.
152. Flanged joints are placed in locations that are open and accessible for visual observation, maintenance, dismantling, repair and installation. It shall not be permitted to locate flanged joints of pipelines carrying chemically hazardous substances above places intended for the passage of people or above work platforms. The material of the flanges and the design of the seal are selected in accordance with the regulatory technical documents for process pipelines, taking into account the operating conditions. When selecting flanged joints for pipelines intended for conveying substances under conditions not specified in these documents, the material of the flanges and the design of the seal are selected taking into account the decisions of research organisations.
153. In chemical-technological systems, to prevent accidents and preclude their escalation, emergency protection devices shall be used: shut-off and shut-off-and-control valves, valves, isolating and other disconnecting devices, and safety devices against overpressure.
154. The selection of the methods and means of the protection system, the development of the sequence of actuation of the protective elements, and the localisation and prevention of the escalation of accidents shall be determined in the documentation for the chemically hazardous production facility on the basis of the results of the analysis of the chemical (toxic) hazards of the technological process, and shall be reflected in the process regulations. When developing documentation for equipment controlled by software, the risks associated with errors in the software shall be taken into account.
155. Emergency protection devices intended for supplying inhibiting and inert substances into the process apparatus shall ensure the specified parameters of throughput and response speed under emergency conditions and shall preclude the possibility of the release of hazardous substances into the atmosphere.
156. When the protection means installed on the equipment are actuated, the possibility of injury to operating personnel and of the release of chemically hazardous products into the working area shall be prevented.
157. The technical devices of a chemically hazardous production facility shall undergo testing and acceptance, commissioning, use for the intended purpose, maintenance, all types of repair, periodic diagnostics, transportation, packaging, preservation and storage conditions in accordance with the requirements of these Rules, and shall ensure the specified parameters under emergency conditions.
158. When selecting, calculating and operating the means of protecting apparatus and lines against overpressure, the technical requirements for the safety of equipment intended for service in chemical media shall be taken into account.
159. The operation of chemical-technological systems with faulty or disconnected emergency protection devices and inert- and inhibitor-supply systems shall not be permitted. The condition of the emergency protection means and of the inert- and inhibitor-supply systems shall be monitored periodically. The frequency and methods of monitoring are established in the process regulations.
160. To eliminate danger to life, harm to human health and the risk of the occurrence of accidents, the equipment forming part of a chemically hazardous production facility shall bear identification marking, where this is provided for by the design.
161. Pipelines shall have identification colouring, warning signs and marking plates in accordance with the requirements of the regulatory technical documents and/or those specified in the process (design) documentation.
162. Systems for monitoring, automatic and remote control and regulation of technological processes (hereinafter referred to as 'control systems'), signalling systems and automatic emergency protection systems, as well as communication and emergency-situation notification systems (hereinafter referred to as 'communication and notification systems'), including those supplied as a complete set with the equipment, shall comply with the requirements of these Rules, the current regulatory technical documentation and the documentation for the chemically hazardous production facility.
163. Control and automatic emergency protection systems shall undergo comprehensive testing (the bringing of the setting parameters of the software and hardware, the communication channels and the application software to the values (state) at which the automatic emergency protection system may be used in operation).
164. Light and sound alarms indicating gas contamination of the air environment of a chemically hazardous production facility shall be provided: at the entrance doors - on the outside, to warn personnel of the danger; inside the premises - in the working areas.
165. The control and automatic emergency protection systems, as well as the communication and notification systems, are placed in locations that are convenient and safe for maintenance and that exclude vibration whose quantitative characteristics exceed the permissible values of the vibration indicators for the technical means used, contamination by substances handled in the technological process, and mechanical and other harmful effects affecting the accuracy, reliability and response speed of the systems. In doing so, measures and means for dismantling the systems and their elements without depressurising the equipment and pipelines shall be provided.
166. Chemically hazardous production facilities of hazard classes I and II shall be equipped with automatic and/or automated control systems built on the basis of software and hardware complexes using microprocessor technology.
167. An automated process control system based on computing equipment shall comply with the requirements of the documentation for the chemically hazardous production facility.
168. Automatic emergency protection systems shall ensure the protection of personnel, process equipment and the environment in the event of the occurrence, at the controlled object, of an abnormal situation the escalation of which may lead to an accident.
169. A malfunction of the control system shall not affect the operation of the automatic emergency protection system.
170. The automatic emergency protection system performs the following functions: automatic detection of potentially hazardous changes in the state of the process object or of its automation system; automatic measurement of the process variables important for the safe conduct of the technological process (for example, the measurement of variables whose values characterise the proximity of the object to the limits of the safe process operating regime); automatic diagnostics of failures occurring in the automatic emergency protection system and/or in the hardware and software used by it; automatic pre-emergency alarm informing the operator of the technological process of potentially hazardous changes that have occurred in the object or in the automatic emergency protection system; automatic protection against unauthorised access to the setting parameters and/or the selection of the operating mode of the automatic emergency protection system.
171. Automatic emergency protection systems for chemically hazardous production facilities of hazard classes I and II shall be built on the basis of controllers capable of operating in a fail-safe configuration. In the event of a failure of the automatic emergency protection, the protected technological process shall be automatically brought to a safe state.
172. The methods and means of automatic emergency protection are selected on the basis of an analysis of the hazards arising during the operation of the process objects, the conditions of occurrence and escalation of possible emergency situations, and the features of the technological processes and the equipment arrangement. The rational selection of the means for automatic emergency protection systems is carried out taking into account their reliability and response speed in accordance with their technical characteristics.
173. For chemically hazardous production facilities of hazard classes I and II, automatic emergency protection systems shall use their own sensors. The sensors of the control systems may be used for the automatic emergency protection of the object as additional means.
174. For chemically hazardous production facilities of classes I and II, automatic emergency protection systems shall use their own actuators. The actuators of the control systems may be used for the automatic emergency protection of objects as additional means.
175. Monitoring of the current values of the parameters that determine the chemical hazard of the technological processes of chemically hazardous production facilities of hazard classes I and II is carried out from no fewer than two independent sensors with separate sampling points. The list of monitored parameters that determine the chemical hazard of the process in each specific case is drawn up by the process developer and specified by it in the initial data for the development of the documentation for the chemically hazardous production facility.
176. In automatic emergency protection systems, the use of multi-point instruments for monitoring the parameters that determine the chemical hazard of the technological process shall not be permitted.
177. The development of the documentation for automatic emergency protection systems and the selection of their elements are carried out on the basis of the conditions for ensuring the operation of the system during operation, maintenance and repair throughout the entire life cycle of the protected object.
178. The response time of the protection system shall be such that the hazardous escalation of a possible accident is precluded.
179. The following requirements are imposed on the performance of the control functions of automatic emergency protection systems: the control commands generated by the protection (interlock) algorithms shall take priority over any other commands for controlling the process equipment, including the commands generated by the operating personnel of the automated process control system (unless otherwise stipulated in the technical specification for its creation); the actuation of one automatic emergency protection system shall not create at the object a situation requiring the actuation of another such system; the protection actuation algorithms shall provide for the possibility of enabling the interlocking of control commands for equipment technologically connected with the apparatus, unit or other equipment that caused such actuation; automatic emergency protection systems shall be implemented on the principles of priority protection of technological processes as a complete set, with the simultaneous protection of individual items of equipment.
180. In the automatic emergency protection and process control systems of a chemically hazardous production facility, their actuation by short-term signals of disturbance of the normal course of the technological process shall be precluded, including in the event of switching to a standby or emergency power supply source.
181. In the documentation for the chemically hazardous production facility, the process regulations and the lists of automatic emergency protection systems of chemically hazardous production facilities of hazard classes I and II, the limits of the critical values of the parameters shall be indicated along with the protection set points for the chemically hazardous parameters.
182. The values of the set points of the protection systems are determined taking into account the actuation errors of the measuring instruments (used as part of the alarm devices), the response speed of the system, and the possible rate of change of the parameters. In doing so, the response time of the protection systems shall be less than the time required for the parameter to pass from the warning value to the maximum permissible value. The specific values of the set points are given in the documentation for the chemically hazardous production facility and in the process regulations.
183. For chemically hazardous production facilities, a pre-emergency alarm based on the warning values of the parameters that determine the chemical hazard of the objects is provided.
184. In the event of a power outage or an interruption of the compressed-air supply for feeding the monitoring and control systems, the automatic emergency protection systems shall ensure the transfer of the process object to a safe state. The possibility of arbitrary switching in these systems upon the restoration of the supply shall be precluded. The return of the process object to the working state after the actuation of the automatic emergency protection system is performed by the operating personnel in accordance with the instructions.
185. The actuators of automatic emergency protection systems, in addition to the extreme-position indicators located directly on these mechanisms, shall have devices enabling the indication of the extreme positions in the control room.
186. The reliability of automatic emergency protection systems shall be ensured by hardware redundancy of various types (duplication, triplication), by temporal and functional redundancy, and by the presence of diagnostic systems with indication of the operating state and of self-diagnostic systems with comparison of the values of the technologically related parameters. The sufficiency of the redundancy and its type is substantiated by the developer of the documentation for the chemically hazardous production facility.
187. The reliability indicators of automatic emergency protection systems are established and verified for no fewer than two types of failure of these systems: failures of the "failure-to-actuate" type and failures of the "false actuation" type.
188. The technical solutions for ensuring the reliability of monitoring the parameters that have critical values at the objects of chemically hazardous production facilities of hazard classes III and IV are substantiated by the developer of the documentation for the chemically hazardous production facility.
189. All computer software intended for use as part of any automatic emergency protection system shall undergo mandatory verification of compliance with the requirements specified in the technical specification, which is carried out by its manufacturer or supplier in accordance with a programme agreed with the customer of the automatic emergency protection system.
190. For monitoring gas contamination against the maximum permissible concentration (MPC) in production premises and in the working area of open outdoor installations of a chemically hazardous production facility, means of automatic continuous gas monitoring and analysis shall be provided, with an alarm that is actuated when the maximum permissible values are reached and with the issuing of signals to the automatic emergency protection system. In doing so, all cases of gas contamination shall be recorded by instruments with automatic recording and shall be documented.
191. The installation locations and the number of sensors or sampling devices of the analysers shall be determined in the documentation for the chemically hazardous production facility, taking into account the requirements of the regulatory technical documents on the placement of gas-contamination monitoring sensors.
192. The organisation and procedure for notifying production personnel and the civilian population of an accident at a chemically hazardous production facility, and the responsibility for maintaining the technical means and the corresponding services for eliminating the threat of chemical injury in a state of readiness, shall be determined by the action plans.
193. The conduct of technological processes and the operation of equipment with faulty or disconnected monitoring, control, alarm and automatic emergency protection systems shall not be permitted.
194. The use of monitoring and measuring instruments and automation means that have not been certified in accordance with the established procedure, or whose calibration period has expired, shall not be permitted.
195. The arrangement, installation, maintenance and repair of electrical installations shall comply with the requirements for ensuring the reliability and safety of power-receiving installations, with the technical regulations and with these Rules.
196. The power supply of a chemically hazardous production facility shall be provided under reliability category I or II. In doing so, the possibility of an accident-free transfer of the technological process to a safe state shall be ensured in all operating modes of the production, including in the event of the simultaneous interruption of the power supply from two independent mutually redundant power sources.
197. Power supply lines from external sources, regardless of the voltage class, feeding consumers of the special group of reliability category I of power supply, are not equipped with automatic frequency load-shedding devices.
198. The laying of cables over the territory of enterprises and installations may be carried out openly: along overpasses, in galleries and on the cable structures of process overpasses. The placement of cable structures on process overpasses shall be carried out taking into account the provision of the possibility of installing and dismantling pipelines in accordance with the requirements for ensuring the reliability and safety of power-receiving installations, with the technical regulations and with these Rules. The laying of cables in channels filled with sand and in trenches is also permitted. Cables laid over the territory of process installations and production facilities shall have insulation and a sheath made of materials that do not propagate combustion.
199. The electric lighting of outdoor process installations shall have remote switching-on from the operator room and local switching-on by service zones.
200. When carrying out repair work under conditions of confinement and possible gas contamination, including inside process apparatus, lighting shall be provided by means of portable explosion-protected battery lamps of a design corresponding to the medium, or portable electric lamps of explosion-proof design complying with the requirements for ensuring the reliability and safety of power-receiving installations, with the technical regulations and with these Rules.
201. The power supply of the emergency lighting of workplaces shall be provided under the special group of reliability category I. The power supply of the automated process control system and the automatic emergency protection systems for chemically hazardous production facilities of hazard classes I and II shall be provided under the special group of reliability category I.
202. On tall columns, apparatus and other process equipment, the obstruction lights shall be of explosion-protected design.
203. Process installations and production facilities shall be equipped with a stationary network for connecting welding electrical equipment.
204. For connecting welding machines, switching boxes (cabinets) shall be used.
205. The network for connecting welding machines shall be de-energised before the start of work. The supply of voltage to this network and the connection of welding electrical equipment shall be carried out in accordance with the requirements of the technical regulations and other regulatory technical documents on the safe operation of electrical installations and on fire safety.
206. Electric welding work shall be carried out in accordance with the instructions for performing hot work approved by the organisation operating the chemically hazardous production facility.
207. Heating and ventilation systems shall, in terms of their purpose, arrangement, technical characteristics, design, maintenance and operating conditions, comply with the requirements of the technical regulations, the regulatory legal acts and these Rules.
208. The arrangement of ventilation systems, including emergency ventilation, and the air-exchange rate shall be determined by the need to ensure reliable and effective air exchange. For the premises of a chemically hazardous production facility, the assessment of the possibility of using all types of ventilation in the event of emergency, salvo, maximum possible releases of toxic products from the process equipment into the premises shall be carried out during the development of the documentation for the chemically hazardous production facility and shall be reflected in the operational documentation.
209. The procedure for the operation, maintenance, repair, adjustment and conducting of instrumental checks of the effectiveness of the ventilation systems shall be determined by the operating instructions for industrial ventilation and shall comply with the requirements of Federal Law No. 384-FZ of 30 December 2009 "Technical Regulations on the Safety of Buildings and Structures" (Collected Legislation of the Russian Federation, 2010, No. 1, Article 5; 2013, No. 27, Article 3477).
210. Air intake for supply ventilation systems shall be provided from locations that preclude the entry of chemically hazardous vapours and gases into the ventilation system in all operating modes of the production.
211. Emergency ventilation systems shall be equipped with means for their automatic switching-on upon the actuation of the gas analysers installed in the premises when the MPC of chemically hazardous substances is exceeded. Local ventilation systems that remove chemically hazardous substances shall be interlocked with the starting device of the process equipment and shall switch on simultaneously with the switching-on of the equipment and switch off after the equipment is switched off.
212. In control rooms and production premises, an alarm indicating the faulty operation of the ventilation systems shall be provided.
213. The development of documentation for, and the operation of, the water-supply and sewerage systems of a chemically hazardous production facility shall be carried out in accordance with the requirements of the technical regulations, the legislation of the Russian Federation on town-planning activities and these Rules. The composition of the effluents discharged from the plant-wide treatment facilities is established in the process regulations.
214. Chemically hazardous production facilities shall have local treatment facilities, the need for which is substantiated in the documentation for the chemically hazardous production facility.
215. The water supply of a chemically hazardous production facility shall, in each specific case, be provided taking into account the features of the technological process and the prevention of accidents and releases of chemically hazardous (toxic) substances.
216. The recirculating water-supply systems of a chemically hazardous production facility shall be equipped with means for monitoring and alarm regarding the presence of chemically hazardous substances in the recirculating water system at the outlet of the process apparatus (at the header). In doing so, measures shall be taken to preclude the entry of these substances into the recirculating water system.
217. The siting of chemically hazardous production facilities, the layout of their territory and the space-planning solutions for the objects shall be carried out in accordance with the requirements of the legislation of the Russian Federation on technical regulation.
218. On the territory of an organisation that includes a chemically hazardous production facility, the presence of natural ravines, hollows and depressions, and the construction of open trenches, pits and sumps in which chemically hazardous substances may accumulate, shall not be permitted.
219. Chemically hazardous production facilities, premises for production, administrative-economic and welfare purposes, and places of permanent or temporary presence of people that are, in the event of an accident, within the hazardous zone, shall be equipped with effective systems for notifying personnel of an accident at the chemically hazardous production facility.
220. The action plans shall provide for measures for the removal to a safe place of people not directly engaged in the performance of work to eliminate the accident.
221. Buildings in which the control rooms (operator rooms) are located shall ensure the chemical safety of the personnel present in them and shall have autonomous means for ensuring the functioning of the monitoring, control and automatic emergency protection systems for the transfer of technological processes to a safe state in an emergency situation; the means for ensuring the functioning of the monitoring, control and automatic emergency protection systems for the transfer of technological processes to a safe state in an emergency situation, located in separate free-standing buildings (controller rooms), shall ensure chemical safety.
222. Work with chemically hazardous substances shall be carried out using personal protective equipment. In production premises, storage facilities for chemically hazardous substances and places where work with chemically hazardous substances is carried out, an emergency set of personal protective equipment shall be kept, as well as means for containing the emergency situation and for providing first aid to the injured in the event of an emergency situation (a self-help shower or bath, a self-help sink).
223. The maintenance of a chemically hazardous production facility shall ensure the operation of the process equipment between repairs in the specified modes provided for by the process regulations.
224. Repair work involving the use of open flame at a chemically hazardous production facility shall be carried out in accordance with the requirements of Federal Law No. 123-FZ and the instructions on the organisation of the safe conduct of hot work at explosion- and fire-hazardous and chemically hazardous production facilities, developed and approved by the operating organisation.
225. A chemically hazardous production facility whose repair has been completed shall be accepted under a report and admitted to operation after checking the assembly of the process flow diagram, the removal of the blanking plugs, the leak-tightness testing of the systems, the checking of the operability of the monitoring, alarm, control and automatic emergency protection systems, the availability and serviceable condition of the safety devices, the compliance of the installed electrical equipment with the requirements for ensuring the reliability and safety of power-receiving installations, with the technical regulations and with these Rules, and the serviceable condition and required efficiency of the ventilation systems. The completeness and quality of the as-built repair documentation, the condition of the object's territory and workplaces, the readiness of the operating personnel to carry out their principal duties, and other requirements provided for by the regulatory technical documentation shall be checked. The report on the acceptance of the object from repair (technical re-equipment), authorising its start-up into operation, is approved in accordance with the procedure established by the internal documents of the operating organisation.
226. The withdrawal of a chemically hazardous production facility from operation for a long period and the putting of these chemically hazardous production facilities into operation after long shutdowns shall be carried out in accordance with the regulatory legal acts governing these procedures.
227. The organisation and procedure for carrying out work on the maintenance and repair of the process equipment of a chemically hazardous production facility shall comply with the Federal Norms and Rules in the field of industrial safety establishing the general rules of explosion safety for explosion- and fire-hazardous production facilities and objects.
228. Process equipment and pipelines for acids and alkalis in which, under the operating conditions, a pressure may arise that exceeds the maximum permissible parameters provided for by the developer of the documentation for the chemically hazardous production facility, shall be equipped with safety devices protecting against a rise in pressure above the permissible value.
229. Safety devices against overpressure shall be protected from the corrosive effect of inorganic acids and/or alkalis, while ensuring the possibility of monitoring their serviceable condition.
230. The throughput capacity of the safety devices is calculated in accordance with the requirements of the regulatory technical documents.
231. When the safety devices installed on the process equipment are actuated, the possibility of injury to the operating personnel and of the release of acids and/or alkalis into the working area and the environment shall be prevented. The discharge of acids or alkalis from the safety valves is carried out into special vessels.
232. The methods of emptying the vessels for storing acids and alkalis and the arrangement of the drainage units are determined by the developer of the documentation for the chemically hazardous production facility.
233. On vessel equipment for storing liquid acids or alkalis (tanks and collectors with a volume of 1 m3 and more), the bottom-drainage pipelines shall be equipped with two shut-off devices, one of which is connected directly to, or in the immediate vicinity of, the branch pipe of the vessel. The installation locations are substantiated during the design.
234. For the manufacture, installation and repair of the process equipment and pipelines for acids or alkalis, materials ensuring their corrosion resistance to the working medium shall be used. For the manufacture of pipelines, seamless pipes of structural steel joined by welding shall predominantly be used. Drainage devices and removable sections shall also be made of materials ensuring their resistance to the aggressive action of the medium. In cases substantiated in the design, the laying of pipelines made of non-metallic materials is permitted. The use of materials and semi-finished products of inadequate quality, as well as of used ones, shall not be permitted.
235. When installing steel pipelines, standard shaped elements manufactured in accordance with the regulatory technical documentation shall be used. When manufacturing bends by the bending method on special machines, the radius of curvature of the bend shall be not less than three diameters of the pipe.
236. Pipelines for conveying acids and alkalis laid along overpasses shall be protected against mechanical damage, including: (a) against falling objects (the placement of lifting devices and easily-jettisoned canopies above the pipeline shall not be permitted); (b) against possible impacts from vehicles, for which purpose the pipeline is placed at a distance from the hazardous areas, or they are separated by barriers; (c) in the case of multi-tier laying, the pipelines for acids and alkalis shall be placed on the lowest tiers.
237. For an inter-plant pipeline for acids or alkalis laid outside the territory of enterprises, a protection zone at least 2 metres wide on each of its sides shall be provided, within which the performance of work without the agreement and supervision of a representative of the organisation operating the pipeline shall not be permitted.
238. Flanged joints of pipelines for acids and alkalis shall have protective casings. Equipment is equipped with protective casings in cases substantiated by the design documentation.
239. On pipelines for acids and alkalis, sealed shut-off valves shall be used in accordance with the requirements of the regulatory technical documents. The structural materials of the fittings are selected on the condition of resistance to the conveyed medium and of ensuring the reliable operation of the fittings within the permissible range of the medium parameters.
240. Shut-off valves shall be installed in locations convenient for maintenance.
241. The laying of pipelines for acids and alkalis along the external walls of buildings not connected with the handling of acids and alkalis, and through auxiliary, ancillary, administrative and welfare premises, shall not be permitted. At the points of intersection of railways and motor roads and of pedestrian passages, the pipelines shall be enclosed in special troughs or ducts (collectors) with the drainage of leaks of acids and alkalis to safe places determined by the design.
242. Other pipelines shall not be fastened to pipelines conveying acids and alkalis (except for heat-tracing lines fastened without welding).
243. When conveying acids and alkalis through pipelines, to prevent solidification (crystallisation), the laying of external pipelines with heat-tracing lines and thermal insulation of the pipelines shall be provided.
244. When laying pipelines for acids and alkalis, their shortest length shall be ensured, and sagging and the formation of stagnant zones shall be precluded.
245. Pipelines for acids and alkalis shall be laid with a slope ensuring the fullest possible emptying of them into a process vessel or into special tanks.
246. For acid and alkali pipelines, provision shall be made for the possibility of their flushing, steaming, vacuum treatment, and purging with compressed air, including dried air, or nitrogen.
247. Shut-off valves are installed on acid and alkali pipelines that allow both the entire pipeline and its individual sections to be isolated from operating process systems, allow blanks to be fitted, and provide the possibility of draining, flushing, purging, and strength and tightness testing of the pipelines.
248. Acid and alkali pipelines shall be tested for strength and density by hydraulic or pneumatic pressure testing in accordance with the requirements of regulatory technical documents.
249. Before being put into operation, pipelines and valves for acids and alkalis shall be tested for tightness at working pressure in accordance with the requirements of regulatory technical documents.
250. The intervals for the inspection of pipelines, shut-off valves, and safety valves for acids and alkalis are established, depending on the rate of corrosion-erosion wear, by the enterprise owning the pipeline, with the inspection results being entered in the pipeline data sheet.
251. The procedure for checking and preparing equipment and pipelines before commissioning and before shutdown for repair is established in accordance with the instructions approved by the technical manager of the organisation.
252. The monitoring and control of process operations in which acids and/or alkalis are used shall be carried out from the operator's workstation located in the control room, with duplication at the equipment location of the means for monitoring the process parameters that determine process safety and for controlling them, and of the alarm signalling for pre-emergency and emergency situations.
253. The measurement and regulation of process parameters (flow rate, pressure, temperature) shall be carried out by technical devices that are corrosion-resistant in the working medium or protected from its effects.
254. The proper functioning of the emergency automatic protection (PAZ) systems and of the alarm signalling shall be checked in accordance with a schedule approved by the technical manager of the operating organisation, and for continuous process operations - before each start-up and after shutdown for repair. Manual override in automatic process control systems shall not be permitted.
255. Vessels for the storage of acids and alkalis shall be equipped with means for the measurement, monitoring, and regulation of the level of these liquids, with alarm signalling of the level limit values, and with means for automatically shutting off their supply into the vessels when the specified limit level is reached, or with other means that preclude the possibility of overflow.
256. In rooms where work involving the use of acids and alkalis is carried out, regular monitoring of the state of the air environment shall be organised. In rooms where, under operating conditions, the release of acid and alkali vapours is possible, automatic monitoring of their content in the air shall be provided, with alarm signalling of exceedance of the maximum permissible concentration (MPC). Where the MPC is exceeded in the specified rooms, the following shall be activated: (a) light and sound signals in the control room and at the location; (b) emergency ventilation, interlocked where necessary with the system for the emergency absorption of harmful-substance emissions into the atmosphere.
257. At warehouses and loading-unloading points located in open areas where, under operating conditions, the entry of acid and alkali vapours into the working-zone air is possible, provision shall be made for automatic monitoring with alarm signalling of exceedance of the MPC. Where the MPC is exceeded at the specified locations, light and sound signals shall be activated in the control room and at the location. In this case, all instances of gas contamination shall be recorded by instruments. The sensitivity threshold of the sensors, their number, and their location shall be justified and specified in the documentation for the chemically hazardous production facility.
258. Production rooms and locations where acids and/or alkalis are used shall be provided with two-way loudspeaker and/or telephone communication as envisaged by the design and process documentation.
259. Depending on their purpose, acid and alkali warehouses are divided into: (a) service warehouses for acids and alkalis in tanks at consumer organisations that receive acids and/or alkalis in rail tank cars; (b) service warehouses for acids and alkalis in receptacles, intended for storing them in the quantities required for the current needs of the organisation between deliveries. The quantity of liquid acids and/or alkalis present at any one time within the territory of the enterprise or organisation shall be the minimum necessary to sustain the production cycle and shall be justified in the documentation for the chemically hazardous production facility; where necessary, a safety justification for the chemically hazardous production facility is developed, taking into account the specific operating conditions of the facility (the remoteness of the facility from the supplier enterprise, the seasonal reliability of transport links).
260. For warehouses where concentrated acids are stored, the spillage of which may form a cloud as a result of the instantaneous (less than 1-3 min) transfer of part of the acids into the atmosphere (a primary cloud), a calculation of the radius of the hazardous zone is performed. Locating residential and cultural-amenity facilities within the calculated radius of the hazardous zone shall not be permitted.
261. The minimum permissible distances from acid and alkali warehouses to the production and auxiliary facilities of the enterprise that are not connected with the consumption of liquid acids and alkalis are established in accordance with the requirements of the legislation of the Russian Federation on technical regulation. Production facilities located within the calculated radius of the hazardous zone shall be equipped with a system for warning of the occurrence of a hazardous situation, and the personnel shall be provided with the appropriate personal protective equipment.
262. The minimum permissible distances from acid and alkali warehouses to explosion-hazardous facilities are established taking into account the radii of intensive impact of the blast shock wave and thermal radiation. They shall ensure the resistance of the warehouse buildings to the effects of these factors.
263. When developing the documentation for acid warehouses in which the formation of a primary acid cloud is possible, they shall be located in lower-lying places relative to other buildings and structures, predominantly on the leeward side of the prevailing wind directions (in accordance with the meteorological "wind rose" chart for the given locality) relative to the location of the nearest populated areas.
264. In the territory of acid warehouses capable of forming a primary cloud, a wind-direction indicator visible from any point of the warehouse territory shall be installed, and automatic monitoring of the gas-contamination level and signalling of emergency leaks shall be provided.
265. In the territory of an acid and alkali warehouse, locating facilities not directly related to the production activity of the warehouse shall not be allowed, and the presence of unauthorised persons shall not be permitted.
266. Steel service storage vessels for the storage of acids shall be provided with means (devices) that prevent the ingress of moist air and/or moisture into them.
267. Vessel equipment for the use of acids and/or alkalis with a volume of 1000 l or more shall be equipped with drip trays whose capacity is sufficient to contain one apparatus of maximum capacity in the event of its emergency failure. The height of the protective bund of each group of tanks shall be 0.2 m higher than the level of the calculated volume of spilled liquid. The drip trays and kerbed areas shall be equipped with stationary or mobile devices for removing emergency spills and their subsequent neutralisation. Drip trays for open warehouses without drains into the organisation's special sewer system shall be additionally protected from atmospheric precipitation.
268. For warehouses storing acids and alkalis in tanks, the possibility shall be provided of the emergency emptying of any of the tanks into other tanks of the warehouse, into special emergency systems, or into the equipment of process units whose material is corrosion-resistant to the product being evacuated. The procedure for and the conditions of emergency evacuation for all cases shall be defined by the Action Plan.
269. Production rooms intended for the use and storage of acids and alkalis shall be equipped with general-exchange ventilation in accordance with the requirements of technical regulations, regulatory legal acts, and the Rules. Rooms for storing acids and alkalis in receptacles (without permanent workplaces) may be left without general-exchange ventilation systems. In this case, at the entrances to the acid storage room, provision shall be made for light signalling of the exceedance of the gas-contamination level in the room.
270. The conveyance through pipelines of solidifying products and melts capable of crystallising (phthalic and maleic anhydrides, rosin) shall be carried out through heated pipelines of the "pipe-in-pipe" type or with heat-carrier tracing lines, in a regime that precludes the blocking of the pipelines. The type of heating and heat carrier is selected taking into account the physico-chemical properties of the chemically hazardous products being conveyed.
271. The selection of the design and structural materials and of the sealing devices for pumps and compressors is carried out in accordance with the current regulatory technical documents, taking into account the toxic properties of the medium being conveyed and the working parameters of the process.
272. To separate the liquid phase from the gas medium being conveyed, separators, receivers, and droplet eliminators are installed on the suction line of the compressor, vacuum pump, and gas blower; these may be equipped with level-monitoring instruments, maximum-level alarm signalling, and interlocking means.
273. In systems for conveying chemically hazardous substances where deposits of resinification, polymerisation, and polycondensation products on the internal surfaces of pipelines and apparatus are possible, provision shall be made for effective and safe methods and means of cleaning off these deposits, as well as for establishing the frequency of these operations.
274. For conveying bulk dusting chemically hazardous materials, devices that preclude dust release shall be used. The conveyance of bulk and dusting chemically hazardous materials in pigment production shall be carried out in sealed conveying means.
275. The points of transfer and conveyance of a dusting chemically hazardous product in pigment production shall be sealed and provided with enclosures connected to the aspiration ventilation units. The air from the aspiration systems shall be cleaned of dust before being discharged into the atmosphere. The air velocity in the funnels of the local extraction points of the aspiration ducts shall not exceed 2 m/s.
276. Elevators and closed conveyors shall have devices indicating that the given equipment is in working condition.
277. Belt conveyors shall have devices for cleaning the belt when sticking materials are conveyed on them. The conveyance on belt conveyors of lead- and chromium-containing pigments, as well as of other highly toxic materials, both in dry and in paste form, shall not be permitted.
278. To disconnect hoppers from the equipment, gate valves or other shut-off devices that cut off the flow of bulk material shall be installed between them.
279. Hoppers for caking materials shall have intrinsically safe loosening devices that preclude bridging.
280. The discharge of product from dust-collecting chambers shall be mechanised and sealed.
281. In pigment production, the feeding devices and the equipment associated with the conveyance and loading of bulk raw material shall be equipped with automatic interlocks that stop the supply of materials and fuel when the main equipment stops.
282. Process operations for the separation of chemically hazardous products (distillation of solvents) shall be carried out taking into account the need to ensure compliance with the chemical safety requirements.
283. Equipment for the separation of suspensions and for filtration shall be equipped with interlocks that ensure the shutdown and stopping of the supply of suspensions in the event of impermissible deviations of the inert-medium parameters. In centrifuges and separators, measures shall be provided that prevent the formation of chemically hazardous mixtures both in the apparatus themselves and in the air of the working zone of the room.
284. When carrying out mass-transfer processes in which, upon deviations of the process parameters from the regulated values, the formation of unstable chemically hazardous compounds is possible, means for the automatic regulation of these parameters shall be provided.
285. In batch mixing processes, where the development of self-accelerating exothermic reactions is possible, to preclude their uncontrolled course the sequence and permissible quantities of the substances loaded into the apparatus, the rate of loading (feeding) of the reagents, and the supply of phlegmatising agents are regulated.
286. In the grinding-and-packaging departments for the finished product of pigment production, the mechanised return to the process of the pigment captured by the aspiration systems shall be ensured.
287. The grinding-and-packaging departments of pigment production facilities shall be located in separate rooms.
288. The units for packaging the finished product into receptacles (bags, drums, containers) shall be equipped with local extraction points. In this case, the dust removal from the packaging units in the production of Milori blue, lead chromes, and oxides shall be ensured by a separate exhaust ventilation system.
289. The drying department and the grinding-and-packaging department in Milori blue production shall be equipped with emergency ventilation that is activated automatically by a signal from the gas analyser.
290. The organisation of heat exchange and the selection of the heat carrier (refrigerant) and its parameters are carried out taking into account the physico-chemical properties of the material being heated (cooled), so as to ensure the necessary heat removal and to preclude the possibility of overheating and decomposition of the product.
291. In the heat-exchange process, the use of heat carriers that form chemically hazardous products upon chemical interaction shall not be permitted.
292. In heat-exchange processes, including reaction processes, in which, upon deviations of the process regimes from the regulated ones, the development of uncontrolled, self-accelerating exothermic reactions is possible, means that prevent the development of such reactions are provided.
293. When organising heat-exchange processes using high-temperature organic heat carriers (VOT), systems for the removal of volatile products formed as a result of their partial decomposition are provided. When conducting the process near the upper permissible limit of the use of VOT, monitoring of the change in the composition of the heat carrier shall be carried out.
294. The drying agent and the drying regimes are selected taking into account the toxic properties of the material being dried, the heat carrier, and the possibilities for reducing the level of (toxic) hazard.
295. Chemical-engineering systems and apparatus that combine several processes (hydrodynamic, heat-and-mass-transfer, reaction) are equipped with instruments for monitoring the regulated parameters. The control and regulation means shall ensure the stability and chemical safety of the process.
296. Where the deposition of solid chemically hazardous products on the internal surfaces of equipment and pipelines, and their blocking, including that of the emergency-discharge devices of process systems, is possible, monitoring of the presence of these deposits shall be carried out, and, where necessary, reserve equipment and pipelines shall be provided.
297. To preclude the possibility of overheating of the substances participating in the process, their spontaneous ignition, or their thermal decomposition with the formation of chemically hazardous products as a result of contact with heated elements of the apparatus, the following are determined and regulated: the temperature regimes, the optimum rates of conveyance of the products (the maximum permissible residence time of the products in the high-temperature zone).
298. To preclude the hazard of an uncontrolled process, provision shall be made for measures for its stabilisation, emergency containment, or the emptying of the apparatus.
299. The apparatus of liquid-phase processes is equipped with systems for monitoring and regulating the liquid level in it and/or with means for automatically shutting off the supply of this liquid into the apparatus when the specified level is exceeded, or with other means that preclude the possibility of overflow.
300. In the production of varnishes based on condensation resins, the varnish-discharge departments are located: in an isolated room of the synthesis building; in a separate building; in open areas.
301. Storing colloxylin and dry-milled pastes (SVP) based on it in the premises of shops intended for varnishes and enamels based on cellulose ethers shall not be permitted. The storage of SVP in the shop may be carried out only for the tinting of enamels, but in a limited quantity of no more than 2 per cent of the shift requirement.
302. Pumps for pumping colloxylin solutions shall be low-speed and shall comply with the requirements of toxic safety. In the production of titanium dioxide, each reduction apparatus shall be equipped with an air ejector, and each hydrolysis apparatus - with an individual natural-draught extraction.
303. The high supports of rotary kilns and dryers shall be provided with service platforms located at a distance of no more than 300 mm from the top of the support.
304. The discharge of combustion products into a single flue duct from units operating on different types of fuel shall not be permitted.
305. Systems conveying hydrogen sulphide shall be tight and shall preclude the possibility of the suction of outside air.
306. The drives of apparatus located in rooms where the accumulation of dust is possible shall be arranged on the same shaft as the electric motor, or closed gearboxes shall be used. In individual cases, when installing standard equipment, V-belt drives with belts made of electrically conductive rubber may be used. The use of flat-belt drives shall not be permitted.
307. In the lining of stationary furnaces and in the heads of rotary kilns operating on gaseous fuel, safety valves or rupture membranes shall be installed.
308. During the loading of zinc dross into the reactors for the production of zinc sulphate, the opening of the cover of the charging hatch shall be interlocked with the supply of steam around the perimeter of the hatch.
309. The frequency of monitoring the content of chemically hazardous substances in production rooms is established in the documentation for the chemically hazardous production facility.
310. Workplaces shall be located outside the lines of movement of loads conveyed by lifting-and-conveying mechanisms.
311. At the places of passage of people and of vehicles under overhead conveyors and transporters, guards shall be provided at a height of no less than 2.2 m.
312. The inter-shop and intra-shop transport of bulk and dusting materials shall be equipped with devices for the extraction of dust at the loading and unloading points of the raw material.
313. The conveyance of phosphorus to warehouses from the shops producing phosphorus, as well as from the warehouses to the shops that consume phosphorus and are located in the same territory, shall be carried out through heated pipelines or in heated montejus.
314. All areas where units are installed during the operation of which dust release is possible (crushers, screening units, packing and conveying devices) shall be sealed to the maximum extent, and, where complete sealing is impossible, shall be provided with easily removable enclosures with local extraction points to preclude the ingress of dust into the atmosphere.
315. The surfaces of apparatus located in a room and having a temperature of 45 °C or above shall be thermally insulated with non-combustible materials. If the use of thermal insulation is not permitted under the conditions of the process regime, guarding of the heated surfaces shall be provided. Where equipment with heated surfaces is located in places that preclude the possibility of touching by the operating personnel, the guards may be omitted.
316. Production equipment during the operation of which noise above the permissible norms is generated shall be equipped with anti-noise structures, or other measures for the protection of the personnel shall be taken.
317. In case of a breakthrough of acid and acidic water through the glands of centrifugal pumps, drip trays or troughs with outlets, made of corrosion-resistant materials, shall be installed under the glands. The collection of contaminated effluents is carried out into receiving collectors (sumps).
318. Phosphorus and phosphorus sludge in the apparatus shall at all times remain under a layer of water no less than 300 mm high.
319. The temperature of phosphorus and phosphorus sludge during storage and pumping shall not exceed 80 °C. The steam lines supplying live steam for heating the phosphorus and maintaining it in a molten state shall be equipped with steam-pressure monitoring instruments and shall also be provided with devices ("air vents") to prevent the formation of a vacuum and the ingress of phosphorus into the steam line.
320. Production vessels containing phosphorus shall be installed in a drip tray with reinforced waterproofing. The side walls of the drip tray shall be designed for the hydrostatic pressure of the spilled phosphorus. The capacity of the drip tray shall be designed to receive the possible spills of the stored phosphorus in a volume of no less than the capacity of the single largest tank plus a layer of water of no less than 200 mm. The drip tray shall be made with a slope towards a pit for collecting the possible spills of phosphorus and water.
321. All vessels containing phosphorus shall have a supply of inert gas.
322. The use of furnace gas (after the condensation of phosphorus from it) shall be carried out in accordance with the instruction approved by the technical manager of the organisation.
323. Intermediate hoppers, if they are not filled by means of tripping trolleys, shall be closed. When tripping trolleys are used, provision shall be made for charging openings closed with grids having cells of a size no greater than 200 x 200 mm.
324. When unloading receiving hoppers, the residual layer of materials shall be 0.7 m higher than the discharge opening to prevent the entry of dust-laden air into the room.
325. Drying drums shall be equipped with systems for the extraction of gases and the collection of dust. To prevent the release of gases and dust into the production rooms, the drying drums shall operate under negative pressure.
