Order of the Federal Environmental, Industrial and Nuclear Supervision Service (Rostechnadzor) No. 536 of 15 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, the "Rules of Industrial Safety in the Use of Equipment Operating under Excess Pressure" (hereinafter - the Federal Norms and Rules), have been developed in accordance with Federal Law No. 116-FZ of 21 July 1997 "On the Industrial Safety of Hazardous Production Facilities" (Collection of Legislation of the Russian Federation, 1997, No. 30, Art. 3588) (hereinafter - Federal Law No. 116-FZ); and the Regulation on the Federal Environmental, Industrial and Nuclear Supervision Service, approved by Government Resolution of the Russian Federation No. 401 of 30 July 2004 (Collection of Legislation of the Russian Federation, 2004, No. 32, Art. 3348; 2020, No. 27, Art. 4248).
2. The Federal Norms and Rules are aimed at ensuring industrial safety and at preventing accidents, incidents and injuries at hazardous production facilities (hereinafter - HPF) in the use of equipment listed in paragraph 3 of the Federal Norms and Rules operating under excess pressure of more than 0.07 megapascals (MPa) (0.7 kilograms-force per square centimetre (kgf/cm2)): (a) steam, gas in a gaseous or liquefied state (compressed, liquefied and dissolved-under-pressure gases); (b) water at a temperature of more than 115 degrees Celsius (°C); (c) other liquids at a temperature exceeding their boiling temperature at an excess pressure of 0.07 MPa (0.7 kgf/cm2), and also in the operation of buildings and structures intended for carrying out technological processes that incorporate equipment listed in paragraph 3 of the Federal Norms and Rules.
3. The Federal Norms and Rules establish industrial safety requirements that are mandatory during the development and performance of technological processes, during the design, construction, operation, reconstruction, capital repair, technical re-equipment, conservation and liquidation of HPFs at which the below-listed equipment operating under excess pressure (hereinafter - pressure equipment) is used and which meets one or more of the characteristics specified in sub-clauses "a", "b" and "c" of paragraph 2 of these Federal Norms and Rules, during the industrial safety expert examination of equipment, buildings and structures at an HPF, and also during the siting, installation and operation (including commissioning, servicing, repair, reconstruction (modernisation), technical inspection and technical diagnostics) of pressure equipment. These Federal Norms and Rules apply to the following kinds (types) of pressure equipment: (a) steam boilers, including boiler-heaters, and also stand-alone superheaters and economisers; (b) hot-water and steam-hot-water boilers; (c) power-technological boilers: steam and hot-water, including soda-recovery boilers; (d) waste-heat recovery boilers; (e) boilers of mobile and transportable installations; (f) steam and liquid boilers operating with organic and inorganic heat carriers (other than water and water steam), and the pipeline systems transporting them; (g) electric boilers; (h) steam and hot-water pipelines; (i) vessels operating under the excess pressure of steam, gases or liquids; (j) cylinders intended for compressed, liquefied and dissolved-under-pressure gases; (k) tanks and drums for compressed and liquefied gases; (l) tanks and vessels for compressed and liquefied gases, liquids and bulk solids in which excess pressure is created periodically for their emptying; (m) pressure chambers; (n) pressure equipment used in the development, manufacture, testing, operation and disposal of nuclear weapons and nuclear installations of military purpose at hazardous production facilities operated by organisations of the Rosatom State Corporation.
4. To attribute equipment to the scope of the Federal Norms and Rules, the maximum working values of the pressure and temperature of the working medium, established in the technical documentation of the equipment and the design documentation of the HPF, are taken as the basis, taking into account the normative indicators of the physico-chemical properties of the working medium (the characteristics of the working medium established in technical regulations and standards or, in the absence thereof, determined by experimental and computational methods) and all hazard factors (risks) affecting the safety of the equipment in its use in accordance with the requirements of the legislation of the Russian Federation on technical regulation, in the field of industrial safety, and also of the Federal Norms and Rules. The list of parameters (the maximum values of the pressure and temperature of the working medium) adopted to ensure the specified purposes in respect of specific kinds and types of equipment, and also the operational categories IE, IIE, IIIE and IVE of steam and hot-water pipelines depending on their parameters, are established in Appendix No. 1 to these Federal Norms and Rules.
5. The Federal Norms and Rules do not apply to the use of kinds (types) of equipment not listed in paragraph 3 of these Federal Norms and Rules, and also to the following pressure equipment: (a) boilers, including electric boilers, and also stand-alone superheaters and economisers, steam and hot-water pipelines, and vessels installed on sea-going and river vessels and other floating craft (except dredgers and floating drilling rigs) and underwater-application facilities; (b) heating and locomotive boilers of railway rolling stock; (c) boilers with a steam and water space volume of 0.001 cubic metres (m3) or less, in which the product of the values of the working pressure (MPa) and the volume (m3) does not exceed 0.002; (d) electric boilers with a capacity of no more than 0.025 m3; (e) tube furnaces and superheaters of tube furnaces; (f) vessels with a capacity of no more than 0.025 m3 regardless of pressure, used for scientific and experimental purposes. For the purposes of these Federal Norms and Rules, when determining the capacity of a vessel, the volume occupied by the lining, tubes and other internal devices is excluded from the total volume of the vessel; a group of vessels, and also vessels consisting of separate bodies interconnected by tubes with an internal diameter of more than 100 mm, are regarded as one vessel. A group comprises vessels combined in accordance with the design into a group of two or more units by a common working-medium inlet/outlet pipeline with shut-off valves and a safety device(s) installed on it, and intended for simultaneous joint operation, for storing (accumulating) the gas held in them under pressure in a quantity determined by the total capacity of the group of vessels and its supply to consumers; the need to equip each vessel of the group, in addition to the common shut-off device (shut-off valves), individually with other devices (valves) for draining and for releasing gas pressure is determined by the design; (g) vessels with a capacity of no more than 0.025 m3 in which the product of the values of the working pressure (MPa) and the capacity (m3) does not exceed 0.02; (h) vessels operating under pressure created by an explosion inside them in accordance with the technological process or by combustion in the mode of self-propagating high-temperature synthesis; (i) vessels and pipelines operating under vacuum; (j) vessels installed on aircraft and other flying vehicles; (k) air reservoirs of the braking equipment of the rolling stock of railway transport, of motor vehicles and of other means of conveyance; (l) pressure equipment forming part of armament and military hardware, and also equipment used in conditions of the liquidation of natural and man-made emergency situations; (m) vessels and pipelines of nuclear power installations, vessels operating with a radioactive medium, and also equipment operating under pressure specially designed for use in the field of the use of atomic energy, falling within the scope of the federal norms and rules in the field of the use of atomic energy; (n) heating appliances of steam and water heating systems; (o) vessels consisting of tubes with an internal diameter of no more than 150 mm without headers, and also with headers made of tubes with an internal diameter of no more than 150 mm; (p) parts of machines that do not constitute independent vessels (the bodies of pumps or turbines, the cylinders of the engines of steam, hydraulic and pneumatic machines and compressors); (q) steam and hot-water pipelines installed on the rolling stock of railway and road transport; (r) pipelines of operational categories IIE, IIIE and IVE for steam and hot water with an outer diameter of less than 76 mm; (s) pipelines of operational category IE for steam and hot water with an outer diameter of less than 51 mm; (t) drainage, blow-off and exhaust pipelines of boilers, pipelines, vessels, reducing-and-cooling and other devices, connected to the atmosphere; (u) equipment manufactured (produced) from a non-metallic flexible (elastic) shell; (v) sterilisers installed in medical organisations for the sterilisation of medical products and the decontamination of medical waste; (w) the bodies of gas-filled electrotechnical equipment that are under the excess pressure of gas to ensure electrical insulation and/or the extinguishing of the electric arc.
6. The requirements of the Federal Norms and Rules are mandatory for compliance by all organisations and individual entrepreneurs (hereinafter - organisations) and their workers carrying out, within the territory of the Russian Federation and in other territories over which the Russian Federation exercises jurisdiction in accordance with the legislation of the Russian Federation and the norms of international law, the activity specified in paragraph 3 of these Federal Norms and Rules.
7. The ensuring of industrial safety and the prevention of accidents, incidents and workplace injuries at hazardous production facilities at which pressure equipment is used shall be carried out through compliance by organisations and their workers with the industrial safety requirements established by the legislation of the Russian Federation, by the federal norms and rules in the field of industrial safety, and also by the administrative documents of organisations adopted in accordance with them.
8. For the purposes of these Federal Norms and Rules, organisations that carry out the operation of an HPF at which equipment operating under excess pressure (a source of increased danger) is used (operated) on the basis of the right of ownership held by it or another lawful ground for the use of the land plots, buildings, edifices and structures, and also the technical devices of such an HPF, including on the basis of a lease agreement or rights of economic management or operational management, shall be regarded as operating organisations.
9. During the design, construction, reconstruction, capital repair and operation of HPFs at which pressure equipment is used (applied), including the buildings and structures forming part of them, and also during the development of the design documentation determining the decisions on the installation (siting) and piping of pressure equipment, compliance with the mandatory requirements of the legislation of the Russian Federation in the field of industrial safety, on town-planning activity and on technical regulation, and of these Federal Norms and Rules, shall be ensured. The selection and composition of pressure equipment during the development of the relevant sections of the design documentation of an HPF shall be made on the basis of the purpose and the operating conditions affecting its safety, including the maximum values of the characteristics of the pressure source (the pressure, temperature, group and physico-chemical properties of the working medium), applying, where necessary, automatic regulating and safety devices, and also on the basis of the characteristics of the surrounding environment depending on the place of installation of the equipment (in an open area, in an unheated or heated premises). The installation and use of equipment shall not be permitted if its technical characteristics and materials specified in the technical documentation do not correspond to the physico-chemical properties of the working medium and other operating conditions affecting its safety. During the construction, reconstruction, capital repair and operation of an HPF, deviations from the design documentation, and also from the documentation for technical re-equipment, shall not be permitted. The making of amendments to the design documentation for the construction or reconstruction of an HPF, and also to the documentation for technical re-equipment, depending on the kind of work performed, shall be carried out in accordance with the requirements of the legislation of the Russian Federation on town-planning activity and in the field of industrial safety.
10. The decisions determined by the design documentation on the installation, siting and piping of boilers and vessels and on the laying of steam and hot-water pipelines shall ensure the safety of their servicing, inspection, repair, flushing and cleaning. Valves shall be installed in places accessible for control, servicing and repair.
11. For the servicing, inspection and repair of pressure equipment, the design shall ensure the presence of stationary metal platforms and ladders, and also of portable and mobile platforms and ladders, whereby: the design of the platforms and ladders shall conform to the requirements of paragraphs 13 to 15 of the Federal Norms and Rules; equipment-servicing platforms and ladders that do not conform to the requirements of paragraphs 12 and 13 of these Federal Norms and Rules and were installed before the entry into force of the order approving the Federal Norms and Rules shall be brought into conformity with the Federal Norms and Rules during the capital repair of the equipment or the reconstruction (modernisation) or technical re-equipment of the HPF, provided that the operating organisation adopts and implements actions to ensure their safe use in the period until the non-conformities are eliminated; the requirements for equipment-servicing platforms and ladders established in these Federal Norms and Rules do not extend to ladders, platforms and passages forming part of the building structures of buildings, the arrangement of which shall conform to the requirements of the legislation on town-planning activity and of technical regulations.
12. The presence of stationary platforms and ladders shall be provided for to ensure access to the servicing zones (the installation of control and measuring instruments, shut-off and control valves and other devices for controlling the operation of the equipment) in which, according to the instructions of the design documentation, the operating manuals (instructions) of the equipment and the production instructions, the constant or repeated (one or more times during a shift) presence of personnel is required for the inspection of the equipment, the monitoring of parameters and the control of its operation (start-up, shutdown, changing of the operating modes of the equipment during the normal course of the technological process, and emergency disconnection (stopping) in emergency situations.
13. The design (arrangement) of service platforms and ladders, the places of their siting and the methods of their fastening to the supporting and load-bearing elements of the frame of the equipment and of the building structures of the building (structure) are established by the drawings that form part (depending on the place of siting and the method of fastening) of the set of engineering documentation of the equipment or the design (working) documentation of the building (structure), and shall not create loads not provided for by the design (engineering) documentation.
14. The design of platforms and ladders for the servicing, inspection and repair of pressure equipment shall ensure the fulfilment of the following conditions: 1) The presence of guard railings with a height of no less than 900 mm with a solid facing along the bottom to a height of no less than 100 mm. 2) In the places of passage of the personnel servicing pressure equipment installed in open areas, and also in buildings (premises) and structures: the clear height from the level of the ground, the floor of the building (premises), the platforms (walkways) and the steps of the service ladders shall be no less than 2 m; the width of the clear passage shall be no less than 600 mm, and in the places of installation of valves, control and measuring instruments, other devices and equipment - no less than 800 mm. 3) In the places of installation of valves, other devices and equipment whose repair is carried out with disassembly and dismantling, the specific width of the clear passage is established by the developer of the section of the design documentation determining the decisions on the placement of the equipment, and also by the developer of the engineering documentation for the platforms and ladders, on the basis of the need to ensure a safe space for personnel of no less than the above-mentioned value, taking into account the dimensions of the equipment and other devices, or of separate parts (elements) thereof, dismantled during replacement or repair. 4) In the places where people pass over pipelines located on the surface of the ground, floor or platform, where the height of such an obstacle from the surface is more than 300 mm, transfer walkways shall be arranged. In this case, where they are arranged on a service platform, the height of the platform railing and the height of the clear passage established by this paragraph shall be taken from the level of the floor of the transfer walkway in the zone of its location. 5) Transfer platforms and ladders shall have railings on both sides. Boiler platforms more than 5 metres long shall have no less than two ladders (two exits) located at opposite ends. 6) The use of smooth platforms and ladder steps, and also their manufacture from bar (round) steel, shall be prohibited. 7) Ladders more than 1.5 metres high shall have an angle of inclination to the horizontal of no more than 50° (hereinafter - inclined ladders), except in the cases provided for in paragraph 15 of these Federal Norms and Rules. Inclined ladders shall have a width of no less than 600 mm, a height between steps of no more than 200 mm, and a width of steps of no less than 80 mm. Ladders of great height shall have intermediate platforms, whereby the height of ascent between the platforms shall be no more than 4 metres. 8) If the design features of the equipment or of the building structures of the building, put into operation before the entry into force of these Federal Norms and Rules, prevent compliance with the requirements for the width and height of the clear passage established by this paragraph in individual zones (hereinafter - zones (places) of increased danger) of movement of personnel, and their elimination leads to a reduction in the level of safety during the operation of the equipment or the building structures of the building, then in that case the operating organisation shall ensure: the determination, in a production instruction or in a separate document, of a route (scheme) for the safe movement of personnel, indicating the places of increased danger, passage through which is prohibited or requires additional caution (additional attention); the closing-off of the places of increased danger for the passage of personnel where an alternative safe route is available; the equipping of the places of passage of personnel in the zones of increased danger, in the absence of a safe route, with information plates and danger signs; the mandatory use by personnel, when passing through the places of increased danger, of personal protective equipment (helmets).
15. To ensure access to the service platforms of pressure equipment intended for the periodic performance of work (scheduled technical servicing, repair) in the places where hatches, valves and other devices equipped with an automatic remote drive are located, and of primary sensors transmitting data to the secondary devices (instruments) of automation systems and (or) control and measuring instruments (installed remotely) that do not require the constant (repeated) presence of personnel (except in the cases established by paragraph 12 of these Federal Norms and Rules), the design for the installation of pressure equipment may provide for the use of portable and mobile platforms and ladders, and also of stationary ladders with an angle of inclination to the horizontal of more than 50°, provided that the possibility of inspecting the equipment in such places from the surface of the floor (ground) or of other platforms is ensured. The vertical ladders provided for by the design in these cases shall be metal, with a width of no less than 600 mm, with a distance between the steps of the ladders of no more than 350 mm, and, starting from a height of 2 metres, shall be equipped with safety hoops with a radius of 350 to 400 mm, positioned at a distance of no more than 800 mm from one another and fastened together by strips, with a distance from the furthest point of the hoop to the steps within 700 to 800 mm.
16. In the cases provided for by the design documentation, the operating manuals (instructions) and the production instructions, for the repair and technical servicing of equipment in places that do not require constant servicing and are not equipped with stationary platforms and ladders, mobile and leaning platforms and ladders and construction scaffolding may be used, the places of installation and the design of which shall be determined by the work execution plan developed for the specific case of their performance. The installation of leaning ladders and stepladders next to and above operating machines and mechanisms (having rotating and reciprocating parts) shall not be permitted, and neither shall the carrying out from their steps of work involving the use of hand-held machines, the performance of welding work, or the moving or holding of loads (parts and materials) during the installation, dismantling and repair of equipment. To perform such work, scaffolding, staging and ladders with platforms guarded by railings shall be used, and for the moving and holding of loads - hoisting machines and mechanisms of the appropriate lifting capacity.
17. Stationary boilers are installed in buildings and premises the design of which shall conform to the requirements of the project, of technical regulations and of the legislation of the Russian Federation on town-planning activity, and shall also ensure the safe operation of the boilers in accordance with the requirements of the legislation of the Russian Federation in the field of industrial safety and of these Federal Norms and Rules. Boilers may be installed outside a premises in the case where the design (engineering) and technical documentation of the boiler provides for the possibility of its operation in the open air in the specified climatic conditions of the boiler installation area.
18. The arrangement of premises and attic ceilings above boilers shall not be permitted, with the exception of boilers installed inside production premises in accordance with these Federal Norms and Rules, where this is provided for and substantiated, taking into account possible risks, by the design documentation.
19. Inside production premises, the installation of the following is permitted: (a) once-through boilers each with a steam output of no more than 4 tonnes of steam per hour (t/h); (b) steam boilers (including electric boilers), other than once-through ones, satisfying the condition (t - 100) x V <= 100 (for each boiler), where t is the temperature of saturated steam at the working pressure, °C; V is the capacity of the boiler, m3; (c) hot-water boilers each with a heat output of no more than 10.5 GJ/h (2.5 Gcal/h) that do not have drums; (d) hot-water electric boilers each with an electrical power of no more than 2.5 MW; (e) waste-heat recovery boilers - without restrictions.
20. The doors for exit from a premises in which boilers are installed shall open outwards. The doors of office, domestic and also auxiliary production premises leading into the boiler house shall open towards the boiler house.
21. The place of installation of boilers and of the systems, devices and auxiliary equipment ensuring their operation (pumps, electrical panels and other equipment in accordance with the project) inside production premises shall be separated from the rest of the premises by non-combustible partitions along the whole height of the boiler, but no lower than 2 metres, with the arrangement of doors. The places of the exits and the direction of opening of the doors are determined by the design organisation. The separation of waste-heat recovery boilers from the rest of the production premises together with the furnaces or units with which they are connected by the technological process is permitted.
22. When siting electric boilers, actions shall be provided for to protect the servicing personnel from contact with the live elements of the electric boiler. As protective devices for electric boilers with an insulated body, non-combustible partitions (guards) are provided - of mesh with a cell size of no more than 25 x 25 mm or solid with glazed openings allowing the operation of the boilers to be observed, whereby: the partitions (guards) used shall have a height of no less than 2 metres and shall be equipped with doors for the passage of personnel; the entrance behind the partition (guard) shall have an interlock prohibiting the opening of the door when the boiler is switched on and the switching-on of the boiler when the door of the guard is open. In the event of a faulty interlock or the opening of the door, the boiler shall automatically be disconnected from the supply mains.
23. In the buildings of thermal power stations, in boiler houses and in premises where boilers and the pipelines, machines and installations technologically interconnected with them are installed, it shall not be permitted to site domestic and office premises not intended for the servicing and repair personnel of the equipment installed in the building, and also workshops not intended for its repair.
24. The site for the installation of a boiler shall not be lower than the planning level of the territory adjoining the building in which the boilers are installed. The arrangement of pits in boiler houses shall not be permitted. By decision of the developer of the design documentation, for the placement of shot-cleaning equipment, the inlet and outlet units of heat pipelines, separators and expanders, pits may be arranged in individual cases substantiated by the technological necessity of such placement of the equipment and the particular features of its design.
25. The premises in which boilers are placed shall be provided with natural light, and at night-time - with electric lighting in accordance with the design documentation. Places that for technical reasons cannot be provided with natural light shall have electric lighting.
26. In addition to the working lighting, emergency electric lighting shall be provided for by the design. The following places shall be subject to mandatory equipping with emergency lighting: (a) the front of the boilers, and also the passages between the boilers, behind the boilers and above the boilers; (b) control panels and consoles; (c) water-gauge and measuring instruments; (d) ash rooms; (e) fan platforms; (f) smoke-exhauster platforms; (g) rooms for tanks and deaerators; (h) water-treatment equipment; (i) the platforms and ladders of the boilers; (j) the places of installation of pumping equipment. The selection of the specific zones subject to being equipped with emergency lighting is carried out during the development of the design documentation, taking into account the particular features of the design of the equipment (including the places where control and measuring instruments and control devices (elements) are located), and also taking into account the particular features of the layout and placement of the equipment on the specific site and the routes of movement of the HPF workers resulting from this, the places of their possible location during the process of work, including for monitoring the parameters and operating modes of the equipment and taking the necessary actions in an emergency situation during the period of switching-off of the working lighting.
27. The distance from the front of the boilers or the projecting parts of the fireboxes to the opposite wall of the boiler room shall be no less than 3 metres, whereby: 1) For boilers operating on gaseous or liquid fuel, the distance from the projecting parts of the burner devices to the wall of the boiler room shall be no less than 1 metre, and for boilers equipped with mechanised fireboxes, the distance from the projecting parts of the fireboxes shall be no less than 2 metres. 2) For boilers with a steam output of no more than 2.5 t/h, the minimum distance from the front of the boilers or the projecting parts of the fireboxes to the wall of the boiler room may be reduced to 2 metres in the following cases: (a) if a firebox with manual loading of solid fuel is serviced from the front and has a length of no more than 1 metre; (b) where there is no need to service the firebox from the front; (c) if the boilers operate on gaseous or liquid fuel (while maintaining the distance from the burner devices to the wall of the boiler room of no less than 1 metre). 3) The distance from the front of the electric boilers to the opposite wall of the boiler house shall be no less than 2 metres. For boilers with an electrical power of no more than 1 MW - this distance may be reduced to 1 metre.
28. The distance between the front of boilers and the projecting parts of fireboxes located opposite one another (with the exception of electric boilers) shall be: (a) for boilers equipped with mechanised fireboxes, no less than 4 metres; (b) for boilers operating on gaseous or liquid fuel, no less than 4 metres, whereby the distance between the burner devices shall be no less than 2 metres; (c) for boilers with manual loading of solid fuel, no less than 5 metres. The distance between the fronts of electric boilers located opposite one another shall be no less than 3 metres.
29. When installing boiler auxiliary equipment and control panels in front of the boilers, a width of the clear passages along the front of no less than 1.5 metres shall be ensured, and the installed equipment shall not hinder the servicing of the boilers.
30. When installing boilers for which side servicing of the firebox or boiler is required (raking, blowing, cleaning of the gas ducts, drums and headers, removal of the packages of the economiser, superheater and tubes, servicing of the burner devices, benchmarks and firebox elements, periodic blowdown), the width of the side passage shall be sufficient for servicing and repair, but no less than: (a) 1.5 metres for boilers with a steam output of less than 4 t/h; (b) 2 metres for boilers with a steam output of 4 t/h or more.
31. In those cases where side servicing of the fireboxes and boilers is not required, the arrangement of passages between the outermost boilers and the walls of the boiler room is mandatory. The width of these passages, and also the width of the passage between the boilers and the rear wall of the boiler room, shall be no less than 1 metre. The width of the side passage, and also of the passage between the electric boilers and the rear wall of the boiler room, shall be no less than 1 metre. In the cases provided for by the project and the operating manual (instruction), the installation of electric boilers directly against the wall of the boiler room is permitted, if this does not impede their servicing during operation and repair. The width of the passage between individual parts of the boilers projecting from the lining (frames, tubes, separators), and also between these parts and the projecting parts of the building (brackets, columns, ladders, working platforms), shall be no less than 0.7 metre.
32. Passageways in the boiler room shall have a clear height of not less than 2 metres. The distance from the platforms used for servicing the boiler, its valves, instrumentation and other equipment to the ceiling or the projecting structural elements of the building (room), the elements of the boiler and the metal structures of its frame shall be not less than 2 metres. Where there is no need to pass over the boiler, or over the drum, steam dome or economiser, the distance from these to the lower structural parts of the boiler-room roof shall be not less than 0.7 metres.
33. For boilers with an electrode group mounted on a removable cover, the vertical distance from the upper part of the boiler to the lower structural elements of the ceiling shall be sufficient to withdraw the electrode group from the boiler body. The distance between boilers or between the walls of the electric boiler room shall be sufficient to withdraw the removable block of electric heating elements.
34. The installation, in the same room as boilers and economisers, of equipment unrelated to the servicing and repair of boilers or to the process of producing steam and (or) hot water shall be prohibited (except in the cases, provided for by these Federal Norms and Rules, of installing boilers in production premises in which other technological processes are carried out). Power-station boilers may be installed in a common room with turbine units or in adjacent rooms without the construction of dividing walls between the boiler hall and the machine hall.
35. The placement of boilers and auxiliary equipment in block containers and in mobile and transportable units shall be carried out in accordance with the design.
36. The vertical distance from the platform for servicing water-level indicators to the middle of the water-level glass (scale) shall be not less than 1 metre and not more than 1.5 metres. For drum diameters of less than 1.2 metres and more than 2 metres, the specified distance shall be taken within the range of 0.6 to 1.8 metres.
37. If the distance from the zero mark of the boiler room to the upper platform of the boilers exceeds 20 metres, then in such cases lifting devices shall be installed for raising persons and loads, with a lifting capacity corresponding to the weight of the loads and persons being moved (in the case of joint lifting), but not less than 1000 kg. The use, for lifting loads (valves, parts and elements of equipment), of a lift whose characteristics are intended only for raising persons shall not be permitted. The number, type, characteristics and installation locations of the lifting devices shall be determined by the design.
38. For the safe operation of boilers, the design of their placement shall provide for piping systems for: (a) supply of feed water or network water; (b) blowdown of the boiler and draining of water when the boiler is shut down; (c) removal of air from the boiler when it is filled with water and during firing-up; (d) blowdown of the superheater and steam line; (e) sampling of water and steam; (f) introduction of corrective reagents into the boiler water during operation and of cleaning reagents during chemical cleaning of the boiler; (g) discharge of water or steam during firing-up and shutdown; (h) heating-up of the drums during firing-up (if this is provided for by the boiler design); (i) discharge of the working medium from the safety valves when they are actuated; (j) supply of fuel to the boiler's burner devices.
39. The number and connection points to the boiler elements of blowdown, drain, drainage and air pipelines shall be selected in such a way as to ensure the removal of water, condensate and sediment from the lowest parts and of air from the upper parts of the boiler. In cases where the removal of the working medium cannot be ensured by gravity flow, forced removal of it shall be provided by blowing with steam, compressed air, nitrogen or other methods provided for by the operating manual (instructions).
40. The blowdown pipeline shall discharge water: (a) into a vessel operating without pressure; (b) into a vessel operating under pressure, provided that the reliability and effectiveness of the blowdown are confirmed by appropriate calculations.
41. On all sections of the steam line that can be isolated by shut-off valves, drains ensuring the discharge of condensate shall be provided at the lower points.
42. The structural and layout solutions of the systems for blowdown, emptying, drainage and reagent introduction shall ensure the reliable operation of the boiler in all modes, including emergency modes, and also its reliable preservation during downtime.
43. Safety valves shall have discharge pipelines to ensure the safety of the operating personnel. These pipelines shall be protected against freezing and equipped with drains for removing (draining off) condensate accumulating in them. The installation of shut-off valves on the discharge pipelines and their drains shall be prohibited.
44. The water-discharge pipe from the safety valves of a hot-water boiler or economiser shall be connected to a free water-drain line, and neither on it nor on the drain line shall there be any shut-off devices. The arrangement of the system of water-discharge pipes and free-drain lines shall exclude the possibility of scalding persons. For draining water when blowing down water-level indicators, funnels with a protective device and a discharge pipe for free drainage shall be provided.
45. On the boiler feed pipeline there shall be installed a check valve preventing the escape of water from the boiler and a shut-off device. The check valve and the shut-off device shall be installed upstream of the economiser that cannot be shut off on the water side. For an economiser that can be shut off on the water side, the check valve and the shut-off device shall also be installed downstream of the economiser.
46. One shut-off device each shall be installed at the water inlet to the hot-water boiler and at the water outlet from the boiler.
47. On each blowdown and drainage pipeline, and also on the water (steam) sampling pipeline of boilers with a working pressure of more than 0.8 MPa, not less than two shut-off devices, or one shut-off device and one regulating device, shall be installed. On these same pipelines of boilers with a working pressure of more than 10 MPa, in addition to the specified valves, throttle washers may be installed. In the cases provided for by the operating manual (instructions), one shut-off device may be installed for blowing down superheater chambers. The nominal bore of the blowdown pipelines and of the valves installed on them shall be not less than: (a) 20 mm - for boilers with a working pressure of less than 14 MPa; (b) 10 mm - for boilers with a working pressure of 14 MPa or more.
48. When the medium is discharged from the boiler into a collecting tank (separator, expander) with a lower pressure than in the boiler, the collecting tank shall be protected against a pressure rise above the design value. The method of protection, and also the number and installation location of the valves, instrumentation and safety devices, are determined by the design.
49. The main steam shut-off devices of steam boilers with a capacity of more than 4 t/h shall be provided with remote control from the workplace of the personnel servicing the boiler. The type and location of the valve actuator are determined by the design.
50. Regulating valves shall be installed on the feed lines of each boiler. With automatic regulation of the boiler feed, remote control of the regulating feed valves from the workplace of the personnel servicing the boiler shall be provided. The type and location of the valve actuator are determined by the design.
51. On the feed lines of boilers with a steam capacity of not more than 2.5 t/h, regulating valves are not installed, provided that the boiler design provides for automatic regulation of the water level by switching the pump on and off or the use of a pump with automatic capacity regulation. The installation of regulating valves on the feed lines of steam boilers that meet the requirements of the Customs Union technical regulation "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), which is binding on the Russian Federation in accordance with the Treaty on the Eurasian Economic Union, ratified by Federal Law No. 279-FZ of 3 October 2014 "On the Ratification of the Treaty on the Eurasian Economic Union" (Collected Legislation of the Russian Federation, 2014, No. 40, Article 5310), and equipped with automatic feed-water supply regulators, shall, regardless of the type and steam capacity, be carried out in accordance with the instructions of the developer of the boiler design in the operating manual.
52. When several feed pumps having common suction and discharge pipelines are installed, shut-off devices shall be installed on each pump on the suction side and on the discharge side. On the discharge side of each centrifugal pump, a check valve shall be installed upstream of the shut-off device.
53. The feeding of boilers is carried out either from a feed pipeline common to the connected boilers (group feeding) or from a feed pipeline for only one boiler (individual feeding). The inclusion of boilers in a single feeding group is permitted only on condition that the difference in working pressures in the different boilers does not exceed 15 per cent. Feed pumps connected to a common main (group feeding) shall have characteristics permitting parallel operation of the pumps.
54. For feeding boilers with water, the following are used: (a) centrifugal, piston and plunger pumps with an electric drive; (b) centrifugal, piston and plunger pumps with a steam drive; (c) steam injectors (a steam-jet injector is classed as a pump with a steam drive); (d) pumps with a manual drive; (e) the water-supply network, provided that the minimum water pressure in the water-supply network upstream of the boiler feed regulating device exceeds the design or permitted pressure in the boiler by not less than 0.15 MPa. The choice of the method of feeding the boiler with water and of the specific type of feed device (where it is not included in the boiler delivery set) is carried out by the developer of the design documentation of the hazardous production facility on the basis of the instructions of the manufacturing organisation in the boiler operating manual.