326. When natural or furnace gas is used as fuel in the drying department and in the raw-material calcination department, safety automatics shall be provided.
327. To prevent harmful emissions into the atmosphere, granulation pans shall be provided with local extraction points.
328. Pitch and electrode paste shall be stored in a special warehouse or in separate compartments of the general warehouse for raw materials and materials.
329. The departments where the crushing of pitch and the preparation or heating of electrode paste are carried out shall be isolated from the other working rooms.
330. The equipment in the department for the preparation or heating of electrode paste shall be sealed or reliably enclosed and provided with local extraction means.
331. In the furnace department, the casting of ferrophosphorus on the casting machine, as well as the receivers and settling tanks of phosphorus, shall be located in separate rooms.
332. The entire system for the electric sublimation of phosphorus, comprising the electric furnace, electrostatic precipitators, condensers, and gas blowers, shall at all times be under a gauge pressure of no less than 3 mm of water column. The maximum gauge pressure in the electric furnace shall not exceed 50 mm of water column. During repair work on the furnace cover, during the replacement of tuyeres and cones, during the repair of the slag and ferrophosphorus tapholes, and during the replacement of electrode holders, the gauge pressure in the furnace may be maintained equal to zero, provided that the pressure in the system of electrostatic precipitators and condensers is no less than 3 mm of water column.
333. On the gas system for furnace gas, protective safety devices that preclude an increase in the pressure in the system above the permissible level shall be installed. The discharge of furnace gas shall be directed to a stack. The safety devices shall be checked in accordance with the instruction approved by the technical manager of the organisation.
334. In the water-cooling system of the electric furnace, the leakage of water into the furnace shall not be permitted. In the water-cooling system of the tapholes (nozzle and tuyere), continuous monitoring of the tightness of the water-cooled elements with automatic alarm signalling shall be carried out, and the leakage of water into the furnace, in the event of a breach of the tightness of the taphole elements, shall be prevented during the period necessary for shutting down the furnace and the taphole water-cooling system.
335. Upstream of the gas cut-off device, a stack shall be installed for the discharge of gases during the ignition of the furnace and during its prolonged shutdowns.
336. The designs of the electric furnaces, condensers, electrostatic precipitators, and other equipment containing furnace gas shall ensure their maximum sealing. All places that cannot be completely sealed shall be under a back-pressure of inert gas.
337. The chutes of the phosphorus furnace and the furnace hoppers shall be filled with charge material to the lower limit level to prevent the breakthrough of furnace gas. The openings and enclosures of the charging hoppers shall be kept closed at all times. Inert gas shall be continuously supplied into the sector gates in the quantity specified by the regulations.
338. The furnace service platform from which the extension of the electrodes and their loading with electrode paste are carried out shall be made of electrically insulating materials and shall not have any through metal connections in contact with earthed metal structures. In the vicinity of the platform there shall be no water-draw-off taps or any other pipelines, faults in which could lead to the flooding of the platform and a reduction in its dielectric strength. The electrodes shall be separated from one another by insulating partitions that preclude the possibility of the operating personnel touching two electrodes simultaneously. When extending the electrodes, the new casings are fastened to the crane hook through a special electrically insulating insert plate. The platform for extending the electrodes shall be kept clean by regular cleaning, or shall be blown with compressed air to preserve its dielectric properties.
339. The conveyance, storage, and extension of the electrode casings shall be carried out in accordance with a special instruction approved by the technical manager of the organisation. The conveyance and storage of electrode casings without special bands shall not be allowed. To prevent the ingress of dust and debris into the electrode housings, they shall be closed with special caps, which are removed when extending the electrodes and loading the electrode paste.
340. Under the ferrophosphorus tapholes, during the intervals between ferrophosphorus tappings, a ladle shall be installed or an emergency chute shall be provided for the discharge of ferrophosphorus into an emergency vessel or pit.
341. The discharge and cooling of ferrophosphorus shall be carried out in casting machines. In emergency cases, ferrophosphorus is discharged into emergency pits or into emergency vessels, where, after 6 hours have elapsed from the discharge, it is cooled with water in accordance with the instruction approved by the technical manager of the organisation. During the removal of ferrophosphorus from the pits, as well as during its cooling with water, the possibility of liquid ferrophosphorus from the furnace entering the pit shall be precluded. After the removal of ferrophosphorus from the pits, the presence of moisture in them shall not be permitted.
342. Under the slag tapholes, during the periodic discharge of slag into slag carriers, reserve slag carriers shall be kept available at all times in the intervals between discharges.
343. The water cooling of the casing and the furnace shall be carried out in such a way that water cannot get into the places of discharge of ferrophosphorus and slag.
344. The condition of the lining (including the temperature) of the furnace and of the near-slag and ferrophosphorus tapholes shall be constantly monitored.
345. In addition to the automatic shutdown of the furnace, provision shall be made for its manual shutdown. The procedure for shutting down the furnace in emergency cases shall be regulated by an instruction approved by the technical manager of the organisation.
346. When the electrostatic precipitators and condensers are disconnected from the electric furnace for repair, cleaning, or inspection, they shall be prepared for these works in accordance with the instruction approved by the technical manager of the organisation. The electrostatic precipitator shall be reliably isolated by blanks on the inlet and outlet sides of the furnace gas and of other services. Where it is necessary to carry out work inside the electrostatic precipitator, the latter shall be purged with inert gas and ventilated until toxic gases are completely removed from it, which shall be confirmed by a laboratory check. The presence of operating personnel on the cover of the electrostatic precipitator during its operation shall not be permitted. The covers of the electrostatic precipitators shall have guards. The doors shall be interlocked to shut down the units when they are opened.
347. Before switching on the furnace after repair carried out with its depressurisation, as well as after the opening of the "electrostatic precipitator - condenser" systems, all apparatus and gas ducts shall be purged with inert gas to an oxygen content of no more than 2 per cent.
348. With the hydraulic method of removing dust from the electrostatic precipitators, the minimum height of the hydraulic seal in the receiving tank shall be no less than 200 mm, taking into account the cone formed during the operation of the agitator.
349. The apparatus on the furnace gas line (after the condensation of phosphorus from it) shall be isolated by means of hydraulic seals. The height of the water seal is established depending on the working pressure. All hydraulic seals shall be constantly flushed with hot water.
350. Where gas blowers are present on the gas path, the gas blowers for furnace gas shall be tight and shall be heated with steam or hot water. Hot water for flushing shall be supplied to the gas blowers. The discharge of condensate and flushing water shall be carried out through a hydraulic seal.
351. To prevent the condensation of phosphorus, the electrostatic precipitators shall have heating.
352. In the upper part of the electrostatic precipitators, purge stacks shall be installed, the gate valves on which shall be kept open at all times. When the electrostatic precipitators are heated with flue gases, monitoring of the oxygen content in the heating gas shall be carried out. When the electrostatic precipitators are heated with nitrogen, automatic monitoring of the oxygen and carbon dioxide content in the nitrogen shall be carried out.
353. Inert gas shall be continuously supplied to the units of electric furnaces and electrostatic precipitators, bunkers and chutes where contact of furnace gas with air or oil is possible during operation, in accordance with the requirement of the process regulations. After each cleaning and performance of work on the "electrostatic precipitator - condenser" systems, the electrostatic precipitator shall be checked for tightness by pressure testing with inert gas, with a report drawn up.
354. In underground tanks and storage facilities, the highest level of phosphorus shall be at least 0.2 m below the planning elevation of the adjacent territory. Semi-underground tanks and storage facilities shall be recessed to a level ensuring a capacity of at least 50 per cent of the stored phosphorus and the possibility of covering it with a water layer at least 0.2 m high. Above-ground tanks shall be installed in pans whose capacity shall be at least the capacity of the largest tank plus a water layer at least 0.2 m high. In the case of placement in one pan of tanks with a total phosphorus capacity of more than 1000 t, the pan is divided into compartments. The capacity of a compartment shall also be at least the capacity of the largest tank located in it.
355. Tanks for storing phosphorus are installed in pans on foundations, the height and design of which shall ensure the possibility of inspection and repair of the bottom. The pans of the warehouse shall have reinforced waterproofing. Phosphorus storage tanks shall be arranged in no more than two rows. The clear distance between tanks shall be at least 0.5 of the diameter of the largest tank. The clear distance from the outermost tanks to the walls of the warehouse or the walls of the pan (compartment) shall be at least 1.5 m.
356. The pans (compartments) of the warehouse shall be made with slopes towards a pit for collecting possible spillages of phosphorus and water. Phosphorus-containing effluents shall be directed for neutralisation through pressure pipelines.
357. The premises of the warehouse for storing phosphorus in drums shall be divided into compartments by fire walls. The capacity of one compartment at the warehouses of enterprises producing yellow phosphorus shall not exceed 100 t; at the warehouses of enterprises consuming yellow phosphorus, the capacity of one compartment shall not exceed 50 t.
358. Drums with phosphorus shall be placed bungs up in a single tier. In each tier there shall be no more than 15 drums along the length and no more than 2 drums along the width.
359. In a yellow phosphorus warehouse, when it is stored in drums, the main passages (for conveying drums) shall be at least 1.8 m wide, and the auxiliary passages (for passage between stacks or racks of drums) shall be at least 1 m.
360. Yellow phosphorus shall be transported in a solidified state in special railway tank cars or drums, under a layer of water or non-freezing solution.
361. The draining and filling of yellow phosphorus into railway tank cars and drums shall be carried out in accordance with instructions approved by the technical manager of the enterprise.
362. Only serviceable tank cars prepared for filling shall be supplied for filling with phosphorus. Before filling tank cars with phosphorus, water or non-freezing solution with a temperature of at least 50 °C shall be poured into them, calculated so that, after the tank car is filled, above the surface of the phosphorus, to protect it from ignition, there is a layer of water or non-freezing solution at least 300 mm high and free space of at least 10 per cent of the tank car volume.
363. Phosphorus shall be displaced from tanks into railway tank cars under pressure by means of hot water or inert gas, or pumped by a pump through a siphon.
364. If faults are detected in a tank car being filled or already filled, the phosphorus shall be returned to the storage facility or an emergency vessel, and the tank car shall be washed and cleaned, after which it shall be sent for repair. Phosphorus shall be drained from such tank cars in accordance with instructions approved by the technical manager of the organisation.
365. Yellow phosphorus shall be poured into drums filled with water or non-freezing solution with a temperature of at least 50 °C. The layer of water or non-freezing solution above the phosphorus in the drums shall be at least 50 mm, and the free volume shall be at least 5 per cent of the drum volume.
366. After the drums have been filled with phosphorus, further packaging operations may be carried out only after the phosphorus has solidified.
367. Yellow phosphorus warehouses shall be provided with railway and road access routes.
368. Tanks with phosphorus in workshops consuming phosphorus shall be located in a special room (dosing section) separated from the main room by a non-combustible wall. In a production room, vessels with phosphorus with a capacity of no more than 20 m3 may be installed.
369. The capacity of the tanks in the dosing section of workshops consuming phosphorus shall not exceed the two-day requirement of the production for phosphorus. In the case where the total capacity of the dispensers does not exceed 600 t, the storage time of phosphorus in the dosing section is not limited.
370. In the phosphorus warehouse, the dosing section and the distillation section, emergency baths and self-help washbasins shall be installed.
371. To prevent phosphoric acid from entering the recirculating water supply system, monitoring of the pH of the heated water shall be provided at the discharge manifold of the heated water. When the pH value established by the process regulations is exceeded, the discharge of water into the recirculating system shall be stopped and the emergency cooler shall be switched off.
372. To prevent phosphoric anhydride from entering the workshop atmosphere, a vacuum of no more than 5 mm water column is maintained in the combustion tower.
373. In the warehouse, passages at least 1 m wide shall be provided between the stacks of bags of sulphur. The width of the main passage is at least 3 m.
374. Liquid sulphur shall be stored in thermally insulated vessels heated by steam or external electrical devices and purged with inert gas. The purge pipelines from the vessels with liquid sulphur shall be heated and shall be led out into the atmosphere by the shortest route to prevent their clogging with sulphur.
375. Railway tank cars with liquid sulphur, before emptying, shall without fail be secured on the rail track by means of special chocks and earthed.
376. Sulphur shall be drained into the vessel through a pipe lowered to the bottom of the vessel to reduce electrostatic charges and prevent intensive gas evolution during draining. Sulphur shall be poured below the level of the sulphur present in the vessel. For this purpose, a mandatory lower level of sulphur shall be established, with an audible or visual signal given when it is reached. Complete emptying of the collectors and measuring vessels of sulphur may be carried out only before cleaning and repair.
377. Vessels for storing liquid sulphur shall be installed in a pan. The volume of the pan shall be designed to receive at least one third of the stored sulphur, but not less than the capacity of one largest tank.
378. The distance between vessels with molten sulphur shall comply with the requirements of regulatory and technical documents.
379. Solidified pipelines with sulphur shall be thawed only with steam; the use of an open flame for this purpose shall be prohibited.
380. Vessels for storing liquid sulphur, as well as tank wagons for its transportation, shall be periodically cleaned of accumulated deposits and contamination.
381. Sulphur shall be released from bags in a machine specially intended for this purpose or at a manual unpacking installation equipped with local exhaust. The operation of loading sulphur into the melting hopper shall be mechanised.
382. The melting hopper shall be equipped with local exhaust. Loading the melting hopper when the ventilation is not operating shall not be permitted.
383. The design of the melting hopper shall ensure the possibility of easy cleaning of it from sludge and sediment.
384. The sulphur filtration installation, including the place for cleaning from cake, shall be equipped with a ventilation system for removing harmful emissions.
385. The filtration installation for phosphorus, as well as the separator and dirt collector, shall be equipped with a mechanical exhaust ventilation system for removing harmful emissions during filter washing and sludge discharge. The filter shall be periodically washed with hot water under pressure.
386. The synthesis reaction and the process of cooling and grinding of phosphorus pentasulphide shall be carried out in sealed apparatus in an inert gas atmosphere. The measuring vessel for phosphorus shall be provided with a device preventing water from entering the reactor.
387. The measuring vessel for sulphur shall be provided with a device ensuring the necessary residual sulphur, to prevent air from entering the reactor.
388. The reactor shall be provided with a device ensuring a guaranteed residue of product in it as a "seed".
389. The reaction shall proceed with the agitator operating and with a constant supply of inert gas.
390. The transfer of the phosphorus pentasulphide melt from the reactor to the intermediate collector shall be carried out by means of inert gas.
391. To prevent overfilling of the phosphorus pentasulphide collector and to ensure the presence of a constant guaranteed residue of product, the collector shall be provided with signalling equipment for level monitoring.
392. The length of the lines intended for conveying molten phosphorus pentasulphide shall be minimal.
393. The distance between the reactor and the phosphorus pentasulphide collector shall be at least the diameter of the largest apparatus.
394. The processing of molten phosphorus pentasulphide into flakes shall be carried out in an inert gas medium.
395. Before each start-up of the flaking machine, the oxygen content shall be monitored. When the oxygen content is above the parameters provided for by the process regulations, start-up of the system shall not be permitted.
396. The temperature of the water supplied for cooling the drum of the flaking machine shall be monitored and maintained within the limits established by the regulations.
397. The reactor, the collector for phosphorus pentasulphide and the flaking machine shall be provided with exhaust branch pipes with safety hydraulic seals ensuring the pressure inside the apparatus: (a) for the reactor and the collector - no more than 25 mm water column; (b) for the flaking machine - no more than 50 mm water column. The pipe of the hydraulic seal of the reactor exhaust branch pipe shall be provided with an automatic shut-off valve allowing the reactor to be sealed during the pressure transfer of phosphorus pentasulphide into the collector. The boxes of the hydraulic seals shall be installed in fume cupboards connected to the exhaust ventilation system.
398. Contaminated wastewater from floor washing, washing of the phosphorus filter, hydraulic seals and phosphorus vessels shall be collected in a collector and directed for treatment.
399. The equipment in the grinding and packaging section of the finished product shall be reliably protected against static electricity.
400. The bunker for phosphorus pentasulphide shall be equipped with instruments signalling its overfilling. The supply of melt to the flaking machine shall be automatically switched off when the product reaches the upper level in the bunker.
401. The mills, the bunker and the screw conveyor shall have a device for pressure equalisation.
402. Phosphorus pentasulphide shall be stored in sealed containers under a layer of inert gas. Packaging of the product may be carried out only into clean and dry drums or containers previously filled with inert gas.
403. Filling of the product into a drum or container is carried out only with the exhaust ventilation operating.
404. A drum or container shall be earthed when being filled with product.
405. Drums or containers, after filling, shall be immediately hermetically closed and removed to the warehouse.
406. Drums and containers with phosphorus pentasulphide shall be stored in dry, ventilated warehouses.
407. During the reaction for producing zinc phosphide, constant reliable monitoring of the zinc - phosphorus ratio shall be ensured.
408. Before each loading of zinc into the reactor, the condition of the reactor (the presence of cracks) shall be checked.
409. The measuring vessel for phosphorus shall be provided with a device preventing water from entering the reactor.
410. The reactor is installed only in a switched-off muffle.
411. Before dosing phosphorus, the reactor shall be thoroughly purged with inert gas for at least 5 minutes.
412. The design of the apparatus shall provide for the secure fastening of the dosing tube and the presence of a protective screen protecting against accidental discharges of phosphorus.
413. The hollow trunnion of the reactor shall be equipped with means for the suction and removal of harmful emissions generated during the loading of phosphorus and the reaction. The suction products shall be subjected to wet cleaning in a scrubber before their release into the atmosphere. Carrying out the reaction when the suction is not operating shall be prohibited.
414. Upon completion of the reaction, the reactor shall be purged with inert gas for at least 15 minutes.
415. The operations of cooling, grinding, unloading and packing of zinc phosphide shall be carried out in an inert gas atmosphere with its continuous supply and suction.
416. The packing of zinc phosphide shall be carried out in a sealed chamber with local exhaust.
417. The equipment for painting and drying cans shall be located in a separate room. Painting of cans may be carried out only with the exhaust ventilation operating.
418. Packed cans with zinc phosphide shall be stored in stacks. The height of the stacks shall not exceed three cans. The cans shall be stacked so that the upper one rests with its bottom on two cans of the lower row. The distance between stacks of cans shall be at least 0.8 m.
419. The routing of pipelines for phosphorus, phosphorus sludge, furnace gas and phosphorus-containing effluents shall be above-ground on non-combustible trestles allowing constant observation of the condition of the pipelines.
420. The outdoor trestles of pipelines for phosphorus, phosphorus sludge, phosphorus-containing effluents and furnace gas shall not pass over buildings or adjoin them, except for the entry and exit of the pipelines. These trestles may be shared with other process pipelines and steam-heat-gas pipelines subject to compliance with the following requirements: (a) the horizontal distance from the pipelines for phosphorus and phosphorus sludge to pipelines containing fire-hazardous and toxic products shall not be less than 1.5 m; (b) the pipelines for phosphorus and phosphorus sludge shall be located on the lower tier of the span structure of the trestles; the placement of other pipelines beneath them shall be prohibited; (c) the laying of phosphorus pipelines and furnace-gas pipelines in enclosed galleries of the trestle type shall not be permitted; (d) the use of the pipelines for phosphorus, phosphorus sludge and furnace gas of phosphorus furnaces as load-bearing building structures shall not be permitted.
421. The pipelines for conveying phosphorus and phosphorus sludge shall be laid with a heat-tracing companion line in common insulation.
422. The pipes for conveying sulphur shall be laid in a steam jacket. The drain pipeline from the sulphur measuring vessel to the reactor is heated by means of external electric heating.
423. The pipelines and shut-off valves for conveying molten phosphorus pentasulphide shall be equipped with electric heaters. The pipeline for phosphorus pentasulphide is divided into separate sections. Each section shall be provided with separate electric heaters with removable thermal insulation, as well as with control points for measuring temperature.
424. The off-gas pipelines to the hydraulic seals in the production of phosphorus pentasulphide shall be provided with branch connections for inspection and cleaning.
425. Laying pipelines for conveying sulphur, phosphorus and phosphorus pentasulphide through domestic, auxiliary, administrative and utility premises, switchgear, electrical switchboard rooms, control and measuring instrument rooms and ventilation chambers shall not be permitted.
426. The in-workshop pipelines shall have slopes of at least: (a) for sulphur - 0.02; (b) for phosphorus pentasulphide - 0.1; (c) for phosphorus - 0.005. The inter-workshop phosphorus pipelines laid together with other process pipelines on common trestles shall have a slope of at least 0.002 in accordance with the regulatory and technical documentation for process pipelines.
427. The flanged joints of pipelines for phosphorus, phosphorus sludge, liquid sulphur, phosphorus pentasulphide and phosphoric acid shall not be permitted to be located above doorways, main passages in workshops, roads, driveways and crossings.
428. Protective casings shall be installed on the flanged joints of pipelines with phosphorus, phosphorus-containing sludge, liquid sulphur, phosphorus pentasulphide and phosphoric acid.
429. The furnace-gas pipelines shall have branch connections for the supply of steam, inert gas and hot water. The branch connections shall have valves with plugs to exclude the possibility of air ingress. The connection of steam, inert gas and hot water shall be made by means of removable sections of pipeline or a flexible hose.
430. The pipelines for conveying phosphorus and phosphorus sludge shall be washed with hot water before and after each pumping of phosphorus. In the case of washing the pipelines from a separate system or with reused water, its connection to the pipelines may be made permanently.
431. To enable the supply of products to the workshop to be stopped, shut-off valves shall be installed at the inlet of the phosphorus and furnace-gas pipelines in the workshop room at a distance of at least 3 m from the wall of the building.
432. The inter-workshop furnace-gas pipelines shall have shut-off devices in the form of hydraulic seals designed for at least one and a half times the pressure developed by the gas blowers. The provision of manholes, hatches and inspection openings in the furnace-gas pipelines shall not be permitted.
433. The furnace-gas pipelines at their lowest points shall be heated and equipped with drainage devices with continuous removal of condensate through drain pipelines. The removal of condensate shall be carried out every 50 - 60 m. The discharge of condensate from individual sections of the gas pipelines shall be carried out through hydraulic seals.
434. The pipelines for removing condensate from furnace gas shall be laid with a heat-tracing companion line in common insulation. The drain pipelines shall be laid with a slope of at least 0.005 towards the network collectors.
435. The network condensate collectors shall, depending on climatic conditions, be located indoors or in the open air, but with their mandatory insulation and heating. The network collectors shall have devices for washing with hot water and purging with inert gas.
436. The phosphorus pentasulphide reactor shall be equipped with: (a) an interlock system excluding the possibility of supplying sulphur and phosphorus to the reactor when the reactor agitator is not operating and when the "seed" temperature is below 350 °C; (b) instruments for monitoring the temperature in the upper and lower zones of the reactor.
437. The phosphorus pentasulphide collector shall have instruments for monitoring and regulating the temperature in the collector and the heater.
438. The machine for flaking phosphorus pentasulphide shall be equipped with instruments for the automatic switching-off of the supply of phosphorus pentasulphide in the event of the stoppage of any unit of the grinding system.
439. The measuring vessels for phosphorus and sulphur in the production of phosphorus pentasulphide shall be equipped with devices for monitoring the mass of the reagents.
440. The charge level in the furnace bunkers shall not fall below the set level. The automation system shall ensure monitoring and maintenance of the level within the set limits.
441. In the production rooms of the furnace section, at places of possible release of carbon monoxide, automatic gas analysers shall be installed with signalling of the maximum permissible values of the carbon monoxide content in the air.
442. For the phosphorus combustion towers, an automatic cut-off of the phosphorus supply shall be provided in the event of an emergency stoppage of the tail fan, in the case of cessation of the spraying of the towers, a drop in the compressed-air pressure, and also in the event of an increase in the temperature of the acid or gas after the towers.
443. All smoke exhausters intended for the discharge of combustion products into the atmosphere shall be interlocked with the forced-draught fans in such a way that, when a smoke exhauster stops, the fan is automatically stopped.
444. The dosing of reagents at the wastewater treatment station shall be carried out according to the readings of automatic pH meters.
445. All collectors and bunkers shall be provided with devices for monitoring the level of the substances contained in them. In apparatus where the quantity of phosphorus received is characterised by the quantity of water displaced by it into a special vessel, monitoring may be limited to the water level in this vessel.
446. The electrical control system for the mechanisms of the flow-transport systems shall ensure: (a) electrical interlocking of all mechanisms against blockage by the conveyed substances, with the use of speed relays for the elevators and conveyors; (b) prevention of the start-up of the mechanisms during repair and preventive maintenance work on the equipment; (c) emergency shutdown of the conveyors by means of a cable connected to a switch; (d) pre-start audible signalling.
447. The production of zinc phosphide shall be equipped with instruments for monitoring the supply of phosphorus to the reactor and the temperature in the reactor.
448. This Section establishes mandatory requirements aimed at ensuring industrial safety and preventing accidents, incidents and their consequences at ammonia refrigeration plants and systems at which hazardous substances are used, stored and transported, including toxic, highly toxic and environmentally hazardous substances, as well as those capable of forming vapour-, gas- and dust-air explosion- and fire-hazardous mixtures, mandatory for all legal entities and individual entrepreneurs carrying out activities in the field of industrial safety connected with stationary refrigeration plants and systems (hereinafter - refrigeration supply systems). The relative energy potential Qv of the process blocks forming part of the refrigeration supply system shall be calculated in accordance with the general principles. Taking into account the hazardous substances handled, design decisions shall be adopted ensuring Qv < 27 (explosion hazard category III).
449. The placement of refrigeration supply systems and their circuit solutions are determined in accordance with Appendix No. 9 to the Rules.
450. Refrigeration supply systems supplied in the form of containers of full factory readiness, as well as block-supply refrigeration machines, shall be designed, manufactured and connected in accordance with the requirements for ensuring the reliability and safety of power-receiving installations, the technical regulations and the Rules. The connection of process consumers to these containers and machines, as well as their placement on the site, shall be carried out in accordance with the regulatory technical documents on the arrangement and operation of electrical installations, the technical regulations and the Rules.
451. All component parts of refrigeration supply systems falling under the technical regulation of the Customs Union "On the Safety of Equipment Operating under Excess Pressure" (TR CU 032/2013), adopted by decision of the Council of the Eurasian Economic Commission No. 41 of 2 July 2013 (hereinafter - TR CU 032/2013) (official website of the Eurasian Economic Commission http://www.eurasiancommission.org, 3 July 2013), the mandatory nature of which is established by the Treaty on the Eurasian Economic Union (Official Internet Portal of Legal Information http://www.pravo.gov.ru, 2015; 2019), belong to equipment for group 1 working media.
452. In the refrigeration supply system, devices shall be provided that prevent droplets of liquid ammonia from entering the suction cavity of the compressors, taking into account the requirements of paragraph 666 of the Rules.
453. The evaporator block for cooling the coolant shall include a device for separating liquid droplets from the vapour-liquid ammonia mixture and returning the separated liquid to the evaporator.
454. For the separation of the liquid phase from the conveyed vapour-liquid mixture in refrigeration supply systems with direct cooling, circulation (or protective) receivers combining the functions of a liquid separator shall be provided for each boiling temperature. In cases justified in the design documentation, separate liquid separators connected by pipelines to circulation (protective) receivers not combining the functions of a liquid separator may be provided for these purposes.
455. The geometric volume of circulation receivers with a riser, combining the functions of a liquid separator, for each boiling temperature in pump schemes with bottom and top supply of ammonia to the cooling devices shall be calculated using the formulas given in Appendix No. 11 to the Rules.
456. The geometric volume of protective receivers (Vz.r), combining the functions of a liquid separator, shall be calculated for each boiling temperature using the formulas: for vertical-type apparatus: Vz.r > Vs x 0.5 m3; for horizontal-type apparatus: Vz.r > Vs x 0.6 m3, where Vs is the total geometric volume of the cooling devices and process apparatus (for one boiling temperature).
457. The size of the vapour zone of a vertical vessel or apparatus performing the functions of a liquid separator shall ensure a velocity of the ammonia vapours in the cross-section of the vapour zone of no more than 0.5 m/s. For horizontal circulation (or protective) receivers combining the functions of a liquid separator, taking into account the corresponding length of the separation zone (the distance between the inlet branch pipes for the ammonia vapour-liquid mixture from the refrigeration consumers and the outlet of the vapours to the compressors), the design velocity of the ammonia vapours in the cross-section of the vapour zone may be taken as up to 1.0 m/s.
458. For the emergency (repair) draining of liquid ammonia from cooling devices, apparatus, vessels and blocks, as well as for the removal of condensate during the defrosting of cooling devices with hot vapours, a drainage receiver shall be provided, designed to receive ammonia from the apparatus, vessel or block with the largest ammonia capacity. The geometric volume of the drainage receiver shall be taken on the condition that it is filled to no more than 80 per cent.
459. The geometric volume of the linear receivers of refrigeration supply systems shall be taken as no more than 30 per cent of the total geometric volume of the cooling devices of the rooms, the ammonia part of the process apparatus and the evaporators. For refrigeration machines with metered ammonia charging, a linear receiver is not provided.
460. Additional linear receivers (receivers) for storing the annual reserve of ammonia may be provided. In this case, the receivers shall not be filled to more than 80 per cent of their geometric volume.
461. For refrigeration supply systems with a quantity of charged ammonia of up to 1000 kg, one linear receiver may be provided, the volume of which shall be designed for the annual reserve of ammonia and shall comply with the requirements of paragraphs 636 - 665 of the Rules.
462. Receivers for storing ammonia may be provided with a capacity justified by the design documentation and allowing the ammonia from one transport unit to be received.
463. In refrigeration supply systems, the use of linear receivers (non-unified) as protective, drainage or circulation receivers, and of shell-and-tube evaporators as condensers and vice versa, shall not be permitted.
464. When ammonia vapours are supplied from the high-pressure side to vessels (apparatus) on the low-pressure side for their draining of liquid ammonia and cleaning of oil, the pressure in these vessels (apparatus) shall not exceed the tightness test pressure in accordance with Appendix No. 12 to the Rules.
465. Where a heat exchanger is present on the common discharge main (for the use of the heat of the superheated ammonia vapours), a bypass line with a shut-off valve on it shall be provided.
466. Air and other non-condensable gases shall be released from the system into a vessel with water through an installed air-separator apparatus.
467. Equipment operating on ammonia may be located: in a special room - a machine room or apparatus room; in the room of the refrigeration consumers; in an open area.
468. Vertical shell-and-tube, evaporative and air condensers, and oil separators on the main discharge pipelines shall be installed in open areas. In cases justified in the design documentation, condensers may be installed above the machine rooms, and linear receivers both inside and outside the rooms.
469. The water pumps of the recirculating water supply system shall be located in a special room - a pumping station, above the building of which condensers may be installed. In cases justified in the design documentation, the recirculating water supply pumps may be placed in the same room as the refrigeration equipment (a machine room or apparatus room).
470. In the machine (apparatus) room, compressor units, block refrigeration machines, circulation (protective) receivers, intermediate vessels, ammonia pumps, oil collectors and horizontal shell-and-tube condensers shall be installed. Evaporator blocks, oil storage receivers, circulation, protective and drainage receivers, and pumps for pumping ammonia and coolant may be placed outside the machine (apparatus) room in open areas, if this is permitted by the design of this equipment established by the manufacturer (taking into account the climatic features of the locality) and by the labour protection norms. The location of placement is determined by the design documentation.
471. The clear distance from apparatus (vessels) located outside the machine (apparatus) room shall be taken as at least 1.0 m from the wall of the building. This requirement does not apply to container-type machine rooms.
472. The placement of refrigeration equipment shall not be permitted: under the trestles of process pipelines with combustible, caustic and explosive products; above the sites of open pump and compressor units, except in cases of the use of sealed (glandless) pumps or when special safety measures are taken that exclude ammonia from getting onto the equipment installed below.
473. For refrigeration supply systems that are newly constructed or reconstructed: the width of the central passageway for servicing the equipment shall be not less than 1.5 m; a passageway not less than 1.0 m wide may, in cases substantiated in the design documentation, be provided between the projecting parts of apparatus, vessels, compressor units and packaged refrigerating machines with electric motors of a power not exceeding 55 kW; the passageway between the projecting parts of free-standing compressor units and packaged refrigerating machines with electric motors of a power exceeding 55 kW shall be not less than 1.5 m (during reconstruction, 1.0 m may be permitted in cases substantiated in the design documentation); where the machinery (apparatus) room is located in premises with internal columns, a distance from the columns to the projecting parts of the equipment of 0.7 m may be permitted provided that other passageways of normal size are present.
474. For the permanent servicing of equipment (fittings) at a level higher than 1.8 m above the floor, a metal platform with railing and a stairway shall be provided. Where the length of the platform exceeds 6 m, stairways shall be provided on both sides of the platform. On one side, a vertical ladder may be used.
475. Beneath circulation receivers with pumps and beneath protective receivers, sumps (pits) shall be provided for the collection of liquid ammonia in the event of depressurisation of a vessel. When designing the sump (pit), it is necessary to proceed from the condition of obtaining the minimum surface area of the spill to reduce the evaporation of ammonia. The design level of liquid ammonia, in the event of an emergency escape of refrigerant from the most ammonia-intensive vessel into the sump (pit), shall be below the rim of the sump (the edge of the pit). The quantity of ammonia spilled from a circulation receiver shall be determined according to the working fill of the vessel, and from a protective receiver - according to the maximum permissible fill of the vessel. The depth of the pit shall be not more than 2.5 m. Pits shall have not less than two stairways, and where the depth of the pit exceeds 2 m - an exit directly to the outside.
476. Linear and drainage receivers shall be placed in a special sump. The design level of liquid ammonia, in the event of its emergency escape into the sump from the most capacious vessel, shall be below the rim of the sump. The quantity of ammonia spilled from a linear or drainage receiver shall be determined on the basis of its maximum permissible fill of 80 per cent. Linear receivers shall be protected by a canopy from the sun's rays and precipitation and shall be enclosed by a fence not less than 1.5 m high with lockable entrances.
477. For charging the system with ammonia, docking assemblies shall be provided for the connection of ammonia tank cars or cylinders.
478. In the machinery or apparatus room, the installation of an air compressor intended for the pneumatic testing of pipelines, apparatus or vessels may be provided. For this purpose, a system of stationary compressed-air pipelines shall be provided to enable the testing of each vessel, apparatus or section of ammonia pipeline. The shut-off valves on the pipelines from the compressor and for pressure relief, the control pressure gauge, and the compressor control buttons shall be located outside the premises in which the equipment is tested. A safety valve shall be installed on the compressed-air pipeline. The use of the air compressor for other purposes shall not be permitted. Pneumatic testing shall be carried out in accordance with the requirements of the federal norms and rules in the field of industrial safety establishing the industrial safety rules for hazardous production facilities at which equipment operating under excess pressure is used.
479. The design, manufacture, installation and operation of pipelines shall be carried out with account taken of the physico-chemical properties and process parameters of the media conveyed, as well as of the technical requirements for the safety of pipelines and fittings in which hazardous substances circulate, including the requirements for the selection of the material design.
480. Pipelines shall have the shortest possible length. Equipment and pipelines shall be arranged in such a way that the possibility of carrying out installation and repair work and external inspection is ensured.
481. In machinery and apparatus rooms, an upper layout (above the compressors) of the gaseous ammonia pipelines shall be provided. A lower layout (below the compressors) of these pipelines may be provided in cases substantiated in the design documentation (for example, for horizontal reciprocating compressors).
482. The laying of ammonia pipelines in horizontal walk-through or non-walk-through ducts shall not be permitted.
483. Where an upper pipeline layout is used in machinery (apparatus) rooms, the connection of the suction and discharge ammonia pipelines to the common pipelines shall be designed from above, to avoid the accumulation of oil and liquid ammonia in the pipelines (of non-operating compressors). In doing so, the suction mains shall have a slope of not less than 0.5 per cent towards the circulation or protective receivers or the liquid separators, and the discharge mains - towards the oil separators or condensers.
484. The laying of ammonia pipelines across the territory of the organisation shall be above-ground only.
485. The laying of ammonia pipelines shall not be permitted through amenity, auxiliary, administrative and utility, electrical machinery, electrical distribution or transformer premises, ventilation chambers, premises for control and measuring instruments, stairwells, or production premises classified in categories A and B in accordance with Federal Law No. 123-FZ.
486. In cases substantiated in the design documentation, ammonia pipelines may be laid together with other process pipelines. The joint laying of ammonia pipelines and power, lighting and other cables shall be carried out in compliance with the requirements for ensuring the reliability and safety of power-receiving installations, of the technical regulations and of the Rules.
487. The places where pipelines pass through the walls or floor slabs of a building shall be equipped with steel sleeves made of pipe, the internal diameter of which is 10 - 20 mm greater than the external diameter of the pipelines (taking into account the thermal insulation). The gap between the pipeline and the sleeve at both ends shall be filled with a non-combustible material permitting movement of the pipeline along its longitudinal axis.
488. Pipelines in refrigerated chambers and process premises shall be arranged in such a way that the possibility of damage by goods being moved or by vehicles is excluded.
489. The laying of ammonia pipelines along the external walls of the production part of a building with door and window openings shall not be permitted. In cases substantiated in the design documentation, the laying of these pipelines along blank walls may be permitted.
490. The laying of ammonia pipelines over buildings and structures shall not be permitted, with the exception of those parts of buildings and structures in which refrigerating and process equipment with direct cooling is located.
491. Pipelines from the cooling devices to the distribution devices shall be laid inside the refrigerated chambers, transport corridors and cargo vestibules.
492. The suction and discharge ammonia pipelines, at the sections where oil and condensate may accumulate in them, shall be equipped in the lower zone with drain valves of a nominal diameter selected on the basis of the size (diameter) of the main pipeline and taking into account the possible drainage capacity.
493. For refrigeration supply systems whose compressor design lacks built-in shut-off devices, shut-off fittings shall be installed on the suction and discharge pipelines to ensure the safety of conducting the process operations.
494. The interconnection of the ammonia pipelines of packaged refrigerating machines or of machines with metered charging shall not be permitted. This requirement does not apply to auxiliary pipelines (for the emergency discharge of ammonia from safety valves, connectors to the drainage receiver, and connections for filling and draining oil). On the auxiliary pipelines (except for the emergency discharge of ammonia vapour), one shut-off valve shall be installed at each end of the auxiliary pipeline.
495. In refrigeration supply systems, on the discharge pipelines of the compressors and on the pressure lines of pumps of all types, check valves shall be installed between the compressor (pump) and the shut-off fittings to ensure the safety of conducting the process operations.
496. On the common liquid pipeline supplying ammonia from the linear receiver (linear receivers) to the process consumers, a shut-off valve shall be installed which is controlled automatically in the event of a power failure of the refrigeration supply system equipment, to prevent the forcing of liquid ammonia to the low-pressure side.
497. In the pipeline layout, provision shall be made for the possibility of drawing off ammonia vapour from any apparatus or vessel.
498. On the pipeline for discharging oil from the oil collector, an additional pressure gauge and a shut-off valve shall be installed, positioned outside near the tank for receiving waste oil.
499. Shut-off and control fittings installed on ammonia pipelines shall be placed in locations accessible for operation and repair. Fittings shall not be placed above door openings, windows or above the passageways for servicing the equipment. The installation of ammonia fittings in refrigerated chambers shall not be permitted.
500. On all ammonia pipelines extending beyond the limits of the machinery or apparatus room to the process consumers, shut-off fittings shall be provided for the prompt cessation of the reception (supply) of refrigerant.
501. Where ammonia is supplied to the cooling devices from below, a rise of the supply pipeline to a height equal to the maximum liquid level in the cooling device shall be ensured, to prevent the draining of ammonia when the pump stops and the check valve malfunctions.
502. Where it is impossible to lay the pipelines on the sections from the cold consumers to the circulation or protective receivers without their standardised slope, a drain from the section with a non-standardised slope into the circulation or protective receivers shall be provided (in the event of a prolonged shutdown for repair).
503. The use of flexible hoses as stationary pipelines for drawing off vapour or supplying liquid ammonia shall not be permitted, with the exception of hoses forming part of factory-supplied quick-freezing apparatus. Flexible hoses shall be used for ammonia when carrying out ammonia-draining operations (when filling the system) from a tank car, and for performing auxiliary operations (freeing the pipelines, apparatus and filters of residual ammonia and oil). The connection of flexible hoses for performing auxiliary operations may be permitted only for the period during which these works are carried out. The hoses shall be connected to the pipeline by means of fittings.