55. In boiler rooms with hot-water boilers, not less than two interchangeable circulating network pumps shall be installed. The head and delivery of the pumps are selected in such a way that, in the event of failure of one of the pumps, the uninterrupted operation of the heat-supply system is ensured. The operation of a boiler with a steam capacity of not more than 4 t/h with a single feed pump with an electric drive is permitted, if the boiler is equipped with safety automatics excluding the possibility of an impermissible lowering of the water level in a boiler with natural or forced multiple circulation, or of an impermissible reduction of the water flow through a once-through boiler, and also excluding the possibility of an impermissible pressure rise.
56. The head created by the pump shall ensure the feeding of the boiler with water at the working pressure downstream of the boiler, taking into account the hydrostatic height and the pressure losses in the boiler path, the regulating device and the feed-water path. The pump characteristic shall also ensure the absence of interruptions in the feeding of the boiler when the safety valves are actuated, taking into account the greatest pressure rise at their full opening. In the case of group feeding of boilers, the pump head shall be selected taking into account the requirements specified above, and also on the basis of the condition of ensuring the feeding of the boiler with the greatest working pressure or with the greatest head loss in the feed pipeline.
57. The delivery of the feed devices shall be determined according to the nominal steam capacity of the boilers, taking into account the water consumption for continuous or periodic blowdown, steam cooling, pressure-reducing-and-cooling devices and cooling devices, and losses of water or steam.
58. The head and water flow created by the circulating and make-up pumps shall exclude the possibility of the water boiling in the hot-water boiler and the heat-supply system. The minimum head and water flow are established by the design.
59. The type, characteristic, number and connection scheme of the feed devices are determined so as to ensure the reliable and safe operation of the boiler in all modes, including emergency shutdowns.
60. On the feed pipeline, between the shut-off device and a piston or plunger pump that has no safety valve and whose created head exceeds the design pressure of the pipeline, a safety valve shall be installed.
61. The installation and connection of economisers to boilers, and also their equipping with instrumentation, shut-off and regulating valves and safety devices, shall be carried out in accordance with the requirements of the design documentation and the operating manuals (instructions), taking into account the economiser connection schemes recommended in them. In doing so, the decisions adopted by the design on the choice of economiser and the scheme of its connection shall ensure the possibility of operation with parameters of the working medium (pressure, temperature) not exceeding the values established by the strength calculation and specified by the manufacturing organisation in the data sheet.
62. For boilers with a steam capacity of 2.5 t/h and above operating on solid fuel, mechanised supply of fuel to the boiler room and the boiler furnace shall be provided. Where the total output of slag and ash from all boilers is 150 kg/h or more (regardless of the capacity of the boilers), the removal of ash and slag shall be mechanised. With manual ash removal, the slag and ash bunkers shall be provided with devices for flooding the ash and slag with water in the bunkers or trolleys. In the latter case, insulated chambers are arranged under the bunker for positioning the trolleys before ash and slag are discharged into them. The chambers shall have tightly closing doors with glazed inspection windows and shall be equipped with ventilation and lighting. The control of the bunker gate and of the slag flooding shall be located outside the chamber in a place safe for servicing. Along the entire path of movement of the trolley, the height of the clear passage shall be not less than 2 metres, and the side clearances not less than 0.7 metres. If ash and slag are removed from the furnace directly onto the working platform, then in the boiler room, above the place of removal and flooding of the furnace residues, exhaust ventilation shall be provided. For shaft furnaces with manual loading for wood fuel or peat, loading bunkers with a lid and a hinged bottom shall be provided.
63. To ensure explosion and fire safety during the operation of boilers, the supply of fuel to the burners, the requirements for shut-off, regulating and cut-off (safety) valves, the list of necessary protections and interlocks, and also the requirements for the preparation and supply of fuel are determined, for each type of fuel, by the requirements of the design documentation and the boiler operating manual (instructions), taking into account the physico-chemical properties of the fuel.
64. On the safety explosion valves installed (in the cases provided for by the design) on the furnaces of boilers, the economisers and the flues discharging the combustion products of the fuel from the boilers to the chimney, protective relief devices (casings, branch pipes) shall be provided, ensuring the relief of excess pressure (discharge of the medium) during explosions and puffs in the boiler furnace and the flues in a direction safe for the personnel. The construction of the relief device shall ensure the possibility of monitoring the condition and tightness (leak-tightness) of the explosion valve during its operation.
65. Vessels shall be installed on open sites in places that exclude the gathering of people, or in separate free-standing buildings together with the machines, equipment and pipelines technologically interconnected with them. Air receivers or gas receivers shall be installed on a foundation outside the building of the feeding source. Their installation site shall have a fence. The distance between air receivers shall be not less than 1.5 metres, and between an air receiver and the wall of a building not less than 1 metre. The distance between gas receivers is determined by the design organisation. The fence of an air receiver shall be located at a distance of not less than 2 metres from the air receiver towards the driveway or passageway. When installing vessels with explosive and fire-hazardous media at the production sites of organisations, and also at facilities located (in cases justified by the design) within populated areas (automobile gas-filling stations), compliance shall be ensured with the safe distances for the placement of vessels from buildings and structures established by the design, taking into account the radius of the danger zone in the event of emergency depressurisation of the vessel.
66. The installation of vessels is permitted: (a) in rooms adjoining production buildings, provided that they are separated by a capital wall whose structural strength is determined by the design documentation, taking into account the maximum possible load that may arise on the destruction (failure) of the vessels; (b) in production premises, including the premises of boiler rooms and of thermal and hydraulic power plants (TPP, HPP), in the cases provided for by the design, taking into account the design standards for these facilities in respect of vessels for which, by the conditions of the technological process or the conditions of operation, their installation outside production premises is impossible; (c) with burial in the ground, provided that access to the valves and protection of the vessel walls against corrosion are ensured.
67. The installation, in residential, public and amenity buildings, and also in premises adjoining them, of vessels subject to registration with the territorial bodies of Rostechnadzor or with other federal executive authorities in the field of industrial safety shall not be permitted.
68. The installation of vessels shall exclude the possibility of their overturning. The specific decisions on the installation of the vessel, the method of fastening and the arrangement of the foundation are determined by the design documentation, taking into account the instructions of the vessel manufacturing organisation in the operating manual (instructions), the installation instructions (if available), the drawings and other technical documentation of the manufacturing organisation.
69. Shut-off and shut-off-regulating valves shall be installed on the nozzles directly connected to the vessel, or on the pipelines supplying the working medium to the vessel and discharging it from it. In the case of series connection of several vessels, the need or the absence of the need to install valves between them is determined by the design documentation. The number and type of valves used and the locations of their installation shall correspond to the design documentation, on the basis of the specific features of the technological process and the operating conditions of the vessel. On the line supplying to the vessels an explosive, fire-hazardous working medium classified in group 1 in accordance with TR CU 032/2013, and also on the line supplying the working medium to evaporators with fire or gas heating, a check valve automatically closing under pressure from the vessel shall be installed. The check valve shall be installed between the pump (compressor) and the shut-off valves of the vessel. The provisions of this paragraph do not apply to vessels with liquefied natural gas.
70. The routing (placement) of pipelines, their equipping with valves and other devices (including for drainage and blowdown) and with elements of the support-and-suspension system, and also the arrangement of the load-bearing and supporting building structures (constructions), buildings and structures intended for routing pipelines and placing valves, pumps and other devices forming part of them, during installation and further operation, shall ensure safety and shall be carried out on the basis of a design developed in accordance with the requirements of the legislation of the Russian Federation on town-planning activity and on technical regulation, the legislation of the Russian Federation in the field of industrial safety, the normative documents adopted in accordance with it (hereinafter - ND), and also the technical regulations and the Federal Norms and Rules, taking into account the climatic conditions of the area where the pipeline is placed and other features of its routing (underground, on the ground or above ground, in the open air or inside heated or unheated buildings and structures).
71. Horizontal sections of steam and hot-water pipelines shall have a gradient of not less than 0.004, and pipelines of heat networks not less than 0.002. The routing of pipelines shall exclude sagging and the formation of water stagnation sections. The routing of pipelines where they cross common-network railways, and also rivers, ravines and open watercourses, shall be provided as above-ground. In doing so, permanent road and railway bridges may be used.
72. When routing steam and hot-water pipelines in semi-passable channels, the clear height of the channels shall be not less than 1.5 metres, and the width of the passage between insulated pipelines shall be not less than 600 mm. The routing of heat-network pipelines where they cross underground railways, roads, main roads, streets and passages of city-wide and district significance, and also tramways and metro lines, shall be carried out in reinforced-concrete non-passable, semi-passable or passable channels. In doing so, on one side a heat chamber shall be provided, and on the other a mounting channel 10 metres long with hatches, the number of which shall be not less than 4. Where it is impossible to fulfil the specified conditions, the design documentation of the heat network shall determine the technology for carrying out repair of the pipeline, taking into account the adopted method of routing. Where crossing streets and roads of local significance, and also yard passages, the routing of heat networks in casings is permitted where it is impossible to perform the work by the open method and the crossing length is up to 40 m. In doing so, the length of the casings at the crossing points shall be taken on each side as not less than 3 metres greater than the dimensions of the crossed sections of the streets and roads.
73. When routing steam and hot-water pipelines in passable tunnels (collectors), the clear height of the tunnel (collector) shall be not less than 2 metres, and the width of the passage between insulated pipelines not less than 0.7 metres. At the locations of shut-off valves (equipment), the width of the tunnel shall be sufficient for the convenient servicing of the installed valves (equipment). When several pipelines are routed in tunnels, their mutual placement shall ensure that repair of the pipelines and replacement of individual parts of them can be carried out.
74. On heat networks, at the places where electrical equipment is installed (pumping stations, heat points, tunnels, chambers), and also at the places where valves with an electric drive, regulators and instrumentation are installed, electric lighting is provided.
75. In the case of above-ground open routing of steam and hot-water pipelines, their joint routing with process pipelines of various purposes is permitted, except in cases where such routing contradicts the requirements of the federal norms and rules establishing industrial safety requirements for the hazardous production facility at which that routing of pipelines is carried out.
76. Passable channels for steam and hot-water pipelines shall have entrance hatches with a ladder or rungs. The distance between hatches shall be not more than 300 metres, and in the case of joint routing with other pipelines not more than 50 metres. Entrance hatches shall also be provided at all end points of dead-end sections, at bends of the route and at valve installation nodes. Passable channels of heat networks are equipped with supply-and-exhaust ventilation in accordance with the design documentation.
77. Regardless of the type of routing, on all pipelines of heat networks anti-corrosion, thermal and waterproofing protection shall be provided: 1) The type and methods of protection shall be determined by the design documentation depending on the operating conditions and the structural design, taking into account the rate of corrosion wear of the materials used. 2) The procedure for monitoring the degree of corrosion wear of equipment and pipelines using non-destructive methods, and the methods, frequency and locations of control measurements, shall be determined in the design, technical and operational documentation, taking into account the specific operating conditions. 3) At the places where the pipeline passes through the walls or foundation of buildings and structures, a protective casing (sleeve) shall be provided that excludes the action on the pipeline of a load from the building structures not provided for by the calculation, the internal diameter of which shall ensure the presence of a clearance sufficient for the free longitudinal movement of the pipeline without damage to the insulating coating. The size of the clearance and the material used for sealing it shall be established by the design in accordance with the requirements of the ND depending on the climatic conditions and the characteristics (properties) of the soil in the area of routing of the heat-network pipeline. The presence of welded joints on a section of the pipeline inaccessible for monitoring, located in the protective casing at the place of passage through the walls or foundation of buildings and structures, shall not be permitted. 4) The anti-corrosion coatings of the pipelines of heat networks and of their load-bearing metal structures shall be made with protective properties ensuring the established service life of the pipeline (structure), and with a guaranteed service life of the coating of not less than 10 years. 5) The commissioning of heat networks without an external anti-corrosion coating of the pipes and metal structures shall not be permitted.
78. Chambers for servicing underground steam and hot-water pipelines shall have not less than two hatches with ladders or rungs. The construction of the chamber shall exclude the possibility of flooding and shall ensure the removal of waters that have entered it by means of waterproofing of the building structures, sealing of the place where the pipeline passes through the chamber wall (where necessary) and other solutions determined by the developer of the heat-network design in accordance with the requirements of the ND depending on the climatic conditions and the characteristics (properties) of the soil in the area of routing of the heat-network pipeline. When pipelines pass through the chamber wall, the possibility of flooding of the chamber shall be excluded.
79. Underground routing of steam and hot-water pipelines of operational category IE of steam and hot water in a single channel together with process pipelines shall not be permitted.
80. The valves of steam and hot-water pipelines shall be installed in places accessible for their safe servicing and repair. Where necessary, stationary ladders and platforms shall be provided in accordance with the design documentation. The use of mobile platforms and portable ladders is permitted for valves used less than once a month, access to the control of which is necessary when disconnecting a section of the pipeline for repair and connecting it after repair. The use of portable ladders for repairing valves with their disassembly and dismantling shall not be permitted. Cast-iron valves of steam and hot-water pipelines being installed shall be protected against bending stresses.
81. The use of shut-off valves as regulating valves shall not be permitted.
82. In the design of steam lines with an internal diameter of more than 150 mm and a steam temperature of 300 °C or more, the need to equip them with thermal-displacement indicators shall be determined, and the locations of their installation and the design values of the displacements at them shall be specified. Access to the thermal-displacement indicators for monitoring displacements, servicing and repair shall be provided and ensured. For pipelines operating at a temperature causing creep of the metal, the design shall provide for the installation of devices for carrying out observations (monitoring) of the growth of residual deformations in the cases established by paragraph 365 of these Federal Norms and Rules.
83. The installation of shut-off valves on heat networks is provided for: (a) on all pipelines of the outlets of heat networks from heat sources, regardless of the parameters of the heat-transfer media; (b) on the pipelines of water networks with an internal diameter of 100 mm and more, at a distance of not more than 1000 metres (sectioning gate valves), with the arrangement of a jumper between the supply and return pipelines; (c) in water and steam heat networks, at the nodes on the pipelines of branches with an internal diameter of 100 mm and more, and also at the nodes on the pipelines of branches to individual buildings, regardless of the diameter of the pipeline; (d) on condensate pipelines at the inlet to the condensate collecting tank.
84. Gate valves and shut-off valves with a nominal diameter of 500 mm and more shall be equipped with drives making it possible to facilitate the operations of controlling the valves (electric, hydraulic, pneumatic drive). In the case of above-ground routing of heat networks, gate valves with electric drives are installed in a room or enclosed in casings protecting the valves and the electric drive against atmospheric precipitation and excluding access to them by unauthorised persons.
85. All pipelines shall have drains for draining off water after the hydraulic test and air vents at the upper points of the pipelines for removing air. The locations and construction of the air and drainage devices on the pipelines are established by the design documentation.
86. Steam pipelines shall have drainage devices for removing condensate at the places of its possible accumulation during start-up (warming-up) and in the course of operation of the steam lines. The construction, type and installation locations of the drainage devices are determined by the design. Continuous discharge of condensate is mandatory for steam lines of saturated steam and for dead-end sections of steam lines of superheated steam. For steam heat networks, continuous discharge of condensate at the lower points of the route is mandatory regardless of the state of the steam.
87. At the lower points of the pipelines of water heat networks and condensate pipelines, and also of the sectioned sections, nozzles with shut-off valves for draining water (drain devices) are mounted.
88. From the steam lines of heat networks, at the lower points and before vertical rises, continuous discharge of condensate through steam traps shall be carried out. At these same places, and also on straight sections of the steam lines every 400 - 500 metres with a following gradient and every 200 - 300 metres with an opposing gradient, a start-up drainage device for the steam lines is mounted.