504. For the process pipelines of the facilities of refrigeration supply systems, the developer of the documentation for the facility shall establish the design service life, which shall be reflected in the pipeline documentation, entered in the pipeline data sheet and taken into account when organising and carrying out activities at the hazardous production facility.
505. The layout of the ammonia pipelines shall ensure the possibility of removing liquid ammonia from any apparatus, vessel or unit into the drainage receiver.
506. The thermal insulation of pipelines and fittings shall be carried out in accordance with the design documentation.
507. Identification coloured rings shall be applied to the ammonia pipelines. The requirements for applying these rings are set out in Appendix No. 13 to the Rules.
508. The decisions taken on the placement and equipping of premises in which ammonia equipment and engineering systems are located shall be substantiated in the design documentation. Premises in which the lower explosive concentration limit may be reached upon an emergency depressurisation of the refrigeration supply system shall have protective (easily releasable) structures.
509. The premises of chambers with direct cooling may be classified in category "D" in accordance with the norms of the technical regulations if, under the process and space-planning design solutions adopted, the concentration of ammonia in the chamber air does not exceed the lower explosive limit upon an emergency opening of the cooling device or pipeline. In doing so, the piping connection of the cooling appliances shall be carried out in such a way that they are divided into separate process units with a minimum quantity of ammonia, and on the ammonia supply and outlet pipelines within the unit, fast-acting automatic shut-off fittings shall be provided which are actuated when the concentration of ammonia in the chamber air reaches 60 mg/m3.
510. The premises for the installation of distribution devices, located in the vicinity of the cold consumers, as well as the premises of production shops that are cold consumers and in whose process equipment ammonia circulates, may be classified in category "D" in accordance with the norms of the technical regulations if, under the process and space-planning design solutions adopted, the concentration of ammonia in the chamber air does not exceed the lower explosive limit upon an emergency opening of the process equipment and pipelines. In doing so, on the liquid ammonia pipelines supplying ammonia to the apparatus or distribution devices, fast-acting automatic shut-off fittings shall be installed which are actuated when the concentration of ammonia in the air of these premises reaches 60 mg/m3.
511. The distances from cold-consuming organisations at which ammonia refrigerating installations are installed and operated to other facilities outside the territory of the enterprise shall be determined in accordance with the requirements of the technical regulations.
512. The distances between buildings in which the machinery and apparatus rooms are located and other structures on the site of the cold-consuming organisation shall be substantiated in the design documentation.
513. The placement of machinery or apparatus rooms in buildings shall be substantiated in the design documentation.
514. The placement of a machinery (apparatus) room in basement and semi-basement floors shall not be permitted.
515. The placement of premises with permanent workplaces, as well as amenity and administrative premises, above the machinery and apparatus room shall not be permitted.
516. In the premises of both the machinery and the apparatus room, there shall be not less than two evacuation exits, positioned as far apart from one another as possible. At least one of the exits shall lead directly to the outside.
517. Where the machinery and apparatus rooms are located in adjacent premises separated by a partition, the exits from these premises shall comply with the requirements of paragraph 516 of the Rules, and the partition shall have an opening with doors.
518. The provision of an exit from the machinery (apparatus) room into premises of an auxiliary purpose (for example, amenity premises, the automation control station) or of another purpose (a fitter's workshop), as well as into the corridor connecting all the above-listed premises, shall be made through an air-lock vestibule, with air pressurisation, with self-closing doors without locks and with sealing gaskets around the perimeter of the door rebate. The effectiveness of these actions shall be substantiated in the design documentation.
519. All the doors of the machinery and apparatus rooms shall open towards the side of lesser danger.
520. The floors of machinery and apparatus rooms shall be level, non-slip and made of a non-combustible and non-sparking material. Non-walk-through ducts and hatches shall be covered flush with the floor by removable slabs or by ribbed metal sheets with a paint coating. The recessing of a machinery or apparatus room below the planning grade shall not be permitted.
521. Equipment for the regeneration, purification and storage of oils shall be placed in a special room having an exit directly to the outside.
522. Machinery and apparatus rooms, as well as condenser rooms and distribution devices located in premises, shall be equipped with supply-and-exhaust and emergency exhaust mechanical ventilation systems. The air exchange rate shall be determined by the design organisation.
523. The air removed may be discharged into the atmosphere without treatment.
524. Transformer substations, distribution devices, electrical switch rooms, dispatcher's rooms, operator rooms, control stations, and premises for control and measuring instruments and automation equipment (hereinafter - I&C) shall comply with the requirements for ensuring the reliability and safety of power-receiving installations, of the technical regulations and of the Rules. At facilities having two power supply sources from independent sources, the luminaires for working and emergency lighting shall be supplied from different power supply sources. For facilities having a single power supply source, the emergency lighting shall automatically switch to supply from storage batteries when the power supply source is disconnected. Machinery, apparatus and condenser rooms, the premises of refrigerated chambers and of other cold consumers, and of distribution devices shall have emergency lighting. The power supply of refrigeration supply systems shall be carried out under reliability category I or II. In doing so, the possibility of trouble-free transfer of the process to a safe state in all modes of production operation shall be ensured, including upon the simultaneous cessation of the supply of electricity from two independent mutually reserving power sources. The following are classified as category I power consumers: the systems for monitoring the gas contamination level, the emergency lighting and alarm systems of the refrigeration supply systems, including the "Person in the Chamber" system, and the power supply of the emergency ventilation. In cases substantiated in the design documentation, the provision of category I power supply may be effected through the use of mobile power stations or storage batteries.
525. Refrigerated chambers shall be equipped with a manual "Person in the Chamber" alarm system. The light and sound signals of "Person in the Chamber" shall be transmitted to a room with permanent on-duty personnel (control room, operator room, checkpoint). The illuminated "Person in the Chamber" panel shall light up on the outside above the door of the chamber in which the person is located. The devices for giving the signal from the chamber shall be placed inside on the right near the exit from the chamber at a height of not more than 0.5 m above the floor, marked with luminous indicators bearing an inscription concerning the inadmissibility of obstructing them with goods, and protected from damage.
526. Refrigerated chambers shall be equipped inside with a permanently switched-on luminaire for illuminating the exit door and with a "Person in the Chamber" alarm device (button). The luminaire shall be installed inside near the exit door on the right, above the alarm signalling button. At the entrance to the refrigerated premises (in the corridor, on the loading platform) an instruction on carrying out work in the refrigerator chambers and on protecting the cooling coils and ammonia pipelines from damage shall be posted.
527. For the manual emergency disconnection of the power supply of all the equipment of the refrigerating installation (with the exception of the ventilation electric motors), special devices (buttons) shall be installed on the outside on the wall at all the entrances to the machinery and apparatus rooms. Simultaneously with the disconnection of the power supply of the relevant equipment, these devices (buttons) shall switch on the emergency and general exhaust ventilation, as well as the light-and-sound alarm.
528. The general and emergency ventilation shall have manual start-up devices inside the ventilated premises.
529. Machinery, apparatus and condenser rooms classified as premises with explosion-hazard zone V-1b shall have building lightning-protection devices of category II, as well as protection against the secondary manifestations of lightning and protection against the introduction of high potential via above-ground and underground utilities. Inside buildings more than 100 m wide, potential-equalisation activities shall be carried out.
530. The premises of machinery and apparatus rooms, transformer substations and distribution devices, electrical switch rooms, dispatcher's stations and operator rooms (the I&C premises) shall be equipped with automatic fire alarm systems, a smoke-removal system, a warning system and other fire-prevention systems, the number and placement of which shall be substantiated in the design documentation. The supply and exhaust fans serving these premises shall be switched off upon receipt of a fire signal.
531. The system for monitoring the gas contamination level and for warning of emergency ammonia leaks (hereinafter - the gas contamination level monitoring system) shall ensure the monitoring of the gas contamination level arising from possible ammonia leaks in the premises and on the territory of the facility.
532. When using process units of explosion-hazard categories I and II: (a) the gas contamination level monitoring system shall ensure the automatic collection and processing of information on the concentration of ammonia in the air at the installation locations of the ammonia-vapour concentration detector-alarms, in a volume sufficient for the formation of the appropriate control actions; (b) the gas contamination level monitoring system, upon the occurrence of an accident involving an ammonia leak, shall automatically switch on the technical devices engaged in the system for containing and eliminating the consequences of the accident and the means for warning of the accident, and shall switch off the equipment of the refrigerating installation whose operation may lead to an increase in the scale and consequences of the accident; (c) the structure of the gas contamination level monitoring system shall be dual-loop and dual-level. The external loop shall ensure the monitoring of the gas contamination level on the territory of the ammonia refrigerating installation, with the issue of data for forecasting the spread of the chemical contamination zone beyond the territory of the facility, and the monitoring of emergency ammonia leaks from the equipment of the refrigerating installation located outside the premises. The internal loop shall ensure the monitoring of the gas contamination level and of emergency ammonia leaks in the premises. The external and internal loops of the gas contamination level monitoring system shall have two levels of monitoring of the concentration of ammonia in the air: Level I. The maximum permissible concentration (hereinafter - MPCwz) - the concentration of ammonia in the air of the working zone of the premises and outside the premises, at the installation locations of the detectors, reaches a value equal to 20 mg/m3 (MPCwz); Level II. Emergency ammonia leak - the concentration of ammonia at the installation locations of the detectors reaches a value equal to 25 MPCwz or 500 mg/m3; (d) the system shall be equipped with automatic means enabling the monitoring of the gas contamination level at the industrial site (Level I of the external monitoring loop) and the forecasting of the spread of the chemical contamination zone beyond the territory of the facility. Such equipping shall be substantiated by an assessment of the possible consequences of an accident, confirmed by the appropriate calculations. A device measuring the direction and speed of the wind, the data from which are used in the calculations of the possible scale of gas contamination, shall be installed at the site.
533. For ammonia refrigerating installations comprising process units of explosion-hazard category III: (a) the installation of ammonia-vapour concentration alarms actuated at set concentration values may be permitted. The information received from the installed alarms shall be sufficient for the formation of the control actions of the gas contamination level monitoring system specified in sub-clauses "b" and "c" of this paragraph when the set value of ammonia concentration is exceeded; (b) the gas contamination level monitoring system, when the set value of ammonia concentration is exceeded, shall ensure the automatic performance of the following actions: the switching on, in the control room (the premises of the servicing personnel), of the warning light and sound alarm and of the general ventilation in the machinery, apparatus and condenser rooms when the concentration of ammonia in the air of the working zone of these premises exceeds a value equal to MPCwz (20 mg/m3); the switching on, in the control room, of the "MPC Level Exceeded" light and sound alarm and of the emergency ventilation when the concentration of ammonia in the air of the working zone of the premises (the machinery, apparatus and condenser rooms) exceeds a value equal to 3 MPCwz (60 mg/m3); the return of all the systems to the initial state when the current concentration value falls below the level of 3 MPCwz (60 mg/m3) and MPCwz (20 mg/m3), without switching off the general ventilation; the switching on, in the control room, of the warning light and sound alarm when the concentration of ammonia in the air of the working zone at the installation locations of the detectors situated near the process units in the open area exceeds a value equal to MPCwz (20 mg/m3); the switching on, in the control room, of the "MPC Level Exceeded" light and sound alarm and of the warning system at the facility when the concentration of ammonia in the air of the working zone at the installation locations of the detectors exceeds a value equal to 3 MPCwz (60 mg/m3); the return of all the systems to the initial state when the current concentration value falls below the level of MPCwz (20 mg/m3); the switching on, in the control room, of the "Accident" warning light and sound alarm when the concentration of ammonia in the air of the working zone of the premises of the distribution devices exceeds a value equal to MPCwz (20 mg/m3), with the simultaneous switching on of the emergency ventilation of these premises; the automatic switching off of the supply of liquid ammonia to the premises of the distribution devices when the concentration of ammonia in the air of the working zone exceeds a value equal to 3 MPCwz (60 mg/m3); the switching on, in the control room, of the "Accident" warning light and sound alarm when the concentration of ammonia in the air of the working zones of the refrigerated chambers and of the premises of other cold consumers exceeds the MPCwz value (20 mg/m3); the switching off of the supply of ammonia to the monitored premises when the concentration of ammonia in them exceeds a value equal to 3 MPCwz (60 mg/m3). In doing so, in the premises of production shops with process equipment containing ammonia, the exhaust ventilation shall be switched on; the switching on, in the control room, of the "Accident" warning light and sound alarm, of the technical means of the accident containment system and of the warning system at the facility, and the switching off of the ammonia equipment when the concentration of ammonia at the installation locations of the detectors in the premises of the machinery, apparatus and condenser rooms exceeds a value equal to 500 mg/m3 (25 MPCwz); the switching on, in the control room, of the "Accident" light and sound alarm, of the technical means of the accident containment system and of the warning system at the facility, and the switching off of the ammonia equipment when the concentration of ammonia at the installation locations of the detectors near the process units and the equipment situated in the open area exceeds a value equal to 500 mg/m3 (25 MPCwz); (c) the gas contamination level monitoring system shall ensure the prompt warning, in the control room, of the specific location of the accident that has occurred and the switching on of the necessary technical means for containing the consequences of the accident.
534. The gas contamination level monitoring system, in terms of ensuring the reliability of its power supply, is classified as a category I reliability power consumer. In the absence at the facility of a second independent power supply source, automatic standby power stations equipped with storage batteries shall be used.
535. The technical characteristics, number and location of the ammonia-vapour concentration detector-alarms shall be determined by the design documentation. The composition and structure of the gas contamination level monitoring system shall be compatible with the technical means for containing and eliminating the consequences of an accident. The design of the gas contamination level monitoring system shall be accompanied by consideration of the scenarios of possible accidents and by an assessment of their consequences, confirmed by the appropriate calculations.
536. The use of measuring instruments not having documentary confirmation of the type approval of the measuring instruments and documents on the passing of verification shall not be permitted. The design of the detectors shall conform to the operating conditions. Protection against unauthorised access and against the effects of atmospheric precipitation and splashes during wet cleaning shall be provided in the design of the detectors.
537. Non-automatic (local or remote) switching on of the technical devices engaged in the system for containing and eliminating the consequences of an accident may be permitted, where substantiated in the design documentation by an assessment of the influence of this technical solution on the possible consequences of the accident.
538. Shell-and-tube apparatus, process equipment with direct cooling (quick-freezing apparatus, freezers and ice generators), as well as pressure vessels with an internal diameter of more than 150 mm, shall be equipped with safety devices against pressure exceedance. Air-cooling apparatus made of seamless pipes with an internal diameter of not more than 70 mm, with headers made of seamless pipes with an internal diameter of not more than 150 mm, may, in cases substantiated in the design documentation, be left without safety devices. In accordance with the design documentation and the documentation of the manufacturing organisation, spring safety valves and rupture-disc safety devices are used as safety devices.
539. In refrigeration supply systems with final and intermediate compressor discharge stages having a theoretical volumetric capacity of 0.025 m3/s and above, to ensure the safety of technological processes the discharge cavity of reciprocating, gear and screw liquid ammonia pumps shall be protected by installing a spring safety valve on the relevant cavity upstream of the non-return valve and the shut-off valves. Liquid ammonia from the discharge cavity stages of the pump and gaseous ammonia from the compressor discharge shall be released to the suction side of each of the specified types of equipment, and for screw compressor units it may also be released into the atmosphere in cases justified in the design documentation.
540. When selecting safety devices, the discharge capacity of self-acting safety devices installed on the cavities of the final and intermediate stages of ammonia vapour compression shall be not less than 0.9 of the mass capacity of the protected compressor or its compression stage.
541. The discharge capacity of safety devices for protecting against the destruction of vessels, apparatus and process equipment containing liquid ammonia (hereinafter in this Chapter - vessels, apparatus) shall ensure the removal of the evaporated ammonia under fire conditions. The required discharge capacity is determined by the formula: kg/s, where q is the density of the heat flux through the outer walls of the vessel or apparatus, taken in all cases as 10 kW/m2; F is the area of the outer surface of the apparatus or vessel, m2; r is the specific heat of vaporisation of ammonia at a saturation pressure 1.15 times greater than the design pressure of the protected vessel (apparatus), kJ/kg.
542. Vessels and apparatus of refrigeration systems shall be equipped with two safety valves fitted with a switching device that precludes both valves from being shut off simultaneously. Each of the valves shall be rated for the full discharge capacity. A vessel may be equipped with a single safety valve if the geometric volume of the vessel does not exceed 0.3 m3.
543. The size of the flow cross-sections of spring safety devices shall be determined in the design documentation.
544. The safety devices of vessels (apparatus) shall be set to begin opening at an excess pressure not exceeding the design pressure specified in the operational documentation of the manufacturing organisation of the vessels (apparatus). Where vessels (apparatus) with different permitted pressures are present on the suction (discharge) side of the refrigeration unit, their safety valves shall be set to begin opening at a pressure provided for in accordance with the design documentation, but not exceeding the lowest of the design pressures established for the apparatus and vessels of that side. The compressor safety valve which, on opening, connects the discharge and suction cavities (or compression stages) shall be set to open at a pressure difference in accordance with the instructions of the compressor manufacturing organisation.
545. Direct cooling systems with automatic closing of the liquid and suction valves at the cooling devices shall be equipped with safety devices. These safety devices shall be installed on the suction pipelines upstream of the shut-off valve, discharging vapours into the suction mains downstream of the shut-off valves (in the direction of ammonia flow) or into the emergency ammonia discharge pipeline. These devices shall be set to begin opening at the excess pressure permitted for the equipment used on the low-pressure side of the refrigeration unit. The discharge capacity of the safety device for air coolers on which defrosting of snow and ice deposits is carried out by means of electric heaters is determined by the formula: kg/s, where Nel is the power of the electric heaters placed on the coils of the air cooler, kW.
546. In systems with defrosting of the cooling devices by hot ammonia vapour, a safety valve shall be installed on the line for extracting these vapours downstream of the shut-off valve (in the direction of vapour flow from the extraction point to the cooling devices), which shall be set to begin opening at an excess pressure corresponding to the lowest of the design pressures of the cooling devices.
547. The discharge of ammonia vapour into the atmosphere through safety devices shall be effected by means of a pipe brought out 3 m above the ridge of the roof of the tallest building within a radius of 50 m, but not less than 6 m above the level of the site (ground) and not less than 3 m above service platforms located within a radius of 15 m. Directing the mouth of the ammonia discharge pipe downwards shall not be permitted; the pipe shall be protected against the accumulation of atmospheric precipitation. The internal diameter of the pipe carrying away the ammonia vapour shall, along its entire length, be not less than the internal diameter of the outlet branch of the safety device. The connection of safety devices to a common discharge pipe, the cross-section of which shall be not less than 100 per cent of the sum of the cross-sections for 1 to 4 discharge pipes and not less than 50 per cent of the sum of the cross-sections of the individual discharge pipes, is permitted where the number of discharge pipes exceeds four.
548. The safety devices of compressor units shall be checked for the actuation pressure (opening and closing). The intervals for checking are established by the process regulations and the operational documentation. When one of the two safety valves is removed, the valve fitting shall be switched over to the valve in service and sealed in that position. After checking and installation, the safety valves shall be sealed and a check report drawn up. The removal of safety valves for checking, their installation and sealing shall be carried out only on the instructions of the person responsible for the sound condition and safe operation of the vessels (apparatus) and in that person's presence.
549. The compressor safety valve connecting the discharge and suction cavities shall be manufactured and supplied by the compressor manufacturing plant. Replacement of the safety valve shall be carried out in accordance with the requirements of the design documentation and the documentation of the compressor manufacturing plant.
550. Monitoring, automatic and remote control systems, and automatic emergency protection systems (hereinafter - AEP), including those supplied as a set with the equipment, shall meet the requirements of the Rules, the current regulatory and technical documentation, the design documentation and the process regulations, and shall ensure the accuracy of maintaining the process parameters established in accordance with the process regulations, and the reliability and safety of operation of the refrigeration supply systems.
551. The protection rating of the electrical instruments and the automatic and remote control means located in rooms with ammonia equipment shall be not lower than IP44.
552. Ammonia compressors shall be equipped with AEP means that are actuated by the following parameters: the maximum permissible value of the discharge pressure; the maximum permissible discharge temperature; the maximum permissible minimum pressure difference in the lubrication system; the upper maximum permissible level of liquid ammonia in the apparatus or vessel from which ammonia vapours are extracted; the upper maximum permissible level of liquid ammonia in the intermediate vessel (between the compressor stages). The values of the maximum permissible parameters shall be determined in the design documentation on the basis of data from research organisations, the characteristics of the monitoring, measuring and control means, and the documentation of the equipment manufacturing organisations.
553. To protect against overpressure, standard pressure relays shall be provided which act to stop the drive electric motors of the refrigeration supply systems or ensure operations limiting the rise in pressure, but which do not eliminate the need to install safety devices on the equipment (spring safety valves, membranes rupturing in the direction of discharge).
554. Refrigeration supply systems with two or more compressors serving several evaporation systems shall be equipped with devices ensuring that all compressors are stopped when the protective liquid-level relays in the vessel (apparatus) of any system are actuated.
555. Cooling systems with a coolant shall be equipped with instruments that switch off the compressors when the movement of that coolant through the shell-and-tube evaporators ceases or when the boiling temperature of ammonia in them falls to limits leading to freezing of the coolant.
556. In compressors or units of refrigeration supply systems that have water cooling, instruments shall be installed which, to ensure the safety of technological processes, switch off these compressors or units in the absence of water flow or when the water pressure falls below the established limit. Solenoid valves that stop the water supply when the compressor stops shall be installed on the water supply pipelines.
557. Starting and operating compressors with faulty or switched-off protective automation instruments shall not be permitted.
558. When the AEP instruments are actuated, an audible and visual alarm shall be switched on automatically, and its switching off shall be manual.
559. Each of the vessels (apparatus) of the refrigeration supply system listed below shall have protection based on the liquid ammonia level: (a) the evaporator unit (shell-and-tube) - two duplicated level relays that switch off the compressors when the upper maximum permissible ammonia level is reached, with a warning alarm; (b) the circulation receiver (combining the functions of a liquid separator) and the intermediate vessel - two duplicated level relays that switch off the compressors when the upper maximum permissible ammonia level is reached, with a preliminary alarm, and also a relay for a warning alarm indicating a dangerous rise in the ammonia level; (c) the liquid separator - two duplicated level relays that switch off the compressors if the maximum permissible ammonia level in this vessel is exceeded, with a pre-emergency alarm. In installations with a metered ammonia charge, a level relay for a warning alarm may be omitted on the circulation receiver (in accordance with sub-clause (b) of this paragraph) or the liquid separator; (d) the protective receiver (combining the functions of a liquid separator) - two duplicated level relays that switch off the compressors when the maximum permissible ammonia level is reached, with a preliminary alarm, and also a relay for an alarm indicating a dangerous rise in the ammonia level and a relay for a warning alarm indicating the minimum ammonia level; (e) the line and drainage receivers - a relay for a warning alarm indicating that the maximum ammonia level has been reached, and also a relay for a warning alarm indicating the minimum ammonia level.
560. When the liquid ammonia levels in the vessels and apparatus listed in paragraph 559 of the Rules are reached, a visual alarm shall be switched on automatically, which shall be provided with lamps of the following colours: red - a signal indicating the maximum permissible level (pre-emergency alarm); yellow - a signal indicating a dangerous rise in the upper level (warning alarm).
561. The visual signals indicating liquid ammonia levels shall be accompanied simultaneously by an audible signal, the switching off of which shall be manual.
562. The feeding of the apparatus (vessels) with liquid ammonia shall be assessed by means of automatic level regulators on the low-pressure side, and in systems with a metered charge - on the high-pressure side.
563. Each of the apparatus (vessels) of the installations (machines) into which liquid ammonia is fed from the high-pressure side shall be equipped with automatic shut-off valves that stop the inflow of liquid into them when the compressors extracting vapours from the apparatus (vessels) stop. The installation of a single automatic shut-off device on the common liquid ammonia pipeline feeding several evaporation systems is permitted if the extraction of ammonia vapour from these systems is carried out by one compressor.
564. The simultaneous use of the same instrument for regulation and protection shall not be permitted.
565. The use of multipoint instruments with scanning devices as means of emergency protection shall not be permitted.
566. The electrical automatic protection instruments of refrigeration systems shall have a closed output circuit or closed contacts under the normal state of the monitored parameters, which shall open in the event of an accident or failure of the instrument.
567. The electrical circuits shall preclude the possibility of automatic starting of the compressor after the protection instruments have been actuated. Its starting shall be possible only after manual resetting of the protection.
568. The intermediate columns used for mounting the level relays of the apparatus (vessels) shall be connected above the maximum possible level of oil accumulation in these apparatus (vessels) in a manner that prevents the formation of oil pockets in the columns, and shall have a supply line (pipeline) of liquid ammonia for checking the serviceability of the level relays.
569. On the discharge and suction pipelines of each compressor, thermometer wells shall be installed (at a distance of 200 to 300 mm from the shut-off valves) with sheaths to protect the thermometers against mechanical damage. The use of mercury thermometers and mercury devices for measuring temperature at the control points of the ammonia refrigeration system shall not be permitted.
570. For ammonia refrigeration supply systems, pressure gauges and pressure-vacuum gauges intended for operation in an ammonia environment shall be used. The requirements for selecting the accuracy class, the dimensions and the installation of the measuring instruments shall comply with the requirements of the Federal Norms and Rules in the field of industrial safety establishing the industrial safety rules for hazardous production facilities at which equipment operating under excess pressure is used.
571. The use of other means of measuring and monitoring parameters is permitted in accordance with the design documentation and taking into account the documentation of the manufacturing organisations of the instrumentation.
572. To ensure the safety of technological processes in refrigeration supply systems, pressure gauges (pressure-vacuum gauges) shall be installed on the refrigeration equipment and machines: on the compressor for monitoring the working pressures of suction and discharge, in the lubrication system (where oil is supplied under pressure by a pump) and in the crankcase (of reciprocating compressors that do not have equalisation between the suction and the crankcase); on all apparatus, vessels, ammonia pumps and process equipment with direct cooling, and also on the liquid and defrosting headers of the distribution ammonia devices connected by pipelines to the equipment of the refrigeration chambers. In packaged refrigeration machines and container-type installations, the need to install pressure gauges (pressure-vacuum gauges) on the pipelines and headers shall be determined by the equipment manufacturing organisation. To ensure the safety of technological processes in a centralised system, the following shall be installed: pressure-vacuum gauges - on each suction main of the evaporation system of the refrigeration unit upstream of the liquid separator (in the direction of ammonia vapour flow); a separate pressure gauge - on the discharge pipeline of each compressor that is disconnected by shut-off valves from the common discharge main, downstream of the non-return valve (in the direction of ammonia vapour flow).
573. For visual monitoring of the liquid ammonia level in the vessels (apparatus), sight glasses shall be installed on them in accordance with the instructions of the manufacturing organisation of the vessel (apparatus). The ammonia level indicators shall be manufactured with flat corrugated and thermally toughened glasses for a pressure of up to 3.5 MPa and shall be equipped with devices for their automatic disconnection from the vessel or apparatus in the event of glass damage. The area of the viewing surface of the glasses on one side shall not exceed 100 cm2. To protect the operating personnel against injury in the event of rupture of the sight glasses on the above vessels, a protective device shall be provided.
574. The serviceability of the automatic protection instruments of ammonia compressors, and of the detectors of ammonia vapour concentration in the air of rooms and outdoor areas, shall be checked at least once a month, and the serviceability of the protective level relays on the apparatus (vessels) - once every 10 days.
575. Equipment manufactured for refrigeration supply systems shall meet the requirements of the technical regulations and the Rules.
576. Strength calculations for refrigeration equipment shall be carried out on the basis of the design pressure values Pp adopted for the relevant side of the refrigeration supply systems (low or high pressure).
577. The design pressure is determined as the maximum excess pressure that may arise in a refrigeration unit whether operating or stopped.
578. The design pressure for the equipment of refrigeration supply systems shall comply with the regulatory and technical documents, but shall be not lower than those given in paragraphs 619 to 635 of the Rules.
579. For the high-pressure side equipment of refrigeration supply systems into which ammonia vapours enter directly from the compressors, the design wall temperature shall take into account the permissible discharge temperatures of the refrigerant.
580. The values of the trial pressures for checking the strength and for setting the safety devices and the working-pressure limiting instruments shall be established depending on the values of the design pressures of the equipment in accordance with Appendix No. 14 to the Rules.
581. Refrigeration units and machines fitted with positive-displacement compressors shall have manual shut-off valves located: on the discharge and suction of the compressors; at the liquid ammonia outlet of the receivers or condensers whose design includes receiver ammonia collectors.
582. On the suction lines of compressors and pumps, removable (temporary) filter elements shall be provided which preclude the danger of foreign objects, dirt and scale entering this equipment.
583. The moving parts of the equipment shall have protective guards.
584. On vessels and apparatus whose geometric volume by the ammonia cavity exceeds 0.3 m3, liquid refrigerant level indicators (for visual monitoring) shall be installed, as well as on apparatus with headers made of pipes of DN 150 mm and above.
585. To ensure the safety of technological processes, the tightness of the flanged joints of refrigeration supply systems shall be ensured by the use of sealing surfaces of the flanged joints on the vessels and apparatus, the valves, the instruments and the pipelines.
586. Permanent joints shall be made by welding.
587. The design of the valves shall preclude complete unscrewing of the spindle. Valves with a gland seal of the spindle shall have a device that, in the fully open position, separates the gland chamber from the ammonia flow channel.
588. Vessels and apparatus of refrigeration supply systems shall be designed and manufactured in accordance with the requirements of the technical regulations. Machines and equipment, vessels and other components of refrigeration supply systems to which the technical regulations apply shall comply with the requirements of these technical regulations.
589. To ensure the safety of technological processes, compressor and compressor-apparatus units, as well as apparatus, vessels and completely supplied refrigeration machines (units, stations) forming part of refrigeration supply systems, shall be equipped with instruments and devices in accordance with the requirements of paragraphs 543 to 579 of the Rules.
590. To ensure the safety of technological processes, periodic or continuous instrument monitoring shall be established over the level of vibration and noise of the dynamic equipment of refrigeration supply systems.
591. Electric motors, electrical automation instruments and control panels forming part of refrigeration equipment sets shall comply with the requirements for ensuring the reliability and safety of power-receiving installations, the technical regulations and the Rules.
592. The documentation supplied to the consumer with the vessels and apparatus shall comply with the requirements of the technical regulations.
593. The documentation supplied to the consumer with refrigeration compressors, pumps, compressor-apparatus units, complete units (stations) and machines shall contain: (a) a data sheet (logbook) with the technical characteristics of the equipment and of the materials used for its manufacture, including data on the vibration and noise characteristics and the service life of the equipment, and also on the scope and results of the acceptance tests; (b) operating instructions, including: a technical description of the equipment; installation instructions with requirements for the foundation, the units for fastening to it, requirements for the rooms (where the equipment is located), the connections of external pipelines, the power supply and the earthing; rules for putting into operation and safe servicing; instructions for repair and the limiting wear standards of the main rapidly wearing parts.
594. The following shall be attached to the operating instructions: drawings of the equipment, the main units and the rapidly wearing parts (general view) indicating the materials of their manufacture; data sheets of the safety valves and instruments.
595. The installation of refrigeration units or their assemblies shall be carried out where design documentation is available. To ensure the safety of technological processes, the performance of installation work with deviations from the design documentation shall not be permitted.
596. To ensure the safety of technological processes, before the installation of refrigeration supply systems the conformity of the equipment (products) and materials to the working documentation according to which the installation is to be carried out, and the availability of installation instructions, shall be checked.
597. When accepting the equipment and assemblies of refrigeration supply systems for installation, their inspection and a check of completeness and technical condition shall be carried out. Products with defects shall not be permitted for installation.
598. Equipment and other products with an expired warranty period may be permitted for installation only after a set of works provided for by the documentation of the manufacturing organisation has been carried out on them. The results of the works carried out shall be entered in the data sheets (logbooks) of the equipment.
599. Equipment, products and materials shall, prior to installation, be stored in accordance with the requirements of the documentation of the manufacturing organisations. During storage, access for their inspection shall be provided, and conditions shall be created that prevent damage and the ingress of moisture and dust into the internal cavities.
600. When moving equipment, pipelines and other assemblies of refrigeration supply systems during installation work, the documentation of the equipment manufacturing organisation, the requirements of the technical regulations and the provisions of the legislation of the Russian Federation on town-planning activities shall be followed.
601. Where it is necessary to carry out welding work on vessels operating under pressure, the technical documentation for the manufacture of the vessels, the design decisions and the Federal Norms and Rules in the field of industrial safety establishing the industrial safety rules for hazardous production facilities at which equipment operating under excess pressure is used shall be followed.
602. The installation of manual gland valves with the handwheels pointing downwards shall not be permitted.
603. For solenoid valves and actuated valves, the direction of ammonia flow shall correspond to the direction indicated in the instructions of the manufacturing organisation.
604. Pipelines shall be mounted on special supports or hangers, which shall be rated for the dead weight of the pipeline, the weight of the refrigerant and the thermal insulation, taken with a safety factor of 1.2.
605. The welded joints of pipelines shall be located at a distance of not less than 100 mm from the supports and hangers for pipes with a diameter of less than 50 mm and not less than 200 mm for pipes with a diameter of 50 mm and above.
606. The thermal insulation of pipelines shall be applied, mounted or installed after the pipelines have been tested for strength and tightness and after all the defects detected during this have been eliminated.
607. Welding work on the pipelines of refrigeration supply systems shall be carried out when they are disconnected and freed of ammonia (with purging by air or inert gas) and where there is written permission for hot work and (or) gas-hazardous work from the head of the refrigeration supply system.
608. The supply of compressed air or inert gas (nitrogen) for testing (purging) apparatus and pipelines shall be carried out through a pipeline with the possibility of connecting it to the apparatus or a section of the pipeline via a valve. The apparatus, vessel or section of pipelines being tested shall be disconnected from the system using blanks.
609. When installing pipelines, standard pipeline parts (steel seamless weld-on pipeline parts) shall be used. The use of welded petal reducers shall not be permitted.
610. The devices intended to provide convenience of installation work and the safety of the workers (ladders, stepladders, scaffolding, working platforms) shall comply with the requirements of the regulatory and technical documents.
611. In modular refrigeration machines and units, including container-type ones, supplied as a set to the installation site by the manufacturing organisation, the structural arrangement of the pipelines shall be determined by the documentation of that organisation.
612. The list and content of the documentation drawn up during the installation of equipment and pipelines shall comply with the requirements of the legislation of the Russian Federation on town-planning activities.
613. When carrying out installation work in a room and on sections of an operating refrigeration system, and also under conditions of non-operating assemblies that are under ammonia or not disconnected from the rest of the system, a permit to work for this work shall be issued.
614. Vessels, apparatus and pipelines of refrigeration units shall undergo technical examination after installation prior to being put into operation, during operation, after repair or a prolonged (more than a year) shutdown, and also in the cases established by the requirements of the Federal Norms and Rules in the field of industrial safety establishing the industrial safety rules for hazardous production facilities at which equipment operating under excess pressure is used.
615. The technical examination of vessels, apparatus and pipelines consists of: external and internal inspection (where hatches are present); pneumatic tests for the strength and tightness of the vessels (apparatus) and pipelines. The pneumatic tests for the strength and tightness of the vessels (apparatus) and pipelines shall be carried out by the acoustic emission (hereinafter - AE) method or by another non-destructive testing method determined by the design documentation. When monitoring the pneumatic tests by the AE method: the loading of the vessel with pressure, the AE monitoring of the tests and the evaluation of the results shall be carried out in accordance with the requirements for organising and carrying out AE monitoring of vessels, boilers and process pipelines; the value of the test pressure at the next examination and technical diagnosis shall be determined on the basis of the permitted working pressure. In this case, the following inequality shall be satisfied: 1.05 x Prab < Pisp < 1.25 x Prab. In other cases, the test pressure shall correspond to the value specified in Appendix No. 12 to the Rules.
616. The frequency of technical examination of vessels and apparatus shall be determined taking into account the requirements of the Federal Norms and Rules in the field of industrial safety establishing the industrial safety rules for hazardous production facilities at which equipment operating under excess pressure is used.
617. The commissioning of equipment operating under pressure shall be carried out in accordance with the requirements of the Federal Norms and Rules in the field of industrial safety establishing the industrial safety rules for hazardous production facilities at which equipment operating under excess pressure is used. The examination intervals for shell-and-tube condensers and evaporators may be shortened if, in the course of work, corrosive activity or mechanical impurities with abrasive properties are detected in the cooling water or coolants.
618. The technical examination of pipelines shall be carried out at the following intervals: external inspection and testing with the trial pressure - on completion of the installation work before being put into operation; external inspection - at least once every 2 years; external inspection and testing with the trial pressure - at least once every 8 years. Where pneumatic strength tests of pipelines are applied accompanied by AE methods, the value of the recommended pressure is determined by the formula: .
619. During the technical examination of the refrigeration supply system after installation and before being put into operation, the test pressure shall be determined in accordance with Appendix No. 12 to the Rules. Using ammonia as the loading medium and an ammonia compressor as an air compressor shall not be permitted. During the next technical examination and monitoring of the tests by the AE method, gaseous ammonia may be used as the loading medium, provided that: the maximum test pressure does not exceed the permissible pressure obtained in the strength calculation (for vessels); the wall thickness of the pipeline and its elements is above the rejection thickness determined in accordance with the requirements of the regulatory and technical documents (for pipelines).
620. The procedure and intervals for the examination of refrigeration supply systems with a limited ammonia charge (not more than 50 kg) supplied complete by manufacturing organisations are established by the operational documentation of the manufacturing organisations.
621. The thermal insulation and corrosion protection means of vessels, apparatus and pipelines shall be removed where they show signs of soaking or swelling indicating the possibility of corrosion of the external surface of the item under inspection. The welded and assembly joints and the flanged connections of pipelines shall be accessible for inspection.
622. During a strength test after installation and before commissioning, the vessel (apparatus) or pipeline (or a section thereof) being tested shall be disconnected from other vessels, apparatus and other pipelines by means of metal blanks with gaskets, having tails projecting beyond the flanges by not less than 20 mm. The thickness of the blank shall be calculated for operation at a pressure 1.5 times higher than the test pressure. The use of shut-off valves to disconnect the vessel (apparatus) and pipeline being tested shall not be permitted. The locations of the blanks shall be marked with warning signs for the duration of the test. The presence of persons near them shall not be permitted. During periodic examination and technical diagnostics using the AE method and ammonia as the loading medium, individual process lines may be tested as a single block.
623. During testing, all shut-off valves installed on the vessel (apparatus) and pipeline shall be fully open and the glands sealed. Spool pieces shall be installed in place of the control valves and measuring devices. All tie-ins, nozzles and bosses for instrumentation and control devices shall be blanked off. Instrumentation and control devices not rated for the test pressure shall be disconnected.
624. The pressure during the test shall be monitored by two pressure gauges that are sealed and have undergone verification. The pressure gauges shall be of the same accuracy class, not lower than 1.5, with a body diameter of not less than 160 mm and a scale for a nominal pressure equal to 4/3 of the pressure being measured. One pressure gauge shall be installed at the pressure source (air compressor, cylinder with inert gas), and the other on the vessel (apparatus) and pipeline at the point most remote from the air compressor. When testing pipelines, the test pressure value for the discharge and suction sides shall correspond to the test pressure of the strength test of the vessels and apparatus on the same side of the pipeline. Where new equipment operates together with previously installed equipment having a lower working pressure, the test pressure value shall be taken as the lower value.
625. The pressure of the loading medium in the vessel (apparatus) or pipeline shall be raised to the test pressure at a rate of pressure rise not exceeding 0.1 MPa (1 kgf/cm2) per minute. On reaching a pressure equal to 0.3 and 0.6 of the test pressure, and also at the working pressure, the increase in pressure shall be stopped and an intermediate inspection and check of the external surface of the vessel (apparatus) or pipeline shall be carried out. The recording of AE information shall be carried out throughout the entire holding of the test object at the specified pressures.