89. For draining water from the pipelines of water heating networks, discharge wells are provided, located separately from the pipeline channel, with the discharge of water into sewerage systems.
90. All sections of steam pipelines which may be shut off by shut-off devices shall, to enable their warming up and blow-down, be provided at their end points with a fitting having a shut-off device, and at a pressure exceeding 2.2 MPa - with a fitting and two devices arranged in series: a shut-off device and a control device. Steam pipelines with a pressure of 20 MPa and above shall be provided with fittings having a shut-off valve and a control valve arranged in series and a throttle washer. Where a section of a steam pipeline is warmed up in both directions, blow-down shall be provided from both ends of the section. The arrangement of drains shall provide for the possibility of monitoring their operation during the warming up of the steam pipeline.
91. The lower end points of steam pipelines and the lower points of their bends shall be provided with a device for blow-down.
92. On water heating networks with an internal diameter of 500 mm and above at a working pressure of 1.6 MPa and above, with an internal diameter of 300 mm and above at a working pressure of 2.5 MPa and above, on steam networks with an internal diameter of 200 mm and above at a working pressure of 1.6 MPa and above, gate valves and shut-off gates shall have bypass pipelines (bypasses) with shut-off fittings.
93. For the arrangement of thermal insulation of pipelines and fittings, materials shall be used with characteristics corresponding to the parameters and operating conditions of the pipeline, ensuring that the insulation remains in serviceable condition for the period guaranteed by the manufacturer and a temperature on its surface, at an ambient air temperature of 25 °C in accordance with the design documentation, of not more than 55 °C.
94. The thermal insulation of flanged connections, fittings and sections of pipelines subject to periodic inspection (welded joints, bosses for measuring creep) shall be removable.
95. The thermal insulation of pipelines located in the open air and near oil tanks, oil pipelines and fuel oil pipelines shall have a metallic or other coating to protect it from being saturated with moisture or combustible petroleum products. Pipelines located near cable lines shall also have a metallic coating. Pipelines with a temperature of the working medium below the ambient air temperature shall be protected against corrosion and have waterproofing and thermal insulation. For thermal insulation, materials shall be used which do not cause corrosion of the pipeline metal.
96. The installation (dismantling), repair involving welding, reconstruction (modernisation) and commissioning of equipment operating under pressure during the construction, operation, reconstruction, technical re-equipment, mothballing and decommissioning of a hazardous production facility shall be carried out by specialised organisations, as well as by individual entrepreneurs specialising in the performance of the works listed in this paragraph of the Federal Norms and Rules while carrying out one or more types of activity in the field of industrial safety (hereinafter - specialised organisations), including works on: the installation (assembly) into the design position of equipment supplied in assembled form, as well as the assembly, manufacture (completion of manufacture) of equipment at the site of use from finished parts and elements using permanent and (or) detachable joints with installation into the design position; the final assembly (manufacture, completion of manufacture) by the manufacturing organisation of equipment operating under pressure at its place of installation using permanent and (or) detachable joints; changing the technical characteristics of the equipment by replacing (changing) its individual elements, assemblies, control devices and devices for ensuring the operating mode (automated process control systems, control devices, burner devices) and (or) changing the design of the equipment operating under pressure and its elements by using permanent (welded) joints, giving rise to the need to perform strength calculations and to amend the data sheet and the operating manual (instructions) and to draw up a new data sheet and operating manual (hereinafter - reconstruction (modernisation) of the equipment); commissioning of the equipment, in the cases provided for by the operating manual of the manufacturing organisation, or commissioning of the system (technological complex) of which the equipment forms part, in the cases provided for by the design documentation of the hazardous production facility, before being put into operation after installation (start-up and commissioning) and during operation (operating-mode commissioning); repair, involving the performance of a set of technological operations and organisational actions to restore the operability, serviceability and service life of the equipment and (or) its elements (component parts). The repairs the performance of which is necessary to maintain the equipment in an operable condition include: 1) scheduled (planned preventive, routine) repair is carried out according to a schedule approved within the organisation, with the frequency and to the extent established in the normative documents and (or) technical documentation. The taking out for scheduled repair shall be carried out irrespective of the technical condition of the equipment at the start of the repair, within the periods established by the schedule, including, depending on the volume and nature of the work performed: current repair, performed to ensure or restore the operability of the equipment and consisting of the replacement and (or) restoration of its individual parts; medium repair, performed to restore serviceability and to partially restore the service life of the equipment, with the replacement or restoration of component parts of a limited range and with monitoring of the technical condition of the component parts, performed to the extent established in the normative documents and (or) technical documentation; major repair, performed to restore serviceability and to fully or nearly fully restore the service life of the equipment, with the replacement or restoration of any of its parts, including the basic main elements specified in paragraph 103 of the Federal Norms and Rules. In this case, the refinement (extension) of the volume of work and the type of repair necessary to maintain the equipment in an operable condition is carried out (where it is necessary to perform it according to the technical condition) based on the results of the inspection, examination and fault detection of the equipment during preparation for repair, as well as based on the results of maintenance work - a set of operations or an operation to maintain the operability or serviceability of equipment operating under pressure when it is used for its intended purpose. 2) unscheduled repair is carried out outside the plan to eliminate the causes of an accident or incident, as well as according to the current condition of the equipment as determined during the performance of its maintenance work.
97. During the installation, repair and commissioning of equipment operating under pressure, the requirements of the design documentation of the hazardous production facility and of the manufacturing organisation (the project developer) of the equipment, set out in its operating manual (instructions) and other technical documentation of the manufacturing organisation, shall be complied with.
98. Where it is necessary to perform works on the reconstruction, modernisation or retrofitting of equipment that result in a change to the characteristics and design of the equipment (hereinafter - change of design or reconstruction) for the purpose of improving its technical and economic indicators, changing the technological process, or changing the intended purpose of the equipment, the following requirements shall be ensured: 1) The change of design of equipment operating under pressure shall be carried out in accordance with a project (design documentation) prepared or agreed by the manufacturing organisation (the project developer) of the equipment, and in the absence thereof - by an organisation specialising in the design of similar equipment and having the rights to perform such works in accordance with the requirements of the legislation of the Russian Federation. Where those works are carried out to the extent of the reconstruction or technical re-equipment of a hazardous production facility, then, in addition to the development of the design (engineering) documentation for the equipment, the requirements for performing the entire set of works shall be determined by design documentation developed in accordance with the legislation on town-planning activity and (or) in the field of industrial safety. 2) Changes to the reconstruction project of the equipment, the need for which arose during the performance of works on changing the design of the equipment, shall be agreed with the developer of the project for performing such works and entered into the design (engineering) documentation. 3) Where the volume and nature of the works provide for a change to the design of the main elements and the technical characteristics of the equipment, giving rise to the need to draw up a new set of technical documentation (including a data sheet, an operating manual (instructions) and a set of drawings), then, upon completion of such works, the following shall be ensured: confirmation of the conformity of the equipment operating under pressure with the requirements of TR CU 032/2013; the performance of an industrial safety expert examination if the form of conformity assessment of the equipment is not established by a technical regulation; commissioning into operation in accordance with the requirements of these Federal Norms and Rules. In this case, responsible for the safety of the equipment after the change of its design is the organisation which developed the design (engineering) documentation for the change of design of the equipment, as well as the organisation which performed the works provided for by that documentation and drew up the corresponding set of technical documentation, and accordingly the need for their agreement, specified in sub-clause 1 of paragraph 98 of these Federal Norms and Rules, with the manufacturing organisation (the project developer) of equipment produced before the entry into force of TR CU 032/2013 is determined by the developer of the reconstruction (modernisation) project of the equipment. The drawing up of a new data sheet is necessary where the volume of changes to the design and characteristics of the equipment provided for by the design (engineering) documentation and actually carried out does not ensure the possibility of further identification of such equipment on the basis of the information about its intended purpose, design (construction) and technical characteristics specified in the previously drawn up data sheet. The drawing up of a new operating manual (instructions) is necessary where the performance of the works has led to a change in the parameters and operating modes, the technological process and the procedure for preparing the equipment for start-up, for start-up and shutdown, as well as for servicing the equipment, as regards the volume and sequence of the actions (technological operations) performed. 4) The need for confirmation of the conformity of equipment produced during the period of validity of TR CU 032/2013 and which underwent confirmation of conformity in the form of certification is determined, in accordance with paragraph 54 of TR CU 032/2013, by the certification body which previously issued the certificate of conformity of such equipment, at the request of the manufacturing organisation or another organisation which previously obtained the certificate. After a change to the design and technical characteristics of equipment produced before the entry into force of TR CU 032/2013, the need to perform confirmation of conformity with the requirements of TR CU 032/2013 or an industrial safety expert examination before the start of use is determined by the developer of the design (engineering) documentation for the performance of such works, depending on their volume and nature, including where the project provides for: the performance of works on the basis of documentation not agreed with the original project developer and the manufacturing organisation of the equipment owing to its absence or for other reasons; a change to the design of the equipment or its main elements the volume of which requires the making of changes to the "technical characteristics" section of the data sheet, and also where the volume of the changes made to the design of the equipment and of the elements replaced in the process renders the information in the old data sheet no longer current, such that it does not ensure the possibility of unambiguous identification of the equipment taking into account the changes made; the full or partial replacement of main elements with the establishment in the technical documentation (the data sheet, the operating manual) of a new service life for the equipment as a whole and a limited period of operation of the non-replaced elements (upon the expiry of which they shall be replaced or subjected to technical diagnostics to determine their actual technical condition and the possibility of further use). 5) Where the performance of works on the reconstruction of equipment to the extent of the reconstruction or technical re-equipment of a hazardous production facility provides for a change to the technological process (or) the intended purpose of the equipment with the loss of the previously existing hazard indicators among those specified in paragraph 3 of these Federal Norms and Rules, by transferring it to an operating mode under a pressure of not more than 0.05 MPa or under gravity filling or with a water temperature of not more than 110 °C, the requirements of TR CU 032/2013 do not apply, and the need to perform an industrial safety expert examination or to fulfil the requirements of other technical regulations is determined by the developer of the design (engineering) documentation depending on the characteristics of the equipment and the presence of other hazard indicators of the changed facility.
99. During the operation of equipment which, by its characteristics, falls within the scope of application of TR CU 032/2013 but was released into circulation before its entry into force, and the design and characteristics of which have not been changed (in respect of which the works specified in paragraph 98 of the Federal Norms and Rules have not been carried out), the following shall be ensured: compliance with the requirements of the Federal Norms and Rules, the conformity of the design (construction) of such equipment, and also the completeness of its fitting with measuring instruments, fittings, safety and other devices provided for by the technical documentation, and with automated control and safety systems, to the instructions of the project and the technical documentation of the manufacturing organisation. Elements and components used in the repair of the equipment shall conform to the requirements of the technical regulations in force at the time of their release into circulation. Equipment operating under pressure intended for use in the development, manufacture, testing, operation and utilisation of nuclear weapons and military nuclear installations at hazardous production facilities operated by organisations of the State Corporation "Rosatom" shall conform to the requirements of the documents on standardisation of nuclear-weapons products intended for the development, manufacture, testing, operation and utilisation of nuclear weapons and military nuclear installations. During the operation of equipment operating under pressure, its operable condition and its conformity with the requirements established for it shall be ensured by the performance of maintenance, planned preventive and unscheduled repairs (where it is necessary to perform them according to the technical condition of the equipment) by the workers of the relevant subdivisions of the operating organisations, as well as of specialised organisations (where necessary), in accordance with the instructions of the operating manual (instructions), the normative documents applied by the operating organisation, and the requirements of the Federal Norms and Rules.
100. The materials and semi-finished products used in the installation, repair and reconstruction (modernisation) of equipment operating under pressure shall ensure safe operating parameters, determined by their mechanical properties, chemical composition, manufacturing technology, the methods and volumes of testing and quality control, and the guaranteed level of design and technological characteristics, and shall conform to the requirements of the technical documentation of the manufacturing organisation and the design documentation. The use of other materials in the repair of the equipment is permitted provided that the possibility of their application is agreed with the project developer and (or) the manufacturing organisation of the equipment, and in the absence thereof on the basis of the recommendations (opinions) of design organisations and of organisations carrying out research or scientific-technical activity and competent in the field of materials science and the design of similar equipment.
101. The workers of a specialised organisation directly carrying out the works on the installation (dismantling), repair, reconstruction (modernisation) and commissioning of equipment operating under pressure in accordance with the procedure established, in accordance with the provisions of the legislation of the Russian Federation in the field of industrial safety and the Federal Norms and Rules, by the administrative documents of the organisation shall undergo: (a) managers and engineering and technical workers - attestation in the field of industrial safety to the extent of the industrial safety requirements necessary for the performance of their labour duties in accordance with the provisions of Article 14.1 of Federal Law No. 116-FZ. (b) workers - training to the extent of the qualification requirements (as part of vocational training), a knowledge check to the extent of the requirements of the production instructions and (or) the instructions for the given occupation, as well as to the extent of the technological processes, instructions and charts for the performance of particular types of work. The knowledge check of the requirements of the production instructions and (or) the instructions for the given occupation for workers is carried out once every 12 months. The familiarisation with and knowledge check of the technological processes, instructions and charts for the performance of a specific type of work is carried out immediately before the start of its performance.
102. The competence of welders, welding production specialists and non-destructive testing specialists participating in the works on the repair, installation and reconstruction (modernisation) of equipment operating under pressure, for the purpose of establishing the possibility of their admission to the performance of the works, shall be confirmed in accordance with the provisions of the legislation of the Russian Federation.
103. Elements, fittings, safety devices and other components withstanding the effect of excess pressure, used in the installation and repair (for the replacement of inoperable ones) of equipment operating under pressure, shall conform to the requirements of these Federal Norms and Rules, the design and technical documentation, as well as the requirements of the technical regulations in force in respect of the listed articles during the period of their release into circulation and supply to the operating organisation. In this case, the main elements of the equipment include elements withstanding the effect of the pressure and temperature of the working medium, as well as other elements ensuring the performance of the main functions of the equipment of which they form part according to the project, including, for the purpose of ensuring the requirements of the Federal Norms and Rules for specific kinds (types) of equipment, the following are regarded: economisers, heating surfaces, superheaters, drums, cyclones, heat exchangers, headers, unheated pipelines within the boundaries of the boiler (down-comer, bypass and connecting pipelines) which are subjected to the effect of excess pressure and temperature of the working medium (water, steam), as well as the furnace, gas ducts and air heaters forming part of the design of the boiler according to the project (hereinafter - the main elements (parts) of the boiler); the body of the vessel and its component parts (cylindrical and conical shell courses, welded-on and removable heads, body flanges, manholes, quick-release covers), internal elements, conical transitions, bosses, fittings and branch pipes (permanently attached to the body), forming part of the design of the vessel within the boundaries determined by the project developer, information on which has been entered by the manufacturing organisation into the data sheet of the vessel (hereinafter - the main elements (parts) of the vessel); assembly units manufactured under the conditions of the manufacturing organisation, intended for the performance of one of the main functions of the pipeline, including straight and curved sections, headers, as well as shaped parts ensuring a change of direction, the merging or division, expansion or narrowing of the flow of the working medium (hereinafter - the main elements (parts) of the pipeline). The boundaries (limits) of the boiler are determined by the shut-off devices, specified in its data sheet, of the feed, drainage and other pipelines, as well as by the safety and other valves and gate valves limiting the internal cavities of the elements of the boiler and of the pipelines attached to them. Where, in accordance with the decisions of the design documentation, those fittings are installed on pipelines connected to the boiler that do not form part of the design (delivery set) of the boiler and are not specified in its data sheet, then the points of connection of such pipelines to the fittings at the inlet and outlet of the boiler, to the pipelines within the boiler, may be determined as the limits of the boundaries of the boiler. The boundaries of the vessel are determined by the inlet and outlet fittings, as well as by the branch pipes attached to them (the connecting piping) with the fittings, safety and other devices installed on them (where present, in the cases established by the project), forming part of the design of the vessel and specified by the manufacturing organisation in the data sheet and the general-view drawings of the vessel.
104. A specialised organisation shall: (a) ensure the availability of managers and specialists satisfying the requirements of paragraph 101 of these Federal Norms and Rules, for ensuring the performance of the works within the framework of their job duties and powers, including the detection of cases of deviation from the requirements for the quality of the works, from the procedures for performing the works, and the taking of measures to prevent or reduce such deviations; (b) have personnel in the number established by the administrative documents of the specialised organisation and allowing the performance of the technological processes to be ensured during the performance of the relevant works; (c) not admit to the performance of works on the installation (dismantling), commissioning or repair or reconstruction (modernisation) of equipment operating under pressure persons who do not have qualifications corresponding to the nature of the works performed, who have not reached eighteen years of age, and also who have medical contraindications to the performance of those works; (d) determine the procedures for monitoring compliance with the technological processes; (e) establish the responsibility, powers and procedure for the relationships of the workers engaged in the management, performance or verification of the performance of the works.
105. The technological preparation of the performance of the works and the conduct of the production and technological process in a specialised organisation shall exclude the use of materials and articles for which there are no documents confirming their conformity and quality (certificates, data sheets, log books). During the installation, repair and reconstruction (modernisation) of equipment, the use of steel pipes and other materials previously in use shall be prohibited, with the exception of cases of the use of such pipes as part of bypass and blow-down lines temporarily arranged for a limited period of time determined by the project for the installation, repair or reconstruction (modernisation) of the pipeline system.
106. A specialised organisation shall have the necessary documentation ensuring the performance of the declared types of work, which includes: (a) normative documents, the need to apply which to ensure the industrial safety requirements established by the legislation in the field of industrial safety and the Federal Norms and Rules during the performance of the relevant works has been established by the specialised organisation in the form of an approved list or another administrative document; (b) the design (engineering) and technical documentation for the equipment operating under pressure whose installation (dismantling), commissioning, repair or reconstruction (modernisation) is carried out (including a set of working drawings, a set of the manufacturing organisation's drawings for the elements replaced during the repair of the equipment, updated by the manufacturing organisation or (in its absence) by the organisation performing the repair works in accordance with the requirements in force at the time of their performance); (c) technological documentation for the performance of the declared types of work (technological instructions, processes, charts, projects for the performance of installation and dismantling works), developed before the start of these works; (d) standard programmes (methodologies) for the start-up and commissioning, testing and comprehensive trial of the equipment operating under pressure being installed (repaired, reconstructed), carried out upon completion of the installation, repair or reconstruction.
107. To ensure the technological processes during the performance of works on the installation (dismantling), commissioning or repair or reconstruction (modernisation), a specialised organisation, depending on the types of activity carried out, shall have: (a) sets of equipment, instruments and devices necessary for monitoring the technical condition of the equipment operating under pressure before the start of the performance of the works, during their performance and after completion, including the quality control of the works performed; (b) assembly and welding, thermal equipment necessary for the performance of works on the cutting, straightening, welding and heat treatment of metal, as well as the necessary welding materials; (c) inspection equipment, instruments and tools necessary for the detection of impermissible defects in welded joints, and specialists with qualifications corresponding to the inspection methods applied; (d) measuring and monitoring instruments which have passed verification and allow commissioning works to be performed, the operability to be assessed, and repair and reconstruction (modernisation) to be performed; (e) technological tooling and equipment, including rigging and installation devices, lifting mechanisms, jacks and slings necessary for carrying out works on the installation (dismantling), repair and reconstruction (modernisation), as well as auxiliary devices (staging, guards, scaffolding) which may be used when carrying out the works.
108. The workers of specialised organisations directly performing works on the installation (dismantling), commissioning or repair or reconstruction (modernisation) of equipment operating under pressure shall meet the following requirements: (a) have documents confirming the completion of vocational training in the relevant kinds of working occupations, as well as a document on admission to independent work (for workers), drawn up in accordance with the procedure established by the administrative documents of the organisation; (b) have documents on the completion of attestation (for managers and engineering and technical workers); (c) know and comply with the requirements of the technological documents and instructions for carrying out the declared works; (d) know the main sources of hazards when carrying out the works performed, know and apply in practice the methods of protection against them, as well as the safe methods of performing the works; (e) know and be able to apply the methods of detection and the technology of elimination of defects during the installation, repair and reconstruction (modernisation); (f) know and be able to apply, for the performance of the installation (dismantling), repair and reconstruction (modernisation) of the equipment, rigging and installation devices, lifting mechanisms and slings corresponding in lifting capacity to the masses of the elements being installed (dismantled), repaired and reconstructed (modernised); (g) know and be able to apply the procedure, established in the instructions approved by the administrative documents of the organisation, for the exchange of conventional signals between the worker directing the works on the installation (dismantling) of the equipment and the other workers involved in the installation (dismantling) of the equipment; (h) know and comply with the rules of slinging, the main schemes of slinging of loads (when performing the duties of a slinger), as well as the industrial safety requirements when lifting and moving loads; (i) know the procedure and methods for performing works on the commissioning and adjustment of the equipment; (j) be able to apply inspection means, instruments and devices during checking, commissioning and testing.
109. The installation, repair and reconstruction (modernisation) of equipment operating under pressure using welding and heat treatment shall be carried out according to a technology developed before the start of the performance of the works by the specialised organisation performing the relevant works, on the basis of the working drawings and other engineering documentation of the project developer and the documentation of the manufacturing organisation of the equipment for newly installed or reconstructed equipment, as well as the manufacturer's drawings for the elements replaced during the repair of the equipment, updated by the manufacturing organisation or (in its absence) by the organisation performing the repair works in accordance with the requirements in force at the time of their performance). All the provisions of the adopted technology shall be reflected in the technological documentation (technological instructions, processes, charts, the project for the performance of works during installation (dismantling), repair or reconstruction) governing the content and procedure for the performance of all technological and inspection operations.
110. During the installation, repair and reconstruction (modernisation) using welding and heat treatment, the quality control system established by the administrative documents of the specialised organisation (incoming, in-process and acceptance) ensuring the performance of the works in accordance with these Federal Norms and Rules and the technological documentation shall be applied. The incoming inspection of additionally used materials and semi-finished products not included in the delivery set (not specified in the data sheets) of the manufacturing organisation of the equipment or its elements shall, in addition to carrying out a check of the conformity of the marking applied to them with the information specified in the accompanying documentation, provide for a selective check of the conformity of the actual characteristics of the purchased material before the start of its use, using non-destructive testing methods or destructive (where necessary) testing.
111. Current preventive repair and maintenance of the equipment not requiring the use of welding and heat treatment are performed by the workers (repair personnel) of the relevant subdivisions of the operating or specialised organisation. The procedure for performance, the volume and the frequency of performance of the works are determined by the production and technological instructions approved within the operating organisation, developed taking into account the requirements of the operating manuals (instructions) and the actual condition of the equipment.
112. The cutting of sheets, pipes and other semi-finished products, as well as the cutting of holes, may be carried out by any method (mechanical, gas-flame, electric-arc, plasma). The specific method and cutting technology is established by the technological documentation depending on the steel classes (material characteristics).
113. The thermal cutting technology applied to materials sensitive to local heating and cooling shall preclude the formation of cracks on the edges and the deterioration of the metal properties in the heat-affected zone. In cases provided for by the technological documentation, preliminary heating and subsequent machining of the edges shall be provided to remove the layer of metal with properties impaired during cutting.
114. The bending of pipes may be performed by any method mastered by the specialised organisation that ensures a bend quality conforming to the requirements of the technological documentation.
115. To ensure the mating of the transverse pipe joints, boring, flaring or crimping of the pipe ends is permitted. The values of the boring, and the deformation of flaring or crimping, are adopted within the limits established by the technological documentation. 116 Cold pull of pipelines, if provided for by the design, may be performed only after the completion of all welded joints, except the closing one, the final fixing of the fixed supports at the ends of the section subject to cold pull, and also after the heat treatment (where its performance is necessary) and the quality control of the welded joints located along the entire length of the section on which the cold pull is to be performed.
117. When performing welding work, the requirements of the federal norms and rules establishing the general requirements for the performance of welding work at hazardous production facilities, and the provisions of these Federal Norms and Rules, shall be followed.
118. Before the start of welding, the quality of the assembly of the elements to be joined, and also the condition of the edges to be butted and the surfaces adjacent to them, shall be checked. During assembly, the fitting of edges by impact or by local heating shall not be permitted.
119. The preparation of edges and surfaces for welding shall be performed by machining or by thermal cutting or gouging (oxygen, air-arc, plasma-arc) with subsequent machining (with a cutter, milling cutter or abrasive tool). The depth of machining after thermal cutting (gouging) shall be specified in the technological documentation depending on the susceptibility of the specific steel grade to the thermal cycle of the cutting (gouging).
120. When assembling butt joints of pipes with single-sided edge preparation and welded without backing rings and without sealing of the weld root, the offset (misalignment) of the internal edges shall not exceed the values established in the technological documentation.
121. The edges of parts to be welded and the areas adjacent to them shall be cleaned of scale, paint, oil and other contaminants in accordance with the requirements of the technological documentation.
122. The welding-on and removal of auxiliary elements (assembly devices, temporary fastenings) shall be performed in accordance with the instructions of the drawings and the technological documentation, using a technology that precludes the formation of cracks and hardening zones in the metal of the equipment operating under pressure. The welding-on of these elements shall be performed by a welder authorised to carry out welding work on the given equipment operating under pressure.
123. The sequence of welding shall ensure the least deformation of the products and materials.
124. The tacking of the elements assembled for welding shall be performed using the same welding consumables that will be used (or are permitted for use) for welding the given joint. During the subsequent performance of welding work, the tack welds are removed or remelted by the main weld run.
125. The welding consumables shall be inspected: (a) for the presence of the appropriate accompanying documentation; (b) each batch of electrodes - for welding-technological properties, and also for conformity of the content of alloying elements to the standardised composition by means of stiloscopy (or another spectral method ensuring confirmation of the presence of alloying elements in the metal) of the deposited metal produced with alloyed electrodes; (c) each batch of flux-cored wire - for welding-technological properties; (d) each coil (skein, spool) of alloyed welding wire - for the presence of the main alloying elements by means of stiloscopy or another spectral method ensuring confirmation of the presence of alloying elements in the metal; (e) each batch of wire together with each batch of flux that will be used jointly for automatic submerged-arc welding - for the mechanical properties of the weld metal.
126. The welding technology for the installation, repair, reconstruction (modernisation) of equipment operating under pressure is permitted for use provided that its manufacturability is confirmed on actual products, the entire set of required properties (characteristics) of the welded joints is verified, and effective methods for monitoring their quality are mastered, and it shall be certified.
127. The certification of welding technology is divided into research certification and production certification. Research certification shall be carried out when preparing for the introduction of a new welding technology. The production certification of welding technology is carried out before the start of its application, as part of verifying the readiness of organisations to perform welding work under the conditions of a specific production.
128. Research certification of welding technology is carried out to determine the characteristics of the welded joints required for calculations during design and for issuing technological recommendations (field of application of the technology, welding consumables, modes of preheating, welding and heat treatment, guaranteed indicators of the acceptance characteristics of the welded joint, methods of monitoring). The characteristics of the welded joints determined during research certification are selected depending on the type and purpose of the base metal and the following operating conditions of the welded joints: (a) mechanical properties at normal (20 +/- 10 °C) and working temperature, including the ultimate tensile strength, the yield strength, the relative elongation and relative reduction of area of the weld metal, the impact toughness of the weld metal and of the heat-affected zone of the weld, and the ultimate tensile strength and bending angle of the welded joint; (b) long-term strength, ductility and creep; (c) cyclic strength; (d) critical brittleness temperature of the weld metal and of the heat-affected zone of the weld; (e) stability of the properties of the welded joints after thermal ageing at working temperature; (f) intensity of oxidation in the working medium; (g) absence of impermissible defects; (h) resistance to intergranular corrosion (for welded joints of elements made of austenitic-class steels); (i) characteristics specific to the welded joints being performed, established by the organisation carrying out their research certification.
129. The production certification of welding technology shall be carried out to confirm that the organisation engaged in the installation, repair, reconstruction (modernisation) of equipment operating under pressure possesses the technical and organisational capabilities and the qualified personnel for performing welding by the technologies being certified, and also to verify that the welded joints (weld overlays) made under the conditions of a specific production by the technology being certified ensure conformity with the requirements of the Federal Norms and Rules, the regulatory documents and the welding technological documentation. Where the results of the verification of the availability of the technical, personnel and organisational capabilities of the organisation are positive, the welding of check welded joints shall be performed using the specific technology, at the site of performance of welding work at the facility during construction, installation, repair, manufacture, or at a specially organised (for the period of construction, installation, repair or on a permanent basis) area (base) for performing work that includes the assembly and welding of production welded joints.
130. Production certification is carried out in accordance with a programme developed before the start of its performance, which shall provide for the non-destructive and destructive testing of the welded joints, the assessment of the welding quality based on the results of the testing, and the drawing up of a final document on the results of the production certification. The procedure for carrying out production certification is determined in the technological documentation. If unsatisfactory results are obtained for any type of test during the production certification of the welding technology, the certification commission shall take measures to establish the causes of the non-conformity of the obtained results with the established requirements and shall take a decision on carrying out repeat tests or on the impossibility of using the given technology for welding production joints and the need for its refinement.
131. In the event of deterioration of the properties or quality of the welded joints relative to the level established by the production certification, the organisation shall suspend the application of the welding technology, establish and eliminate the causes that led to their deterioration, and carry out a repeat production certification and, where necessary, also a research certification.
132. During the installation, repair, reconstruction (modernisation) of equipment operating under pressure, certified welding technologies are used that are provided for by the design, technical and technological documentation and that ensure the quality of the performance of the work, taking into account the materials used in the construction of the equipment. The use of gas welding shall not be permitted for parts made of austenitic steels and high-chromium steels of the martensitic and martensitic-ferritic class.
133. The welding of elements operating under excess pressure shall be carried out at a positive ambient air temperature. Welding may be performed under conditions of negative temperature subject to compliance with the requirements of the technological documentation and the creation of the necessary conditions to protect the welding location and the welder from the effects of wind and atmospheric precipitation. At a negative ambient air temperature, the metal in the area of the welded joint shall, before welding, be dried and heated, bringing the temperature to a positive value.
134. The necessity and mode of the preliminary and concurrent heating of the parts to be welded are determined by the welding technology and shall be specified in the technological documentation. At a negative ambient air temperature, the heating of the parts to be welded is carried out in the same cases as at a positive temperature, the heating temperature in this case being higher by 50 °C.
135. After welding, the weld and the adjacent areas shall be cleaned of slag, metal spatter and other contaminants. The internal flash in the joints of pipes made by resistance welding shall be removed to ensure the specified flow cross-section.
136. The heat treatment of equipment elements during installation, repair, reconstruction (modernisation) is carried out in the cases established by the technological documentation, taking into account the recommendations of the manufacturing organisation specified in the operating manual (instructions), whereby: 1) Butt joints of pipes made of steels 12Kh1MF and 15Kh1M1F (and correspondingly of cast parts) with a wall thickness of more than 45 mm regardless of the pipe diameter, and with a wall thickness of more than 25 mm at a pipe diameter of 600 mm and more, shall be subjected to heat treatment immediately after the completion of welding, not allowing the joint to cool below 300 °C. Where, for technical reasons (including interruption of the power supply, damage to equipment, the need to reposition the inductor), it is impossible to carry out the heat treatment of such welded joints directly after welding, the joint shall be cooled slowly under a layer of thermal insulation 8 - 15 mm thick, and after the elimination of the causes of the interruption of the heat treatment, the heat treatment process shall be resumed immediately. If the hardness of the weld metal after heat treatment exceeds the permissible value, a repeat tempering shall be performed, but no more than three times including the initial one. The heat treatment shall be completed no later than 3 days after the completion of welding. 2) Before the heat treatment is carried out, it shall be prohibited to subject the welded joints to loads, to remove blocks from supports, to tilt them or to transport them. 3) Before heat treatment, on sections of pipelines located horizontally, temporary supports shall be installed at a distance of no more than 1 metre on both sides of the welded joint, and for sections of pipelines located vertically, the welded joint shall be relieved of the weight of the pipeline by fixing it. The temporary supports may be removed only after the joint has completely cooled. 4) The heat treatment of pipe joints shall be performed before the cold pull of the pipeline, that is, before the assembly and welding of the closing joint.