626. The vessel (apparatus) or pipeline shall be held under the test pressure for not less than 15 minutes, after which the pressure shall gradually be reduced to the design pressure, at which an inspection of the external surface of the vessel (apparatus, pipeline) is carried out, with a check of the tightness of its seams and detachable connections using a soap solution or another method. Where the tests are monitored by the AE method, the assessment of the tightness of the welded seams and detachable connections is carried out from the readings of the instruments on the basis of an analysis of the recorded AE monitoring data.
627. Tightness tests of the entire system of vessels, apparatus and pipelines shall be carried out separately for the high- and low-pressure sides in accordance with Appendix No. 12 to the Rules. The final tightness tests shall be carried out after the temperatures of the internal and external media have been equalised over the course of several (not less than 3) hours. The duration of the tests shall be not less than 12 hours. A change in pressure, other than one caused by fluctuations in the ambient temperature, shall not be permitted.
628. The results of the strength and tightness test of the vessel (apparatus) and pipeline are deemed satisfactory if, during the tests, there have been no ruptures, visible deformations or drop in pressure on the pressure gauge, and a positive conclusion has been obtained from the results of AE monitoring or monitoring by another method accompanying the test.
629. The results of the technical examination of vessels, apparatus and pipelines, stating the permitted operating parameters, and the dates for the next technical examination shall be recorded in the data sheets of the equipment and pipelines by the person who carried out the examination.
630. After pneumatic testing and before the refrigeration unit is put into operation, it shall be evacuated for 18 hours at a residual pressure of 0.01 MPa (0.1 kgf/cm2). The pressure shall be recorded during this period every hour. The pressure may increase by up to 50 per cent during the first 6 hours. For the remaining time, the pressure shall remain constant. The pressure at which operation of the vessel (pipeline) is permitted shall be determined on the basis of the level of test pressure achieved (Ptest). If the tests were carried out accompanied by AE monitoring, the permitted pressure may not be greater than Ptest / 1.05.
631. The total quantity of liquid ammonia required for the initial charging of the refrigeration system shall be determined by the design documentation and the process regulations on the basis of a calculation of the total filling of its elements. In doing so, the filling of the internal volume of the equipment with liquid ammonia shall not exceed the following values (per cent): evaporators: shell-and-tube and vertical-tube - 80; coil-type and sheet-and-tube (panel), irrespective of the presence of liquid separators - 50; cold-chamber batteries: with top ammonia feed - 30; with bottom ammonia feed - 70; air coolers: with top ammonia feed - 50; with bottom ammonia feed - 70; condensers: shell-and-tube with a receiver part of the shell (casing) - the full volume of the receiver part of the shell (casing); shell-and-tube horizontal and vertical condensers, test, of evaporative and air cooling - 0; shells of other types - 80 per cent of the volume of the liquid-ammonia collectors; liquid separators - 0; receivers: linear - 50; circulation (vertical and horizontal, with liquid standpipes) - 15; circulation (vertical and horizontal, without liquid standpipes) - 30; protective - 0; drainage - 0; liquid-ammonia subcoolers - 100; intermediate vessels in two-stage compression units: vertical - 30; horizontal - 50; bubbling-type oil separators - 30; liquid-ammonia pipelines - 100; freezing and plate apparatus of direct cooling - 80; pipelines for the combined suction of vapours and drainage of liquid ammonia - 30. Packaged refrigeration units shall be filled with and emptied of liquid ammonia in accordance with the documentation of the manufacturing organisation.
632. The readiness of the system for charging with refrigerant shall be determined by a commission of the operating organisation after completion of the installation work and the conduct of the strength and tightness tests. The decision to charge the system shall be formalised in a report reflecting the following matters: the readiness of the general and emergency ventilation system for operation; the staffing of the organisation with trained technical personnel; the provision of personnel with personal protective equipment against chemical factors, including personal protective equipment for the respiratory organs, eyes, hands and feet, and means of providing first aid; the availability of design and process documentation and the action plan.
633. When replenishing refrigeration systems with ammonia, the quantity of liquid ammonia in the system shall not exceed the values established by the design documentation and the process regulations. The assessment of the required quantity of ammonia to be added (the assessment of the quantity of ammonia in the system) shall be carried out with the system stopped (not operating), by recording the ammonia level in the linear, circulation, drainage and protective receivers and the intermediate vessels. The degree of filling of the evaporation system shall be assessed taking into account the requirements of paragraph 631 of the Rules.
634. The ammonia shall comply with the requirements of the design documentation and the process regulations. The sampling of liquid ammonia and the checking of its quality shall be carried out through the valves of the transport tanks intended for these purposes.
635. The operation of draining liquid ammonia shall be carried out in accordance with the requirements of the federal norms and rules in the field of industrial safety that establish the rules for the safe conduct of gas-hazardous, hot and repair work.
636. The liquid-ammonia pipelines of the drainage assembly shall be equipped with pressure gauges and also with automatic devices preventing the reverse flow of liquid ammonia from the liquid-ammonia collectors of the ammonia refrigeration unit in the event of depressurisation of the removable section of the liquid-ammonia drainage pipeline.
637. The connection of a railway tank car to the stationary assemblies of the refrigeration unit shall be flexible and shall ensure the natural vertical movement of the tank car on its suspension, as well as the possibility of convenient connection of the coupling assembly and its tightness. The following types of temporary connections may be used for coupling: flexible coupling by means of a cantilever section of steel pipe 5 to 7 m long, bent in the form of an elbow or a coil; flexible metal hoses; flexible hoses of non-metallic materials; articulated swivel connections.
638. The draining of liquid ammonia from a road tanker shall be carried out through the removable pipeline of the tanker vehicle.
639. The procedure and time limits for the operation, examination and repair, and the marking of the removable flexible and articulated sections of the pipelines of the drainage point are determined in the design documentation.
640. The liquid-ammonia drainage point shall be equipped with sensors of the system for monitoring the level of ammonia gas contamination, tank-car displacement alarms, automatic systems for stopping the draining of ammonia, and stationary and mobile technical devices of the system for the containment and elimination of the consequences of an accident.
641. The residual excess pressure in the transport tanks upon their complete emptying shall be monitored and shall be not less than 0.05 MPa.
642. Work to eliminate ammonia leaks from the transport tanks at the seals of detachable connections, the closures of the valves and through-damage of the valves, and to replace the valves, shall be carried out after the pressure in the tanks has been reduced to atmospheric.
643. The area for draining liquid ammonia from railway and road tank cars shall have an asphalt or concrete surface, as well as a drainage network or a slope for moving possible spills of liquid ammonia and of the ammonia water formed during the containment and elimination of accidents involving the tank cars into special pits. The design and capacity of the pit shall preclude the free overflow of its contents into the sewerage systems and are determined in the design documentation.
644. At the drainage point, conditions shall be provided for the convenient and safe connection of the tank car to the stationary pipelines. The platform for personnel access to the valves of the transport tanks shall have a non-combustible structure convenient for carrying out routine work and for evacuation in the event of an accident.
645. In an organisation whose activity involves the receipt and dispatch of ammonia in tank cars, special instructions shall be developed governing the procedure for draining, filling, receiving, preparing and processing tank cars with ammonia. A tank car with ammonia that has arrived at the organisation shall be accepted against a report.
646. Throughout the entire time that the tank cars are on the territory of the organisation, round-the-clock monitoring of them shall be arranged.
647. A tank car with ammonia that has arrived at the organisation shall be subject to visual inspection and to a check of the presence of seals and of the serviceability and tightness of the shut-off valves. The cargo is transferred against an acceptance and transfer report and is checked for conformity with the tank car's data-sheet particulars.
648. After inspection of the tank car, a written conclusion on the condition of the tank car and the possibility of carrying out draining work shall be issued, of which a corresponding entry is made in the register of the receipt and draining of ammonia, and the mass (net, gross) and number of the tank car are noted. The register of the receipt and draining of ammonia shall be numbered, laced and sealed with a stamp.
649. Where violations of the requirements of the Rules are detected, draining ammonia from the tank car shall be prohibited. In such a case, a report shall be drawn up at the organisation and the filling organisation shall be notified thereof.
650. Before the draining of ammonia from a railway tank car begins, the locomotive shall be moved beyond the points or the guard beam. The points on the organisation's access tracks shall be set to a position that precludes the possibility of rolling stock entering, and shall be locked.
651. On the organisation's internal railway tracks that have no points, a locking safety beam shall be installed at a distance of not less than 3 m from the tank car. The wheels of the tank car on the rail track shall be secured and chocked on both sides with brake shoes. Before and during the draining, the tank car shall be fenced off with portable red signals, and a sign measuring 400 x 600 mm bearing the inscription "Stop! Passage closed. Ammonia" shall be installed. Before the draining of ammonia, the tank car shall be earthed and connected to the tank-car displacement interlock.
652. A road tanker shall be braked and chocked on both sides with brake shoes, earthed, connected to the tank-car displacement interlock and fenced off in a manner analogous to that for a railway tank car. If the positioning of a road tanker for draining is carried out in an area that directly adjoins the internal road-transport routes, then all measures shall be taken to prevent the entry of unauthorised vehicles into the hazardous area, including the barring of possible approach routes and the posting of a guard.
653. Before the ammonia draining operation, the pit intended for collecting possible spills of ammonia (ammonia water) during unloading shall be emptied, and the technical devices of the system for the containment and elimination of an accident shall be brought into working condition.
654. If the draining of ammonia is not being carried out, leaving the tank car connected to the system shall not be permitted. In the event of an interruption, the removable sections of the pipelines shall be disconnected from the tank car.
655. During the draining of ammonia from the tank car, the presence of unauthorised persons, work with fire or spark-generating tools and smoking near the tank car shall not be permitted. In the event of a fire or other abnormal situations, the personnel shall comply with the requirements of the action plans for the containment and elimination of the consequences of accidents.
656. Operations to connect the tank car to the stationary pipelines of the drainage assembly and to disconnect it shall be carried out wearing personal protective equipment against chemical factors, including personal protective equipment for the respiratory organs, eyes, hands and feet.
657. Liquid ammonia from a road tanker or railway tank car shall be forced into the refrigeration system under the action of the pressure difference in the tank car and in the receiving part of the refrigeration system. The pressure differential required for this shall be provided by first creating a vacuum in the receiving part of the system (the evaporation part, the circulation receivers) by suction of ammonia vapours by the compressor. The sufficiency of the filling of the refrigeration system shall be monitored by the ammonia level indicators in the receiving part of the system. Complete draining of ammonia from the tank car (emptying) shall be determined by the absence of any escape of liquid ammonia from the control valves of the tank car.
658. After partial or complete draining of ammonia, the tank car shall be sealed and a certificate of the quantity of ammonia in the tank car shall be drawn up for it. After completion of all work on draining ammonia, the receiving valves of the refrigeration unit shall be closed and sealed, and the entire receiving part of the unit shall be locked.
659. The preparation for draining liquid ammonia at the organisation shall be carried out under the supervision of an engineering and technical worker appointed by an order of the organisation.
660. The draining of ammonia into standby receivers shall be carried out in compliance with additional requirements: the evacuation of the standby receivers shall be carried out by compressors through liquid separators or apparatus (vessels) performing those functions; the standby receivers shall be filled to not more than 80 per cent of their geometric volume.
661. The initial starting of a compressor into operation after a prolonged shutdown, repair or maintenance, and also after a shutdown of the compressor upon the actuation of the pre-emergency protection devices, shall be performed manually with the suction valves closed, in accordance with the instructions of the manufacturing organisation. Before starting the compressor into operation, it shall be ensured that all shut-off valves on the discharge pipeline from the compressor to the condenser are open. When starting the compressor using the built-in bypass, the discharge valve of the compressor shall be closed and the bypass valve open, if this is provided for by the instructions of the manufacturing organisation.
662. The suction of ammonia vapours by compressors from the evaporators of the refrigeration unit, bypassing the liquid separator or the vessel replacing it, shall not be permitted, except for factory-made packaged machines operating separately from the main refrigeration system.
663. An ammonia leak through the gland seals of compressors, pumps or valve stems shall be eliminated immediately after it is detected. Before repair work, evacuation of the suction cavity of the compressor shall be carried out (brief operation with the suction valve closed). Next, the discharge valve is closed and the remaining ammonia is released through a rubber hose, one end of which is fitted onto a special valve located on the compressor and the other is lowered into a vessel of water, below the water level. To prevent water from entering the compressors during the release of ammonia, the pressure in the crankcase shall be monitored, without allowing the pressure to drop below atmospheric.
664. The superheat of the ammonia vapours drawn in by the compressor shall be not less than 5 °K (°C) for single-stage compressors and the high-pressure stage of two-stage compressors, and 10 °K (°C) for the low-pressure stage of two-stage compressors. This superheat is determined as the difference between the vapour temperature measured by a thermometer at the compressor suction and the boiling temperature of the ammonia. The latter is determined, for the suction pressure measured by a pressure-vacuum gauge, from the temperature scale of that instrument or from the table of saturated ammonia vapours. The upper limit of the scale of the pressure-vacuum gauge shall be not more than 1 MPa (10 kgf/cm2), the accuracy class not lower than 1.5.
665. The temperature at the points of regular monitoring of the operation of the ammonia refrigeration unit shall be determined by permanently installed, continuously operating instruments. The use of portable instruments in this case shall not be permitted. The discharge temperature shall be, for reciprocating compressors, not higher than 160 °C, for screw compressors - 90 °C, and for horizontal low-speed compressors - 135 °C, unless a different value is provided for by the instructions of the manufacturing organisation.
666. The injection of liquid ammonia into the suction pipeline (cavity) of a reciprocating compressor shall not be permitted. Screw compressors may be operated with the injection of liquid ammonia if this is provided for by the instructions of the manufacturing organisation. The installation of injection devices not provided for by the instructions of the manufacturing organisation shall not be permitted.
667. When knocking appears in the compressor, the operator shall immediately stop it and notify the senior operator thereof, recording the reason for stopping the compressor in the daily log of the operation of the machine room.
668. In the event of a decrease in superheat and a rapid drop in the temperature of the ammonia vapours discharged by the compressor, icing (an increase in the degree of icing) of the walls of the suction cavities and the appearance of other signs of wet operation (in a reciprocating compressor - a muffled knocking in the discharge valves and a drop in lubrication pressure; in a screw compressor - a change in the character of the operating noise and a drop in lubrication pressure; in a rotary multi-vane compressor - a change in the character of the operating noise and an increase in the level in the oil separator), the compressor shall be stopped immediately, after which the shut-off suction and discharge valves and the control valve shall be closed and the cause of the wet operation of the compressor shall be eliminated. Before the subsequent starting of the compressor, its suction pipeline shall be freed of any possible accumulation of liquid. When suctioning ammonia from a stopped compressor, the water shall be drained from its jackets.
669. After repair and maintenance of individual refrigeration equipment, and also after a forced shutdown of the compressor caused by disturbances in its operation, its starting into operation is carried out taking into account the requirements of paragraphs 703 to 723 of the Rules. Before starting a screw compressor that has a device for manual regulation of the amount of ammonia supply, the minimum capacity shall be set by means of this device.
670. During interruptions in the operation of the refrigeration unit in the winter period and where there is a possibility of the water freezing, it shall be drained from the cooling jackets of the cylinders and glands of the compressors, from the water pumps, closed-type condensers, subcoolers and other apparatus, and also from the water pipelines through the drain taps at the lowest points of the systems.
671. All moving and rotating parts of the equipment, including flywheels, shafts, couplings and drives, shall be enclosed by solid or mesh guards that are removable and easily dismountable. The assemblies and parts of the guard shall be secured and shall have sufficient strength and rigidity.
672. The water for cooling the compressor shall have a temperature at the inlet of not lower than 10 °C and at the outlet of the cylinder jackets of not more than 45 °C, unless other limit values are provided for by the manufacturing plant.
673. Only oils intended for them shall be used for lubricating refrigeration ammonia compressors. The grade of lubricating oil for each type of compressor shall correspond to the grade specified in the instructions of the manufacturing organisation.
674. On compressors and pumps operating in automatic mode, signs shall be posted in a conspicuous place: "Caution! Starts automatically".
675. The noise level at workplaces shall not exceed the norms set out in the current regulatory documents. In the event that the noise level exceeds the norm, measures shall be taken to reduce it.
676. The checking and running-in of ammonia compressors after installation and repair shall be performed in accordance with the documentation of the manufacturing organisation.
677. At operating cold stores that have pumpless flooded direct-cooling systems feeding the evaporation equipment through liquid separators located above it, the maintenance of the liquid-ammonia level in them shall not be permitted, owing to the danger of a discharge from the system into the suction line of the compressors when the thermal load increases. If this scheme of supplying liquid ammonia to the cooling device cannot be changed, then an additional dry liquid separator with a protective receiver, or a receiver combining the function of a liquid separator, shall be installed before the compressor.
678. The operation of an ammonia pump incorporated into the refrigeration circuit shall be carried out in accordance with the requirements of the documentation of the manufacturing organisation.
679. Before each starting of the pump, it shall be inspected, it shall be ensured that it is in serviceable condition, and this shall be confirmed by a corresponding entry in the daily log of the operation of the compressor shop.
680. Before the initial starting of an ammonia pump or after its prolonged shutdown, the valves on the suction and delivery lines shall be opened, thereby ensuring the filling of the unit (including its working cavities) with liquid refrigerant; the valve on the delivery line shall be closed as far as it will go and turned back by one to one and a half turns; and the pump shall be switched on. After the pump reaches a mode stable in delivery pressure, the value of this delivery pressure shall be adjusted by means of the valve on the delivery branch.
681. It shall not be permitted to start an ammonia pump when: the valves at its inlet and outlet are closed; the pump is incompletely filled with liquid refrigerant; the protective coupling guard is absent (for units with a clutch coupling between the pump and the electric motor).
682. The pump shall be stopped immediately if: the delivery pressure or the difference between the delivery and suction pressures has fallen (in the absence or failure of the automation devices); ammonia leaks have appeared through the unit's leaky points; faults have been detected in the pressure gauges, check valves or instrumentation and control devices.
683. Servicing of ammonia pumps shall be carried out after the complete shutdown of the unit, disconnection of the power supply, posting of signs on the starting devices and valves, and an entry in the daily log of the operation of the compressor shop.
684. Faults in the pumps associated with ammonia leakage shall be eliminated immediately.
685. The cooling of vessels and apparatus during the initial start-up after a prolonged shutdown, or preparation for examination or repair, shall be carried out at a rate of reduction of the wall temperature of not more than 30 °C per hour, to avoid deterioration of the mechanical properties of the material. Apparatus that has been freed of ammonia may be opened when the temperature of its walls is not lower than minus 35 °C.
686. Ice forming in the winter period on the spray condensers and cooling towers, and on the platforms and stairs for servicing them, shall be removed.
687. Mechanical cleaning of the condenser tubes to remove water scale shall be performed under the supervision of the shop manager, with the issuing of a permit to work and only after the condenser has been freed of ammonia. Not less than once a month, the water leaving the condenser shall be checked for the presence of ammonia.
688. The doors of separately standing apparatus rooms and condenser rooms or areas shall be kept locked.
689. When shell-and-tube evaporators are used, a coolant with a freezing temperature 8 °C below the working boiling temperature of the ammonia shall be used. When water is cooled in shell-and-tube evaporators with ammonia boiling in the inter-tube space, the boiling temperature of the ammonia shall be not lower than 2 °C. In cooling systems with an intermediate coolant, it shall be checked for the presence of ammonia not less than once a month.
690. In the absence of automatic transfer into the crankcase of the compressor, the oil from the oil separators and the apparatus of the high- and low-pressure sides shall be transferred into the oil collectors at the periodicity established by the design documentation and the manufacturing organisation. From the oil collectors, it shall be discharged at a pressure not more than 0.01 to 0.02 MPa (0.1 to 0.2 kg/cm2) above atmospheric, after the suction of ammonia vapours through the liquid-separation device. The discharge of oil from vessels (apparatus) directly into an open container, bypassing the oil collector, shall not be permitted. Pressure-vacuum gauges shall be installed on the oil collectors. The oil discharge system shall completely preclude contact of the personnel with the medium in the system. During the discharge of oil, the servicing personnel shall use a breathing apparatus and rubber gloves and shall continuously observe the discharge process.
691. During the shift, the servicing personnel on duty shall record in the daily log the main operating parameters of the refrigeration unit according to the instrument readings, remarks on the operation of the refrigeration equipment and ventilation devices, the reasons for stopping the compressors, information on the operation of the ventilation systems, the measures taken to eliminate deficiencies in the operation of the equipment, and other remarks on the operation of the equipment.
692. An apparatus (vessel) shall be withdrawn from operation in the event of: (a) an increase in pressure in the vessel above the permitted level, notwithstanding compliance with all the requirements specified in the instructions; (b) a fault in the safety valves; (c) the detection in the main elements of the vessel of cracks, bulges, leaks or sweating in the welded seams, leakage in the connections, or a reduction in the wall thickness as a result of corrosion or erosion wear beyond the minimum value established by the strength calculation; (d) the occurrence of a fire directly threatening the vessel (apparatus) under pressure; (e) a fault in the pressure gauge and the impossibility of determining the pressure by other instruments; (f) a fault in the fastening parts of the covers and manholes; (g) a fault in the liquid level indicator; (h) a fault in the instrumentation and control devices and automation equipment provided for by the design documentation; (i) leakage of ammonia from the system connected to this apparatus.
693. During the operation of refrigeration supply systems, measures shall be taken to maintain the tightness of the ammonia system. To detect the locations of ammonia leakage, chemical and other special indicators shall be used.
694. All shut-off valves on the ammonia gas discharge pipelines shall be sealed in the open position, with the exception of the main shut-off valves of the compressors. The shut-off valves on the drain pipes of the liquid separators and separating vessels shall be sealed in the open position. An entry shall be made in the daily log in respect of all cases of removal of seals and subsequent sealing of the valves.
695. The shut-off valves on the liquid pipelines between the condensers and the control station, on the permanently operating equalising liquid and gas pipelines connecting the receivers with the condensers, and on the columns for the level relays shall be sealed in the open position.
696. Where it is necessary to remove the seal from a valve on the discharge pipeline and to close it, the compressors connected to this pipeline shall be switched off. Where there are two or more discharge mains, the shut-off valves connecting them shall be sealed.
697. To avoid jamming of the shut-off valves, keeping them in the fully open position shall not be permitted. After fully opening the valve, its handwheel shall be turned back by approximately 1/8 of a turn.
698. On the panel of the control station, next to each valve, there shall be an inscription indicating which apparatus or which cooled room the given control valve serves.
699. Before tightening the bolts in flange connections, or the full or partial replacement of the gland packing of shut-off valves (without a gland non-return closure) of apparatus (vessels), the ammonia shall be completely removed from the damaged section and the section shall be disconnected from the rest of the refrigeration supply system. These operations shall be carried out wearing a breathing apparatus and gloves.
700. The stacking of loads directly against ceiling-mounted and wall-mounted ammonia batteries and air coolers, or onto the tubes of the batteries and the connecting pipelines in cold chambers, shall not be permitted. The distance from the batteries to the load stack shall be maintained in accordance with the process instructions, but shall be not less than 0.3 m.
701. During the defrosting of snow and ice deposits from cooling devices, the pressure in the batteries and air coolers shall not exceed the tightness test pressure for the apparatus (vessels) of the low-pressure side. The pressure in the batteries and air coolers shall be monitored by a pressure gauge. Before defrosting the batteries and air coolers, they shall be freed of liquid ammonia and accumulated oil, which shall be drained into the drainage (circulation) receiver, with the subsequent discharge of oil from it through the oil collector. The discharge of oil directly from the batteries and air coolers shall not be permitted. Defrosting shall be carried out in accordance with the process regulations regularly to avoid the excessive accumulation of snow and ice, which may lead to the rupture of the batteries and a loss of leak-tightness of the system.
702. Repair may be carried out either with the refrigeration system fully stopped or during its partial operation (for individual units and sections of the installation), depending on the type of equipment, the availability of a reserve, the possibility of isolating the section under repair from the rest of the installation, the scope of the repair, and the assurance of the safety of the repair work.
703. The repair of refrigeration equipment shall be carried out in accordance with a schedule. The annual and monthly repair schedules (taking into account the actual operating hours of the equipment) shall be approved by the technical manager of the organisation.
704. The organisation shall maintain documentation confirming the timeliness and quality of the repair work carried out, in accordance with the requirements of the regulatory and technical documents. The repair work shall be carried out in accordance with the requirements of the federal norms and rules in the field of industrial safety that establish the rules for the safe conduct of gas-hazardous, hot and repair work.
705. Before repair work is carried out, the section or element of the refrigeration installation to be repaired shall be closed off by valves from the rest of that installation and freed of ammonia and other substances in accordance with the documentation of the manufacturer of the refrigeration installation.
706. The section or element of the refrigeration installation freed of ammonia is additionally filled with air at atmospheric pressure. The adjacent sections (elements) of that installation containing ammonia shall be disconnected by valves and blanks. The blanks shall be numbered, shall have appropriate strength, and shall also have red-coloured handles (tails) extending beyond the flange and the insulation, for the rapid identification of their location. The handwheels of the shut-off valves shall be sealed and shall bear plates with the inscription "Do not open! Repair in progress". The actions of installing and removing the blanks shall be recorded in the log for the installation and removal of blanks, with the signature of the person who installed and removed the blank.
707. The opening of an ammonia pump at the place of operation or its dismantling shall be carried out only after the complete removal of the refrigerant from the pump. The procedure for freeing the equipment of the refrigerant shall be established in the documentation for its servicing. After the repair and maintenance of ammonia pumps, and also after their forced stoppage, the putting of the pumps into operation may be carried out only on the basis of an acceptance certificate from repair.
708. Refrigeration equipment under repair and the electrical devices associated with it shall be disconnected from the electrical networks to prevent accidental contact or unauthorised start-up.
709. The handover of equipment, pipelines or part of the refrigeration supply systems for repair shall be documented by a certificate, which shall reflect, among other things: (a) the completeness and sufficiency of the freeing of ammonia, oil, water and coolant, and also of the isolation of the section from the rest of the refrigeration supply system; (b) the measures for the complete de-energisation of the refrigeration equipment under repair; (c) the date and time of the handover for repair, stating the position, surname and signature of the person handing over and of the person receiving.
710. All repair work on the refrigeration supply systems shall be carried out with a permit to work in place, drawn up in accordance with the federal norms and rules in the field of industrial safety that establish the rules for the safe conduct of gas-hazardous, hot and repair work.
711. Within the area of the part of the refrigeration supply system under repair, warning boards and plates concerning the repair and the prohibition of entry by unauthorised persons into the repair zone shall be posted. An entry concerning the fact of being under repair shall be made in the daily log of the compressor shop.
712. The repair personnel shall have personal protective equipment and shall know the rules for its use and the measures of pre-medical aid.
713. The parts and materials used during repair for the refrigeration supply systems shall comply with the requirements of the regulatory and technical documents. The parts and materials shall be accompanied by documents confirming their conformity with technical regulations.
714. The repair of pipelines shall be carried out in compliance with the requirements of the documentation of the manufacturing organisation.
715. In the course of organising and carrying out repair work, the matters connected with the power supply of the refrigeration supply systems, lighting, the use of power tools and electrical appliances, and the repair of electrical equipment and apparatus shall be resolved taking into account the requirements for ensuring the reliability and safety of power-receiving installations, technical regulations and the Rules.
716. Persons who have been certified taking into account the requirements of paragraphs 6 and 26 of the Rules may be admitted to carrying out electric welding, gas welding and other hot work on the refrigeration supply systems.
717. The electrified tools used during the repair of the refrigeration supply systems shall comply with the requirements of the regulatory and technical documents.
718. Portable ladders and stepladders used during the repair of the refrigeration supply systems shall comply with the requirements of the norms for ensuring the safe conduct of work and with paragraph 610 of the Rules.
719. For the maintenance and repair of equipment installed in the machine, apparatus or condenser rooms, or in the process shops (in which ammonia equipment is installed), tools and appliances made of materials that preclude spark formation during operation shall be used.
720. The start-up and running-in of compressors, pumps and fans after repair shall be carried out in accordance with the documentation of the manufacturing organisation and taking into account the requirements of paragraphs 661 - 701 of the Rules.
721. Upon completion of the repair work, the readings of the newly installed monitoring, measuring and protective instruments shall be checked in accordance with the instructions of the manufacturing organisation.
722. The assessment of the quality of the repair of the equipment and the refrigeration supply systems and their admission into operation shall be carried out with the drawing up of certificates in accordance with the procedure established in the operating organisation.
723. For the purpose of the emergency disconnection of the power supply of all equipment and the working lighting, the automatic and manual disconnection of the refrigeration supply systems shall be provided for. The emergency disconnection buttons shall be mounted outside the machine (apparatus) room - one each at the working entrance and the emergency exit. Simultaneously with the stopping of the refrigeration supply system, the emergency buttons (devices) shall bring into operation the emergency and the exhaust general ventilation, as well as the audible and visual alarms.
724. For the elimination of the consequences of possible accidents, the refrigeration supply systems shall be equipped with systems and means for suppressing the evaporation and neutralising the spills of liquid ammonia, and with systems for localising and dispersing gaseous ammonia.
725. After the elimination of an accident, all participants who worked in the gas-contaminated zone shall undergo a medical examination.
726. The specific measures and technical means for the prevention, localisation and elimination of emergency situations on the refrigeration supply systems shall be determined in the design documentation and the process regulations.
727. The following process sections of oil production facilities are classified as chemically hazardous production facilities for the production of vegetable oils (hereinafter - oil production facilities): the reception, cleaning, drying, storage, production cleaning, and hulling of oil-bearing raw material; the separation of husk (chaff, hull, shell) (hereinafter - hull); the grinding of oil-bearing raw material, moisture-heat treatment, pressing, coarse cleaning of oil, storage of oil and cake, preparation of the material for extraction; extraction (with the systems of: extraction proper, the stripping of the extraction solvent (hereinafter - solvent) from the extracted material, testing, drying and cooling of the meal, distillation of the miscella, recovery of the solvent from the vapour-air mixture, recovery of the solvent from waste water), including the tanks of recirculated solvent, the tanks for the emergency emptying of the apparatus of the extraction line, the system for capturing solvent and oil from waste water, and the recirculating water supply system; the tanks for the storage of solvent with a system for draining solvent from vehicles; the tanks for the storage of vegetable oils.
728. During the design of new oil production facilities or during the technical re-equipment or reconstruction of existing oil production facilities, the following is done by the design organisation in the documentation being developed: an assessment of the explosion hazard of the process blocks is carried out; the radii of the zones by levels of hazard of possible destruction and injury to personnel are calculated; conclusions are drawn up on the effectiveness and reliability of the protective measures and means and on their ability to ensure the explosion safety of the process block and of the process facility as a whole in accordance with the norms of the technical documentation; the categories of premises, buildings and outdoor installations by explosion-and-fire and fire hazard are established; the need for and the type of a protection system by automatic fire-extinguishing and fire-detection installations are established in accordance with the fire safety norms; the requirements for electrical safety are determined; the selection of electrical equipment and electrotechnical devices by the level and types of explosion safety corresponding to the categories and groups of substances is carried out. For existing production, the explosion-hazard category of the process blocks, the radii of the destruction zones, the categories of premises, buildings and outdoor installations, and the requirements for electrical installations in explosion-hazardous and fire-hazardous zones may be determined by the developer of the documentation or by an organisation specialising in the development of documentation for similar facilities, in accordance with the requirements of the regulatory and technical documents and these Rules.
729. The procedure for conducting the process operations and work, and also the conditions for the safe operation of technical devices, are determined by the process regulations and by the technical documentation of the equipment manufacturer. The use in production of new substances (solvents, absorbents, and also oil-containing materials, for example cakes) is agreed with the specialised organisation that develops the regulatory and technical documentation for the process in which that substance is used.
730. Experimental work and the trial of new equipment and automation systems at operating explosion-and-fire-hazardous production facilities with process blocks of explosion hazard categories II and III are carried out in accordance with a one-off (experimental) process regulation developed, in accordance with the design documentation, by the organisation that is the developer of the process, and shall be agreed with the organisation operating the oil production facilities. For the conduct of the experimental work, the organisation operating the oil production facilities also develops and approves technical documentation and a plan of actions for the safe conduct of the work.
731. For explosion-and-fire-hazardous oil production facilities, measures are provided for the maximum reduction of the level of explosion hazard of the process blocks included in them, for the prevention of explosions and ignitions inside the process equipment, production premises and outdoor installations, for the prevention or limitation of the release of combustible substances into waste water in the event of an emergency loss of tightness of the equipment, and for the reduction of the severity of the consequences of possible accidents. The sufficiency of the selected measures and means for explosion-and-fire-hazardous oil production facilities is substantiated in the design documentation.
732. The values of the process parameters and of the permissible ranges of their variation, which preclude the possibility of the occurrence of hazardous deviations capable of causing an emergency situation or an accident, are established by the developer of the process and are set out in the process regulations. The methods and means that preclude the parameters from exceeding the permissible values are given in the design documentation and the process regulations. In the event of a need, substantiated in the design documentation, to conduct the process in the region of critical temperature values, measures are provided that preclude the presence of, or prevent the appearance of, sources of ignition capable of igniting the mixture of solvent vapours with air.
733. During the design, construction, operation, reconstruction, capital repair, technical re-equipment, mothballing and liquidation of oil production facilities, to avoid the occurrence of permanent and accidental destabilising factors, the conditions for stable operation are ensured, including: the supply of electric power, steam, water, compressed air and inert gas (nitrogen); the provision of a stock of raw material, regulated in the design documentation and sufficient to ensure the conditions for stable operation, and of materials (taking into account the frequency of their delivery), and also the monitoring of their quality in accordance with the requirements of the regulatory and technical documents; the provision of the production with systems for monitoring and regulating the process parameters within the specified range; the ensuring of the functioning of a reliable system of preventive maintenance of the process equipment; the timely diagnosis of the technical condition of the process equipment.
734. Process equipment in which the formation of explosive mixtures is possible is provided with systems for the supply of a phlegmatiser (nitrogen). Instead of inert gas, in places where the use of steam is permitted according to the process conditions, measures are provided that preclude the occurrence of sources of ignition.
735. The effectiveness of the purging and the exclusion of the possibility of the formation of stagnant zones are ensured by the choice of the method of supplying the phlegmatiser and by its quantity (determined by the design documentation).
736. The control of the systems for the supply of phlegmatising substances for production with blocks of categories I and II is carried out automatically, and with blocks of category III - remotely, while at relative energy potentials Qv < 10 manual local control is permitted.
737. Oil production facilities are equipped with automatic means for monitoring the parameters whose values determine the explosion hazard of the process, with the signalling of limit values and with interlock systems that prevent the occurrence of emergency situations, in accordance with paragraphs 631 - 660 of the Rules. For blocks having a relative energy potential Qv < 10, the use of automatic monitoring means and manual regulation is permitted.
738. For the purpose of excluding the possibility of the formation of explosive concentrations of mixtures of solvent vapours with air in the production premises, equipment containing solvent or miscella shall be leak-tight.
739. For the maximum reduction of the release into the environment of solvent in the form of vapours and of the liquid phase in the event of an emergency loss of tightness of the system, the following is provided in the process systems of oil production facilities: for process blocks of explosion hazard category I - the installation of automatic fast-acting shut-off and (or) cut-off devices with an actuation time of not more than 12 seconds; for process blocks of explosion hazard categories II and III - the installation of shut-off and (or) cut-off devices with remote control and an actuation time of not more than 120 seconds; for process blocks with a value of the relative energy potential Qv < 10, the installation of shut-off devices with a manual drive is permitted, whereby the minimum time for putting them into action is provided through their rational placement (the maximum permissible proximity to the operator's workplace), but not more than 300 seconds.
740. The premises of the extraction shop, of the stripping of solvent from the meal, and of distillation, and the pump rooms for pumping solvent, shall be equipped with gas detectors of pre-explosive concentrations of combustible gases, with the signalling of an exceedance of the 10 per cent level from the lower concentration limit of flame propagation.
741. The process equipment and systems of the processes of cleaning, drying, conveying, and hulling of oil-bearing raw material and of the separation of the hull (husk), grinding, warehousing and storage of oil-bearing raw material and meals shall be leak-tight. The places of possible dust release, determined by the design documentation, shall be equipped with aspiration devices sufficient in number and capacity, substantiated by the design decisions.
742. The procedure, methods and frequency of dust cleaning in the production premises are determined by the head of the organisation. It shall not be permitted to remove dust from hard-to-reach places by blowing it off with a jet of compressed air or other gas.
743. The dust content of meal dust in the premises of the warehouse and (or) the meal elevator shall be monitored with the aid of portable instruments or by inspection, with the recording of the results of the analysis (inspection) in a log.
744. The monitoring of the dust content in the air of the production premises is carried out in accordance with an approved schedule. The schedule is determined by the technical manager of the organisation. The schedule specifies the frequency of monitoring for specific production sections.
745. For the purpose of ensuring the safety of conducting the process operations, the surface of the walls is made smooth (without protrusions, hollows or roughnesses) and convenient for cleaning. The walls and ceilings are finished with a material that permits wet cleaning.
746. In the premises, for the purpose of ensuring the safety of conducting the process operations, there shall be no places that impede the visual monitoring of the presence of settled dust and its cleaning.
747. During the loading (unloading) into vehicles, and also during the transportation of oil-bearing raw material, cakes and meals, the fulfilment of the safety requirements shall be ensured.
748. All operations of unloading, loading and conveying of oil-bearing raw material, cakes and meals in the warehouse facilities shall be mechanised. The control of the conveying elements shall be performed by remote and local means and shall be equipped with automatic anti-clogging interlocks. The start-up of the conveying systems shall be preceded by the switching-on of the audible and visual alarms.
749. A conveyor located in the lower gallery of a mechanised warehouse under a bunker with a gravity discharge of oil-bearing raw material shall be equipped with remote control outside and inside the building.
750. The basement and semi-basement premises of oil-bearing raw material warehouses, and the galleries and tunnels intended for the conveying of oil-bearing raw material, shall be equipped with mechanical ventilation and lighting. Pits more than 0.5 metres deep, in which equipment for the conveying of oil-bearing raw material is placed, shall be equipped with mechanical ventilation and shall be closed with covers or fenced off. In the event of a malfunction of the ventilation of the basement and semi-basement premises of oil-bearing raw material warehouses, and of the galleries and tunnels intended for the conveying of oil seeds, and also of the pits in which equipment for the conveying of oil-bearing raw material is placed, the monitoring of their air environment for the presence of carbon dioxide shall be carried out, the content of which shall not exceed 0.5 per cent by volume, with oxygen present of not less than 20 per cent. The monitoring of the air environment in the basement and semi-basement premises of oil-bearing raw material warehouses, and in the galleries, tunnels and pits connected with the conveying of oil-bearing raw material, shall be carried out in accordance with an approved schedule. The schedule is determined by the technical manager of the organisation. The places where the release of carbon dioxide is possible shall be marked with warning signs and (or) inscriptions. For newly designed and constructed enterprises, and also for reconstructed sections of oil production facilities, the arrangement of pits, trenches and other stagnant zones shall not be permitted.
751. For inspection and repair work inside silo cells (bunkers, dump pits), a manhole of a size of not less than 500 x 500 mm, fitted with a removable grating with a cell size of not more than 100 x 100 mm and a leak-tight cover, shall be provided in the ceiling of each silo cell (bunker, dump pit). The gratings and covers of the manholes of the silo cells of the meal warehouse shall be made of non-sparking material.
752. Above all discharge openings in the bunkers, dump pits and oil-bearing raw material warehouses where the pile of oil-bearing raw material exceeds 1.5 metres (for highly volatile oil-bearing raw material), above the base of the horizontal grating, pyramidal lattice guards or other devices ensuring the safety of people shall be installed. The height of the vertical lattice guard for bunkers and dump pits is provided at not less than 0.5 metres above the level of loading of the oil-bearing raw material.
753. Elevators for the storage of oil-bearing raw material and meal shall be provided with movable winches with cradles for lowering people inside the silo cell where necessary, or, inside, for the entire depth, with stationary metal ladders (rungs).
754. To avoid self-heating and spontaneous combustion, and also hang-ups in the warehouse bunkers and the silo cells of the elevators, oil-bearing raw material shall be subjected to cleaning and drying before warehousing. The moisture content of the oil-bearing raw material during warehousing shall comply with the established norms for the corresponding type of raw material. The temperature of the oil-bearing raw material may not exceed 40 °C.