137. During the assembly (manufacture) at the place of operation, installation, repair, reconstruction (modernisation) of equipment operating under pressure, a quality control system (incoming, in-process, acceptance) for the welded joints and materials shall be applied that guarantees the detection of impermissible defects and the high quality and reliability of the operation of this equipment and its elements.
138. The incoming inspection of the materials, semi-finished products, parts, elements and other component items used (hereinafter - materials and products or production) shall ensure their identification (verification) before the start of their use in the performance of work, including by carrying out the checking (inspection) of: (a) the documents (certificates, declarations) confirming the conformity of the production with the requirements of technical regulations (if such requirements are established for them), for their presence, for verification of authenticity, and also for a comparative assessment of the conformity of the information stated in them with the actual name, characteristics, kind (type, model) of the delivered production and other available information ensuring its identification; (b) the accompanying documentation for the production certifying the quality and completeness of the production, for its presence and for verification of the actual conformity of the completeness of the delivered production and the marking applied to it with the information stated in the accompanying documentation; (c) the conformity of the completeness, quality and characteristics of the delivered production with the requirements of the design (constructional) and normative-technical documentation. The inspection shall provide for a selective check of the conformity of the actual characteristics of the materials and products using non-destructive testing methods or destructive (where necessary) testing.
139. During the incoming inspection of welding consumables, the following shall be checked: (a) the presence of the appropriate accompanying documentation; (b) the welding-technological properties of each batch of electrodes, including the conformity of the content of alloying elements to the standardised composition by means of stiloscopy (or another spectral method ensuring confirmation of the presence of alloying elements in the metal) of the deposited metal produced with alloyed electrodes; (c) the welding-technological properties of each batch of flux-cored wire; (d) the presence of the main alloying elements of each coil (skein, spool) of alloyed welding wire by means of stiloscopy or another spectral method ensuring confirmation of the presence of alloying elements in the metal; (e) the mechanical properties of the weld metal of each batch of wire together with each batch of flux that will be used jointly for automatic submerged-arc welding.
140. Each part of welding wire separated from the coil (skein) shall be provided with a tag on which the grade, heat number and diameter of the wire are indicated.
141. Materials and products that have not undergone identification or incoming inspection, and that do not have accompanying documentation and marking, may not be admitted for the further performance of installation, repair, reconstruction (modernisation).
142. In-process inspection shall ensure the step-by-step performance of the inspection of the geometric parameters of parts and blanks, including after their machining, the assembly of the structure or of the parts and elements of the equipment for welding, and also the quality control of the welded joints during the performance of the work.
143. The acceptance quality control of the welded joints shall be carried out after the completion of all stages of the in-process inspection and the technological operations.
144. The methods and scope of inspection shall be provided for in accordance with the requirements of these Federal Norms and Rules and specified in the technological documentation.
145. The quality control of the welded joints and of the materials of the parts, components and elements of the equipment being joined thereby (hereinafter - materials) shall be carried out in the manner provided for by the design (constructional) and technological documentation.
146. The quality control of the welded joints and materials during installation, repair, modernisation (reconstruction), in the course of operational monitoring, technical diagnostics, and also during the industrial safety expert examination, the certification of welding technology, the certification of welders and the inspection of the check welded joints performed by them before admission to the performance of work, is carried out by laboratories that have confirmed their competence in the manner provided for by the legislation of the Russian Federation. Visual and measuring inspection, and also the checking of the characteristics of materials (metal grade, presence of alloying elements) by an automatic device (metal analyser), carried out within the scope of incoming inspection and in-process inspection, may be carried out by employees, of a qualification corresponding to those types of inspection, of the subdivisions of the organisation whose duties provide for the performance of those operations.
147. The quality control of the welded joints and materials shall be carried out using the following methods: (a) visual and measuring inspection; (b) ultrasonic testing; (c) radiographic testing; (d) capillary and magnetic particle testing; (e) stiloscopy or another spectral method ensuring confirmation of the actual grade of the metal or the presence of alloying elements in it; (f) hardness measurement; (g) monitoring of mechanical properties, testing for resistance to intergranular corrosion, metallographic examinations (destructive testing); (h) hydraulic tests; (i) acoustic emission; (j) radioscopy; (k) eddy-current testing; (l) determination of the content of the ferrite phase in the weld metal; (m) pneumatic tests, if hydraulic tests are not carried out on the instruction of the manufacturing organisation; (n) passage of a metal ball (for elements of the tube heating surfaces of boilers where welding is used for their assembly during installation or repair).
148. Depending on the design and materials of the welded joint, the inspection methods specified in paragraph 147 of these Federal Norms and Rules may be applied during the certification of welding technology, the certification of welders and the inspection of the check welded joints performed by them before admission to the performance of work, in the cases provided for by the design and technological documentation, and also during the industrial safety expert examination and the operational monitoring (technical diagnostics) of equipment or individual elements, in the cases established in Chapter VI of these Federal Norms and Rules, the technical documentation of the manufacturing organisation, and the regulatory documents for the specific type and model of equipment operating under pressure. When applying non-destructive testing methods, Appendix No. 2 to the Federal Norms and Rules shall be followed.
149. Visual and measuring inspection, and also the stiloscopy provided for by the technological documentation (or another spectral method ensuring confirmation of the actual grade of the metal or the presence of alloying elements in it), shall precede inspection by other methods.
150. The results of each type of inspection carried out and the locations of the inspection shall be recorded in the reporting documentation (logs, record forms, reports, route sheets).
151. The inspection equipment shall undergo metrological verification and testing in accordance with the legislation of the Russian Federation on standardisation and the uniformity of measurements.
152. Each batch of materials for flaw detection (penetrants, powder, suspensions, radiographic film, chemical reagents) shall, before the start of their use, be subjected to incoming inspection.
153. The methods and scopes of inspection of the welded joints of welded-on parts not operating under internal pressure shall be established by the technological documentation.
154. The results of the quality control of the welded joints are recognised as positive if, in any prescribed type of inspection, no internal or surface defects are detected that exceed the permissible limits established by the design (constructional) and technological documentation and by these Federal Norms and Rules.
155. All welded joints shall be subjected to visual and measuring inspection to detect the following defects: (a) cracks of all types and directions; (b) wormholes and porosity of the outer surface of the weld; (c) undercuts; (d) overlaps, burn-throughs, unfilled craters; (e) deviations in the geometric dimensions and mutual arrangement of the elements to be welded; (f) offsets and joint deflection of the edges of the elements to be welded beyond the prescribed norms; (g) non-conformity of the shape and dimensions of the weld with the requirements of the technological documentation; (h) defects on the surface of the base metal and welded joints (dents, laminations, cavities, lack of fusion, pores, inclusions).
156. Before visual inspection, the surfaces of the weld and of the adjacent areas of the base metal, over a width of not less than 20 mm on both sides of the weld, shall be cleaned of slag and other contaminants. The visual and measuring inspection of the welded joints shall be carried out from the outer and inner sides (where structurally possible) along the entire length of the welds. Where visual and measuring inspection of a welded joint from two sides is impossible, its inspection shall be carried out in the manner provided for by the developer of the design of the equipment operating under pressure, specified in the constructional and technical documentation of the manufacturing organisation. The assessment of the results of the visual and measuring inspection shall be carried out in accordance with the design (constructional) and technological documentation and Appendix No. 2 to these Federal Norms and Rules.
157. Surface defects detected during visual and measuring inspection shall be rectified before inspection by other non-destructive methods is carried out.
158. Ultrasonic and radiographic testing are carried out to detect discontinuities in welded joints made of metals and alloys, including: cracks, lack of fusion, pores, non-metallic and metallic inclusions, burn-throughs of the backing ring, taking into account the following. 1) The method of testing (ultrasonic, radiographic or both methods in combination) shall be selected on the basis of the ability to ensure the most complete and accurate detection of defects of the specific type of welded joints, taking into account the features of the physical properties of the metal and of the given method of testing. 2) For the specific kind (type) of construction of the equipment operating under pressure and of the welded joint, the necessity of carrying out and the scope of testing, and the types and sizes of the discontinuities (defects) subject to detection, are established in standards and are specified in the design (constructional) and technological documentation. 3) Based on the results of ultrasonic testing of welded joints and weld overlays, grouped defects, extended and individual non-extended defects exceeding the norms established by the regulatory documents and the constructional and technological documentation (Appendix No. 2 to the Federal Norms and Rules) shall not be permitted. 4) Based on the results of radiographic testing, cracks of all types and directions, wormholes, burn-throughs and defects exceeding those permissible in size and number (Appendix No. 2 to these Federal Norms and Rules) shall not be permitted.
159. A butt welded joint that has been subjected to repair re-welding (rectification of a weld defect) shall be inspected by ultrasonic or radiographic testing along the entire length of the welded joint. Repair welds of metal excavations shall be inspected by ultrasonic or radiographic testing over the entire area of the weld, including the heat-affected zone of the weld in the base metal; in addition to this, the surface of the area shall be inspected by capillary or magnetic particle testing. Where welding is performed through the entire wall thickness, the surface inspection shall be carried out from both sides, except in cases where the inner side is inaccessible for inspection.
160. If, during selective inspection of the welded joints made by a welder, impermissible defects are detected, then all welded joints of the same type made by the given welder shall be subjected to inspection along their entire length.
161. Ultrasonic and radiographic testing of butt welded joints may, by agreement with the developer of the design documentation, be replaced by other non-destructive testing methods that make it possible to detect internal defects in the welded joints.
162. Capillary and magnetic particle testing shall be carried out where it is necessary to detect: surface defects: cracks, pores, slag inclusions, cavities, intergranular corrosion, corrosion cracking and other discontinuities, and also the locations, extent and nature of their propagation - capillary testing; surface and subsurface defects in steel ferromagnetic structures and parts - magnetic particle testing.
163. The scope, class and level of sensitivity of capillary and magnetic particle testing shall be established by the technological documentation developed on the basis of the design (constructional) documentation and the regulatory documents, taking into account Appendix No. 2 to the Federal Norms and Rules and the following conditions. 1) Acceptance capillary testing shall be carried out after the rectification of the defective surface areas and the final heat treatment, if its performance is provided for by the technological process in accordance with the technological documentation. 2) When several types of testing are applied to one object, capillary testing shall be performed before ultrasonic and magnetic particle testing is carried out. Where capillary testing is carried out after magnetic particle testing, the object of testing shall be subjected to demagnetisation and cleaning of the cavities of the discontinuities. 3) Based on the results of capillary testing, single and grouped indications of round or elongated shape shall not be permitted on the surface of welded joints and weld overlays. 4) Based on the results of testing by the magnetic particle method, indications of magnetic powder deposits shall not be permitted on the surface of welded joints and weld overlays. 5) When capillary and (or) magnetic particle testing is used as an additional method, the following shall not be permitted on the surface of forgings, stamped blanks, equipment elements, section rolled products, the cladding layer of double-layer steel, and edges prepared for welding: cracks, forging laps, rolled-in laps, scabs, sand spots, cavities, laminations, tears.
164. During inspection by stiloscopy or by a spectral method that ensures the determination of the presence of alloying elements in the metal or of its actual grade, for confirmation of the conformity of the metal of the welds and of the parts and elements of equipment operating under pressure made of alloyed steel with the requirements of the design (constructional) and technological documentation, the following shall be ensured. 1) During installation, repair, reconstruction, the following shall be subjected to stiloscopy: all parts of structures and components to be welded (pipes, fittings, reducers, bends, tees, branch pipes, bosses and other parts and elements), regardless of the presence of a certificate, marking and the forthcoming service life, which according to the design are to be made of alloyed steel (except low-alloy structural materials), whereby the presence (content) of the characteristic alloying elements in the material of the item being inspected is determined and its conformity with the steel grade specified in the drawings or technical specifications is established. Stiloscopy of the parts to be welded is carried out before assembly or directly during assembly, and also after the completion of installation (repair); the weld metal of welded joints made with alloyed filler material, to the extent of 100 per cent of pipeline joints, 20 per cent of joints of heating-surface tubes and 10 per cent of fillet welded joints (welding-on of branch pipes, bosses, fastening parts and other elements to headers and pipes). 2) Stiloscopy of the weld metal is performed before the heat treatment of the welded joints (except in the cases stipulated in sub-clause 1 of paragraph 136 of the Federal Norms and Rules). A welded joint made simultaneously by two welders shall be stiloscoped at two diametrically opposite areas of the weld; where the work is performed by one welder, stiloscopy may be carried out at one area.
165. To verify the quality of the performance of the heat treatment of welded joints, hardness measurement of the metal of welded joints made of alloyed heat-resistant steels of the pearlitic and martensitic-ferritic classes shall be carried out, by the methods and to the extent established by the technological documentation. Hardness measurement of the base metal and of the welded joints during technical examination, technical diagnostics and industrial safety expert examination shall be carried out in cases of: (a) severe operating conditions or an emergency situation as a result of which irreversible changes could have occurred in the hardness indicator, which is one of the determining characteristics of the properties of the base metal and welded joints according to the passport; (b) irreversible changes in mechanical properties as a result of the operation of the equipment under conditions of an emergency situation, for the assessment of mechanical properties by the hardness indicator; (c) the need for identification of base and welding materials in the absence of information about them, and also the need for identification of imported steels - for the assessment of mechanical properties.
166. Control butt-welded joints shall be subjected to mechanical testing to verify that their mechanical properties conform to the requirements of the design and process documentation. The mandatory types of mechanical testing are static tensile testing, static bending or flattening testing. For vessels operating under pressure, impact bending testing is also a mandatory type of testing. Impact bending testing is carried out for vessels made of steels prone to hardening during welding, as well as for other vessels intended to operate at a pressure of more than 5 MPa or a temperature above 450 °C, or to operate at a temperature below -20 °C. Mechanical testing is carried out during: (a) certification of the welding technology; (b) certification of welders; (c) incoming inspection of the welding consumables used for welding (surfacing) during the installation, repair, reconstruction (modernisation) of pressure equipment (in accordance with the requirements of paragraph 139 of these Federal Norms and Rules). Where unsatisfactory results are obtained for any type of mechanical testing, a repeat test may be carried out on a doubled number of specimens cut from the same control welded joints, for the type of testing in which the unsatisfactory results were obtained. If, during the repeat test, at least one of the specimens shows property values that do not satisfy the standards established in the regulatory documents and in the design, technical and process documentation, the overall assessment of this type of testing is deemed unsatisfactory.
167. The necessity, scope and procedure for mechanical testing of the welded joints of cast and forged elements, of pipes with cast parts, of elements made of steels of various classes, as well as of other individual welded joints are established by the design and process documentation.
168. To identify possible internal defects (cracks, lack of penetration, pores, slag and non-metallic inclusions), as well as areas with a metal structure that adversely affects the properties of the welded joints, metallographic examinations shall be carried out.
169. Metallographic examinations shall be carried out during: (a) certification of the welding technology, certification of welders and inspection of the control welded joints performed by them before their admission to the performance of the work, in the cases provided for by the design-engineering and process documentation; (b) the conduct of an industrial safety expert review and operational inspection (technical diagnostics) of equipment or individual elements, in the cases indicated below in this paragraph and established in the technical documentation of the manufacturing organisation and in the regulatory documents for the specific type or model of pressure equipment; (c) inspection of butt-welded joints made by gas and resistance welding, as well as of parts made of steels of different structural classes (regardless of the welding method); (d) inspection of welded corner and T-joints, including joints of pipes (nozzles) with shells, drums, headers and pipelines, as well as tee joints; (e) inspection of the degree of graphitisation of the welded joints of equipment elements made of carbon steels and operating under pressure with a working medium temperature above 350 °C.