755. The temperature of the oil-bearing raw material placed into storage is monitored either automatically, with the issuing of a signal when the temperature rises above the permissible value, or remotely, by the manual switching-on of each monitored point, in accordance with an approved schedule. The schedule is approved by the technical manager of the organisation. In the event of a rise of the temperature of the oil-bearing raw material above the permissible value specified in the process regulations, active ventilation shall be applied and the transfer of the seeds from one silo (bunker) to another, from one platform to another, shall be carried out. For this purpose, a free tank (platform) shall be provided.
756. The temperature of the cake and meal placed into storage shall be checked in accordance with a schedule approved in the operating organisation, with the aid of remote stationary thermometers (temperature suspensions), taking into account the instructions of the design documentation.
757. For newly constructed elevators for meal, devices ensuring the loosening of caked meal and its mechanised unloading shall be provided.
758. The pneumatic conveying of meal from the extraction shop to the elevator is provided of the suction type. The receiving device of the pneumatic conveying system shall be located outside the extraction shop (outside the building) and shall have protection against the ingress into the pneumatic conveying system of foreign objects - stones and metallic and other mechanical impurities. The section of the conveying element before the gravity pipeline, and the gravity pipeline itself that feeds the meal into the receiver of the pneumatic conveying system, shall be open and provided with a protective grating. The meal unloader, the micro-cyclones and the meal duct shall be equipped with safety valves of the diaphragm type. In the meal unloader, the micro-cyclones and the meal duct, the necessary number of hermetically closing hatches for inspection and cleaning shall be provided.
759. For protection against static electricity during the movement of meal through the gravity pipes, through the pneumatic conveying system, and also at other production sections where it may arise, the meal shall be conditioned with respect to moisture. The pneumatic conveying system and its elements shall be earthed by the installation of electrically conductive jumpers at the places of the flange connections of the elements. The conveying elements, the pneumatic duct, the metal ladders (rungs) inside the silo cells and bunkers (in the warehouses and elevators for meal), and also other equipment in which the accumulation of static electricity charges is possible, are earthed.
760. In the event of the manual sampling of oil-bearing raw material or meal from floor-type warehouses, walkways with a lattice decking of a width of not less than 0.7 metres and with railings of a height of not less than 0.9 metres shall be arranged.
761. Entrances to floor-type warehouses (raw material or meal) shall be arranged only through doors interlocked with the electric motors of the conveyors serving the discharge gravity chutes, in such a way that, when the doors are opened, the electric motor is switched off. The subsequent start-up of the electric motor is possible only manually, after an audible and visual warning. During the movement of the discharge conveyor, a visual alarm shall operate, which is automatically switched off when the conveyor stops. The operation of warehouses without the interlocking of the doors with the electric motors of the discharge conveyors is permitted where serviceable pyramidal lattice guards are present above the discharge openings.
762. When tank cars are moved into position for discharge (loading) with the aid of a diesel locomotive, a cover of not less than four axles shall be ensured between the diesel locomotive and the tank car. Diesel locomotives shall be equipped with a spark arrester.
763. During the discharge of railway tank cars, measures shall be provided that prevent the possibility of the spontaneous movement of the tank cars under discharge, of the loss of tightness of the discharge devices and equipment, and of the release into the atmosphere of solvent and its vapours, and also measures that preclude the presence of permanent or accidental sources of ignition in the zone of possible gas contamination. Tank cars located on the tracks of the loading-and-discharge racks shall be secured with non-sparking brake shoes. The number of shoes for securing various types of tank cars is determined by a calculation of the owner of the infrastructure or of the owner of the non-public railway track, and is specified in the instruction for conducting the loading-and-discharge work.
764. Tank cars under discharge (loading) shall be earthed. For the discharge of solvent from railway tank cars, installations intended for the bottom discharge-and-loading of oil and oil products from railway tank cars are used. The use of mechanised loading-and-discharge risers with a stationary platform, a ladder and a folding gangway for servicing the neck of the tank car is permitted. The parts of the gangway that come into contact with the tank car shall have edging of non-sparking material.
765. The arriving solvent undergoes incoming inspection. The sampling of solvent from tank cars shall be carried out after the movement of the liquid in the tank car has ceased, following its stopping, in accordance with the requirements of the regulatory and technical documents.
766. The opening and closing of the hatch covers of tank cars, and also the lowering and raising of the discharge devices during the discharge and loading of solvent, shall be done carefully, allowing no impacts.
767. It shall not be permitted to use railway tank cars with solvents located on railway tracks as stationary storage (service) tanks.
768. Motor vehicles, tractors and other mechanised transport entering the territory of solvent warehouses shall be equipped with special spark arresters and fire-extinguishing means.
769. The lightning protection of loading-and-discharge devices and tanks is carried out in accordance with the requirements of the regulatory and technical documents. The loading (discharge) of solvent during a thunderstorm is not carried out.
770. Flexible hoses are used for conducting the operations of discharge and loading into railway tank cars and other non-standard equipment, and also for performing auxiliary operations (the purging of apparatus, sections of pipelines and pumps, the freeing of pipelines of residues of solvent, miscella, oil and other products). The connection of flexible hoses for performing auxiliary operations is permitted only for the period of conducting the work. The connection of the hoses to the pipelines is carried out with the aid of standard clamps.
771. Flexible hoses (including rubber and plastic ones) at explosion-and-fire-hazardous production facilities are not used as stationary pipelines for the conveying of solvent, miscella or oil.
772. The selection of hoses taking into account the properties of the conveyed product and its parameters, and also their installation and operation, and the determination of the guaranteed period of storage and operation of the hoses, are carried out in accordance with the requirements of the regulatory and technical documents.
773. During the design of loading-and-discharge racks and during the conduct of loading-and-discharge operations, measures for protection against atmospheric and static electricity shall be provided and implemented.
774. Rubber hoses with metal tips intended for loading-and-discharge operations shall have protection against static electricity. The tips of the hoses are made of a metal that does not give a spark upon impact (for example, bronze or copper).
775. Road tankers transporting solvent shall be equipped with an earthing conductor, and the exhaust pipes shall be routed under the radiator and equipped with spark arresters. Road tankers, for the duration of the discharge of solvent from them, are connected to an earthing device.
776. When filling tanks with solvent, not less than 10 per cent of free volume shall be left for the damping of the thermal expansion of the product.
777. In loading-and-discharge systems, devices and parts made of materials resistant to the pumped solvents shall be used.
778. The tanks of the main solvent storage facility shall be equipped with a level monitoring system, a breather valve and a flame arrester. The tanks of the circulating solvent storage facility and the emergency vessel shall be connected by a vapour-air mixture line to the solvent recovery system of the extraction shop.
779. During the operation of the tanks of the solvent storage facilities, continuous monitoring of the serviceability of the breather valves and flame arresters shall be carried out. Flame arresters shall be checked at least once a month, and at a temperature below 0 °C - at least once every 10 days.
780. Solvent warehouses and loading and unloading racks shall be provided with primary and stationary fire-extinguishing, alarm and communication means.
781. Before dehulling, oilseed raw material shall be cleaned of stones, metal and other mechanical impurities. The kernel - before grinding, the crushed seed material - before treatment in the cooker, and the press cake - before crushing shall be cleaned of metal impurities.
782. The grinding of oilseed raw material is carried out only when guard screens are fitted on the roller mills.
783. In the event of a sudden stoppage of the cooker, its electric motors, the electric motors of the inactivator or of the steaming-and-moistening screw conveyor and of all the conveying elements feeding the cooker shall be de-energised, and the supply of indirect steam to the cooker shall be stopped. If the duration of the cooker stoppage exceeds 1 hour, then, to prevent spontaneous combustion of the cooked meal, it shall be discharged and the vats shall be cleaned of material residues after they have cooled.
784. If a metallic knocking or grinding sound appears in the vats of the cooker, it shall be stopped immediately, the steam supply shall be stopped, and the cooker shall be freed of cooked meal by discharging it onto the floor manually in sequence, starting from the lowest vat, through the manways of the vats. After the cooker has cooled, a full inspection of the vats shall be made, paying particular attention to the possible presence of metal between the knives and the bottoms; the metal shall be removed, any possible damage shall be found and eliminated, and the cooked meal shall be processed. Monitoring of the temperature of the cooked meal is established.
785. In the event of a sudden stoppage of the screw press, the supply of cooked meal to the press feeder shall be stopped and the cone shall be squeezed out, and if the press is stopped for more than 10 minutes, the feeder and the press shall be cleaned of material.
786. If metal enters the press, the electric motor of the press and of the feeder shall be switched off immediately. After cooling, the press shall be dismantled and the metal shall be removed from it.
787. In the event of a sudden stoppage of the extraction shop, the storage of press cake in the pressing shop shall be carried out in a quantity not exceeding the working volume of the cookers. Monitoring of the temperature of the stored press cake shall be established. If the temperature of the press cake rises, it shall be moved for cooling. After the cause that necessitated discharging the press cake onto the floor has been eliminated, it shall be processed immediately. The equipping of the locations of the discharge zones is justified in the design documentation.
788. For material entering extraction, technical means for monitoring and screening out fine fractions shall be provided, except in cases justified by the design documentation. Screening out of fine fractions and their return for reprocessing shall be carried out before the material to be extracted enters the extraction shop. Return of material by the return branch of the scraper conveyor from the extraction shop to the preparation section, where they have a common wall, is not carried out, to prevent solvent vapours from entering premises of another category via the conveying elements, except in cases where the electrical equipment of the preparation section corresponds to class V-1a.
789. The temperature of the material entering extraction shall be monitored. The maximum permissible temperature value is specified in the process regulations.
790. To prevent solvent vapours from the extraction shop (category A) from entering adjacent premises of another category, the supply of the material to be extracted to the extraction shop shall be carried out in such a way that part of the conveying elements performing the supply is located outside the building, or that the requirements of paragraph 788 of the Rules regarding the design of the electrical equipment of the adjacent sections are met.
791. For newly built enterprises, the extraction shop shall be located in a separate standalone building.
792. The material to be extracted shall be cleaned of metal impurities before it enters the extractor.
793. Screw extractors shall be equipped with instruments for monitoring and regulating the rotational speed of the shafts, and belt extractors and extractors of other types that incorporate conveyors - with systems for regulating the speed of movement of the belt (conveyor) depending on the quantity of material being fed.
794. To prevent carry-over of solvent together with material from the extractor into the toaster, the installation of a petrol draw-off device - a "strainer" - shall be provided: for extractors of the "ND" type - to remove miscella from the upper zone of the extraction column into the decanter; for extractors of other types, from which the extracted material is fed into the toaster by means of the vertical "Gusak" conveyor - at the lowest point of the "Gusak". The removal of carried-over miscella shall be directed to the emergency vessel or to the first extraction stage.
795. To prevent the spread of an emergency situation from the toaster into the extractor, an airlock gate or other quick-acting shut-off devices shall be installed between them.
796. Safety valves installed on the heaters of solvent and miscella shall have a removal of the vapour-gas phase into the solvent recovery system for the vapour-air mixture. All heaters shall be provided with automatic regulators for maintaining the heating temperature.
797. The drives of extractors and toasters shall be provided with systems protecting against exceeding the maximum permissible load on the shafts, which prevent their breakage in the event of packing and seizure caused by the ingress of foreign objects.
798. To exclude the formation of explosive mixtures in extractors and miscella filters during start-up and shutdown of the extraction line, purging of their internal space with inert gas (nitrogen) shall be carried out. Steam is used as a phlegmatiser for the toaster and the distillation system. The completion of purging is determined by analysis of the composition of the purge gas or is calculated in accordance with the requirements of regulatory and technical documents. When the purge gas is analysed, the oxygen content is determined - it shall not exceed 7 per cent by volume. Purging of the extractors with inert gas shall be carried out after a gas seal has been created in their loading devices by means of the material being extracted (or meal).
799. Apparatus and pipelines containing solvent or miscella shall, upon any type of stoppage (accident, repair, preventive maintenance), be purged with nitrogen or steam after being emptied.
800. To prevent the spreading (spillage) of solvent (miscella) from the equipment of the extraction shop, the sections of the floor structures beneath the equipment (filters, extractors, miscella collectors and other equipment containing solvent or miscella) shall be made without openings, in the form of pans, and shall be bounded by a kerb at least 0.15 metres high, with removal of the spilt solvent (miscella) into the emergency vessel.
801. The vapour-air mixture from the process equipment is directed to the recovery unit for capturing solvent vapours, and the spent air after the unit, which has a temperature no higher than 40 °C, is discharged into the atmosphere.
802. Where dephlegmation apparatus cooled by brine coming from a general-plant or dedicated refrigeration unit is used for recovering solvent vapours, two circulating brine circuits through a separate heat exchanger made of stainless steel are used, to prevent solvent from entering the refrigeration unit: one closed circuit - for use in the dephlegmator, the other - connected to the refrigeration unit.
803. The processes of recovering solvent from the vapour-air mixture in systems of dephlegmators and surface condensers and by oil absorption shall be carried out under conditions that exclude the presence of ignition sources capable of igniting the mixture of solvent vapours with air.
804. When the processes of stripping solvent from the meal, and of drying and cooling the meal with air, are carried out in the sections of a single apparatus, automatic maintenance of the height of the separating layer of material shall be ensured to exclude the ingress of air from the drying sections into the solvent-stripping sections. When these processes are carried out separately, the apparatus for drying and cooling the meal shall be located outside the extraction shop or, if the apparatus for drying and cooling the meal is located in the shop, the conveying elements connecting it to the apparatus for stripping solvent from the meal shall be brought outside, beyond the shop, with transfer of the material arranged there.
805. When the vat evaporator (toaster) is stopped, to prevent possible charring of the meal in it and the occurrence of an emergency situation, the supply of indirect steam shall be shut off. Before opening the hatches of the toaster, direct steam shall be supplied to all the vats. When the toaster is unloaded, thorough cleaning of the vats of meal residues shall be carried out. Loading the vat evaporator with non-extracted material (flakes, grits) shall not be permitted.
806. The temperature of the condensate at the outlet of the condensers, as well as of the incoming and outgoing circulating water, shall be monitored in accordance with the design documentation and the process regulations.
807. The condition of the condenser tubes shall be checked according to a schedule determined by the head of the organisation, by inspection with opening of the covers, but at least once a year. In the cases established by the design documentation and by the documentation of the manufacturer, they shall be cleaned.
808. The electric motors of the process equipment and conveying elements, from the feeding of material into the extractor through to the pneumatic conveying of the meal (the screw conveyor discharging the meal from the shop), shall be equipped with interlocks in such a way that, when a conveying element or a piece of process equipment stops, all the preceding conveying elements and the equipment of the preceding stages of the technological process are switched off, with the simultaneous emission of an audible and/or visible signal.
809. Backup control of the gate valve on the steam supply main to the extraction shop shall be carried out from a safe location outside the shop.
810. Screw conveyors intended for conveying meal from the toaster (screw evaporator) within the extraction shop shall be tightly closed during operation.
811. During stoppages of the extraction line, the following shall not be permitted: switching off the forced ventilation of the shop; stopping the circulation of cooling water, brine or absorbent in the process apparatus.
812. Discharge of water from the water separator into the petrol trap without additional treatment in the sludge evaporator and cooling shall not be permitted.
813. In extraction production, monitoring shall be carried out of the moisture content in the solvent, and of the solvent content in the meal, in the oil and in the waste water discharged from the petrol trap. The frequency of monitoring of these indicators is reflected in the process regulations.
814. Pumping-out of extraction oil from the shop vessels shall be carried out after checking the flash point, which shall comply with the standard for the oil being produced.
815. Premises in which vessels for the intermediate storage of extraction oil are located are classified as category A for fire and explosion hazard.
816. The piping of pumps that pump solvent, miscella and extraction oil shall be arranged in such a way as to prevent the pumps from operating without being filled with the liquid being pumped (dry running).
817. Machines and equipment, vessels and other components of oil production facilities to which technical regulations apply shall comply with the requirements of those technical regulations.
818. For sealing the moving connections of pumps, the use of gland packings shall not be permitted. Process systems shall be leak-tight. In justified cases, the use of equipment in which, according to its data-sheet, regulated leaks of combustible substances are possible (with an indication of the permissible values of these leaks in operating mode) is permitted. The procedure for their collection and removal shall be defined in the design documentation.
819. The temperature of the outer surfaces of equipment and/or thermal insulation coatings located in the working or serviced zone of premises shall be: at a medium temperature above 100 °C - no more than 45 °C; at a medium temperature of 100 °C and below - no more than 35 °C; at a solvent-vapour flash point no higher than 45 °C - no more than 35 °C; with a metal covering layer - no more than 55 °C, for other types of covering layer - no more than 60 °C. For insulated surfaces of equipment and/or thermal insulation coatings located in the open air in the working or serviced zone, with: a metal covering layer - no more than 55 °C; other types of covering layer - no more than 60 °C.
820. For the thermal insulation of apparatus and of process pipelines for vegetable oils and miscella, non-porous non-combustible material shall be used. Measures shall be provided to protect against oil, miscella or solvent getting onto the insulation or beneath its layer. Thermal insulation products made of mineral wool or of basalt or superfine glass are used only with facings on all sides made of glass or silica fabric and beneath a metal covering layer.
821. The placement, arrangement and operation of refrigeration units and air compressor units shall be carried out in accordance with the requirements of regulatory and technical documents.
822. The placement of process equipment of fire-and-explosion-hazardous production operations shall not be permitted: above or below auxiliary premises; beneath racks of process pipelines carrying solvent. During design, the necessary space shall be provided for shaft withdrawal during repairs of screw extractors, dryers and vat evaporators.
823. For servicing equipment that requires the presence or movement of persons working above floor level, stationary platforms and stairs to them shall be provided. The arrangement of the platforms and stairs shall be carried out in accordance with the requirements of regulatory and technical documents. Platforms located at a height of 0.8 metres or more above floor level, open pits, and also open installation openings shall have railings around the perimeter at least 1.0 metres high. At a height of 0.5 metres from the floor (platform), the railings shall have an additional longitudinal guard rail. The vertical posts of the railings shall have a spacing of no more than 1.2 metres. The decking of the platforms shall have a continuous toe board at least 0.15 metres high.
824. Bucket elevators shall be equipped with an electrical interlock that provides automatic switching-off of the electric motor when the bucket elevator is overloaded.
825. Bucket elevators shall be equipped with a device preventing reverse travel of the belt and chain. The buckets of meal bucket elevators shall be made of non-sparking material.
826. The design, the arrangement of protective devices and the placement of conveyors shall comply with the requirements of regulatory and technical documents.
827. The connection of the electrical equipment of movable conveyors to the distribution box and to the earthing devices shall be carried out under a written order from the shop (section) manager and shall be performed by a person authorised for the specified work.
828. The troughs of screw and scraper conveyors shall be closed with solid covers or with gratings with a mesh size no larger than 100 x 100 mm. The covers shall be strong and tightly closing; depending on the operating conditions, they may be hinged on hinges or pivots. In locations where required by the process, replacement of the solid cover of the conveyors with rigidly fixed gratings is permitted.
829. Screw conveyors that rise above the floor shall be equipped with crossover walkways with railings.
830. The bearing assemblies of screw feeders, belt conveyors, bucket elevators, scraper conveyors, shafts, screw conveyors and the agitators of extractors and toasters shall be located outside the zone into which the products being moved may enter and accumulate, or shall have protection against the ingress of these products into them.
831. Equipment processing dust-generating products shall be equipped with local exhausts, which are made in accordance with the design documentation. Aspiration systems built into the equipment shall be interlocked with the starting device of the equipment.
832. To exclude the possibility of overfilling with solvent, miscella or oil in the event of failure of the automatic devices, the vessel equipment of the extraction shop, including the decanter of the screw extractor, shall be provided with an overflow pipeline that has no shut-off devices and is fitted with a sight glass. Excess solvent, miscella and oil shall be directed into the emergency vessel.
833. The upper part of extractors of all types shall be connected to a self-contained condenser for removing the vapour-gas phase, which, in turn, shall be connected to the common solvent recovery system. A multiple-spray extractor shall be maintained under a vacuum in the range of 0.05 - 0.10 kPa (5 - 10 mm water column), which is monitored by a pressure-vacuum gauge. The gas duct for removing the vapour-gas phase from the extractor volume shall have a sight glass, shall be laid with a slope towards the condenser, and shall be assembled on flanged connections necessary for periodic inspection of the pipeline. The pressure-vacuum gauge shall be installed directly on the extractors, with the vacuum readings brought out to the control console.
834. All types of water separators shall be provided with hydraulic seals, in addition to the existing pipeline connected to the common gas-air system, for relieving excess pressure. For each type of water separator, the hydraulic seal is calculated and selected by the design organisation.
835. Pumps that pump solvent (miscella) shall be equipped with automatic safety systems. Operation of a pump without priming with the liquid being pumped shall not be permitted.
836. The gas duct connecting the toaster and the wet meal trap shall have: a slope towards the wet meal trap of at least 2 cm per 1 linear metre of the gas duct pipe; hatches at the ends for inspection and cleaning of the internal surface; a steam supply for steaming the gas duct and the meal trap before opening them for inspection or repair.
837. The design of heat-exchange apparatus (condensers, heaters, distillers, desorbers) shall exclude the possibility of mutual penetration of steam (water) and the heated (cooled) product, except for equipment where this is provided for by the process, for example, mixing condensers.
838. A miscella filter shall be equipped with: a pressure gauge for measuring the pressure of the liquid being filtered; a safety valve with removal of miscella to the unfiltered-miscella collector, which has an overflow pipe to the emergency vessel (the safety valve and the pressure gauge are installed directly on the filter); a sight glass on the discharge pipe of the filtered miscella; a branch connection for sampling; a branch connection with a pressure gauge for purging the filter with inert gas. Disc filters shall be equipped with a device for washing off the settled sludge with solvent.
839. Pipes for removing the vapour-gas phase with traces of solvent from the extraction shop shall be equipped with flame arresters installed inside the heated building in a location convenient for servicing. Installation of a shut-off device on the extraction pipe of a dephlegmator, condenser or absorber shall not be permitted, except in cases where the extraction pipe is equipped with a steam ejector or a fan. The hermetically sealing hatch of the exhaust pipe of a dephlegmator, condenser or absorber, intended for taking samples and measuring the velocity of the vapour-air medium, shall be located in an accessible place.
840. On the cyclone meal discharger, the microcyclones and the pneumatic conveying line there shall be the necessary number of hermetically sealing hatches for inspection, examination and cleaning.
841. Guards for coupling connectors, for the pulleys of the electric motors of petrol and miscella pumps and for other equipment installed in premises of categories A and B shall be made of non-sparking materials.
842. Safety valves installed on apparatus (vessels) and pipelines not containing liquid solvent or miscella shall be provided with removal of the vapour-gas phase into the atmosphere at a safe location.
843. Pipelines for solvent, miscella and solvent vapours shall be made in compliance with the requirements for the design and safe operation of process pipelines.
844. The placement of process pipelines carrying solvent (miscella) or oil on racks, on the platforms of outdoor installations and in premises shall be carried out taking into account the possibility of performing visual monitoring of their condition, of performing servicing and repair work and, if necessary, of replacing the pipelines.
845. The length of an individual pipe (section) of a dismantled pipeline shall be such that, with the existing arrangement of apparatus and of window and door openings, the pipe can be freely carried out of the premises.
846. Pipelines shall have numerical designations adopted for the marking of pipelines, and distinctive colouring applied in accordance with the requirements of regulatory and technical documents. Arrows indicating the directions of their rotation shall be applied to the handwheels or handles of the valves and fittings.
847. Underground laying of solvent and miscella pipelines shall not be permitted, except in cases where this process necessity is justified by the design documentation. Flanged connections shall not be permitted on buried sections of solvent and miscella pipelines.
848. When laying pipelines through the building structures of buildings and other obstacles, measures shall be taken to exclude the possibility of transferring additional loads to the pipes (for example, installation of sleeves and casings), with sealing made of non-combustible materials.
849. Laying of pipelines for conveying solvent (miscella) through domestic, auxiliary and administrative-and-utility premises, electrical distribution devices, rooms of automation panels and consoles, and ventilation chambers, and also through production premises with a fire-and-explosion-hazard category and a premises (zone) class lower than those of the extraction shop, shall not be permitted.
850. On pipelines supplying direct steam to apparatus for solvent stripping, steaming and sparging (not excluding toasters, sludge evaporators, distillers and absorbers), a check valve and a shut-off valve, a reducing valve and a safety valve (with a pressure gauge) shall be installed. The location for installing the reducing valve and the safety valve (with a pressure gauge) is determined in the design documentation.
851. Flanged connections shall be provided only at the locations for installing valves and fittings or connecting pipelines to apparatus, and also on sections where, under the process conditions, periodic dismantling is required for cleaning and repair of the pipelines.
852. Flanged connections shall be located in places that are open and accessible for visual observation, servicing, dismantling, repair and installation. Locating flanged connections of pipelines carrying solvent (miscella) or oil above places of constant passage of people and above working platforms shall not be permitted.
853. The required degree of tightness of a detachable connection throughout the period between overhauls of the process system shall be ensured by the design of the seal, the material of the gaskets and the installation of the flanged connections.
854. In the extraction shop, steel valves and fittings resistant to the corrosive action of solvent (miscella) under its operating conditions shall be used. In cases where equipment and pipelines are protected with corrosion-resistant non-metallic coatings, their use shall be justified. The use of equipment and pipelines made of corrosion-resistant non-metallic materials, including composite materials, is permitted subject to appropriate justification confirmed by the results of studies, and the development of safety measures.
855. Subject to appropriate justification, the use of valves and fittings made of cast iron and of non-metallic structural materials, within the pressure and temperature limits specified in the technical specification, is permitted in process units of category III having Qv < 10.
856. Shut-off valves installed on the discharge and suction pipelines of pumps shall be located as close as possible to the pumps and shall be in a zone convenient for servicing. To exclude the possibility of solvent (miscella) moving in the reverse direction, a check valve shall be installed on the discharge line of the pumps.
857. Hatches and gate valves on the transfer chutes (extractor, meal solvent evaporator) shall be made of non-ferrous non-sparking metal.
858. When control valves with remote control are used as shut-off devices, backup manually operated shut-off valves shall be provided.
859. The use of cast-iron plug cocks as anti-emergency fittings or backup fittings shall not be permitted.
860. New or repaired safety valves shall be checked for tightness and adjusted on a test bench: those installed on vessels operating at a pressure above 0.07 MPa (0.7 kg/cm2) shall comply with the requirements established for the design and safe operation of vessels operating under pressure; those installed on vessels operating at a pressure up to and including 0.07 MPa (0.7 kg/cm2) - for the start of opening at a pressure no more than 0.07 MPa (0.7 kg/cm2) and for tightness.
861. The selection of monitoring, control and PAZ systems, as well as of SiO, by reliability, response speed, permissible error of the measuring systems and other technical characteristics shall be carried out in accordance with the requirements of the Rules, the current regulatory and technical documentation and the documentation for the chemically hazardous production facility.
862. The frequency of work (schedules for monitoring air dustiness in production premises, for dust removal and for measuring the temperature of stored substances (for example, oilseed raw material, meal)) is approved by the organisation operating the hazardous production facility.
863. The placement of electrical means and of the elements of monitoring, control and PAZ systems, as well as of communication and alerting systems, in the explosion-hazardous zones of production premises and outdoor installations, and the degree of their explosion protection, shall comply with the requirements of regulatory and technical documents.
864. In explosion-hazardous premises, in the process control room and outside, in front of the entrance doors, an audible and visible alarm device for gas contamination of the air environment shall be provided.
865. Automatic monitoring and control systems for technological processes shall provide: continuous monitoring of the parameters of the technological process and control of the operating mode to maintain their regulated values; alarm and real-time recording of deviations of the main process parameters, including those determining the safety of the process; alarm and real-time recording of the actuation of PAZ facilities; continuous monitoring, recording of deviations and alarm of the state of the air environment within the facility, in accordance with paragraphs 879 and 880 of the Rules; operation of control and PAZ facilities that stop the development of hazardous situations; control of trouble-free start-up, shutdown and all the switching operations necessary for this.
866. The automated process control system (APCS) based on computer technology shall comply with the requirements of the Rules, the current regulatory and technical documentation, the designs and the process regulations, and shall ensure the specified accuracy of maintaining the process parameters, the reliability and safety of the technological processes and the performance of the functions specified in paragraph 865 of the Rules, and also: recording of the actuation and monitoring of the operable state of PAZ facilities; continuous analysis of the change of parameters towards critical values and forecasting of a possible accident; operation of the means for containing the emergency situation and selection and implementation of optimal control actions; provision of information on the state of safety at the facility to the higher-level control system.
867. In control rooms, visible and audible alarms shall be provided that are actuated when the permissible values of the process parameters determining its explosion hazard are reached.
868. In the event of a power failure, a drop in the pressure of the compressed air supplying the monitoring and control system and the PAZ system below 0.2 MPa (2 kgf/cm2), or a cessation of the compressed-air supply to the monitoring and control systems, the PAZ systems shall bring the process facility to a safe state. The possibility of accidental (unprogrammed) switching in the above-mentioned systems when the supply is restored shall be excluded. The return of the process facility to the operating state after the actuation of the PAZ is performed by the operating personnel in accordance with the process regulations. The values of the actuation setpoints of the PAZ systems are given in the design documentation and the process regulations.
869. In the design documentation, the process regulations and the lists of PAZ systems of facilities with process units of all explosion-hazard categories, in addition to the protection setpoints for hazardous parameters, the limits of the critical values of the parameters (from the warning value to the maximum permissible value) shall be indicated.
870. The values of the setpoints of the protection systems are determined taking into account the actuation errors of the signalling devices of the measuring instruments, the response speed of the system, the possible rate of change of the parameters and the explosion-hazard category of the process unit. At the same time, the actuation time of the protection systems shall be less than the time required for the parameter to pass from the warning value to the maximum permissible value.
871. For facilities with process units of any explosion-hazard category, pre-emergency alarm signalling shall be provided based on the warning values of the parameters that determine the explosion hazard of the facilities.
872. Vessel-type apparatus containing solvent and miscella shall be fitted with instruments for measuring and signalling the level (indicating hazardous deviations of parameter values). Signalling of the upper level limit shall be provided from two level gauges (level alarm devices). The actuating mechanisms of emergency protection systems, in addition to the extreme-position indicators located directly on those mechanisms, shall be equipped with devices enabling the indication of extreme positions in the control room.
873. Pumps used for the pressure feeding of flammable and combustible liquids (vegetable and mineral oil, miscella, solvent) shall be equipped with: interlocks preventing the pump from starting and running "dry" or stopping the pump when the pressure of the conveyed liquid in the pump discharge branch falls below the value established by the operating procedure or by the data-sheet data, or when its levels in the receiving and discharge vessels deviate from the maximum permissible values (upper and lower levels); warning alarm means for violations of operating parameters that affect safety; local and remote shutdown means located in readily accessible places.
874. Technical solutions for ensuring the reliability of monitoring parameters that have critical values at facilities with process units of explosion-hazard category III are developed and substantiated by the project developer. The sequence in which the interlock systems of process equipment and pumps operate is determined by: the interlock diagram presented in the operating procedure and (or) the design documentation; the operating programme (algorithm) of the emergency protection system of the process installation.
875. Override keys in the emergency protection diagrams of oil-production facilities may be installed only to ensure start-up, shutdown, or switching. The number of such keys shall be kept to a minimum. Emergency protection diagrams shall be equipped with devices that record the number and duration of protection-parameter shutdowns.
876. Extractors shall be fitted with means for monitoring and signalling the level of the material being extracted in the charging device and the discharge hopper (for carousel extractors) and with interlocks that ensure the stopping of: the extractor when the level of the material being extracted in the charging hopper (shell ring) of the extractor falls to the minimum permissible mark; the conveyor feeding material into the extractor when the level of material in the charging hopper (shell ring) rises to the maximum permissible mark; the discharge screw conveyor when the level of meal in the discharge hopper of carousel extractors falls to the minimum permissible mark; the extractor when the level of meal in the discharge hopper rises to the maximum permissible mark. In addition, carousel-type extractors shall be equipped with an interlock that ensures the closing of the pneumatic gate valve in the gravity-flow pipeline when the concentration of solvent vapours at the top point of the charging hopper rises. The minimum and maximum permissible levels of the material being extracted, depending on the type of extractor, the type of material being extracted, and the specific conditions, are determined by the design documentation and the operating procedure.
877. The extraction installation shall be equipped with devices for continuous monitoring, recording, and signalling and with interlocks that ensure the stopping of the shop upon: a drop in the pressure and temperature of steam in the manifolds; a drop in water pressure in the circulation system; a drop in compressed-air pressure below 0.2 MPa (2 kgf/cm2) supplying the monitoring and control systems of the emergency protection system; a rise in the concentration of solvent vapours in the air environment of the shop to 50 per cent of the lower concentration limit of flame propagation. For the extraction shop, warning alarm signalling shall also be provided for the following parameters: a rise in steam temperature; a drop in vacuum in the condenser of the oil-absorption system; filling of the emergency miscella vessel to 50 per cent of its volume; a rise in the temperature of the circulating water.
878. Extractors with multi-stage irrigation shall be provided with instruments for the continuous monitoring and recording of vacuum that issue a signal when it drops.
879. The maximum permissible values of the parameters specified in paragraphs 876 and 877 of the Rules are specified in the operating procedure.
880. Solvent and miscella heaters shall be equipped with devices for monitoring, regulating, and signalling the temperature of the product being heated.
881. The vat evaporator (toaster) shall be fitted with devices for monitoring, signalling, and recording the temperature of the meal at the toaster outlet. When the temperature of the meal in the fourth vat falls to 85 - 80 °C, the electric drive of the toaster or of the toaster's discharge screw conveyor and all preceding conveying elements and equipment, including the solvent pumps, shall be switched off.
882. Distillers shall be fitted with instruments for monitoring and automatically regulating the miscella temperature stage by stage, for monitoring the vacuum and the miscella level, and with warning alarm signalling upon deviation of the vacuum from the maximum permissible value, which is specified in the operating procedure.
883. In the wastewater treatment system of the extraction shop, the following shall be provided: means for monitoring, automatically regulating, and warning-alarm signalling of the water temperature in the sludge evaporator (recuperator); means for monitoring the solvent level in the benzine trap with signalling or automatic switching-on of the pump for pumping out the solvent when the upper level limit is reached.
884. In production premises and at open outdoor installations, means of automatic gas analysis shall be provided with signalling of the maximum permissible concentration value of the explosive vapour-gas phase - not more than 20 per cent of the lower concentration limit of flame propagation.
885. The locations for installing the sensors or sampling devices of the analysers are determined in accordance with the design. In addition, for carousel-type extractors, two solvent-vapour sensors shall be additionally installed: in the charging hopper of the extractor with actuation set points of: 5 g/m3; 5...10 g/m3; 10 g/m3; in the discharge screw conveyor for meal with actuation set points of: 3 g/m3; 3...4 g/m3; 4 g/m3. Where there is no charging hopper, the installation locations, the number of sensors, and the set points are substantiated in the design documentation.
886. The need to classify the monitoring, control, and emergency protection systems of oil-production facilities as special-group electrical consumers shall be substantiated in the design documentation.
887. For pneumatic monitoring, control, and emergency protection systems, separate compressed-air installations and separate compressed-air networks shall be provided.
888. The air for air compressors, instrumentation and control (I&C) systems, and emergency protection systems shall be cleaned of dust, oil, and moisture. The quality of the compressed air shall be not lower than contamination class I.
889. Systems supplying compressed air to control means and emergency protection systems shall be equipped with buffer vessels (receivers) that supply air to the monitoring, control, and emergency protection systems when the compressors stop, for a period sufficient for the accident-free shutdown of the facility, which shall be confirmed by calculation, but not less than 1 hour. The compressed air from these systems is not used for other purposes.
890. At the inlet to the shop, sampling devices shall be provided for analysing the contamination of the compressed air. The frequency of the analyses is determined by the requirements of regulatory and technical documents and is established by the organisation.
891. Control rooms for process facilities and air-compression installations shall be equipped with light and sound signalling that is triggered when the compressed-air pressure in the network upstream of the buffer vessels (receivers) drops.
892. Inert gas is not used to supply the instrumentation and control (I&C) systems.
893. Control rooms and analyser rooms are constructed as freestanding structures and are located outside the explosion-hazardous zone. In individual cases, with appropriate substantiation by the design organisation, they may be built onto buildings with explosion-hazardous zones. In such cases, the following shall be prohibited: their placement above (or below) explosion- and fire-hazardous premises, premises with a chemically active and harmful environment, supply and exhaust ventilation chambers, or premises with wet processes; the placement of equipment and other devices not connected with the process control system; the transit routing of pipelines, air ducts, or cables through the control rooms; the provision of steam or water heating; the introduction of fire-water mains, impulse lines, and other pipelines carrying combustible, explosive, or harmful products.
894. Control rooms shall meet the following requirements: have air heating and air-conditioning installations (in substantiated cases, the provision of water heating may be permitted in control rooms that have no electronic instruments); the air supplied to the control rooms shall be cleaned of gases, vapours, and dust and shall comply with the operating requirements of the equipment being installed and with sanitary standards; the floors in control rooms shall be warm and non-electrically-conductive, and the cable ducts and raised floors shall comply with the requirements of regulatory and technical documents; the fire-extinguishing means or systems shall comply with the requirements of regulatory and technical documentation; light and sound signalling shall be provided in the control room to warn of gas contamination of the production premises and of the territory of the facility being controlled.
895. For emergency protection systems, in cases substantiated in the design documentation, boards or panels with mimic diagrams of the interlock structure shall be provided, which shall be equipped with light devices signalling the state of the interlocks, the power-supply sources, and the actuating elements.
896. Analyser rooms shall meet the following requirements: preclude the possibility of the formation of an explosive concentration of the products being analysed upon a complete rupture of the gas-supply tube of a single analyser, irrespective of their number in the room, where flow and pressure limiters for these products are present, taking into account the volume of the analyser room and the technical characteristics of the ventilation systems, over a period of 1 hour; have emergency ventilation, where it is impossible to ensure the above condition, which is switched on automatically when the concentration of the substances in circulation in the air of the room reaches 10 per cent of the lower concentration limit of flame propagation, in accordance with the requirements of the legislation of the Russian Federation on town-planning activity; have protective structures.
897. Sampling tubes with a pressure higher than that required for the operation of the analyser shall not be introduced into the analyser room. The flow and pressure limiters on the sampling devices shall be located in a safe place outside the analyser room. The excess of the substance being analysed, after the analysis is completed, is returned to the process system or disposed of.
898. The permanent presence of people in analyser rooms shall not be permitted.
899. Analysers shall have protection against ignition and explosion via the gas lines.
900. Explosion- and fire-hazardous process facilities of oil production (the extraction shop), as well as the process facilities interconnected with it (including the pressing shop, the preparation section, the meal elevator, and the benzine storage), shall be equipped with two-way loudspeaker and telephone or radio communication systems; in cases substantiated in the design documentation - with signalling of the operation of the interconnected process equipment.
901. The electric-power supply to the electrical consumers of oil-production facilities for units of explosion- and fire-hazard categories II and III shall be provided at not lower than reliability category 2, and that to the electrical consumers of recirculating water-supply systems, emergency ventilation, emergency lighting, compressed-air supply for instrumentation and control (I&C), and fire-protection systems - at not lower than category 1.
902. The power supply to the interconnected process units of the extraction shop shall be provided from a single group of power sources (the main source and the standby sources). Where power is supplied from various sources, measures and means shall be provided to ensure the uninterrupted operation of the interconnected facilities of the process system or its transfer to a safe state in the event of the failure of one of the power sources.
903. The electric lighting of outdoor process installations and solvent storages shall be equipped with remote switching-on from the operator's room or from places specially designated by the design, and with local switching-on - by service zones.
904. To supply hand-held lamps in premises classified as premises of increased danger and as especially dangerous, a voltage of not more than 42 volts shall be used. Where the danger of electric shock is aggravated by cramped conditions or by the awkward position of the person carrying out the work (for example, work in a vessel), a voltage of not more than 12 volts is used to supply hand-held lamps.
905. The use of portable lamps for the internal lighting of apparatus (tanks) filled with solvent, miscella, or solvent vapours shall not be permitted, except for lamps operating from storage batteries with a voltage of not more than 12 volts and of explosion-proof design.
906. The routing of electrical wiring in premises with dust emission shall be carried out in a manner that prevents the deposition of dust on its elements and does not hinder the removal of dust.
907. In production premises and at outdoor installations, electrical equipment shall be used that corresponds to the level and types of explosion protection, the groups, and the temperature classes.
908. Heating and ventilation systems shall ensure, in the working area of production premises, meteorological parameters and a content of harmful substances within the limits of the standards established by the requirements of regulatory and technical documents.
909. The content of dust and solvent vapours in the air supplied to the supply-ventilation systems shall not exceed 30 per cent of their maximum permissible concentration in the air of the working area of production premises. The discharge of solvent vapours into non-ventilated zones of the adjacent territory, into permanent passageways, and into zones where people may congregate shall not be permitted.
910. The air drawn by ventilation installations from the seed-cleaning machines of the preparation shop and from the storage (elevator) of oilseed raw material, containing organic dust with mineral impurities, as well as from the storage (elevator) of meal and the pneumatic installation, containing meal dust, shall be subjected to cleaning before being discharged into the atmosphere. The concentration of solvent vapours and dust in the air discharged by the ventilation and recuperation systems into the air of the populated locality on whose territory the enterprise is located shall not, taking into account background concentrations, exceed the maximum permissible standards.
911. Process ventilation systems that remove combustible dust and solvent vapours shall be equipped with interlocks that prevent the starting and operation of the associated process equipment when the ventilation unit is not running.
912. The medium conveyed by a fan that contains combustible dust shall be subjected to cleaning before entering the fan. The cleaning of dust from the flow passage of fans shall be carried out periodically in accordance with the schedule adopted by the organisation, developed individually for each ventilation system.
913. Cyclones shall be used to clean the air of oil-bearing dust. The operating efficiency of the dust-removal installations shall be ensured by a rational choice of cyclone type, taking into account the particle-size composition and physical properties of the dust, and by the use of combinations of various types of cyclones.
914. Dust-collecting equipment for the dry cleaning of air is located indoors. The equipment for cleaning the air of oil-bearing dust after the seed-hulling machines and of mineral dust after the separators shall be located in the premises of the hulling and winnowing shop to avoid heat losses with the outgoing air.
915. Cyclones for dry cleaning (elevators for oilseed raw material, elevators for meal) shall be equipped with explosion-relief devices.
916. Dust collectors for the wet cleaning of the dust-air mixture shall be placed in heated premises. The above-mentioned dust collectors may be placed outside heated premises or outside buildings. In this case, protection against the freezing of water shall be ensured.
917. Where group cyclones combined by a common dust collector and a manifold for cleaned air are used in pneumatic-conveying systems to clean large volumes of air, each cyclone shall be equipped with its own rotary airlock valve for discharging dust.
918. The standby fans of the general-exchange and supply ventilation systems shall have an interlock for their automatic switching-on in the event of the failure of the main fans.
919. In the production premises of the extraction shop where the release of solvent vapours is possible, sound and light signalling shall be provided (with installation in the control-console premises) that gives notice of a malfunction of the fans of the general-exchange ventilation systems.
920. The methods for shutting off, in the event of fire, the ventilation systems serving premises of categories A and B shall be substantiated and regulated in the design documentation.
921. In the extraction shop and the benzine pump station, emergency exhaust ventilation shall be provided. The capacity of the emergency ventilation is determined by the design documentation.
922. The emergency ventilation shall be interlocked with the sensors of the pre-explosion-concentration alarm devices and shall switch on automatically when the concentration of solvent vapours in the air exceeds 10 per cent of the lower concentration limit of flame propagation, in accordance with the requirements of the legislation of the Russian Federation on town-planning activity. Manual switching-on of the emergency ventilation shall also be provided. The starting devices of the emergency ventilation shall be located both inside and, outside the premises, next to the main entrance doors.
923. The equipment of ventilation systems and metal air ducts shall be earthed in accordance with the requirements of regulatory and technical documents.
924. In production premises, air heating combined with supply ventilation shall be provided. The possibility of the systematic cleaning of heating appliances from dust is ensured by the choice of their type and location.
925. The buildings of storages and elevators for oilseed raw material and meal, and the over-silo and under-silo floors, shall be classified as unheated premises. For persons working at the elevators and storages, warming rooms shall be provided.
926. The recirculating water-supply system of the extraction shop is provided as an autonomous system.
927. The replenishment of water losses in the recirculating system shall be effected with condensate or softened water. Where softened water is used for the process facilities of extraction shops located in regions with hard water, water-treatment installations shall be provided to soften it. Where conditionally contaminated condensate from the extraction shop is used to make up the recirculating system, monitoring of its contamination with solvent and oil and a treatment system shall be provided.
928. The recirculating water-supply system of oil-production facilities shall be equipped with a main pump and a standby pump.
929. The frequency of cleaning the cooling towers and of monitoring water quality (the presence of solvent, oil, or debris) is determined on the basis of the conditions for ensuring the failure-free operation of the cooling towers. At the location of the cooling towers, a steam supply shall be provided for blowing out the nozzles and pipelines and for thawing ice in winter.
930. For the draining of domestic water (after floor washing), floor drains or funnels shall be installed in the floor of the first storey of the extraction shop, with their discharge through a hydraulic seal into the benzine trap designated for this purpose.
931. Benzine- and fat-containing wastewater shall be treated according to the scheme provided for in the operating procedure and the design documentation. Wastewater may be discharged into the benzine trap after it has been treated in the sludge evaporator and cooled.
932. The discharge of wastewater containing solvent into the industrial sewerage, including in emergency cases, shall not be permitted.
933. The draining of benzine-water condensate from process equipment into the water separator and of water from the benzine traps into the plant sewerage shall be effected through hydraulic seals located in places where the freezing of the liquid during the cold season is precluded.
934. The extraction shop shall not be operated when the installations for recovering solvent from wastewater are faulty and the industrial sewerage is not functioning.
935. To prevent the ingress of solvent into the sewerage, the requirements of paragraph 883 of the Rules shall be complied with. The content of solvent in the wastewater from the benzine trap shall be monitored every shift.
936. At the wastewater treatment and pumping station, electrical equipment of explosion-proof design shall be used.
937. In the building of the extraction shop, the platforms for servicing process equipment and the inter-storey floors shall be designed in such a way as to preclude the possibility of the formation of non-ventilated spaces, and for newly constructed and reconstructed shops they are made predominantly of a lattice type.
938. Newly constructed oil-extraction shops shall be located in a freestanding building; the possibility of a different arrangement shall be substantiated in the design documentation. The air-cooling apparatus for benzine-containing wastewater (ACA) shall be located in a room or a closed annex with electrical equipment of explosion-proof design. For newly designed and reconstructed shops, materials that do not spark on impact (for example, ceramic tiles or concrete with a lime filler) shall be used for floor coverings, in accordance with the requirements of the legislation of the Russian Federation on town-planning activity, as well as non-sparking metal gratings or gratings with a special coating. The material of the covering and the gratings is specified in the design documentation.
939. Tanks for solvent and benzine traps shall be located outside the shop.
940. On the territory of newly constructed and reconstructed oil-production facilities, the presence of natural ravines, excavations, and low-lying areas, and the provision of open trenches, pits, and sumps in which solvent vapours may accumulate, and the trench and above-ground routing (in artificial or natural depressions) of solvent-pipeline routes, shall not be permitted.
941. The floors, platforms, and stairs of the shops shall be kept clean, without allowing the formation on them of slippery surfaces from spilled lubricating and vegetable oils, solvent, or water.
942. Before the start of repair work, the apparatus and process pipelines of the extraction shop shall be freed of products and steamed with water steam. The heat-exchange surfaces of the apparatus (distillers, condensers, heat exchangers) shall, after steaming, be cleaned of carbon deposits by alkali treatment and washing with water. After the apparatus and process pipelines have been freed of washing water, all the apparatus of the extraction shop shall be disconnected from the process-pipeline system by means of standard numbered blanks with visible tails. All the blanks installed shall be entered under their numbers in the register of the installation and removal of blanks. After the above operations are completed, the covers of the manholes are removed from the apparatus and airing operations are carried out.
943. The repair of explosion-proof electrical equipment and the replacement and restoration of parts shall be carried out by specialised organisations or by the electrical-engineering personnel of organisations. Repaired explosion-proof electrical equipment shall undergo control tests in accordance with the technical specifications for its manufacture. The results of the test and the characteristics of the repair are entered in the data sheet of the equipment concerned.
944. In premises with production processes of categories A and B, tools that do not spark on impact shall be used.
945. The thawing of frozen pipelines containing solvent (miscella) shall be carried out only with steam or water. The use of an open flame for this purpose shall not be permitted.
946. Pipelines for solvent and miscella shall be subjected to hydraulic tests before acceptance from capital repair, at an excess pressure of 1.25Pwork.[G]20 / [G]t, but not less than 0.2 MPa (2 kgf/cm2), in accordance with the requirements of regulatory and technical documents.
947. The strength and tightness tests of the equipment and pipelines of the extraction shop shall be carried out with water or inert gas.
948. The test pressure during the pressure testing of the system shall not exceed the test pressure established for the valves. The pressure testing of a system with bellows valves installed shall be carried out at a pressure not exceeding that specified in the operating documentation for the bellows valves. The pressure testing of the system shall be carried out at a temperature of 20 °C, with the valves in the open position.
949. Facilities for the production and consumption of air separation products (hereinafter - air separation product (ASP) production and consumption facilities) include facilities for the production and consumption of ASP (oxygen, nitrogen, argon, krypton, xenon, neon-helium mixture) and their mixtures.
950. The specific technical requirements for individual technological processes of ASP production and consumption facilities, established by the standards of organisations and by other internal documents of the organisations operating ASP production and consumption facilities, shall not contradict the requirements of these Rules.
951. The operation of air-separation technical devices used at hazardous production facilities for ASP production (hereinafter - ASP production facilities) (air separation units (hereinafter - ASU), a cryogenic complex, an air-purification unit) is permitted if the concentration and composition of explosive impurities in the air being processed do not exceed the standard established by the developer of such a technical device.
952. The degree of contamination of the air being processed shall not exceed the permissible standards established by the developer of the technical device throughout the entire operating period of the technical device and shall be subject to monitoring by the organisation operating the ASP production facilities.
953. Where, during the operation of the technical device by the organisation operating the ASP production facilities, the degree of air contamination exceeds the permissible standard, actions shall be carried out to equip such a technical device with additional air-purification means that ensure the safety of its further operation.
954. The placement, at ASP production facilities, of air-intake points relative to production processes that are sources of contamination, as well as to places for the processing (incineration) of domestic and industrial waste and other possible sources of air contamination, is determined by the design standards for ASP production and consumption facilities and by the results of monitoring.
955. The start-up of ASP production facilities (air separation units and cryogenic complexes) is carried out in accordance with the operating procedure developed on the basis of the requirements of the operating procedure and the Rules.
956. To ensure the explosion-safe operation of the ASU, the organisation operating the ASP production facilities shall carry out monitoring of the content of explosive impurities in the process streams of the unit in accordance with the requirements of the operating procedure.
957. The concentration of explosive impurities in liquid oxygen shall not exceed the limits established by the developer of the ASU for the various stages of the technological process.
958. The sampling of liquid oxygen or liquid air for analysis is carried out into special samplers, as well as into metal cryogenic vessels. The use of these vessels for other purposes shall not be permitted.
959. To ensure the explosion safety of the ASU, the monitoring and automation system shall provide continuous monitoring of the quantity of liquid cryogenic product being drained, taking into account the requirements of the technical documentation of the ASU manufacturer. On an operating ASU, the procedure for switching off the electric valve drives for repair or inspection is determined by the operating procedure. The electric drives of the valves supplying air (nitrogen) to the turbo-expanders and the complex-purification units, supplying air to the ASU, and delivering product oxygen and nitrogen, as well as the valves of the nitrogen-water cooling and the control valves, shall be repaired in accordance with the operating manual for the valves. The pneumatic valve drives shall be repaired only during shutdowns.
960. The monitoring and automation system of the ASU shall provide light and sound signalling upon a disturbance in the operation of the systems and devices of the unit and upon deviation of the technological parameters defined by the operating procedure.
961. ASUs producing gaseous nitrogen shall be equipped with automated devices that prevent the supply of product nitrogen with an oxygen content exceeding the values defined by the design documentation (documentation).
962. The nitrogen-water cooling systems of the ASU shall be equipped with automatic devices that shut off the water supply when the permissible water level in the air scrubber is exceeded.
963. The nitrogen-discharge pipeline from the nitrogen scrubber shall be directed to the side opposite the nearby buildings and structures, to preclude droplet moisture or icing from reaching them.
964. During short-term shutdowns of the ASU due to production necessity (up to 8 hours), the draining of liquid cryogenic products from the apparatus shall be carried out in the manner provided for by the operating procedure.
965. During shutdowns of the ASU lasting more than 8 hours, the liquid oxygen and the bottom liquid shall be drained from the adsorbers, and the adsorbent shall be subjected to regeneration. Deviations from the time interval specified in this paragraph shall be substantiated in the design.
966. During the shutdown of the air separation unit (ASU), uniform cooling of the heat-and-mass-transfer apparatus (for example, regenerators, reversing and non-reversing plate heat exchangers) and of the cryogenic pipelines, valves, liquefied-gas pumps and tanks shall be ensured at a rate specified in the manufacturer's documentation. During the shutdown of an ASU with non-reversing plate-fin heat exchangers, overcooling of the pipelines of the "warm end" of these apparatus shall be prevented.
967. The start-up of the ASU after a shutdown, where the level of liquid oxygen (liquid air) in the main condenser-evaporators is below the nominal level, shall be carried out in the liquid accumulation mode.
968. The duration of operation of the ASU between two complete warm-ups is determined by the process regulations and shall not exceed the period established by the technical specifications of the ASU developer. An extension may be permitted only in agreement with the developer of the unit.
969. The duration of continuous operation of ASU apparatus in which liquid oxygen is evaporated and the warming-up of which during operation of the unit is provided for by the process, shall not exceed the periods determined by the process regulations, and shall also take into account the results of analyses of the hydrocarbon content in the liquid oxygen.
970. The warming-up of ASU apparatus shall be carried out until the temperature of the air leaving the apparatus, over a period of two hours, reaches the temperature determined by the process regulations.
971. The evaporation of liquid cryogenic air separation products drained from individual ASU apparatus before their warming-up is carried out in special quick-drain evaporators provided for by the design documentation (documentation) separately for each unit. For low-capacity ASUs, the draining of liquid cryogenic products from the apparatus may be carried out into portable cryogenic vessels, with subsequent evaporation in a device for the draining and evaporation of liquid air separation products.
972. The combining of pipelines for draining liquid products from the ASU shall not be permitted. Deviations from the requirement specified in this paragraph shall be justified in the design documentation (documentation) in each specific case.
973. The operation of technical devices forming part of the ASU, of cryogenic complexes and of liquid air separation products storage systems is carried out in accordance with the requirements of the process regulations.
974. The temperature regime of operation of the regenerators shall preclude the possibility of hydrocarbons being carried into the air separation block.
975. The ingress of liquid oxygen into the valve boxes of the regenerators shall not be permitted. The absence of liquid oxygen in the valve boxes shall be monitored.
976. The adsorbers of the ASU shall be filled only with the adsorbent provided for by the technical documentation of the ASU developer. The moisture content and bulk density of the adsorbent shall be monitored before the adsorber is filled with it.
977. During the operation of integrated purification blocks (hereinafter referred to as IPB), it shall be prohibited to discharge the regenerating gas into the workshop premises. Before inspection of the internal assemblies of the IPB adsorbers or their repair, the adsorbent shall be subjected to regeneration and then purged with air to prevent poisoning by the nitrogen released. The topping up of adsorbents in the IPB adsorbers shall be carried out with the air separation block out of operation, during a scheduled shutdown of the ASU, under a permit to work. The thermal insulation of the pipelines and apparatus of the IPB shall provide reliable protection against thermal effects on the surrounding equipment and operating personnel. The technical examination of the pipelines and apparatus of the IPB shall be carried out in accordance with the operating manual. During the loading and unloading of adsorbents, reliable and effective air exchange of the ventilation system shall be ensured, and in places of heavy dust emission additional air exhausts shall be provided.
978. During the operation of the IPB, compliance with the operating parameters of the air purification process and with the temperature regime of regeneration and cooling of the adsorbent, provided for by the process regulations, shall be ensured.
979. The checking of the condition of the adsorbent in the IPB, provided that its serviceability is retained, is carried out within the periods determined by the process regulations. This checking of the condition of the adsorbent includes inspection of the adsorbent layer at the inlet of the air being purified into the apparatus. In the cases determined by the documentation of the equipment developer, re-sieving and topping up of the adsorbent shall be carried out. If the adsorbent is contaminated (oil-fouled), it shall be replaced. Replacement of the adsorbent shall be carried out immediately if, under the normal regeneration regime and with compliance with the operating parameters of the purification process, an exceedance of the carbon dioxide concentration above the permissible norms is recorded.
980. To ensure effective purification of the process streams, periodic regeneration of the adsorbent shall be carried out in accordance with the process regulations.
981. Replacement of the adsorbent is carried out within the periods established by the process regulations. In addition, the adsorbent shall be replaced regardless of its period of use if its original colour changes, and also if an exceedance of the acetylene concentration in the liquid oxygen above that specified in the technical documentation of the ASU developer is detected which is not eliminated after high-temperature regeneration of the adsorbent has been carried out.
982. If the ASU has only one adsorber on the bottom liquid stream, the air separation block shall be shut down for the period of its regeneration. The operation of such units through a bypass line shall not be permitted.
983. During operation of the ASU, the flow-through of the condenser-evaporators shall be ensured in accordance with the process regulations.
984. In units that do not produce krypton concentrate, the coiled condenser-evaporators with in-tube boiling of oxygen shall be flushed with liquid oxygen at the frequency established by the process regulations. After flushing, the liquid oxygen is immediately removed from the liquid separator.
985. Shutting off the external condensers for scheduled warming-up may be permitted only in the absence of acetylene in the condensers located upstream of them during the preceding twenty-four hours.
986. The operation of cryogenic turbo-expanders is carried out in accordance with the process regulations after adjustment of the automatic monitoring and control system and of the emergency protection system.
987. If, on liquid carry-over into the turbo-expander or on a drop in the inlet gas temperature below the temperature specified in the process instructions, the automatic protection has not operated, the turbo-expander shall be shut off immediately (the supply of gas to the turbo-expander shall be stopped) and the pipelines upstream and downstream of the turbo-expander shall be purged. Start-up of the turbo-expander is permitted only after the causes that led to the shutdown have been eliminated.
988. The operation of the turbo-expander shall not be permitted where the icing-up of the insulating casing and of the drive of the capacity-control mechanism is increasing.
989. Disconnection of the motor-generator of the turbo-expander from the power supply is carried out only when the cut-off valves and the shut-off valves on the gas supply pipeline to the turbo-expander are closed.
990. In the event of loss of voltage on the motor-generator of a running turbo-expander, the supply of gas to the turbo-expander shall be stopped immediately.
991. During operation of reciprocating and centrifugal pumps for liquid air separation products, icing-up of the pump support frame shall not be permitted, except at the places near the outlet nozzles.
992. If icing-up of the standstill and dynamic seals and glands of the pumps appears, measures shall be taken to reduce gas leakage in accordance with the requirements of the process regulations and the technical documentation of the manufacturer, and analyses of the air for oxygen content shall be carried out in the room where the pumps are located. If the volume fraction of oxygen has risen to 23 per cent or fallen to 19 per cent (for nitrogen and argon pumps), the pump shall be stopped for repair.
993. In the adsorption drying blocks, the condition of the adsorbent shall be checked at least once a year. If the adsorbent is contaminated (oil-fouled or has yellowed), it shall be replaced. In units in which the air compression temperature at any compressor stage is above 433 °K (160 °C), replacement of the adsorbent in the drying block shall be carried out twice a year in accordance with the process regulations.
994. The removal of oil from the air leaving the reciprocating expander is carried out in the expander filters in accordance with the process regulations.
995. In the absence of automatic purging of the moisture-oil separators of reciprocating compressors, their purging is carried out every 30 minutes.
996. If a leak of gaseous or liquid air separation products is detected in the intra-block space of an ASU with perlite insulation, operation of the ASU shall be stopped to eliminate the leak.
997. The arrangement and siting of equipment with liquid air separation products shall comply with the design documentation (documentation) and the requirements of the Rules.
998. In the production premises of air separation products consumers, vessels with liquid air separation products with a total capacity of no more than 10 m3 may be placed, provided that these vessels are process-connected with technical devices located in that production room.
999. In premises classified in categories A, B, V1 - V4 for explosion and fire hazard (Federal Law No. 123-FZ), the siting of vessels with liquid oxygen shall not be permitted. Vessels with liquid air separation products with a total capacity of more than 10 m3 shall be placed in separate premises or outside the building.
1000. The discharge of gaseous air separation products when filling vessels located in premises is carried out outside the building in compliance with the requirements of paragraphs 1085, 1086 of the Rules.
1001. Gasifier vessels and other stationary vessels with liquid air separation products installed outside consumers' buildings, into which liquid air separation products are drained directly from transport tanks or from which transport tanks are filled directly, shall be located near walls having no openings, at a distance of not less than 1.0 m from the overall dimensions of the vessel. Window openings within 6.0 m to each side and 3.0 m above the overall dimensions of the vessels shall not have opening elements. The requirements specified in this paragraph do not apply to vessels for which the connections of the draining and filling devices are located at a distance of more than 9.0 m from the building.
1002. Cryogenic vessels (Dewar vessels) intended for the storage of or work with liquid air separation products, except for vessels with a capacity of up to 15 litres, shall be fitted with safety devices.
1003. The operation of cryogenic vessels and of technical devices of various purposes fitted with Dewar vessels is carried out in accordance with the process instructions, which take into account the requirements of the design documentation (documentation), of the Rules and of the operational documentation of the developer.
1004. In premises with natural ventilation, work with open vessels of liquid air separation products may be carried out where the volume of the room in cubic metres exceeds the volume of the liquid contained in the vessels in litres by not less than 7 times. If this ratio is not met, permanently operating supply-and-exhaust ventilation shall be provided in the room, ensuring a volume fraction of oxygen in the room air of not less than 19 per cent and not more than 23 per cent. In addition, an automatic gas analyser shall be installed in that room, giving light and sound signals of a deviation from the norms of oxygen content in the room air. When a signal is given, the personnel servicing this equipment shall take measures to bring the oxygen content in the room back to normal (for example, switch on the emergency ventilation system, carry out airing of the room, close the source of gas emission) and leave the room. Continuation of the work is permitted only after the oxygen content in the air specified in this paragraph has been reached.
1005. Liquid nitrogen may be used as a coolant without special measures for the prevention of ignition and explosion if the volume fraction of oxygen in it does not exceed 30 per cent. When working with liquid nitrogen containing more than 30 per cent oxygen, the safety measures specified in paragraph 1004 of the Rules shall be provided.
1006. Work with liquid nitrogen in open baths is carried out in accordance with the requirements of the process instructions, while monitoring the oxygen content in the liquid by one of the following methods: (a) by carrying out analyses of the volume fraction of oxygen in the vapour phase above the liquid surface. The volume fraction of oxygen shall not exceed 10 per cent; (b) by carrying out analyses of the liquid nitrogen during evaporation. When using stationary baths for work with liquid nitrogen, the analyses shall be carried out continuously by an automatic gas analyser.
1007. Parts subjected to cooling in baths with liquid nitrogen shall first be degreased and dried.
1008. Baths for cooling parts with liquid nitrogen shall be subject to warming-up where the volume fraction of oxygen in the nitrogen is more than 30 per cent, and to periodic degreasing. Above the baths for cooling parts with liquid nitrogen, local exhausts shall be provided.
1009. The supply of gaseous air separation products to consumers is carried out through pipelines from oxygen distribution (regulating) points (hereinafter referred to as ODP), receivers, gasifiers, discharge manifolds or directly from ASUs located on the consumers' industrial site, in accordance with the design and the requirements of the Rules.
1010. Consumers may be supplied with gaseous air separation products directly from cylinders located near the consumers. For permanent consumers of small quantities of air separation products (for example, gas analysers, chromatographs), no more than two cylinders with a capacity of 40 litres, filled with air separation products at a pressure of up to 20 MPa, may be placed at each point of consumption. The distance between each pair of cylinders shall be not less than 12.0 m at each level of cylinder placement. The cylinders shall be placed in metal cabinets and secured. The cabinets with cylinders shall have locking devices.
1011. The movement of cylinders by lifting devices and vehicles shall be carried out in accordance with the process instructions.
1012. During the loading and unloading of cylinders, their dropping or striking against each other shall not be permitted.
1013. An oxygen cylinder and a combustible-gas cylinder may be transported on a trolley to the workplace.
1014. In oxygen-consuming workshops, the possibility of oxygen flowing over into systems (lines and technical devices) filled with combustible gases, or into systems not connected with the process being carried out, shall be precluded. When discharging oxygen cylinders, the residual pressure in them shall preclude the back-flow of combustible gases from the connected system back into the cylinders. A reduction of the pressure in a cylinder below 0.05 MPa shall not be permitted.
1015. At air separation products consumption facilities, it shall not be permitted to carry out repair of cylinders or to dismantle and repair valves.
1016. During periodic withdrawal of air separation products from pipelines, the isolating valves for connecting flexible pipelines (hoses, sleeves) shall be placed in a metal cabinet with openings for ventilation. After the completion of the work specified in this paragraph, the cabinet shall be locked. The signal-warning inscriptions and identification colouring of the cabinets are carried out in accordance with the design documentation (documentation).
1017. The discharge of air separation products into a production room during the purging of technical devices and lines shall not be permitted.
1018. During the arrangement, siting and operation of technical devices for the processing or purification of primary krypton concentrate and for the production of krypton-xenon mixtures, krypton and xenon, the requirements of the design documentation (documentation), of the Rules and of the process regulations shall be complied with.
1019. Premises in which technical devices intended for the processing and storage of krypton-xenon mixture, krypton and xenon are installed shall be fitted with a permanently operating supply-and-exhaust ventilation system. The operation of the technical devices specified in this paragraph with the ventilation system switched off shall not be permitted. For the technical devices specified in this paragraph, a protective screen between the equipment and the control panel shall be provided, as well as guarding around the equipment, at a distance of 1 m from it.
1020. Cylinders with krypton-xenon mixture, krypton and xenon, after filling, are held for not less than 14 days in the filling room or in the cylinder store. Access to these premises is permitted only to technical personnel carrying out the filling of cylinders with krypton-xenon mixture, krypton and xenon. During the filling of cylinders and during the period of their holding in these premises, only operations connected with the filling of cylinders and their transport to the holding places may be carried out. The transport of cylinders shall be carried out on trolleys or other means of transport. Gas sampling for analysis, weighing of cylinders and other operations with filled cylinders are carried out only after the holding of the cylinders specified in this paragraph.
1021. The discharge of primary krypton concentrate and krypton-xenon mixture is carried out into the primary krypton concentrate gas holder or into the compressor suction (if a gas holder is absent from the scheme).
1022. In the design of argon production facilities at new ASUs, hydrogen-free technologies for the production of pure argon using packed (structured packing) rectification columns and other modern technical devices shall be used.
1023. The arrangement, siting and operation of argon production units and of units for the purification of crude argon from oxygen by the method of catalytic hydrogenation shall comply with the design documentation (documentation), the requirements of the Rules and the process regulations.
1024. The reactors of units for the purification of crude argon from oxygen by the method of catalytic hydrogenation shall be located outside the building. In cases justified in the design documentation, a reactor may be installed in a separate room.
1025. The unit for the purification of crude argon from oxygen shall be fitted with an interlock that stops the supply of hydrogen when the temperature in the reactor rises above the permissible level, and also when the oxygen content in the argon fed for purification exceeds the standard values determined by the process regulations.
1026. In the process of purification of crude argon from oxygen, a system for the automatic measurement of the oxygen content in the crude argon entering the reactor shall be provided.
1027. During start-up of the unit, an increase of the volume fraction of oxygen in the argon of not more than 8 per cent at the inlet to the mixing unit of the reactor is permitted. In this case, the flow rate of the hydrogen supplied shall not exceed 2.5 per cent of the flow rate of that fed to remote control. Local control is permitted when argon is present.
1028. The volume fraction of hydrogen in the technical argon entering the ASU for purification from nitrogen shall not exceed 2.5 per cent.
1029. The units for the purification of crude argon from oxygen and the hydrogen lines, before hydrogen is supplied into them and after shutdown, shall be purged with crude argon or nitrogen with a volume fraction of oxygen of not more than 4 per cent. The completion of purging shall be determined by analysis of the composition of the purge gas. In this case, the volume fraction of oxygen in the purge gas (before start-up) shall not exceed 4 per cent, and hydrogen (after shutdown) shall be absent.
1030. The storage, gasification and transport of liquid (cryogenic) air separation products shall be carried out in technical devices (for example, vessels, apparatus, tanks) specially intended for the given product.
1031. All vessels filled with liquid cryogenic air separation products shall be fitted with filling level indicators. The scales of the level indicators shall correspond to the product poured into the vessel.
1032. Cold sections of low-temperature equipment and lines located in the service zone shall be subject to insulation or guarding.
1033. Transport vessels for liquid air separation products, throughout the entire time they are in the garage, shall be connected to discharge pipelines led out 2.0 m above the ridge of the garage roof. A separate discharge is provided for each vessel.
1034. Sections of pipelines for liquid air separation products enclosed between two isolating devices are fitted with safety devices to protect against overpressure.
1035. The drainage lines of liquid air separation products systems shall provide complete draining of the products.
1036. The operation of portable vessels for liquid air separation products is carried out in accordance with the requirements of the process regulations, taking into account the requirements of the vessel manufacturers and of the Rules. At an air separation products production facility, a device (a site outside the building) is provided for the safe draining and evaporation of small quantities of liquid air separation products (up to 10 litres) from portable vessels during warming-ups of low-capacity ASUs (30 - 300 m3/h of nitrogen or oxygen under normal conditions) after analyses of the liquid air separation products and other work have been carried out. When the device is sited, conditions for its natural airing shall be ensured. The draining place shall have a guard.
1037. The pipelines for draining liquid air separation products from the apparatus of technical devices into the evaporator shall be warmed up to positive temperatures, before and after each draining, in accordance with the process instructions.
1038. Liquid air separation products shall be directed into the evaporator only after it has been switched on - after the supply of heat carrier (steam, water) or of electric power.
1039. For the removal of gases at the outlet of the safety valves installed in the workshop premises, a pipeline (header) with an outlet outside the premises shall be provided.
1040. Safety valves operating on apparatus with cryogenic gases and liquids shall provide leak-tightness of the appropriate class.
1041. All types of compressors (including turbo-compressors, gas blowers) intended for the compression of the air being processed and of air separation products shall comply with the design documentation (documentation) and the requirements of the Rules.
1042. The content of impurities in the air and air separation products supplied to the suction of compressors and gas blowers, both during operation and during running-in, and also in the nitrogen (air) for the fire-fighting of oxygen compressors, shall not exceed the standard values established by the developers of the compressor equipment.
1043. The oil content in the oxygen entering the compressors and gas blowers shall not exceed 0.02 mg/m3.
1044. During the operation of turbo-compressors, contamination of the gases being compressed with oil shall be precluded.
1045. The use of oils in the air filters during the purification of the air, of air separation products, enclosed between, supplied for compression into centrifugal, axial-centrifugal, axial and reciprocating air compressors operating without cylinder lubrication, shall not be permitted.
1046. It shall not be permitted to use softened water and condensate obtained from the plant steam supply system for the lubrication of the cylinders of reciprocating oxygen compressors. For this purpose, distillate obtained from water of drinking quality shall be used.
1047. It shall not be permitted to use reciprocating crossheadless compressors for supplying air for separation and for compressing air separation products.
1048. For the lubrication of the piston group of compressors supplying air to the ASU, oils recommended by the developers of the compressor shall be used.
1049. It shall not be permitted to use, for the lubrication of the piston group of compressors, oil extracted from the oil-moisture separators.
1050. The operation of the oil-scraper glands shall be monitored. The ingress of machine oil into the cylinders shall not be permitted.
1051. The presence of carbon deposits in the valve boxes and pipelines of reciprocating compressors shall not be permitted. The checking and removal of carbon deposits are carried out in accordance with, and within the periods established by, the process regulations.
1052. The methods and periods for cleaning the water cavities of the coolers and the cylinder jackets of the compressors from deposits (for example, scale) are determined by the process regulations and the process instructions.
1053. The design of the purge headers of compressors and apparatus shall preclude the possibility of creating in the header a pressure exceeding the design pressure in any of the compressor stages connected to the header and in any of the connected apparatus. The discharge into the atmosphere of compressor purge gas without the removal of oil shall not be permitted.
1054. The start-up of compressors operating on air with alkaline purification is carried out only with the alkaline purification apparatus switched off and the bypass open, in the procedure provided for by the process regulations.
1055. On an oxygen pipeline more than 250.0 m long, made of carbon steels, switchable filters shall be installed before its connection to the suction header of the oxygen compressors. Directly in front of the suction branch pipe of a centrifugal oxygen compressor, a filter shall be installed.
1056. During the operation of an air centrifugal compressor and air filter, the entry of operating personnel into the chamber premises downstream of the air filter (the clean air chamber) shall not be permitted. Work in the chamber upstream of the filter, with the filter and compressor running, shall be carried out by a work team of not less than two persons. The chambers located along the airflow upstream and downstream of the filter shall be closed and provided with safety signs prohibiting entry into the chambers. The operation of centrifugal, axial-centrifugal and axial compressors with anti-surge devices switched off or not adjusted shall not be permitted.
1057. The start-up, control and monitoring of the operation of centrifugal oxygen compressors shall be carried out remotely from a separate room. In the machine hall, a panel with an additional button for the emergency stop of the compressor is provided. Where the oil tank of a centrifugal oxygen compressor is located within the compressor foundation or directly next to it, the monitoring of the oil level in the tank and the control of the oil topping-up operations are carried out remotely. The ingress of oil onto the compressor foundation shall not be permitted.
1058. When connecting an oxygen compressor to two discharge headers, the connection to each header shall be made through a separate non-return valve precluding the possibility of oxygen flowing over from one header to another.
1059. When two or more centrifugal compressors or two or more reciprocating compressors (with an individual capacity of more than 2000 m3/h) operate onto a single oxygen discharge header, and the oxygen pressure in the oxygen discharge pipeline is above 1.6 MPa, a non-return valve and shut-off devices (isolating valves) with remote control of the electric drive shall be installed after each compressor, for disconnecting the compressor from the header and discharging oxygen into the atmosphere.
1060. On centrifugal oxygen compressors with a discharge pressure above 0.6 MPa, the following shall be provided: (a) automatic protection of the compressor in the event of a fire, with the stopping of the oxygen supply and the supply of nitrogen (air) for fire-fighting; (b) automatic stopping of the compressor when the pressure of the gas supplied to the labyrinth seals drops.
1061. The connection of nitrogen compressors to an ASU without gas holders may be permitted only where there are automatic devices and interlocks precluding an increase of the nitrogen withdrawal above the values that ensure the specified oxygen content in the product nitrogen.
1062. To ensure safety, automatic gas analysers with an interlock system precluding the entry of nitrogen into the compressors or to consumers with an oxygen content exceeding the permissible value provided for by the process regulations shall be installed on the lines supplying nitrogen to the compressors or to consumers (after the header).
1063. When supplying oxygen-enriched air to the compressors (gas blowers) or to consumers (if the mixing of oxygen with air is carried out in the compressors and gas blowers), a system for the automatic maintenance of the specified oxygen content in the enriched air and for the stopping of the oxygen supply when its content increases above that established by the process regulations and by the requirements of the equipment manufacturers shall be provided.
1064. On each centrifugal oxygen compressor with a discharge pressure of more than 0.6 MPa, stationary devices shall be provided allowing samples to be taken for analysis of the gas leaving the labyrinth seals of the compressor. In this case, the operating personnel shall be positioned behind a protective screen.
1065. When the pressure in the suction lines of compressors compressing air separation products drops below 0.5 kPa, these compressors shall be switched off automatically. Before the start-up of a centrifugal oxygen compressor, the oil tank of the compressor shall be purged with dry nitrogen (dry air). The removal of oil vapours from the oil tank of each centrifugal compressor, regardless of its purpose, is carried out through separate pipelines.
1066. At the lowest point of the oil-vapour removal pipeline, the installation of a drainage device is provided for the draining of condensed oil vapours. The combining of drainage pipelines shall not be permitted. The siting of the point of discharge of oil vapours into the atmosphere shall preclude the ingress of these vapours into the air entering the suction of the air compressors and ventilation systems.
1067. During the running-in of compressors, the possibility of oxygen entering the suction line shall be precluded.
1068. The switching-on of a compressor that has been switched off owing to the stopping of the cooling water supply may be carried out only after it has cooled down and the water supply has been resumed.
1069. The arrangement, installation and operation of pipelines for air, oxygen and inert gases at air separation products production and consumption facilities shall comply with the design documentation (documentation) and also with the requirements of the Rules. The air and nitrogen pipelines used for the running-in of oxygen compressors shall comply with the requirements of the Rules. All process pipelines, after installation and repair, shall be accompanied by certificates of installation quality with the relevant appendices (for example, certificates for pipes, fittings, valves, supports, welding materials, copies of welders' certificates, documents on the results of quality control of the work).
1070. Oxygen pipelines with a working pressure of more than 1.6 MPa, the capacity of which, together with the vessels connected to them (receivers), exceeds 200 m3, shall be equipped with an automatically operating protection system that stops the supply of oxygen from the receivers into the pipeline in the event of a breach of its integrity.
1071. On oxygen pipelines made of carbon or low-alloy steels operating under a pressure of more than 1.6 MPa, filters shall be installed in the direction of the oxygen flow ahead of: (a) control valves; (b) shut-off valves where the pipeline length is more than 250 m. Where shut-off valves are opened and closed only in the absence of an oxygen flow, filters may be omitted.
1072. Remote control of the valves of process pipelines is provided for in the following cases: (a) where the valves are incorporated into an automatic regulation or control system; (b) at the inlets of oxygen and nitrogen pipelines into the building and their outlets from the building where flow rates exceed 5000 m3/h; (c) for switching in standby regulation lines; (d) for switching in standby supply sources of air separation products; (e) where remote control of the valves is required for safety reasons; (f) on oxygen pipelines at a pressure of more than 1.6 MPa and with a diameter of 100 mm or more.
1073. It shall not be permitted to place oxygen valves (irrespective of pressure) in control panel rooms (the panel room).
1074. If remotely controlled shut-off and control valves installed on an oxygen pipeline with a pressure above 1.6 MPa are located at a distance of less than 3.0 m from workplaces, then, to protect personnel in the event of ignition of the valves, protective screens shall be installed. If, under local conditions, a protective screen cannot be installed, then the remotely controlled valves used shall correspond to locally controlled valves.
1075. During the operation of process pipelines, the valves shall be subject to periodic inspections, revision and examination in accordance with the process regulations.
1076. Process pipelines shall undergo hydraulic or pneumatic strength tests and pneumatic tightness tests after installation, repairs and reconstructions involving welding work (for example, tapping into a pipeline, replacement of part of a pipeline) or dismantling of pipelines, and also upon the start-up of pipelines that have been in preservation for more than one year. The content of oils in the water used for hydraulic testing of oxygen pipelines shall not exceed 5.0 mg/l. The content of oils in the air or nitrogen used for pneumatic testing and purging of oxygen pipelines shall not exceed 10.0 mg/m3.
1077. Before the start of operation, and also where an oxygen pipeline with a pressure of 0.6 MPa or above has not been operated for more than one month, it shall be purged with air or nitrogen before start-up at an outlet velocity of not less than 40 m/s. The duration of purging shall be not less than 2 hours. The completion of purging is determined by the absence of impurities in the outgoing flow.