170. Metallographic examinations shall include: (a) examination of the macrostructure and the shape of the weld; (b) examination of the microstructure of the various zones of the welded joint.
171. Metallographic examinations need not be carried out: (a) for the welded joints of vessels and their elements made of austenitic-class steels not more than 20 mm thick; (b) for the welded joints of boilers and pipelines made of pearlitic-class steel, provided that ultrasonic or radiographic inspection of these joints is carried out to the extent of 100 per cent; (c) for the welded joints of the pipes of the heating surfaces of boilers and pipelines made by resistance welding on special machines for resistance butt welding with an automated work cycle, subject to verification each shift of the quality of the machine setup by testing control specimens.
172. Testing for resistance to intergranular corrosion for boilers, pipelines and their elements is carried out in the cases provided for by the process documentation, to confirm the corrosion resistance of the welded joints of parts made of austenitic steels. Testing of the welded joints for resistance to intergranular corrosion shall be carried out for vessels and their elements made of steels of the austenitic, ferritic and austenitic-ferritic classes and of two-layer steels with a corrosion-resistant layer of austenitic and ferritic steels. The shape, dimensions and number of specimens, the testing methods and the criteria for assessing the specimens' susceptibility to intergranular corrosion shall conform to the requirements of the design and process documentation.
173. Mechanical testing, metallographic examinations and testing for resistance to intergranular corrosion shall be performed on specimens made from control welded joints. The control welded joints shall be identical to the production joints being inspected (in terms of steel grade, plate thickness or pipe dimensions, the shape of the edge preparation, the welding method, the welding consumables, the position of the weld in space, the preheating conditions and temperature, and the heat treatment) and shall be made by the same welder and on the same welding equipment simultaneously with the production joint being inspected. The control welded joint is subjected to 100 per cent inspection by the same non-destructive inspection methods as those provided for the production welded joints. If the inspection results are unsatisfactory, the control joints shall be made anew in a doubled quantity. If unsatisfactory results are obtained during the repeat non-destructive inspection, then the overall result too is deemed unsatisfactory. In this case, the quality of the materials, the equipment and the welder's qualification shall be subjected to additional verification. The dimensions of the control joints shall be sufficient for cutting from them the required number of specimens for all the envisaged types of testing and examination, as well as for repeat testing and examination. From each control butt-welded joint the following shall be cut: (a) two specimens for static tensile testing; (b) two specimens for static bending or flattening testing; (c) three specimens for impact bending testing; (d) one specimen (microsection) for metallographic examinations in the inspection of welded joints of carbon and low-alloy steel, and not fewer than two in the inspection of welded joints of high-alloy steel, if this is provided for by the process documentation; (e) two specimens for testing for resistance to intergranular corrosion.
174. Static bending testing of the control joints of tubular elements with a pipe internal diameter of less than 100 mm and a wall thickness of less than 12 mm may be replaced by flattening testing.
175. Hydraulic testing at test pressure to verify the tightness and strength of the pressure equipment, as well as of all welded and other joints, is carried out: (a) after the final assembly (manufacture, completion of manufacture) during the installation of equipment transported to its place of installation as separate parts, elements or units; (b) after reconstruction (modernisation) or repair of equipment involving the welding of elements operating under pressure; (c) during technical examinations and technical diagnostics of equipment in the cases established by these Federal Norms and Rules. Hydraulic testing of individual parts, elements or units of equipment before their use (installation) as part of the equipment during installation or repair is not mandatory if they have undergone hydraulic testing at their place of manufacture or have been subjected to 100 per cent ultrasonic inspection or an equivalent non-destructive flaw-detection method. Hydraulic testing of individual and assembled elements together with the equipment is permitted if, under the conditions of installation or repair, testing them separately from the equipment is impossible. Hydraulic testing of equipment and its elements is carried out after all types of inspection, as well as after the elimination of the defects found.
176. Vessels having a protective coating or insulation are subjected to hydraulic testing before the coating or insulation is applied. Vessels having an outer casing are subjected to hydraulic testing before the casing is fitted. Enamelled vessels may be subjected to hydraulic testing at working pressure after enamelling.
177. The minimum value of the test pressure for the hydraulic testing of steam and hot-water boilers (with the exception of electric boilers), stand-alone superheaters and economisers, as well as of pipelines within the boiler, shall be taken as: (a) at a working pressure of not more than 0.5 MPa - 1.5 times the working pressure, but not less than 0.2 MPa; (b) at a working pressure of more than 0.5 MPa - 1.25 times the working pressure, but not less than the working pressure plus 0.3 MPa. When carrying out the hydraulic testing of drum boilers, as well as their superheaters, economisers and pipelines within the boiler, the pressure in the boiler drum shall be taken as the working pressure when determining the value of the test pressure, and for drumless and once-through boilers with forced circulation - the feedwater pressure at the boiler inlet established by the design documentation. The maximum value of the test pressure shall be confirmed by strength calculations for the steam and hot-water boilers. The value of the test pressure taken within the interval between its maximum and minimum values shall ensure the greatest detectability of defects in the boiler or its elements subjected to the hydraulic testing.
178. The value of the test pressure for the hydraulic testing of metal vessels (with the exception of cast ones), as well as of electric boilers, is determined by the formula:
where: P - the design pressure in the case of assembly (completion of manufacture) of the vessel at the place of operation from separate elements, where the test is carried out after the completion of such work, and in the other cases of testing during the operation of the equipment - the working pressure (MPa) stated in the vessel's data sheet by the manufacturing organisation or according to the results of the initial technical examination;
, - the permissible stresses for the material of the vessel (electric boiler) or its elements at 20 °C and the design temperature respectively, MPa.
The ratio of the materials of the assembly units (elements) of the vessel (electric boiler) operating under pressure is taken from whichever of the materials used for the elements (shells, heads, flanges, branch pipes, etc.) of the vessel it is smallest for, with the exception of bolts (studs), as well as the heat-exchange tubes of shell-and-tube heat exchangers.
The test pressure for testing a vessel calculated by zones shall be determined taking into account the zone whose design pressure or design temperature has the lower value.
The test pressure for testing a vessel intended to operate under several regimes with different design parameters (pressures and temperatures) shall be taken as equal to the maximum of the determined values of the test pressures for each regime.
Where, to ensure the conditions of strength and tightness during testing, it becomes necessary to increase the diameter or number of the bolts (studs) of the flanged joints or to change their material, the test pressure may be reduced to the maximum value at which the strength conditions of the bolts (studs) are ensured during testing without increasing their diameter or number or changing their material.
Where the vessel as a whole or individual parts of the vessel operate within the creep temperature range and the permissible stress for the materials of these parts at the design temperature is determined on the basis of the long-term strength limit or the creep limit, it is permitted, in formulae (1) and (7), to use instead the value of the permissible stress at the design temperature, obtained only on the basis of time-independent characteristics: the yield strength and the ultimate tensile strength, without taking creep and long-term strength into account.
For the hydraulic testing of pipelines from boilers with organic and inorganic heat-transfer media, the value of the test pressure Ppr is determined by formula (1).
179. The value of the test pressure Ppr for the hydraulic testing of cast and forged vessels is determined by the formula: . (2) The testing of cast vessels is permitted provided that the castings undergo 100 per cent inspection by non-destructive methods.
180. The hydraulic testing of vessels and parts made of non-metallic materials with an impact toughness of more than 20 J/cm2 shall be carried out at a test pressure determined by the formula: . (3) The hydraulic testing of vessels and parts made of non-metallic materials with an impact toughness of 20 J/cm2 or less shall be carried out at a test pressure determined by the formula: . (4)
181. The value of the test pressure Ppr for the hydraulic testing of cryogenic vessels where there is a vacuum in the insulation space is determined by the formula: Ppr = 1.25P - 0.1. (5)
182. The hydraulic testing of metal-plastic vessels shall be carried out at a test pressure determined by the formula: , (6) where Km - the ratio of the mass of the metal structure to the total mass of the vessel; = 1.3 - for non-metallic materials with an impact toughness of more than 20 J/cm2; = 1.6 - for non-metallic materials with an impact toughness of 20 J/cm2 or less.
183. The hydraulic testing of vessels installed vertically is permitted to be carried out in a horizontal position, in which case a strength calculation for the vessel body shall be performed taking into account the support method adopted for carrying out the hydraulic testing. In combined vessels with two or more working cavities designed for different pressures, each cavity shall be subjected to hydraulic testing at a test pressure determined in accordance with the design pressure of the cavity. The procedure for testing such vessels shall be established by the developer of the design technical documentation and stated in the vessel's operating manual.
184. The minimum value of the test pressure for the hydraulic testing of steam and hot-water pipelines shall be 1.25 times the working pressure (stated in the data sheet by the manufacturing organisation or according to the results of the initial technical examination), but not less than 0.2 MPa. The maximum value of the test pressure shall be established by strength calculations for the pipelines. The value of the test pressure (between the maximum and the minimum) shall ensure the greatest detectability of defects in the pipeline or its elements subjected to the hydraulic testing.
185. Water shall be used for the hydraulic testing of pressure equipment. The water temperature shall be not lower than 5 °C and not higher than 40 °C, unless a specific temperature value permissible under the conditions for preventing brittle fracture is stated in the technical documentation of the equipment manufacturing organisation. The hydraulic testing of pipelines shall be carried out at a positive ambient air temperature. In the hydraulic testing of steam pipelines with a working pressure of 10 MPa or more, the temperature of their walls shall be not less than 10 °C. In the hydraulic testing of steam and hot-water boilers, the upper limit of the water temperature may be increased, in agreement with the design organisation, to 80 °C. If the metal temperature of the top of the drum exceeds 140 °C, filling it with water to carry out the hydraulic testing shall not be permitted. The water used for the hydraulic testing shall not contaminate the equipment or cause intensive corrosion. The difference between the temperatures of the metal and the ambient air during the hydraulic testing shall not lead to the condensation of moisture on the surface of the equipment walls. In technically justified cases provided for by the manufacturing organisation, another liquid may be used when carrying out the hydraulic testing during the operation of vessels. Carrying out testing with a toxic or corrosive liquid shall not be permitted.
186. When filling the equipment with water, the air shall be completely removed from it. The pressure in the equipment being tested shall be raised smoothly and evenly. The total time for raising the pressure (to the test value) shall be stated in the process documentation. The water pressure during the hydraulic testing shall be monitored by not fewer than two pressure gauges. Both pressure gauges are selected of the same type and measuring range, of identical accuracy classes (not lower than 1.5) and of the same scale division. The use of compressed air or another gas to raise the pressure in equipment filled with water shall not be permitted. The holding time under test pressure for steam and hot-water boilers, including electric boilers, for steam and hot-water pipelines, as well as for vessels delivered to the place of installation fully assembled, is established by the manufacturing organisation in the operating manual and shall be not less than 10 min. The holding time under test pressure for vessels of element-by-element block delivery, completed during installation at the place of operation, shall be not less than: (a) 30 min for a vessel wall thickness of up to 50 mm inclusive; (b) 60 min for a vessel wall thickness of more than 50 up to 100 mm inclusive; (c) 120 min for a vessel wall thickness of more than 100 mm. For cast, non-metallic and multilayer vessels, regardless of the wall thickness, the holding time shall be not less than 60 min.
187. After the holding under test pressure, the pressure is reduced to a value justified by the strength calculation, but not less than the working pressure, at which a visual inspection of the outer surface of the equipment and of all its detachable and permanent joints is carried out.
188. Pressure equipment shall be deemed to have passed the hydraulic testing if none of the following is found: (a) visible residual deformations; (b) cracks or signs of rupture; (c) leakage or sweating in welded, expanded and riveted joints and in the base metal; (d) leakage in detachable joints; (e) a drop in pressure on the pressure gauge. In the expanded and detachable joints of boilers and in the detachable joints of pipelines and vessels, the appearance of individual droplets that do not increase in size over the holding time is permitted.
189. After the hydraulic testing has been carried out, the removal of water from the equipment being tested shall be ensured. Equipment and its elements in which defects were identified during the hydraulic testing are, after those defects have been eliminated, subjected to repeat hydraulic testing at test pressure.
190. The hydraulic testing of vessels may be replaced by pneumatic testing (with compressed air, inert gas or a mixture of air and inert gas), provided that simultaneous monitoring by the acoustic emission method is carried out. The test pressure for the pneumatic testing shall be determined by the formula:
Where the probability of brittle fracture during pneumatic testing is greater than under operating conditions and its consequences pose a significant hazard, the test pressure shall be reduced to a technically justified level, but not less than the working pressure. The test temperature shall be not less than 25 °C above the brittle-fracture temperature of the materials of the equipment being tested.
In technically justified cases provided for by the manufacturing organisation, when carrying out pneumatic testing during the operation of equipment, the gaseous working medium of the object being tested may be used as the loading medium, in which case the test pressure shall exceed the working pressure by not less than 5 per cent but shall not exceed the test pressure determined by formula (7).
The holding time of the vessel under test pressure during pneumatic testing shall be stated in the technical documentation and shall be not less than 15 min.
After the holding under test pressure, the pressure shall be reduced to a value justified by the strength calculation, but not less than the working pressure, at which a visual inspection of the outer surface and a tightness check of the welded and detachable joints shall be carried out.
191. Impermissible defects found during the installation (completion of manufacture), repair, reconstruction (modernisation) or testing shall be eliminated (corrected), with subsequent inspection of the corrected areas. The technology for eliminating defects is established by the process documentation. Deviations from the adopted technology for correcting defects shall be agreed with its developer. The methods and quality of defect elimination shall ensure the required reliability and safety of the equipment's operation.
192. The removal of defects shall be carried out by a mechanical method, ensuring smooth transitions at the excavation sites. The maximum dimensions and shape of the excavations to be welded up are established by the process documentation. The use of thermal cutting (gouging) methods for removing internal defects is permitted, with subsequent treatment of the excavation surface by a mechanical method. The completeness of defect removal shall be checked visually and by a non-destructive inspection method (penetrant or magnetic-particle flaw detection or etching).
193. The excavation of the defect locations found, without subsequent welding up, is permitted provided that the minimum permissible wall thickness of the part is retained at the point of maximum excavation depth and is confirmed by a strength calculation.
194. If defects are found during the inspection of a corrected area, repeat correction shall be carried out in the same manner as the first. The correction of defects in one and the same area of a welded joint may be carried out not more than three times. In the case of cutting out a defective welded joint of pipes and the subsequent welding in of an insert in the form of a length of pipe, the two newly made welded joints are not considered to be a correction of defects.
195. Upon completion of the work carried out during installation, the organisation that performed it compiles and submits to the operating organisation (the customer) a set of as-built documentation, including the documents (statements, protocols, conclusions) drawn up in stages according to the results of the incoming inspection and acceptance (admission) of materials, equipment and its elements for installation, of the verification (acceptance) of concealed works and critical structures, and of the operation-by-operation quality control of the work carried out, as well as the as-built diagrams (drawings) confirming the conformity of the work carried out to the design documentation.
196. The quality control of installation shall be confirmed by a certificate (attestation) of installation quality. The certificate (attestation) of installation quality shall be drawn up on the basis of the set of as-built documentation by the organisation that performed the installation, signed by the managers (technical managers) or authorised officials of the installation and operating organisation (or its separate structural subdivision), as well as by an authorised representative of the project developer organisation or of the manufacturing organisation that carried out designer supervision (installation supervision) of the performance of the work in the cases established by the legislation of the Russian Federation, sealed with stamps (where available) and transmitted to the operating organisation for attachment to the equipment data sheet.