1078. Before installation, pipes intended for the manufacture of oxygen pipelines shall be subject to inspection to identify defects (for example, laminations, scale, weld burr). The internal surface of the pipes is checked for the absence of grease contamination. The procedure for inspecting the pipelines is determined by the design. Pipes that have, on the internal surface, the defects listed in this paragraph or grease contamination (traces of oil) exceeding the norms permitted by the design documentation (documentation) shall not be permitted for installation. Upon completion of inspection and degreasing, the pipes permitted for installation shall be closed at the ends with blanks that prevent contamination of the pipes during transportation and storage.
1079. Upon completion of the welding and installation of oxygen pipelines, the presence of slag, burr and metal splashes, and also contamination with fatty substances, on the internal surface of the pipes shall not be permitted.
1080. During the operation of technical devices and communications, their tightness shall be monitored.
1081. The alternating use of technical devices and communications operating with oxygen for work with air and inert gases shall not be permitted, except in cases provided for by the process (for example, warming-up, regeneration, purging).
1082. During the operation of oxygen technical devices, the flow of oxygen into the streams of other gases shall not be permitted. The mixing of oxygen with other gases is permitted in the cases and using the devices provided for by the design documentation (documentation).
1083. Technical devices used for work with one of the air separation products (ASP) may be used for work with other ASP subject to compliance with the following conditions: (a) where the technical specifications provide for operation of the device with air, other ASP and products (gases); (b) the technical device, where warming-up is required, is completely warmed up to positive temperatures, purged and thereafter filled with the new product; (c) before the technical device is used for work with oxygen, its internal surface (flow path) has been checked for the presence of traces of oil and, where necessary, degreased; (d) the safety signs, distinctive colouring and inscriptions on the technical device and communications, and also the control and measuring instruments and the process diagrams of the communications, shall be brought into conformity with the new operating conditions of the device; (e) after the first filling of the technical device with the new product, control analyses of the product confirming its purity are carried out; (f) the conversion of the technical device to operation with another product is documented by a certificate confirming fulfilment of all the requirements of this paragraph and is approved by the technical manager of the organisation operating the facilities for the consumption and production of ASP, with the attachment of documents on the results of the work performed, including by third-party organisations.
1084. Checking of the serviceability and adjustment of safety valves and other protective devices installed on low-temperature technical devices shall be carried out at each scheduled complete warming-up of the low-temperature equipment. In the design of technical devices and in their operation, measures shall be provided for that preclude the icing-up of safety valves in the closed position.
1085. Pipelines for the discharge of air separation products from safety valves and other protective devices with a throughput of more than 100 m3/h shall be routed outside the building. The discharge pipelines from protective devices installed on one and the same technical device or pipeline section may be combined, provided that the common discharge manifold is designed for the quantity of gas coming from all the protective devices that operate simultaneously.
1086. The design and placement of the devices for the discharge of nitrogen and oxygen into the atmosphere shall ensure a volume fraction of oxygen in the air within the range from 19 per cent to 23 per cent in places where operating personnel may be present and where air is taken in for ventilation and process needs.
1087. Warming-up of pipeline valves is carried out from the outside with hot air, steam or hot water. The use of an open flame for warming up the valves shall not be permitted.
1088. Before disconnecting the impulse and other tubes of the instrumentation and automation systems from the valves and communications located on the casing of the low-temperature technical device, it shall be ensured that the valves isolating them are closed.
1089. The thermal and sound insulation of technical devices and communications is made of non-combustible materials (the main insulating materials) in accordance with the design documentation (documentation).
1090. In the intra-block space of air separation units (ASU), cryogenic complexes and in storages of liquid ASP, the use of structural elements made of materials that are explosive in liquid oxygen (for example, organic materials, wood) shall not be permitted.
1091. The lubrication system of the mechanisms shall be leak-tight. For the lubrication of hard-to-reach and also frequently lubricated assemblies of the mechanisms where these are numerous, a centralised automated lubrication system is provided. Manual lubrication of the mechanisms is permitted only when they are completely stopped.
1092. The use of an open flame or smouldering objects to locate leaks of gaseous products shall not be permitted.
1093. A centralised system for oil distribution and oil storage (the oil-distribution facility) shall be designed in accordance with the design norms where several centrifugal compressors are installed in production premises.
1094. Each batch of oil intended for the lubrication of machines and mechanisms shall be subject to incoming inspection (laboratory analysis) before use. Lubricating oil shall be stored in closed containers, separately for each grade.
1095. During installation, operation and repair, the degreasing of technical devices and pipelines in contact with oxygen is carried out on the basis of the results of the analysis of grease contamination; where the established permissible values (norms) of the content of grease contamination are exceeded, degreasing of their surface is carried out in accordance with the process regulations. The process regulations determine the frequency of degreasing and the types of work performed under a permit to work, and also specify the methods of determination and the norms for the content of grease contamination on the surfaces of equipment and pipelines in contact with gaseous and liquid oxygen. The results of degreasing shall be confirmed by protocols forming part of the certificates of installation quality.
1096. Upon the oil concentration in liquid oxygen reaching 0.40 mg/dm or above, confirmed by five consecutively performed analyses, the ASU shall undergo degreasing.
1097. Degreasing of the unit may be omitted within the periods determined by the developer of the ASU if the means of protection against the ingress of oil have ensured, throughout the entire period since the last degreasing, the absence of oil in the liquid oxygen within the sensitivity of the adopted analysis method.
1098. Degreasing of the fully assembled ASU after installation or capital repair may be omitted where the following conditions are met: (a) all parts, pipeline assemblies and tools used during the work were previously cleaned of preservative lubricant and degreased; (b) the work was carried out under conditions precluding the contamination of the internal surfaces of the equipment with fatty substances.
1099. The periods for degreasing ASU operating on a high- and medium-pressure scheme with integrated purification units based on zeolites and with turboexpanders, and also on a low-pressure scheme, are not regulated. Where degreasing of the unit is required, the organisation operating the facilities for the production and consumption of ASP shall develop the degreasing technology and agree it with the developer of the unit.
1100. During the operation of the ASU, the following apparatus and communications shall be subject to degreasing: (a) high- and low-pressure columns; (b) regenerators; (c) air sections of heat exchangers; (d) apparatus and communications in the air stream from the piston expander and from the booster piston compressor; (e) apparatus and communications in the liquid oxygen stream; (f) apparatus and communications in the stream of high-pressure gaseous oxygen.
1101. Newly installed valves intended for work with oxygen shall be subject to degreasing. Valves are not subject to degreasing before installation if the degreasing was performed at the manufacturing plant (which is confirmed by the accompanying documents or by appropriate stamping) and the packaging has not been broken.
1102. Before degreasing of equipment and valves, the preservative lubricant is removed in accordance with the requirements of the factory de-preservation instruction.
1103. Before degreasing of the ASU, pressure testing of the equipment is carried out and all detected leaks are eliminated.
1104. The following are not subject to degreasing: (a) measuring instruments operating at a pressure of up to 0.6 MPa, the design of which permits them to be installed in a position ensuring the free draining of oil from the internal surfaces in contact with oxygen (where the free draining of oil from the internal surfaces is not possible, they shall undergo degreasing in accordance with the process instruction); (b) general-purpose measuring instruments intended for operation in an oxygen-containing medium with an oxygen volume fraction of up to 40 per cent and a pressure of up to 1.6 MPa.
1105. Workshops in which oxygen compressors are installed are equipped with installations for degreasing the assemblies and parts of the compressors, the valves and the pipelines with aqueous cleaning solutions. In doing so, contamination of the air of the production premises with the vapours of the cleaning solutions shall be precluded.
1106. Degreasing of individual parts and removable assemblies by immersing them in baths shall be carried out in closed or semi-closed apparatus equipped with a local exhaust and precluding the ingress of solvent vapours into the air of the premises. In doing so, the processes of degreasing, unloading and drying of the parts shall be continuous. When degreasing the parts and assemblies of oxygen equipment, the compatibility of the materials of the article with the solvents used shall be taken into account.
1107. Baths with aqueous cleaning solutions containing caustic soda shall operate with the local exhausts permanently switched on.
1108. When degreasing oxygen pipelines, it shall not be permitted to use separators (blanks) or other articles placed inside the oxygen pipeline that are made of organic materials.
1109. Where there is a justified need to carry out degreasing with solvents, the following requirements shall be complied with: (a) access to the premises where solvents are stored is permitted only to persons authorised to work with them; (b) the transfer of solvents from one vessel to another is permitted only by a closed method where the workers have personal protective equipment against chemical factors; (c) solvent containers shall be tightly closed and stored only in the premises designated for this purpose or in the open air; (d) spills of solvents onto the floor shall not be permitted; an accidentally spilled solvent shall be removed immediately using dry materials (for example, sawdust, sand). The special premises in which degreasing is carried out and solvents are stored are equipped with permanently operating supply and exhaust ventilation in accordance with the design and the requirements of the Rules. Work with solvents when the ventilation is not operating shall not be permitted.
1110. The quality of the solvents used for degreasing technical devices and communications shall be monitored.
1111. When degreasing the ASU and other special equipment with solvents, complete tightness of the equipment and mechanisation of the process shall be ensured, precluding the possibility of workers coming into contact with the solvents and of solvent vapours entering the air of the production premises.
1112. Purge gas (air, nitrogen) containing solvent vapours shall, before being released into the atmosphere, be subject to purification from the vapours or to absorption of the solvent vapours. The discharge of purge gas into a production room shall not be permitted, even after purification or absorption of the solvent vapours. Before the entrance to the room where degreasing with solvents is carried out, appropriate safety signs with explanatory inscriptions shall be posted.
1113. During operation, the draining of solvent from the equipment and baths is carried out into closed vessels through pipelines.
1114. In the degreasing room, in the vicinity of the units being degreased and the baths with solvents, an analysis of the air for the content of solvent vapours shall be carried out periodically. The content of harmful substances in the air of the working area shall not exceed the maximum permissible concentrations, which are specified in the process regulations.
1115. When degreasing vessels (capacitive apparatus) by the wiping method, the following requirements shall be complied with: (a) before the degreasing work is carried out, a vessel that has been in service is warmed up to a temperature of not less than plus 20 °C and purged with air. Work shall be started only where the volume fraction of oxygen in the air inside the vessel is not less than 19 per cent and not more than 23 per cent; (b) the workers carrying out the degreasing shall use personal protective equipment against chemical factors and shall also be trained in safe methods of carrying out work inside a vessel; (c) the person responsible for carrying out the degreasing shall inspect the place of work and ensure that the vessel is warmed up and prepared for the work.
1116. When degreasing technical devices with petrol and other explosion- and fire-hazardous solvents, the requirements of the Federal Norms and Rules in the field of industrial safety establishing the general explosion safety rules for explosion- and fire-hazardous production operations and facilities shall be complied with.
1117. Spent solvents shall be drained into special closed vessels and sent for regeneration and disposal. The procedure for draining and disposing of aqueous cleaning solutions is determined by the design documentation (documentation).
1118. Before opening devices or pipelines filled with liquid or gaseous air separation products, the following shall be done: (a) reduce to atmospheric the pressure in the devices and pipelines subject to repair; (b) drain the liquid ASP from the vessels and pipelines; (c) warm up the disconnected technical device and pipelines in accordance with the requirements of the Rules; (d) purge the device with air until the volume fraction of oxygen in the outgoing gas is 19 to 23 per cent, whereby sampling for oxygen content shall be carried out not earlier than 5 minutes after the cessation of purging. The discharge of the outgoing gas into the room shall not be permitted; (e) switch off the power supply to the drives of the technical devices and valves; (f) isolate the technical devices or pipeline sections under repair by blanks from all technical devices (for example, apparatus, compressors) and pipelines. The blanks may be omitted if the isolation from the specified equipment and pipelines is effected by not less than two shut-off elements (including forced-action valves) and there is a discharge pipeline (vent stack) with an open valve between them. Before carrying out repair work in the flow path of oxygen, nitrogen and argon compressors, the compressors shall be isolated by blanks from the discharge and suction manifolds, and also from other gas communications, and purged in accordance with the process regulations.
1119. Air separation blocks, before repair or warm pressure tests, shall be disconnected from other equipment.
1120. Repair work in the compartments of technical devices filled with perlite sand, and also in perlite storages, shall be carried out after the complete removal of the perlite sand. The specified work is permitted without the complete removal of the perlite sand where there are appropriate justifications in the design documentation.
1121. Work inside apparatus and in the intra-block space shall be carried out under a permit to work for the performance of gas-hazardous work.
1122. The unloading of perlite sand from the compartments of the air separation block into open vessels or into the machine hall shall not be permitted.
1123. The transfer of perlite sand from storages into air separation blocks and back is carried out using the pneumatic conveying system provided for by the design.
1124. On an operating or not warmed-up air separation block, it shall not be permitted to open the hatches of the block casing for passage into the intra-block space, except for the compartments of the valve boxes (reverse-rotating valves) of the regenerators. Entry into these compartments to repair the valves is permitted only after the pressure has been released from the apparatus of the block, after local warming-up of the compartments of the valve boxes (reverse-rotating valves) and under a permit to work.
1125. Before the start of repair inside the casing of the air separation block, an analysis of the air of the working area shall be carried out, in which the volume fraction of oxygen shall be 19 to 23 per cent.
1126. When carrying out repairs inside air separation blocks filled with mineral wool, the wool shall be removed to such an extent as to preclude its spilling. Where necessary, temporary partitions made of boards or metal meshes and gratings that prevent the spilling of the insulation may be installed inside the compartments; these shall be removed upon completion of the repair.
1127. During the dismantling and repair of assemblies operating in an oxygen medium, contact with grease contamination shall be precluded. The tools intended for this work are degreased and have a distinctive blue stripe. All parts in contact with oxygen are degreased and dried before assembly.
1128. When repairing an air separation block, after the degreasing of its apparatus and communications, purging of the block with air is carried out. The concentration of solvent vapours at the place of repair shall not exceed the maximum permissible concentration specified in the design documentation (documentation) and the process regulations.
1129. Repair work on low-temperature technical devices without their complete warming-up, and also on equipment or a pipeline section disconnected from an operating ASU, is carried out under a permit to work.
1130. When repairing turboexpanders or replacing the filter elements of expander filters, the valves at the air inlet to the turboexpander and at its outlet shall be closed, and the power supply shall be switched off. On nitrogen turboexpanders, blanks shall be installed on the gas supply to and outlet from the turboexpander. Nitrogen turboexpanders are purged with air before repair.
1131. The removal of thermal insulation to provide access to the adsorbers shall be carried out only after the warming-up of these apparatus and the adjacent layer of insulation. The warming-up of the insulation layers adjacent to the apparatus is carried out by means of the heat supplied to the apparatus being warmed up, while the warming-up of frozen insulation is carried out directly with dry heated air. The use of an open flame to warm up the insulation shall not be permitted.
1132. All surfaces of technical devices that come into contact with oxygen during operation are checked for contamination with fatty substances and, where necessary, degreased.
1133. The stopping of all types of technical devices for inspection, cleaning or repair, and also their start-up after repair, is carried out in compliance with the requirements of the process instructions approved by the technical manager of the organisation.
1134. For facilities for the production and consumption of ASP, work of increased hazard includes, among other things, work in the following premises and places: (a) the basement premises of low-temperature technical devices (ASU, cryogenic complexes, storages of liquid air separation products); (b) the intra-block space and compartments of low-temperature technical devices; pipelines, valves, wells, closed trenches, gasholder pits, sites with equipment located outside the building, and structures in the vicinity of discharge pipelines or at a distance of less than 10.0 m from nitrogen-water cooling systems (hereinafter referred to as NWC). Repair work in these places shall be carried out under a permit to work, which specifies the frequency of monitoring the volume fraction of oxygen in the air during the performance of the work.
1135. Repair work inside the pipelines and valves of the warm and cold ends of the regenerators (for example, the forced switching valves of the nitrogen and oxygen regenerators with opening of the valve covers; the three-way dampers and pipelines in the nitrogen stream after the regenerators; the support shells of the regenerators, open valve boxes and compartments of reverse-rotating valves) during the period of shutdown of the blocks without draining the liquid shall be carried out under a permit to work.
1136. The simultaneous performance of repairs shall not be permitted on: (a) the pipelines and valves of the warm and cold ends of the regenerators; (b) the pipelines and valves of the warm (or cold) end of the regenerators and the "command" air system for switching the regenerators or the switching mechanism (for example, a switching machine (shalt-machine), the automatic control system of the regenerators); (c) the forced switching valves of the regenerators and the three-way dampers after the regenerators.
1137. For the entire period of repair, the valve on the discharge of gas from the block into the atmosphere shall be open.
1138. Before repair, the electric gate valve at the air inlet to the block shall be closed and manually tightened.
1139. The regenerator switching mechanism (the switching machine (shalt-machine)) shall be stopped for the period of repair of the valves (pipelines).
1140. Before carrying out work on one or both three-way dampers involving access to the pipelines leading to them, blanks are installed (in the direction of the gas flow) ahead of both three-way dampers, or other measures ensuring the safety of the workers are taken.
1141. Repair of the forced valves of the warm end of the regenerators, the three-way dampers after the regenerators, and the automatic and reverse-rotating valves is carried out in accordance with the instruction of their developer.
1142. The operation (maintenance, supervision and repair) of the building structures of production buildings and structures and the monitoring of their condition are carried out in accordance with the requirements of Federal Law No. 384-FZ of 30 December 2009 "Technical Regulations on the Safety of Buildings and Structures" (Collected Legislation of the Russian Federation, 2010, No. 1, Art. 5; 2013, No. 27, Art. 34477), and also in accordance with the design documentation (documentation) and the Rules.
1143. The sites on which the vessels and filling-and-draining devices for liquid air separation products are located, and also the places for filling and emptying transport vessels with liquid air separation products, shall have a continuous covering of concrete or other non-combustible materials. The use of asphalt, organic coverings and wooden sleepers on the railway tracks, at the places of transfer of liquid air separation products, shall not be permitted. Within the boundaries of the sites, the arrangement of channels, trenches, pits, wells, storm drainage traps and other underground structures shall not be permitted.
1144. All metal structures (for example, supports for vessels and communications, platforms, stairs) located within the sites in accordance with paragraph 1143 of the Rules, and also at a distance from the vessels with liquid air separation products determined by the norms for the design of facilities producing air separation products, are installed on concrete foundations with a top elevation exceeding the elevation of the site by not less than 0.2 m.
1145. Storm drainage traps, pits and basements located outside the sites with vessels and filling-and-draining devices for liquid air separation products at a distance of less than 10.0 m shall have a concrete barrier (threshold) with a height of not less than 0.2 m on the side facing the site, and shall project beyond the outline of the enclosed objects by not less than 1.0 m.
1146. It shall not be permitted to place any technical devices and materials or articles unrelated to the process of production, reception, storage and dispensing of liquid air separation products within the boundaries of the sites with ASU apparatus, vessels of liquid air separation products and filling-and-draining devices.
1147. Sites with technical devices (for example, stationary vessels, filling-and-draining devices and gasifiers for liquid air separation products, gasholders, receivers and filling (discharge) manifolds) located outside the building at facilities consuming air separation products shall have fencing of non-combustible materials. The height of the fencing, where the sites are located on a territory having a common fence, shall be not less than 1.2 m, and where the sites are located outside the fenced territory, not less than 2.0 m. Metal mesh is permitted for the construction of the fencing. The parking places for road and rail transport vessels during the transfer or gasification of liquid air separation products may be excluded from within the fencing, provided that, for the duration of the operations, these places are closed to the passage of transport of another purpose.
1148. In premises intended for the parking of vehicles with vessels of liquid air separation products, the arrangement of inspection pits and other pits shall not be permitted.
1149. On the territory of organisations, the clearance gauges of buildings and structures and of the rolling stock of railways of 1520 (1524) mm gauge and 750 mm gauge are adopted in accordance with the design standards and norms.
1150. The places where railway tracks cross with roads and pedestrian crossings at a hazardous production facility shall comply with the design documentation and the requirements of the Rules.
1151. The organisation operating the facilities for the production and consumption of ASP shall develop schemes for the movement of vehicles and pedestrians across the territory of the production, the facility. These movement schemes are posted on the territory of the organisation and in all production premises (for example, workshops and sections).
1152. The design of the elements of buildings housing operations that use hydrogen and other combustible gases shall preclude the formation of stagnant zones and unventilated areas.
1153. The arrangement of floors shall comply with the design documentation (documentation) and the requirements of the Rules. The floors in the premises shall be resistant to the mechanical, temperature, chemical and other impacts produced during the production process. In the explosion-hazardous and fire-hazardous zones of the premises, the floors are made in a non-sparking design.
1154. All building structures of buildings and structures exposed to an aggressive environment are protected against corrosion in accordance with the design documentation (documentation), taking into account the requirements of the Rules.
1155. The boundaries of passageways and walkways in production premises shall have barriers or special marking.
1156. The arrangement of protection of buildings, structures and outdoor installations against direct lightning strikes and its secondary manifestations is determined by the design documentation (documentation).
1157. During the operation of low-temperature technical devices, monitoring of the settlement of the foundations shall be ensured in accordance with the requirements of the design documentation (documentation). In the basement premises of the foundations and in the pits adjoining them, the accumulation of water shall not be permitted.
1158. The use of basement premises beneath low-temperature technical devices, and also of the pits of ASP gasholders, for storage or other needs shall not be permitted.
1159. In premises connected with the production, storage and consumption of air separation products, the condition of the air environment is monitored. The volume fraction of oxygen in the air of these premises shall be not less than 19 per cent and not more than 23 per cent. The procedure for monitoring the air environment - the use of automatic gas analysers with an alarm device - and the frequency of air sampling in the premises and at workplaces are determined during design by the design organisation, taking into account the specific operating conditions, the types of technical devices and the design standards.
1160. Within an organisation operating facilities for the production and consumption of air separation products, a list is drawn up of premises and locations where the oxygen content by volume fraction may be less than 19 per cent or more than 23 per cent (in an emergency situation), specifying the types and frequency of monitoring and the measures to normalise the composition of the air. This list is approved by the technical manager of the organisation operating the facilities for the production and consumption of air separation products.
1161. Where the oxygen content in the air is monitored continuously and automatically, the signalling devices give signals (visual and (or) audible) when the volume fraction of oxygen falls below 19 per cent or rises above 23 per cent.
1162. When the limiting concentrations of oxygen in the air of the monitored premises are reached, measures to normalise the composition of the air are taken immediately by the automatic or manual (by the operating personnel) activation of the ventilation systems.
1163. The arrangement and siting of gasholders and receivers for air separation products shall comply with the design documentation (documentation) and the requirements of the Rules.
1164. Wet and dry steel constant-pressure gasholders for air separation products shall be fitted with remote indicators of the gasholder filling level with alarms by filling level - minimum, pre-minimum, pre-maximum and maximum, or respectively 10, 20, 80 and 90 per cent of the full volume.
1165. When the minimum filling level of the gasholder is reached, the compressors (blowers) connected to the gasholder are automatically shut down. In addition, the gasholders shall be fitted with protection against vacuum formation. When the maximum filling level of the gasholder is reached, automatic opening of the device for discharging gas into the atmosphere is provided.
1166. The water seals of the gasholder drain tanks shall be kept filled with water at all times.
1167. The outer surface of steel gasholders and receivers located outside a building is painted to reduce their heating by sunlight. The inner surface of wet constant-pressure gasholders is painted with corrosion-resistant paints.
1168. On an individual receiver vessel or on a group of receiver vessels shut off by a single shut-off device, fittings for discharging gas into the atmosphere shall be provided.
1169. For receivers with a capacity of more than 200 m3 and a working pressure of more than 1.6 MPa, remotely controlled shut-off gate valves shall be installed at the point of their connection to the inter-shop oxygen pipelines.
1170. Receivers located outside buildings shall have a fence at least 1.2 m high. On the outer surface of the gasholders and at the entrance to the fenced area containing the receivers, inscriptions with the name of the gas stored in the gasholder or receiver shall be provided.
1171. Operations to reduce and maintain the oxygen pressure and to regulate its flow rate in oxygen supply systems with flow rates exceeding 6000 m3/h and a pressure from 0.6 MPa to 4.0 MPa shall be carried out in a control and regulation point (CRP).
1172. The conditions for siting the CRP (in a free-standing building or in separate premises of the facilities for the production and consumption of air separation products and of the oxygen-consuming shops) and its arrangement are determined by the design documentation (documentation) and the requirements of the Rules.
1173. For CRPs located in free-standing buildings, the following conditions shall be observed: (a) each regulation line with a cut-off valve and a control valve shall be placed in a separate isolated room. The walls between the regulation lines (and other rooms) are made without openings; (b) each room in which a regulation line is placed shall be equipped with a ventilation system; (c) in the CRP room, the placing of various equipment and devices not connected with its operation shall not be permitted; (d) automatic control of the control and cut-off valves and remote control of the shut-off electric gate valves shall be provided; (e) the CRP control room shall not have a direct passage (entrance) into the regulation line room. Passage into the CRP regulation line room shall be only through external entrances (exits) located at opposite ends of each room.
1174. For CRPs located in separate rooms of the facilities for the production and consumption of air separation products and in oxygen-consuming shops, the following conditions shall be observed: (a) each regulation line of the CRP is equipped with automatically operating control devices. The use of remote control is permitted; (b) the two entrances (exits) to the CRP are made at opposite ends of the room; (c) the distance between the rooms of adjacent CRPs shall be not less than 6.0 m.
1175. In the flanged joints of the shut-off gate valves of each regulation line (before and after the regulator), spacer rings shall be installed on the regulator side, in place of which, when the control fittings are shut off for repair, blanking plates are installed.
1176. On each oxygen pipeline, before the CRP, at a distance of not less than 10.0 m and not more than 50.0 m, a remotely controlled shut-off gate valve shall be installed. The power supply category of these gate valves is determined by the design (the design standards).
1177. Each regulation line of the CRP is equipped with an interlock that stops the supply of oxygen when the alarm indicating a rise in the oxygen temperature after the pressure regulator above plus 100 °C is triggered.
1178. On an oxygen pipeline more than 250.0 m long made of carbon steels, switchable filters shall be installed before its connection to the suction manifold of the oxygen compressors. A filter shall be installed directly before the suction branch of the centrifugal oxygen compressor. On oxygen pipelines operating at a pressure of more than 1.6 MPa, filters complying with the above-mentioned requirement of this paragraph of the Rules shall be installed before the CRP.
1179. The opening and closing of the gate valve installed before the filter (in the direction of gas flow) shall be carried out with the gate valve installed after the filter closed.
1180. The stationary bypass lines (bypasses) provided for purging the oxygen pipelines shall have removable branch pipes and blanks, and these bypass lines (bypasses) shall be located outside the CRP premises.
1181. The doors of the CRP regulation line rooms shall be kept closed. Operating workers are permitted to be in these rooms only while carrying out work, and the locks on the doors of both exits shall be open.
1182. Where oxygen is supplied through pipelines with a diameter of 300 mm or more to a CRP located in a free-standing building or in premises attached to other buildings, the CRP control room shall be set apart from the regulation line room by a distance of not less than 15.0 m.
1183. The permanent presence of operating personnel in the CRP control room shall be prohibited.
1184. The inspection and operation of cylinders containing air separation products are carried out in accordance with the requirements of the federal norms and rules in the field of industrial safety establishing the industrial safety rules for hazardous production facilities using equipment operating under excess pressure.
1185. The filling of cylinders with gaseous air separation products is carried out in accordance with the process regulations.
1186. Automatic monitoring of the air environment shall be carried out in the cylinder filling room. Work in the cylinder filling, storage and discharging rooms shall not be permitted when the volume fraction of oxygen in the air is less than 19 per cent and more than 23 per cent.
1187. The gasket and sealing materials used in the fittings installation assemblies and in detachable joints shall comply with the design documentation (documentation). In an oxygen environment, the use of gasket and sealing materials of organic origin shall not be permitted.
1188. To avoid contamination of oxygen by residual gas from cylinders received from the consumer, before filling the cylinders placed on the rack, the residual gas from all cylinders shall be released into the drainage system down to atmospheric pressure. Cylinders of medical oxygen, after the residual pressure has been released, shall be purged before filling by a single filling with oxygen to a pressure of not less than 0.98 MPa, followed by the release of the gas.
1189. The transport of cylinders containing air separation products is carried out in a vertical position in containers. The loading and unloading of containers shall be mechanised.
1190. Filled and empty cylinders shall be stored in containers or cages.
1191. Two-way communication shall be provided between the filling room and the room from which the equipment (compressors, gasifiers, liquid pumps of the air separation unit (ASU)) supplying compressed air separation products for the filling of cylinders is controlled.
1192. The technical devices of the facilities for the production and consumption of air separation products shall be equipped with systems for automatic and remote control and for the monitoring of process operations, with emergency protection, communication and alarm systems, in accordance with the design documentation (documentation) and taking into account the requirements of the Rules.
1193. The measuring and control instruments used to measure the parameters of oxygen and of gas mixtures with a volume fraction of oxygen of more than 23 per cent shall be protected against grease contamination.
1194. Operation of the equipment shall not be permitted when the alarm and protection systems are faulty or disconnected. Operation with the automatic control systems disconnected is permitted only where this is provided for by the process regulations. The use of faulty control and technical instruments and automation equipment shall not be permitted, nor the use of such equipment not complying with the requirements of the legislation of the Russian Federation on ensuring the uniformity of measurements, including the requirements for the performance of verification and calibration.
1195. The disconnection of an alarm or an interlock for the inspection of apparatus and the calibration of gas analysers shall be recorded in the process log.
1196. In the chromatography room, the storage of more than two cylinders of reference and calibration gas mixtures shall not be permitted. The capacity of each cylinder shall not be more than 40 l, and the pressure not more than 20 MPa.
1197. The oxygen sampling lines for analysis shall be made of corrosion-resistant steel or copper alloys, regardless of the oxygen parameters.
1198. The arrangement, installation, maintenance and repair of electrical installations shall comply with the requirements for ensuring the reliability and safety of power-receiving installations, with the technical regulations and with the Rules. Power consumers ensuring the process operations at the facilities for the production and consumption of air separation products shall be assigned to category II of electricity supply reliability. Power consumers ensuring the continuity of the production process shall be assigned to category I of reliability. It is permitted not to provide a reserve power supply for the production of air separation products consisting of a single process unit.
1199. Protection against static electricity of technical devices (for example, ASUs, rare gas production units, oxygen compressors and gasholders, vessels of stationary liquid oxygen storage facilities) and of utility lines (pipelines and fittings) for gaseous oxygen and liquid air separation products is carried out in accordance with the design documentation (documentation).
1200. The presence of water and oil in the tunnels and ducts for electric cables shall not be permitted. Systematic monitoring of the condition of the tunnels and ducts shall be established in accordance with the procedure and frequency established by the operating organisation.
1201. The arrangement and siting of the heating, ventilation and air-conditioning systems of the facilities shall comply with the design documentation (documentation), taking into account the requirements of the Rules.
1202. The volume fraction of oxygen in the air of the production premises of the air separation product production shall be not less than 19 per cent and not more than 23 per cent, and the uninterrupted operation of the supply-and-exhaust ventilation systems shall be ensured. The operation of technical devices whose operation is accompanied by the release of harmful, explosion-and-fire-hazardous and fire-hazardous substances shall not be permitted where the ventilation system is faulty.
1203. Instrumental checking of the effectiveness of the ventilation systems shall be carried out not less than once a year, and also after each major repair or reconstruction of these systems. The inspection reports are approved by the technical manager of the organisation.
1204. For all ventilation systems, the appropriate operational documents (data sheets or logbooks) are drawn up.
1205. When the process operation is changed or the production section is reconstructed, the ventilation systems operating in that section are brought into conformity with the new production conditions. Design work on the modification or adjustment of ventilation systems shall be supported by calculation and agreed with the design organisation.
1206. Persons not connected with the operation of the ventilation systems shall not be permitted to enter the ventilation rooms, to switch the fans on and off, or to open or close the fittings (for example, valves, dampers) of the ventilation systems.
1207. Where a basement is constructed beneath the air separation blocks, an air temperature of not less than plus 5 °C shall be maintained in it, and an exhaust ventilation system shall be provided.
1208. The purging system for oxygen, nitrogen and argon technical devices and utility lines shall exclude the possibility of air separation products entering the room. In the event of a normative (regulated) leak or discharge of air separation products into the room (in individual cases determined by the design documentation (documentation)), their removal by the supply-and-exhaust ventilation system is provided.
1209. The connection of domestic-and-drinking water supply networks to water supply networks delivering water of industrial quality shall not be permitted.
1210. In production premises where an elevated oxygen content is possible that may lead to the ignition of clothing, or where there are hazardous substances that may cause chemical burns, drinking fountains, taps, sinks or self-help baths and emergency showers shall be installed. The devices specified in this paragraph shall be located in easily accessible places and connected to the domestic-and-drinking water supply. It shall not be permitted to locate these devices in premises in which substances are handled or stored that decompose explosively or ignite on contact with water, or that release explosive or toxic gases.
1211. The inspection and cleaning of sewerage networks and wells are carried out according to schedules and in accordance with the procedure for carrying out gas-hazardous work.
1212. Natural and artificial lighting in the production and auxiliary buildings and premises of the facilities for the production and consumption of air separation products, including the emergency lighting of the main workplaces, shall comply with the design documentation (documentation) and the requirements of the Rules.
1213. In explosion-hazardous premises, lighting systems of explosion-proof design shall be provided.
1214. Systematic checks of the serviceability of the emergency lighting network are carried out by organisations operating facilities for the production and consumption of air separation products, in accordance with the procedure and frequency established by the operating organisation.
1215. To prevent the shadowing of workplaces by overhead cranes, additional lighting fixtures shall be provided on the crane trusses.
1216. The structural design of portable lighting fixtures is selected taking into account the nature of the environment and the place of their use.
1217. The obstruction of the light openings of premises shall not be permitted.
1218. The chemically hazardous production facilities of aboveground liquid ammonia storage facilities include: liquid ammonia storage facilities being designed, being reconstructed and in operation; factory storage facilities located on the territory of organisations producing ammonia, using it as a raw material or auxiliary material for the manufacture of marketable products, or using ammonia in industrial refrigeration installations or for other purposes; transhipment storage facilities located at near-port plants or water-transport bases; track-side storage facilities located outside the territory of enterprises and intended for the receipt of liquid ammonia from railway tank cars, its storage in tanks and its dispensing to consumers into road tankers; deep-lying agricultural storage facilities located within the territory of an agricultural district; dispensing stations located in agricultural districts receiving ammonia from an ammonia pipeline.
1219. This Section does not apply to storage facilities for ammonia in cylinders or to unmanned automated underground storage facilities.
1220. The method of storing liquid ammonia and the number, capacity and type of tanks are determined by the design on the basis of ensuring safe operation.
1221. The storage of liquid ammonia at storage facilities may be carried out: in tanks under an excess pressure of up to 2.0 MPa inclusive without removal of ammonia. The working pressure in the tank is taken on the basis of the maximum ambient air temperature, taking into account solar radiation and the presence of thermal insulation and protective structures; in tanks under an excess pressure of up to 1.0 MPa inclusive with removal of the ammonia evaporating from heat ingress, with its delivery to the consumer or with compression of the evaporated ammonia followed by its condensation and return to the tank; in isothermal tanks under a pressure close to atmospheric, with removal of the evaporating ammonia, compression, condensation and return to the tank or to the consumer (the isothermal storage method).
1222. The filling coefficient of the tanks is determined by the design organisation on the basis of the storage conditions and the parameters of the incoming ammonia, but not more than 0.85 of the geometric volume of the tank for the storage of ammonia under excess pressure, and 0.93 of the height of the cylindrical part of the isothermal tank.
1223. The number and type of tanks at a single storage facility are determined by the design organisation. When ammonia is stored under pressure, the possibility of transferring it to other tanks or to a specially installed reserve tank shall be ensured. The capacity of the reserve tank is not taken into account when determining the capacity of the storage facility. In the event of a failure of an isothermal tank, the design documentation provides for actions for its emptying and for the collection and elimination of ammonia spills.
1224. The siting of the liquid ammonia storage facility and of the utility networks, the layout of the storage facility territory, the space-planning solutions of the storage facility buildings and structures, and the heating and ventilation of the premises are carried out in accordance with the requirements of the regulatory and technical documents and of these Rules.
1225. The storage facility shall be located on non-floodable land plots on the leeward side of the prevailing wind directions in relation to residential areas with the largest numbers of people, kindergartens and nurseries, schools, hospitals and other places where large numbers of people gather, taking into account the situational plan of the district and the natural conditions of the territory.
1226. The distances from liquid ammonia storage facilities to civil and industrial facilities are determined taking into account the calculation of the concentrations of ammonia in the air and the spread of the gas cloud in the event of accidents at liquid ammonia storage facilities, while ensuring compliance with the requirements of industrial safety.
1227. Liquid ammonia storage facilities shall be equipped with means preventing the spread of the ammonia gas cloud in the event of a spill (accelerated dissolution of it in dispersed water, the use of water curtains) and reducing the rate of evaporation (covering the spill with carbon-dioxide or foam compositions).
1228. The distances from a liquid ammonia storage facility to facilities located outside the territory of the storage facility shall be determined horizontally from the upper inner edges of the enclosures of these tanks (the boundaries of evaporation of the ammonia spilled from the tank in the event of an accident).
1229. The territory of a storage facility located outside an enterprise is enclosed with a fence of non-combustible materials at least 2 m high, and that of a storage facility located within an enterprise with a mesh fence.
1230. A wind-direction indicator, clearly visible to the storage facility workers, is installed on the territory of the liquid ammonia storage facility.
1231. Only those buildings and structures that are necessary for the process operations of receiving, storing and dispensing ammonia to consumers and for ensuring the normal operation of the storage facility and its workers are permitted to be located on the territory of the storage facility, including: tanks for the receipt and storage of liquid ammonia; the compressor rooms of the ammonia refrigeration installations and the pump rooms; the oil collection point; installations for the preparation of aqueous ammonia and tanks for its storage; a propane or natural gas store with an evaporation installation; a liquid ammonia evaporation installation; an installation for superheating gaseous ammonia; installations for compressing the air of the instrumentation and automation equipment, with air-drying and buffer-nitrogen units; a reduction cooling installation for producing steam of the required parameters; a condensate collection station; loading-and-unloading points for liquid ammonia and aqueous ammonia, including the loading-and-unloading racks for railway and road tank cars; the flare installation of the storage facility; installations for filling ammonia cylinders and for their storage; blocks of nitrogen cylinders with a rack, and blocks of air cylinders; an emergency tank, emergency showers, a gas-analyser room; water supply and sewerage networks; power supply networks; the central control point of the storage facility; buildings and premises of auxiliary and production purpose, and welfare and administrative premises intended for the storage facility workers.
1232. Each free-standing tank or each group of tanks for the storage of liquid ammonia is equipped with a continuous enclosure (for example, an earthen bank, a reinforced-concrete wall). The horizontal distance from the outer wall of the tank to the enclosure (to the lower edge of the inner slope), the height of the enclosure and the distance between the tanks are determined by the design, taking into account the exclusion of the outflow of ammonia from a damaged tank beyond the enclosure and the minimum surface area of evaporation of the ammonia spilling within the enclosure in the event of an accident.
1233. The enclosure of isothermal tanks being designed or of a group of isothermal tanks, except for steel tanks with equal-strength shells, shall be calculated for the dynamic impact of the spilling liquid (ammonia or water) in the event of possible destruction of the tank.
1234. The height of the enclosure of tanks for the storage of liquid ammonia is determined as being not less than 0.3 m above the design level of the spilled liquid ammonia, but not less than 1 m, and for isothermal tanks not less than 1.5 m. The earthen bank and the slopes of the excavation shall be protected against erosion by atmospheric waters. The width of the top of the earthen bank is set at not less than 1 m.
1235. The free volume within the enclosure of the tanks, from the planning mark to the design level of the liquid ammonia, less the volumes of the supporting structures beneath the ammonia storage tanks, of the crossings and of the dividing partitions, is determined: for the installation of a single tank, as not less than its capacity; for the installation of a group of tanks, as not less than the capacity of the largest tank.
1236. Where tanks of different types are installed together, a continuous partition may be installed between the tanks to contain spills of liquid ammonia. The advisability and the arrangement of the partition are determined by the storage facility design.
1237. The joining of two outer enclosures of tanks for the storage of liquid ammonia is permitted.
1238. Stairs are installed for crossings over the tank enclosure. The distance between the stairs within the enclosure is set at not more than 80 m, and the number of stairs at not less than two.
1239. Tanks for the storage of liquid ammonia are equipped with servicing platforms ensuring the safety of the performance of work during maintenance and repair.
1240. For access to the storage facility and for passage across its territory to the buildings and structures, roads and a bypass around the enclosure of the tank or group of tanks at least 3.5 m wide are provided. On the side of the buildings and open installations adjoining the tank enclosure, the bypass is permitted to be located at a distance of not more than 39 m from the tank enclosure.
1241. Within the enclosure of tanks for the storage of liquid ammonia, a sump is provided for the collection and removal of ammonia spills and atmospheric precipitation. The territory within the enclosure of tanks for the storage of liquid ammonia shall be graded with a slope towards the sump. To reduce the area of spread of ammonia over the territory during small spills within the enclosure of spherical isothermal tanks, the territory shall be graded with a slope from the tank enclosure towards the foundation on which they are located. The perimeter of the foundation, at the level of the lower mark of the territory slope, is fitted with a ditch to drain the ammonia into the sump. In this case, the upper surface of the tank foundation shall be located 10 - 15 cm above the lower mark of the territory slope and shall have slopes towards the ditch.
1242. The soil within the enclosure shall be compacted. It is recommended to make concrete screeds or a facing with slabs on the inner side of the enclosure. For agricultural-purpose storage facilities, a grass covering is permitted, and the grass shall be mown and removed from the territory of the storage facility. The territory within the tank enclosure and of the inner slopes of the earthen bank shall not be covered with crushed stone, gravel or porous materials.
1243. The distances from the tank enclosure and from the boundaries of the sites of the loading-and-unloading points to the buildings and structures located on the territory of the storage facility are determined by the design, taking into account the requirements for ensuring safety.
1244. The height of the flare stack and the minimum horizontal distance from the flare stack to the buildings and structures located on the territory of the storage facility are determined by the design organisation, taking into account the thermal load.
1245. It shall not be permitted to route transit pipelines not relating to the tanks for the storage of liquid ammonia, or cables, through the enclosed territories of the tanks for the storage of liquid ammonia.
1246. Loading-and-unloading racks shall be located on a straight horizontal section of the railway track. The loading-and-unloading devices and the rack shall be located on one side of the track.
1247. Loading-and-unloading devices are permitted to be located between adjacent tracks. In this case, a rack with two-sided branches to the tank cars shall be installed, and the distance between the axes of the loading-and-unloading railway tracks at this rack shall be taken as not less than 6 m. Between loading-and-unloading racks located in parallel, a clear strip shall be provided for the through passage of fire-fighting and ambulance vehicles.
1248. The number and design lengths of the loading-and-unloading railway tracks are determined by the design. Loading-and-unloading devices are permitted to be located on a dead-end railway track. For loading-and-unloading racks with two or more discharge points, the design length of the dead-end loading-and-unloading track shall be increased by not less than 20 m towards the buffer stop within the boundary of the loading-and-unloading site.
1249. Loading-and-unloading racks are provided as walk-through racks with stairs and approaches to the valves on the manholes of the tank-car shells. The width of the passage on the rack is taken as not less than 0.8 m. The stairs shall be located at the ends of the rack, and also along its length at a distance from one another of not more than 80 m. The sites for the loading-and-unloading racks shall have a hard surface.
1250. Buildings on the territory of the storage facility shall be of not lower than fire-resistance degree II. The structures of the storage facility (for example, frameworks, servicing platforms, loading-and-unloading racks, supports of spherical tanks, canopies) shall be made of non-combustible materials with a fire-resistance limit of not less than 0.25 h.
1251. It is not recommended to provide doors and opening windows in the walls of buildings on the side facing the ammonia tanks, except for emergency-shower doors. The external doors in the storage facility buildings shall be self-closing with sealing at the rebates.
1252. In places of possible prolonged exposure of building structures and foundations to the low temperatures of ammonia, the design provides for measures excluding impermissible deformations of the soil and of the building structures.
1253. Liquid ammonia pumps are permitted to be located beneath pipe racks.
1254. The arrangements of the tanks for the storage of ammonia shall ensure reliable and safe operation throughout the service life specified in the data sheet of the manufacturer, and shall provide for the possibility of their complete emptying, cleaning, washing, purging, inspection, technical examination and repair. The procedure for, the scope of and the frequency of the technical examination are determined by the regulatory technical documentation.
1255. Tanks used at a hazardous production facility are manufactured by organisations possessing the necessary technical means and qualified specialists, in accordance with the design (engineering) documentation, which takes into account the achievements of science and technology and the requirements of industrial safety.
1256. The design documentation for a tank specifies the following: the requirements for the manufacture and testing of the tank; information on the sheet-by-sheet inspection of the metal for the absence of impermissible external and internal defects and for the conformity of the chemical composition and mechanical properties to the requirements established for the given grade of metal.
1257. The steel grade and the requirements for its quality are determined by the design organisation, taking into account the conditions of manufacture and operation of the tank, as well as the requirements of the relevant standards. Sheet steel intended for the manufacture of tank bottoms and walls shall be inspected for the absence of laminations. Testing of steel for impact toughness at a temperature of minus 70 °C shall be carried out by the manufacturing organisation in the following cases: where the steel is intended for the manufacture of tanks installed in climatic areas with a temperature of the coldest five-day period below minus 41 °C; where cooling of the tank by liquid ammonia spilled within the bund from neighbouring tanks is possible in the event of the destruction of the latter. In other cases the design temperature for the selection of the steel grade and the testing conditions are determined by the design.
1258. The welds of tanks shall be subject to 100 per cent inspection. The assessment of the quality of welded joints shall comply with the requirements established by regulatory and technical documents.
1259. Tanks shall comply with the requirements of technical regulations, the requirements for the design and safe operation of vessels operating under excess pressure, these Rules and the documentation of the manufacturing organisation.
1260. The type and scope of heat treatment of welded structural elements of tanks operating under excess internal pressure, for the purpose of reducing residual stresses in welded joints, are determined by the design.
1261. The use of heating devices located inside or on the external surface of tanks may be permitted where the capacity of the tanks does not exceed 50 t. Non-combustible, non-corrosive substances shall be used as the heat-transfer medium for internal heating devices. The design of heating devices shall ensure the complete drainage of the heat-transfer medium. The branch pipes of internal heating devices shall be located on the bottom of the tanks.
1262. Branch pipes for the discharge of liquid ammonia, drainage, flushing and instrumentation and control equipment (I&C) may be located in the lower part of the tanks, and the remaining branch pipes in the upper part of the tanks.
1263. Manholes shall be located in the upper part of the tanks. The provision of additional manholes in the lower part of spherical tanks may be permitted where there is a corresponding design decision.
1264. During operation, periodic examination of the shells of a spherical tank shall be carried out, and the condition of the insulation (paragraphs 1309 - 1319 of these Rules), the magnitude and uniformity of settlement of the foundations of spherical tanks shall be monitored before and after the hydraulic testing of the tank and before liquid ammonia is supplied to it, as well as periodically during operation (paragraph 1285 of these Rules).
1265. Isothermal tanks shall be manufactured from steels with increased requirements imposed on the chemical composition, mechanical properties and quality of the sheet, in accordance with the technical specifications of the developer of the process and the design of the tank.
1266. The design temperature when selecting the steel grade for isothermal tanks shall be taken with account of the following requirements: where a tank is located in an individual bund (earthen embankment, wall) - not higher than the air temperature of the coldest five-day period in the given area, but not higher than minus 34 °C; where several tanks are located in a single bund: for the lower part of the tank shell that may come into contact with spilled ammonia in the event of the destruction of a neighbouring tank - not higher than minus 67 °C; for the remaining part of the tank shell that does not come into contact with spilled ammonia, the same as for a tank located in an individual bund. The design temperature when selecting the steel grade for the supporting structures beneath tanks that are not protected from spilled ammonia shall be taken with account of the possibility of their cooling to minus 67 °C.
1267. Steel intended for the manufacture of single-wall vertical tanks and the inner shells and cups of double-wall vertical tanks installed in climatic areas with a temperature of the coldest five-day period below minus 41 °C, and also steel, taking into account its possible cooling by liquid ammonia spilled into the bund, is tested by the manufacturing organisation for impact toughness at a temperature of minus 70 °C.
1268. The design pressure of isothermal tanks shall be taken to be greater than the working pressure by 25 per cent, but by not less than 98.06 Pa (10 mm of water column). The design pressure in the inter-wall space of single-wall isothermal tanks shall be taken to be not less than 490.3 Pa (50 mm of water column).
1269. Isothermal tanks shall be designed with account of a possible vacuum of not less than 490.3 Pa (50 mm of water column), the maximum and minimum barometric pressure, and the wind load.
1270. The method of welding and manufacture of the bottoms and roofs of isothermal tanks is determined by the design.
1271. The outer shell of a tank with fill-type insulation is equipped with manholes for filling the inter-wall space with heat-insulating material (perlite), and also with branch pipes for supplying dry nitrogen with a dew point of minus 40 °C at a pressure of 98.06 - 196.1 Pa (10 - 20 mm of water column) into the inter-wall space and for taking samples for analysis during the drying of the perlite and the operation of the tank.
1272. For cooling the tank by evaporating ammonia, a spraying device is installed inside the tank above the permissible level of liquid ammonia, which may also be used for filling with liquid ammonia.
1273. The roof and the side walls of the lower part of isothermal tanks are equipped with manholes. The number of manholes and their type are established by the design.
1274. The arrangement of the passages of branch pipes through the outer wall of a double-wall tank shall be provided with expansion joints.
1275. A passport is drawn up for an isothermal tank by the manufacturing organisation.
1276. The organisation operating an isothermal tank appoints, in accordance with the system of maintenance and repair, a person responsible, from among specialists who have undergone special training, for monitoring the conformity of the isothermal tank being manufactured to the technical requirements of the design, and for the technical condition, operation and technical examination of the tank.
1277. The assessment of the technical condition of isothermal tanks for the storage of liquid ammonia (including metal structures, thermal insulation, bases and foundations) shall be carried out in accordance with the requirements of regulatory documents.
1278. The magnitude and uniformity of the settlement of the foundations of tanks are monitored before the hydraulic testing of the tank, before liquid ammonia is supplied to it, and periodically during operation. The measurement of the settlement of the foundation of isothermal tanks shall be carried out by levelling in absolute elevations against a deep benchmark and a benchmark on the foundation or supports of the tank. The monitoring is carried out during the period of rising groundwater, and also during the maximum unloading (loading) of the tank.
1279. Where isothermal tanks are equipped with permanently operating means of technical diagnostics and operational monitoring using acoustic emission methods, the date of the next technical examination is set according to the actual technical condition of the structures on the basis of the conclusion of specialised organisations carrying out industrial safety expert examination.
1280. Tanks located in seismically active zones are additionally designed for seismic loads. Vertical cylindrical tanks are equipped with devices for suppressing the wave of liquid ammonia (for example, floating pontoons).
1281. Tanks for the storage of liquid ammonia shall be isolated from pipelines by two shut-off devices with a control valve located between them. Valves located directly at spherical, isothermal and horizontal tanks with a capacity of 100 t or more shall have remote and manual control. Remote control shall be carried out from the central control point of the storage facility.
1282. On the pipelines for supplying liquid ammonia to tanks and for discharging it from them, protective devices (shut-off valves, excess-flow valves, non-return valves, gate valves with electric drive) shall be installed to prevent the outflow of ammonia from the tank in the event of damage to the pipeline. The protective devices shall be installed between the tank and the shut-off valve on the ammonia supply pipeline and after the shut-off valve on the discharge pipeline.
1283. It is recommended that pipelines connected to tanks for the storage of liquid ammonia be laid not below the elevation of the top of the tank bund. The arrangement of the assembly for the passage of pipelines through the tank bund shall exclude the possibility of leakage of liquid ammonia beyond the bunded area.
1284. The design of the flange seals of ammonia pipelines is determined by the design and shall comply with the requirements of regulatory technical documents. To reduce stresses at the points of connection of pipelines to the tank walls arising from thermal movements, as well as during the settlement of the tank, self-compensation of pipeline deformations or the installation of expansion joints is provided for. The connection of pipelines to the tank shall be carried out after the hydraulic testing of the tank.
1285. The compensation of the ammonia pipelines and the purge pipeline of an isothermal tank shall be calculated with account of the possibility of their cooling to a temperature of minus 34 °C or to the air temperature of the coldest five-day period, if it is below minus 34 °C.
1286. Ammonia pipelines shall be located on pipe racks above pipelines transporting acids and other aggressive liquids.
1287. On pipelines for liquid or gaseous ammonia, steel valves and shaped parts are used. The use of cast-iron shut-off and control valves, as well as valves and fittings with parts made of copper, zinc and their alloys, shall not be permitted.
1288. Tanks with ammonia are equipped with safety valves. The number of working safety valves on a tank, their dimensions and throughput capacity are established by the design. In parallel with the working safety valves, standby safety valves shall be installed. The characteristics of the standby safety valves shall be identical to those of the working valves. Where safety valves are installed in groups, each group shall have the same number of valves. The use of lever-weight safety valves shall not be permitted. Safety and vacuum valves for isothermal tanks may be made of aluminium alloys. On the outer shells of isothermal tanks with fill-type insulation, it may be permitted not to install safety valves if such valves are present on the nitrogen buffer vessel (gas holder) or on the pipeline connecting the outer shell to the buffer vessel.
1289. Switching devices shall be installed at the safety valves to prevent the disconnection of working valves without bringing into operation the same number of standby valves.
1290. The manifolds for the outlets of liquid and gaseous ammonia are made separate. The throughput capacity of each safety-valve manifold is calculated with account of the permissible back-pressure at the valve outlet during the simultaneous maximum discharge of ammonia from the safety valves.
1291. Inspection and repair of safety valves, with their removal from the installation sites, checking and adjustment on a test bench, shall be carried out within the periods established by the process regulations and the operating documentation.
1292. Isothermal tanks are equipped with vacuum valves for relieving the vacuum on reaching a value equal to 490.3 Pa (50 mm of water column). The installation and periodic checking of vacuum and safety valves are carried out in accordance with the requirements for the design and safe operation of vessels operating under pressure.
1293. For the draining (filling) of tank cars, the racks are equipped with articulated-lever loading-and-unloading devices (loading arms). Metal hoses are used for loading and unloading operations. The use of rubber or rubber-metal hoses resistant to the ammonia medium and rated for a working pressure of not less than 2 MPa may be permitted. In justified cases, hoses with an internal diameter of 38 mm with a textile carcass are used.
1294. Before the connection of pipelines to the hose, an automatic cut-off device is installed: an excess-flow valve or shut-off valve on the pipeline for filling into the tank car and a non-return valve or shut-off valve on the pipeline for draining from the tank car. The section of pipeline between the cut-off device and the hose is equipped with a branch pipe with a valve for relieving pressure from the hose into the manifold of the disposal system.
1295. The organisation of the transportation of liquid ammonia in railway tank cars and the performance of draining and filling operations shall comply with the safety requirements for the operation of railway tank wagons for the transportation of liquid ammonia.
1296. The performance of preparatory and auxiliary operations (for example, filling the tank, purging equipment and pipelines) is carried out using a removable section (spool piece) on which shut-off valves are installed on both sides, which is fitted before the operations are performed and dismantled at the end of the work.
1297. Refrigeration units intended for the condensation of ammonia evaporating in isothermal and spherical tanks for the storage of liquid ammonia shall be individual for each group of tanks with the same working pressure and shall have 100 per cent standby equipment to allow repairs to be carried out. The capacity of the unit is calculated on the basis of ensuring the compression and liquefaction of all the gaseous ammonia evaporating due to heat ingress from the environment at the maximum temperature for the given climatic zone.
1298. For the draining, filling and evacuation pumps for liquid ammonia, a minimum temperature equal to minus 34 °C shall be adopted. For pumps installed in open areas, the minimum air temperature of the coldest five-day period is adopted, if it is below minus 34 °C.
1299. Evacuation pumps shall be located at the bund (inside or outside) and shall be equipped with remote control.
1300. Ammonia releases during the purging of equipment and pipelines, the reduction of pressure in them, the draining (filling) of tank cars, and discharges from safety valves are disposed of or directed to the flare system.
1301. The flare installation shall comply with the requirements for the design and safe operation of flare systems.
1302. On the lines for the discharge of gaseous ammonia to the flare system from the safety valves of tanks operating under excess internal pressure, a separator is installed.
1303. To maintain a constant value of excess pressure in the inter-wall space of a tank with fill-type insulation during changes in barometric pressure and air temperature, gas holders with an elastic or movable diaphragm rated for a design pressure of 490.3 Pa (50 mm of water column) shall be installed on the nitrogen supply line. The capacity of the gas holder shall be not less than 8 - 10 per cent of the volume of the inter-wall space of the tank to which the gas holder is connected.
1304. The design, materials and operation of the thermal insulation of pipelines and equipment shall comply with the requirements of these Rules.
1305. Tanks for the storage of liquid ammonia rated for a working pressure of up to 1.0 MPa, and isothermal tanks, shall be provided with thermal insulation. The need for thermal insulation of tanks rated for a working pressure of more than 1.0 MPa is determined by the design depending on the air temperature, the permissible minimum working pressure and with account of the requirement of paragraph 1350 of these Rules. The thickness of the thermal insulation and the heat flux shall be determined with account of the effect of solar radiation.
1306. Thermal insulation is made of non-combustible or low-combustibility materials. Where low-combustibility materials and polyurethane foam are used as external insulation, measures are provided to exclude the possibility of ignition of the insulation (for example, water spraying, protection with non-combustible coatings).
1307. For the insulation of the inner walls and roof of isothermal tanks, it is recommended to use expanded perlite sand of standard granulometric composition with a moisture content of not more than 0.8 per cent by mass. The filling of the inter-wall space with perlite shall be continuous, without voids. Before filling, the inter-wall space shall be dried. In the event of settlement and compaction of the heat-insulating fill after the cooling of the tank (icing-up or the appearance of condensate on the upper part of the outer wall), additional filling with perlite sand shall be carried out.
1308. The moistening of heat-insulating materials and devices during their storage, transportation and installation shall not be permitted.
1309. The arrangement of the thermal insulation of the bottom of an isothermal tank shall exclude the ingress of moisture, the continuous freezing of the soil beneath the foundation caused by the stored ammonia, and the deformation of the structural elements of the tank.
1310. The insulation of the bottom of an isothermal tank in the zone of the edge plates shall be continuous, made of strong hard materials, which shall rest on the concrete foundation of a single-wall tank and on the edge plates of the outer bottom of a double-wall tank. The use of bulk materials and materials with flowing properties (asphalt, bitumen) to achieve the tight laying of the insulation on the base in the zone of the bottom edge plates, and also of the edge plates of the bottom of the inner tank on the insulation, shall not be permitted.
1311. The unevenness of the surfaces of the bases beneath the insulation of the bottoms of isothermal tanks, and of the lower and upper surfaces of this insulation, shall be limited by tolerances. The tolerances are determined by the design organisations.
1312. To prevent the ingress of water vapour from the surrounding air into the heat-insulating layer of isothermal tanks with fill-type insulation, the inter-wall space shall be permanently filled with dried nitrogen with a dew point of minus 40 °C and an excess pressure of 98.06 - 490.3 Pa (10 - 50 mm of water column).
1313. The installation of the insulation of isothermal tanks is carried out only in the warm season at a temperature not lower than that provided for by the technical specifications and in the absence of atmospheric precipitation. Particular attention is paid to the sealing of the seams between the joints of the insulation elements and the protective covering layer.
1314. To ensure the safe operation of the thermal insulation, periodic inspection and technical examination of its condition are carried out in accordance with the requirements for the technical examination of the shells of tanks for the storage of liquid ammonia. In addition, once a quarter a visual inspection of the thermal insulation is carried out, with the results recorded in the repair work log. Thermographic imaging of the outer surface of the tank for the purpose of identifying areas with damaged thermal insulation is carried out once a year.
1315. The systems of monitoring, control and alarm, emergency protection, and also the communication and warning systems for emergency situations (CWS), in terms of reliability, speed of response, permissible error of the measuring systems and other technical characteristics, shall ensure the safe conduct of technological processes and operations in the regulated modes, and in emergency situations shall ensure the transfer of the controlled system to a safe state.
1316. Tanks for the storage of liquid ammonia are equipped with instruments for measuring level, temperature and pressure. Instruments monitoring the parameters that determine the safety of the process are duplicated. The measurement of the specified parameters of the storage of liquid ammonia shall be carried out with standardised accuracy. The permissible measurement errors are determined by the design.
1317. Exceeding the permissible ammonia level in tanks is guarded against by the emergency protection system: for tanks with a capacity of up to 10 m3 (inclusive) - by the duplication of the parameter monitoring systems; for tanks with a capacity of up to 50 m3 - by the duplication of the monitoring systems and the presence of self-diagnostic systems with indication of the serviceable state; for tanks with a capacity of 50 m3 and more - by the duplication of the monitoring systems, the presence of self-diagnostic systems and the comparison of technologically related parameters.
1318. The use of gauge glasses on tanks for the storage of liquid ammonia shall not be permitted.
1319. The selection of the measurement method (volumetric, gravimetric) for liquid ammonia is determined by the design. When measuring the mass and mass flow rate of liquid ammonia entering the storage facility and being discharged from the storage facility by flow meters, correction for the change in temperature shall be provided for, with the registration of the measurement results. The permissible measurement error shall not exceed +/-2.5 per cent of the highest value of the flow rate. At storage facilities connected to trunk pipelines for the transportation of liquid ammonia, flow meters are installed the measurement accuracy of which is identical to that of those used on the trunk pipelines.
1320. Refrigeration units for the condensation of ammonia evaporating in isothermal and spherical tanks during storage shall be equipped with a system for automatic switching-on at the upper and switching-off at the lower limits of the working pressure in the tanks, and also with audible and light alarms for these values.
1321. On the pipelines for supplying liquid ammonia to an isothermal tank, automatic shutting-off of the supply of ammonia to the lower part of the storage is provided for when its temperature rises to minus 30 °C, with switching of the supply to the upper part.
1322. The operation of the storage facility with faulty or disconnected systems of monitoring, control, alarm and emergency protection (EPS) shall not be permitted. During the period of replacement of the main elements of the control and monitoring system, the use of duplicating systems is provided for.
1323. Liquid ammonia storage facilities are equipped with automatic fire alarm systems.
1324. A liquid ammonia storage facility is equipped with two-way loudspeaker communication systems and telephone communication with the facilities located on its territory. A liquid ammonia storage facility shall have not less than two communication channels depending on the location of the storage facility: on the territory of the enterprise - with the dispatcher of the enterprise, the fire station, the gas-rescue units and the production facilities connected with the storage facility, and other facilities the list of which is established by the design; outside the territory of the enterprise - with neighbouring facilities, organisations and local services. The list of facilities with which telephone communication is established is entered in the action plans for the containment and elimination of the consequences of accidents at hazardous production facilities. At distribution stations and remote agricultural storage facilities, radio communication is used in addition to telephone communication.
1325. Each tank for the storage of liquid ammonia is equipped with instruments for the continuous registration of the main parameters of its operation, and where it is connected with an ammonia production unit, the duplication of readings and their registration, and also light and audible alarms for the limit values in the central control point of the ammonia production unit, are required.
1326. Liquid ammonia storage facilities are equipped with a gas-contamination monitoring system (gas analysers) linked to the warning system for emergency situations.
1327. The system for monitoring the level of gas contamination and for warning of emergency ammonia leaks (hereinafter - the ammonia leak monitoring system) shall ensure the monitoring of the level of gas contamination and of possible ammonia leaks in the process premises and on the territory of the facility.
1328. The ammonia leak monitoring system shall ensure, in automatic mode, the collection and processing of information on ammonia concentrations in the air at the installation locations of the gas-analytical sensors, in a volume sufficient for the formation of adequate control actions.
1329. Upon the occurrence of accidents involving an ammonia leak, the ammonia leak monitoring system shall, in automatic (or automated) mode, switch on the technical devices involved in the system for the containment of emergency situations and the means of warning of an accident, and shall switch off the process equipment the functioning of which may lead to an increase in the scale and consequences of the accident.
1330. The structure of the ammonia leak monitoring system shall be two-loop and two-level. The outer loop shall ensure the monitoring of the level of gas contamination on the industrial site, with the output of data for forecasting the spread of the zone of chemical contamination beyond the territory of the facility, and the monitoring of emergency ammonia leaks from process equipment located outside the premises. The inner loop shall ensure the monitoring of the level of gas contamination and of emergency ammonia leaks in the production premises. The outer and inner loops of the ammonia leak monitoring system shall have two levels of monitoring of the ammonia concentration in the air: the first level - the reaching of ammonia concentration values in the air of the process premises and outside the premises at the installation locations of the gas-analytical sensors equal to the maximum permissible concentration of the working area (MPCW.A. 20 mg/m3); the second level, "Emergency ammonia leak" - the reaching of ammonia concentration values at the installation locations of the gas-analytical sensors equal to 25 MPCW.A. (500 mg/m3).
1331. The system shall ensure, in the control room, prompt warning of the specific location of the accident that has occurred and the switching-on of the necessary group of technical means for the containment and elimination of the consequences of the accident.
1332. The technical characteristics, number and location of the gas-analytical sensors for the indication and signalling of ammonia leaks are determined by the design.
1333. The use of faulty instrumentation and measuring devices, as well as of devices not complying with the requirements of Federal Law No. 102-FZ of 26 June 2008 "On Ensuring the Uniformity of Measurements", shall not be permitted.
1334. Non-automatic (local or remote) switching-on of the technical devices involved in the system for the containment of emergency situations, where justified by the design, may be permitted.
1335. The system is equipped with automatic means enabling monitoring of the level of gas contamination on the industrial site (the first level of the outer monitoring loop) and forecasting of the spread of the zone of chemical contamination beyond the territory of the facility. Such equipping shall be justified by an assessment of the possible consequences of an accident, confirmed by the relevant calculations. A device measuring the direction and speed of the wind shall be installed on the site, the data of which are used in the calculations of the possible scale of gas contamination.
1336. The electrical loads of liquid ammonia storage facilities with isothermal and spherical tanks are consumers of reliability category I.
1337. In justified cases, an internal combustion engine may be used as the standby drive of the compressor unit, and a storage battery or a standby emergency electric generator may be used as an additional source of power supply for the storage facility.
1338. The electrical loads of liquid ammonia storage facilities with tanks under excess pressure and with a capacity of up to 100 t inclusive are consumers of reliability category II.
1339. The classes of explosion-hazardous zones of enclosed premises and outdoor installations and the level of explosion protection of electrical equipment shall be established in accordance with the requirements of regulatory documents.
1340. Liquid ammonia storage facilities are equipped with fire-fighting, domestic-and-drinking and, where necessary, industrial water-supply systems. The water-supply systems may be independent, combined fully or partially. The provision of emergency showers and self-help basins is determined by the design.
1341. As sources of water supply for the storage facility, the water-supply systems of enterprises and settlements, the trunk networks of other enterprises, and also independent water intakes of underground and surface waters, may be adopted.
1342. For track-side and remote agricultural storage facilities and distribution stations, the use of water-supply systems with water towers, and also with the supply of water for fire-fighting by motor pumps or fire-engine pumps from tanks or water bodies, may be permitted. The capacity, number and location of fire-fighting reservoirs shall comply with the requirements for external water-supply networks.
1343. For the water supply of distribution and remote agricultural storage facilities for domestic-and-drinking needs, the use of delivered water may be permitted.
1344. The design water flow rate for fire-fighting is determined by the design.
1345. In the design of liquid ammonia storage facilities, the effect of thermal radiation on tanks with liquid ammonia, and also on equipment and pipelines at the loading-and-unloading point with combustible and readily flammable substances, located at the storage facility or near it, shall be verified by calculation. At these facilities, appropriate insulation on the tanks or stationary water-cooling (spraying) systems shall be provided for. The control of the tank spraying system may be local or remote. The intensity of spraying of the tank being cooled shall be taken as equal to 0.2 l/s per 1 m of the design length of spraying, which shall be equal, for a horizontal tank, to the length of the cylindrical part; for spherical and isothermal tanks, to half the length of their circumferences.
1346. The facilities of the storage facility are equipped with primary fire-extinguishing means in accordance with the current standards.
1347. The removal of atmospheric water from the territory of the bund (embankment) of the tanks, after analysis for the ammonia content has been performed, is carried out through a sump into the sewerage or a drainage tank.
1348. Before tanks for the storage of liquid ammonia, other equipment and the pipelines from them are put into operation, air shall be removed from them, and, before repair is carried out - ammonia. Purging is carried out with nitrogen. Before start-up, air is removed to an oxygen volume fraction of not more than 5.0 per cent, and purging with gaseous ammonia is carried out to an ammonia volume fraction in the blown-out gas of not less than 90 per cent. Before repair, ammonia is removed from the equipment and purging with nitrogen and air is carried out to an oxygen volume fraction of not less than 18 per cent. At track-side deep storage facilities and at distribution stations, purging of the compressor equipment, pumps and pipelines after they have been emptied of liquid ammonia may be carried out with air in accordance with an instruction developed by the organisation; from the tanks, the removal of ammonia is carried out with wash water for domestic and drinking-water needs. Where air or other media are used for purging, the organisation draws up an instruction on the procedure and mode of purging, taking into account the exclusion of the possibility of the formation of explosive mixtures, of a vacuum and of an increase in the single maximum permissible concentrations of ammonia in air and water.
1349. Before ammonia is supplied to an isothermal tank with loose-fill insulation, the inter-wall space of the tank shall be purged with dry nitrogen to remove air and moisture to a nitrogen dew point of minus 40 °C and shall be kept under pressure.
1350. Before liquid ammonia is loaded into it, an isothermal tank shall be purged with gaseous ammonia and cooled to the operating temperature. The cooling of the tank may be combined with its purging to remove nitrogen. The cooling of the isothermal tank shall be carried out by injecting liquid ammonia through a spraying device, without allowing the formation of a vacuum.
1351. During operation, the ammonia volume fraction in the inter-wall space shall not exceed 0.5 per cent. If the ammonia volume fraction increases above 0.5 per cent, the tank shall be shut down for repair.
1352. The territory of the storage facility is equipped with eye-wash fountains and emergency showers for washing off liquid ammonia. Emergency showers and fountains shall be located in visible, accessible places. The number and location of the showers and fountains are determined in the design. At distribution stations and deep storage facilities supplied with delivered water, two washbasins with an upward-directed jet and one non-automated shower with a pressure tank of a capacity of not less than 200 litres shall be installed in accessible places.
1. Laboratory installations. 1.1. Installations assembled from glass: vacuum installations; those operating at atmospheric pressure of inert gases with a total volume of all vessels of not more than 0.1 m3; those operating at atmospheric pressure of toxic or explosive gases with a total volume of all vessels of not more than 0.025 m3. 1.2. Installations assembled from metal apparatus: those operating at a pressure of up to 100 MPa on non-explosive, non-toxic or non-corrosion-hazardous gases, if the free volume of each apparatus does not exceed 0.003 m3 and the total volume of all apparatus does not exceed 0.009 m3; those operating at a pressure of up to 100 MPa on explosive, toxic or corrosion-hazardous gases, if the free volume of each apparatus does not exceed 0.0003 m3 and the total volume of all apparatus does not exceed 0.002 m3; those operating at a pressure of up to 100 MPa on explosive, toxic or corrosion-hazardous gases, with a total volume of all apparatus of not more than 0.005 m3; those operating on various gases at a pressure of from 100 to 1000 MPa, if the product of the pressure (in MPa) and the capacity (in m3) of one apparatus (P · V) does not exceed 0.05 MPa·m3, where the total number of such apparatus is not more than two, and those operating on liquid at any pressure, if the (P · V) of the apparatus does not exceed 0.2 MPa·m3.
2. Bench and model installations: installations operating on non-toxic or non-explosive gases and liquids under a pressure of up to 60 MPa, for which the (P · V) for each apparatus does not exceed 0.5 MPa·m3; installations operating on toxic or explosive gases under a pressure of up to 60 MPa, for which the (P · V) of each apparatus does not exceed 0.1 MPa·m3. The total volume of all apparatus forming part of a model or bench installation, depending on the pressure in it and the properties of the products being processed, shall not exceed the values specified in Table No. 1.
2.1. High-pressure model installations include installations operating on gases and liquids under a pressure exceeding 1000 MPa, for which the (P · V) for each apparatus does not exceed 0.1 MPa·m3.
2.2. Model installations operating under a gauge pressure of up to 0.07 MPa, irrespective of the aggressiveness of the medium, may be created with a volume of up to 1/50 of an industrial-scale installation (both for each apparatus and for the installation as a whole).
3. Pilot-industrial installations include installations created at industrial enterprises as independent installations, intended to master a new technological process, apparatus, systems of automatic monitoring, control and safe conduct of the technological process, and also to produce a pilot batch of product.
In the "Technical characteristics" column, the main data of the equipment are briefly indicated in accordance with the data sheet: type, make, overall dimensions, heat-exchange surface, capacity and other characteristics.
For equipment having electric motors, the design features are indicated depending on the class of the premises and the category and group of explosion hazard.
1. The title page is completed in a form similar to that adopted in the main regulations, with the title: Amendments No. _______________ to technological regulations No. ___________ for the production of ____________________ (name)
2. The text of the amendments (additions) being introduced is drawn up in accordance with the following recommended sample:
3. The last page with the signatures of the officials is completed in accordance with the recommended sample given in the Rules.
4. When amendments are made to the piping of the apparatus, diagrams of the new piping are attached to the text on the amendments. It is not necessary to provide the entire technological diagram in full; it is sufficient to provide the part where the changes have occurred. The part of the diagram with the changes shall contain information on the name of the technological diagram, its number, the number and date of approval of the amendment, the signatures of the developer of the change in the diagram and of the head of the organisation approving the change to the technological regulations.
5. Amendments and additions to the technological regulations are put into effect by an order or another document approved by the head of the organisation.
1. The registration sheet for amendments and additions is placed at the end of the technological regulations.
2. Entries in the registration sheet are made in blue ink.
3. The registration of amendments and additions is carried out by the staff of the production-technical (technical) department of the organisation. Registered amendments and additions, certified by a seal, are kept with the first (control) copy of the technological regulations and are also distributed against signature to the subdivisions where copies of the regulations are located.
1. When amendments are made to the piping of the apparatus, a diagram of the new piping is attached to the text.
2. The document on making amendments is approved by the chief engineer of the organisation.
3. The range of persons signing the statement on making amendments is determined by an order of the organisation.
4. The period of validity of the "Cumulative statement" is six months, after which amendments to the technological regulations are drawn up or the amendments are abolished by an order of the enterprise. The order cancelling the amendments is also filed in the log and certified by a seal.
5. The "Cumulative statements" of amendments are filed in a special log and certified by a seal. The log is kept in the production-technical (technical) department of the enterprise together with the control copy of the technological regulations.
1. A distinction is made between six schematic diagrams of refrigeration supply, the symbolic graphic representations of which are given in Table 1.
1.1. A direct-cooling diagram, in which the ammonia evaporating apparatus (devices) are located inside the cooled chambers and premises or are built into the ducts of the cooled air or into the technological cold-consuming equipment.
1.2. Intermediate-cooling diagrams, in which heat is transferred from the cooled media (objects) to the refrigerant in the evaporator of the refrigeration installation by means of coolants. In this case:
according to diagrams 1.2.1 and 1.2.2, the coolant is sprayed into the air of the premises, providing its cooling together with the cooled object (the cooling of the coolant takes place in closed evaporators of the shell-and-tube or plate types (1.2.1) or in open evaporators of the tubular or panel types (1.2.2);
according to diagrams 1.2.3 and 1.2.4, the coolant, after evaporators of the closed (1.2.3) or open (1.2.4) types, is supplied to the heat-exchange apparatus of the cooled premises, providing recuperative heat exchange between the coolant and the cooled air of the premises or the cooled object;
according to diagram 1.2.5, the coolant, cooled beforehand in a closed heat-exchange apparatus, is sprayed into the air of the cooled premises.
2. Buildings and premises that are served by ammonia refrigeration installations are divided into five categories, the main differences of which are given in Table 2.
3. Refrigeration equipment at cold-consuming facilities may be located in accordance with one of the following options, provided that the sanitary standards in force are complied with: Option 1 - there is no machine compartment and all the equipment of the refrigeration system is located in a separate room. Option 2 - the refrigeration installation is built onto the building or the refrigeration equipment is located on an open area. Option 3 - the refrigeration installation is located in a free-standing building or the refrigeration equipment is located on an open area.
4. The mass charges of individual refrigeration supply systems with ammonia shall not exceed the values given in Table 3.
5. For air-conditioning systems of category E premises, the use of ammonia refrigeration installations operating according to diagrams 1.2.3 (intermediate closed) and 1.2.4 (intermediate closed, with a level in the evaporator) is permitted, as is the location of the refrigeration equipment in accordance with options 2 and 3. For premises of other categories, the use of ammonia refrigeration installations for air-conditioning systems shall not be permitted.
The following shall be reflected in the data sheet of the refrigeration supply system:
1. Information on the availability of a licence for the operation of explosion-and-fire-hazardous and chemically hazardous production facilities of hazard classes I, II and III, including its particulars.
2. Basic information about the organisation (full and abbreviated names, address of the location, taxpayer identification number).
3. Information on the appointment of persons responsible: (a) for supervision of the technical condition and safe operation of the refrigeration system, and for compliance with the requirements of the Rules; (b) for the serviceable condition and operation of the equipment, pipelines, fittings, control and measuring instruments and automation equipment (I&A) and other devices of the refrigeration supply system.
4. General characteristics of the refrigeration supply system.
5. Information on the location of the premises and open areas of the refrigeration supply system.
6. Characteristics of the cold consumers and their cooling devices.
7. Basic data of the refrigeration equipment located in the machine, apparatus and condenser compartments.
8. Calculated data: (a) on the thermal loads of the refrigeration supply systems; (b) on the adequacy of the available refrigeration equipment; (c) on the nominal ammonia capacity of the technological blocks and of the refrigeration system as a whole.
9. Information on the availability of: (a) general-exchange and emergency ventilation; (b) repair and emergency emptying of the equipment and technological blocks of liquid ammonia; (c) defrosting of the cooling devices of the premises from snow-and-ice deposits; (d) oil and air removal from the refrigeration supply system; (e) cooling of the compressors and condensers.
10. Information on: (a) the systems of emergency automatic protection (EAP), monitoring, control, communication and alarm for the refrigeration installation; (b) the power supply and the installed capacity of the electric motors of the refrigeration system; (c) the vessels operating under pressure; (d) the safety valves and diaphragm safety devices, and also the outlet pipelines from them; (e) the personal protective equipment used during operation of the refrigeration supply system; (f) the emergency equipment schedule of the compressor shop; (g) the stocks of ammonia, oil and coolants.
11. Information: (a) on the structure of the maintenance and repair services of the refrigeration supply systems, the shift arrangements and the number of established and actual personnel; (b) on the reconstructions, repairs, technical examinations, inspections and ammonia refills carried out on the refrigeration installation; (c) on the accidents and incidents that have occurred at the refrigeration supply systems.
Vc - the total geometric volume of the cooling devices and technological apparatus (for one boiling temperature), m3;
Vn.t - the geometric volume of the discharge pipeline of the ammonia pump, m3;
Vv.t - the geometric volume of the pipelines for combined suction of vapours and drainage of liquid, m3.
Identification rings are applied to ammonia pipelines that have been fully completed in manufacture (and insulated where necessary):
at the locations where the pipes pass through building structures and enclosures;
at the locations where the pipes connect to the equipment.
For the application of the above-mentioned identification rings, the sections of the ammonia pipelines shall be painted yellow and rings shall be applied to them:
one ring - on the vapour, vapour-liquid and liquid lines of the low-pressure side of the refrigeration supply systems;
two rings - on the vapour lines of the high-pressure side;
three rings - on the liquid lines of the high-pressure side.
The rings are applied in black paint on the yellow background. The direction of movement of the ammonia in the pipes shall also be indicated by black arrows in visible places and near the fittings.
The width of the black rings is taken depending on the size of the outer diameter of the pipeline (including where insulated) in accordance with the table given below.
The distance between the rings is taken equal to the width of a ring.