197. The following data shall be given in the certificate (attestation) of installation quality: (a) the name of the installation organisation; (b) the name of the operating organisation; (c) the name of the equipment manufacturing organisation and its works (serial or identification) number (with the exception of pipelines), assigned according to the numbering system used by the manufacturing organisation; (d) information on the materials used, in accordance with the design documentation, in the pipeline, as well as on the materials used by the installation organisation in other types of equipment not included in the manufacturing organisation's scope of supply and additionally stated in the equipment data sheet; (e) information on the welding, including the type of welding and the type and grade of the electrodes; (f) information on the welders, including the welders' surnames and the numbers of their certificates; (g) information on the heat treatment of the welded joints (type, regime); (h) the methods, scope and results of the quality control of the welded joints; (i) information on the main fittings, flanges and fastening parts, and shaped parts; (j) an overall conclusion on the conformity of the work carried out to the requirements of these Federal Norms and Rules, of the operating manual (instructions), and of the design and process documentation, as well as on the suitability of the equipment for operation at the parameters stated in the data sheet. The final assembly of pressure equipment using permanent and/or detachable joints, carried out by the manufacturing organisation at the place of installation.
198. Upon transfer to the operating organisation, there shall be attached to the certificate (attestation) of installation quality a set, compiled during the performance of the work, of as-built documentation, the specific list of which is determined depending on the specific kind (type) of equipment and on the scope determined by the design documentation and the nature of the work performed during its installation. In particular, the following shall be transmitted to the operating organisation: the data sheets (manufacturing certificates) and other technical documentation of the manufacturing organisations for the installed equipment and for the equipment elements, fittings and other components used in the performance of the work in accordance with the project, as well as documents confirming their conformity to the requirements of TR CU 032/2013 (where TR CU 032/2013 applies to this equipment); copies of the documents (certificates) for the base and welding consumables used during installation; incoming inspection statements (logs); statements on the transfer of equipment, products and materials into installation; a statement on the examination of concealed works, where they have been carried out (the construction and waterproofing of the foundation, the installation of equipment including pipelines, and other works in accordance with the project); statements on the verification of the installation of the equipment on the foundation; statements on the acceptance of the equipment after individual testing; statements on the acceptance of the equipment after integrated commissioning; welding forms (logs) containing information on the work performed involving welding; as-built drawings (diagrams) drawn up on the basis of the set of working drawings submitted for acceptance of the facility, with information (entered in them by the persons responsible for the performance of the construction and installation works and confirmed by the persons who carried out designer supervision) on the conformity of the works actually performed to these drawings or on the changes made in them, agreed with the project developer; documents on the results of the quality control of the work carried out in accordance with these Federal Norms and Rules.
199. The organisation that performed the installation of the pipeline shall, on the basis of the set of as-built documentation, develop an as-built diagram (drawing) of the pipeline, attached to the certificate (attestation) of installation quality, on which the following shall be indicated: (a) information on the materials (stating the grade of the material and the name of the standard or the technical specifications in accordance with which they were produced), the outer diameters and the thicknesses of the pipes and of the parts made from pipes, and the length of the pipeline; (b) the location of the supports, expansion joints, hangers, fittings, instruments (located directly on the pipeline), filters, air vents and drainage devices; (c) the location of the welded joints (where they exist), with separate designation of the welded joints made during the installation of the pipeline and those made at the organisation manufacturing the pipeline elements; (d) the location of the indicators for monitoring thermal displacements, stating the design values of the displacements, and of the devices for measuring creep (for pipelines that operate at temperatures causing creep of the metal); (e) the boundaries (limits) of the pipeline and the direction of movement of the working medium. In doing so, shut-off valves, safety and other devices separating (distancing) the pipeline at the inlet and outlet from the equipment and/or pipelines connected to it may be taken by the design (working) engineering documentation as the boundaries of the pipeline. Permanent or detachable joints, or the projections of the foundation or of the wall of the building (structure) where internal pipeline systems are separated from external networks, may be defined by the project as the boundaries (conditional lines) that conditionally separate individual pipelines from one another and from equipment.
200. Where a pipeline is installed by several organisations, each performing organisation shall, in accordance with the requirements established by this paragraph, draw up a certificate (attestation) of installation quality for the section of pipeline produced by that organisation and transmit it to the final manufacturer of the pipeline as a whole for drawing up the data sheet and the set of technical documentation.
201. The quality control of the repair of equipment involving welding and heat treatment shall be confirmed by final documentation on the results of the work carried out, including: documents on the results of the quality control of the work carried out in accordance with these Federal Norms and Rules; repair working drawings and forms containing, where necessary, information on the sequence and dates of performance of the work and of the critical operations, and on the workers who performed them. The repair working drawings shall indicate: (a) the damaged areas to be repaired or replaced; (b) the materials used in the replacement; (c) the deformed elements and areas of elements to be corrected by straightening, with the straightening method assigned; (d) the types of welded joints and the methods for making them; (e) the types of treatment of the welds after welding; (f) the methods and standards for inspecting the welded joints (the locations to be inspected or checked); (g) the permissible deviations from the nominal dimensions.
202. Control over compliance with the requirements of the process documentation for repair and of the repair working drawings shall be exercised by the technical control division of the organisation carrying out the work on the repair, reconstruction (modernisation) of the equipment, as well as by an authorised representative of the operating organisation, in the manner established by the administrative documents of those organisations.
203. Upon completion of the repair, reconstruction (modernisation) work on the pressure equipment, the organisation that carried out this work shall provide information on the nature of the work performed and information on the materials used, together with a set of repair documentation in accordance with paragraph 200 of these Federal Norms and Rules, on the basis of which the authorised person of the operating organisation makes an entry on the work performed in the passport and repair log of the equipment.
204. Start-up and commissioning work, in the cases provided for by the operating manual (instructions), is carried out on the pressure equipment after the completion of installation work, with the issue of a certificate of installation quality and the performance of the initial technical examination.
205. The adjustment of the pressure equipment shall be carried out in accordance with a programme developed by the organisation performing the relevant work and agreed with the operating organisation before the start of the work. The programme shall reflect the content and procedure for performing all technological and control operations, ensuring adjustment in all operating modes established by the design.
206. The organisation carrying out the adjustment shall ensure quality control and the performance of the necessary scope of work in accordance with the programme for their conduct and these Federal Norms and Rules.
207. The duration of the adjustment work is determined by the programme depending on the complexity of the equipment. The start-up of the equipment for start-up and commissioning work is carried out in the procedure established by the programme, jointly by the workers of the operating organisation and the organisation carrying out the adjustment, after verification of: (a) the presence and serviceability of the measuring and control instruments, safety devices and alarm systems provided for by the requirements of the technical regulations, the design and these Federal Norms and Rules; (b) the presence of trained operating personnel who have passed a knowledge assessment and of certified specialists; (c) the presence at the workplaces of approved production instructions and the necessary operating documentation; (d) the serviceability of the feed devices and the provision of the necessary quality of feedwater (for boilers); (e) the correctness of the connection of the boiler to the common steam line, and also of the connection of the feed, blow-down and drainage lines; (f) the acceptance certificate of the fuel supply equipment (for boilers); (g) the completion of all installation work impeding the adjustment.
208. During the period of adjustment work on the pressure equipment, the responsibility for the safety of its servicing shall be defined by the programme of adjustment work.
209. The programme of adjustment work shall provide for the necessity and procedure for carrying out: (a) the flushing and purging of the equipment and pipelines in the cases established by the design and the operating manual; (b) the testing of the equipment, including standby equipment, the adjustment of the circulation of the working media, the verification of the operation of the shut-off valves and control devices in manual mode; (c) the verification of the measuring instruments, the setting and verification of the operability of the automated control, alarm, emergency protection and interlock systems, and also the regulation of the safety valves; (d) the fine-tuning and stabilisation of the process mode, the recording and analysis of the quantitative and qualitative indicators of the process mode; (e) bringing the process to a stable operating mode with a capacity corresponding to the design requirements. For boilers, the following are additionally carried out: the setting of safe and stable combustion modes within the range of minimum and maximum load values permitted by the manufacturing organisation, the adjustment of the water-chemistry regime of the boiler and the adjustment of the operating modes of the water treatment equipment.
210. When carrying out the adjustment of equipment with the use of hazardous substances or in explosive zones, the programme shall specify the safety measures, and preliminary testing of the stages of the process on inert media with subsequent adjustment on the working media shall be provided for.
211. Upon completion of the adjustment work, comprehensive testing of the pressure equipment, and also of the auxiliary equipment, is carried out at nominal load in accordance with the comprehensive testing programme developed by the organisation carrying out the relevant work and agreed with the operating organisation. The duration of the comprehensive testing of boilers shall be not less than 72 hours, and of the pipelines of heat networks - not less than 24 hours. The completion of the comprehensive testing is documented by a certificate recording the handing over of the pressure equipment into operation. The following shall be submitted with the certificate: a technical report on the adjustment work with tables and instructions, operating charts, graphs and other materials reflecting the established and actually obtained data on the setting and regulation of the devices, and descriptions and drawings of all changes (schematic, design) that were made at the adjustment stage.
212. The decision to put into operation the pressure equipment specified in paragraph 3 of these Federal Norms and Rules shall be taken by the head (or an official authorised by him) of the operating organisation (separate structural subdivision) and shall be documented on the basis of the results of the verification of the readiness of the equipment for start-up and of the organisation of supervision of its operation, carried out by: (a) the worker responsible for exercising production control over the safe operation of the equipment, jointly with the person responsible for the sound condition and safe operation in the cases specified in paragraph 213 of these Federal Norms and Rules; (b) a commission appointed by an administrative document of the operating organisation in the cases specified in paragraphs 213 and 214 of these Federal Norms and Rules.
213. The verifications carried out by the responsible persons or by a commission with their participation, appointed where necessary by decision of the head (technical manager) of the organisation or of its separate structural subdivision, are carried out: (a) after the installation, without the use of permanent joints, of pressure equipment delivered to the operation site in assembled form (with the exception of pressure equipment whose conformity assessment is not provided for by TR CU 032/2013); (b) after the installation, without the use of permanent joints, of pressure equipment that has been dismantled and installed in a new location; (c) before the start of use of transportable pressure equipment; (d) after repair with the replacement of the main elements of the equipment using permanent joints (welding), in cases where the following has been replaced: elements of the boiler to an extent less than that specified in sub-clauses "b" and "c" of paragraph 411 of these Federal Norms and Rules; branch pipes and fittings of the vessel permanently joined to its body; valves and safety devices of pipelines of operational category IIIe and IVe with similar ones, and also valves and pipe elements (with a total length of no more than 20 per cent of the total length of the pipeline, according to the passport) in respect of which, during the examination (diagnostics), a reduction in strength (thinning) and the presence of unacceptable defects and damage have been established, and also the unscheduled replacement of individual parts and elements, the necessity of which has arisen as a result of an incident (damage) during the operation of pipelines of operational category IIIe and IVe.
214. The verifications carried out by the commission are conducted: (a) after the installation of equipment supplied as individual parts, elements or blocks, whose final assembly (completion of manufacture) using permanent joints is performed during installation at the site of its installation (use); (b) after the installation of pressure equipment whose conformity assessment is not provided for by TR CU 032/2013; (c) after the reconstruction (modernisation) or repair with the replacement of the main elements of the equipment (with the exception of the cases specified in sub-clause "d" of paragraph 213 of these Federal Norms and Rules); (d) upon the transfer of a hazardous production facility and (or) pressure equipment that was in operation as part of it, for use by another operating organisation. Upon the transfer of a hazardous production facility with pressure equipment as part of it, for use by another operating organisation (in the case established in sub-clause "d" of this paragraph of the Federal Norms and Rules), the commission verifies the organisation of supervision of the operation of the pressure equipment at the hazardous production facility, and also the results of the verification of the readiness of the equipment for start-up and its actual condition, which in this case are carried out by the person responsible for exercising production control over the safe operation of the equipment, jointly with the person(s) responsible for the sound condition and safe operation. The commission for verifying the readiness of the equipment for start-up and the organisation of supervision of its operation is formed with the following composition: the chairman of the commission - an authorised representative of the operating organisation; the members of the commission: specialists of the operating organisation responsible for exercising production control and for the sound condition and safe operation of the equipment; an authorised representative of the installation or repair organisation (in the case established in sub-clauses "a", "b", "c" of this paragraph of the Federal Norms and Rules); the authorised representative(s) of Rostechnadzor or its territorial body when carrying out verifications (in the cases specified in sub-clauses "a", "b", "c" of this paragraph of the Federal Norms and Rules) of pressure equipment subject to registration with the territorial bodies of Rostechnadzor, or the authorised representative(s) of another federal executive authority in the field of industrial safety when carrying out verifications of equipment at facilities under its supervision. In addition, the composition of the commission includes authorised representatives of: the organisations that carried out the conformity assessment (certification bodies), the initial technical examination, the industrial safety expert review; the manufacturing organisation and (or) the equipment supplier, and also the organisation that previously operated the equipment (in the case established in sub-clause "d" of this paragraph of the Federal Norms and Rules), by agreement with the specified organisations. The organisation of the commission's work is assigned to the operating organisation. The members of the commission are officially notified of the place, date and time of the start of the work no later than 10 working days in advance.
215. When carrying out the verification of the readiness of the equipment for start-up, its actual condition and conformity with the submitted design and technical documentation shall be monitored, including the verification of: (a) the documentation of the equipment manufacturing organisation and its conformity with the requirements of the technical regulations and these Federal Norms and Rules; (b) the documentation certifying the quality of installation (the completeness and quality of the repair or reconstruction work) and the acceptance of the equipment by the operating organisation, drawn up in accordance with the requirements of the Federal Norms and Rules; (c) the presence of positive results of the technical examination; (d) the documentation with the results of the start-up and commissioning tests and comprehensive testing of the equipment (in the cases where their performance is necessary, established by the design and the operating manual (instructions)); (e) the documentation confirming the acceptance of the equipment after the completion of the start-up and commissioning work and the comprehensive testing of the equipment (where their performance is necessary); (f) the presence of documentation confirming the conformity of the equipment with the requirements of the legislation of the Russian Federation on technical regulation and of Article 7 of Federal Law No. 116-FZ; (g) the presence, conformity with the design and serviceability of the valves, measuring and control instruments, safety devices and process protections; (h) the correctness of the installation, placement and piping of the equipment and their conformity with the requirements of industrial safety, the instructions of the design documentation and the operating manual (instructions) of the equipment manufacturing organisation; (i) the serviceability of the feed devices of the boiler and their conformity with the design; (j) the conformity of the water-chemistry regime of the boiler with the requirements of the Federal Norms and Rules.
216. When carrying out the verification of the organisation of supervision of the operation of the pressure equipment, the following shall be monitored: (a) the presence of operating personnel trained and admitted to work in accordance with the requirements of these Federal Norms and Rules and the administrative documents of the operating organisation, and of certified specialists meeting the requirements of the Federal Norms and Rules and of the documentation of the manufacturing organisation; (b) the presence of job instructions for the responsible persons and specialists operating the equipment, and their conformity with the requirements of the Federal Norms and Rules; (c) the presence of production instructions for the operating personnel and of operating documentation, and their conformity with the requirements of the Federal Norms and Rules.
217. The results of the verification of the readiness of the equipment for start-up and of the organisation of supervision of its operation shall be documented by a certificate of readiness of the pressure equipment for putting into operation (hereinafter - the Equipment Readiness Certificate), the recommended form of which is given in Appendix No. 3 to the Federal Norms and Rules, whereby: 1) Each member of the commission, in the event of disagreement with the conclusions of the commission, has the right to set out in writing and submit to the commission a dissenting opinion containing substantiations on the merits of the objections raised, indicating the paragraphs, parts and chapters of the regulatory legal acts, including the federal norms and rules in the field of industrial safety and/or technical regulations, and also the design (engineering) documentation and (or) the technical documentation of the manufacturing organisation, the requirements of which have not been complied with. The dissenting opinion (if any) shall be attached to the equipment readiness certificate, with a note of the presence of a dissenting opinion being made in the Equipment Readiness Certificate. 2) The Equipment Readiness Certificate shall be attached to the passport of the pressure equipment and submitted to the head (technical manager) of the operating organisation (separate subdivision) for taking a decision on the putting into operation (unreadiness for putting into operation) of the equipment, taking into account the conclusions contained in the Equipment Readiness Certificate, the dissenting opinion (if any) and the recommendations (if any) for the elimination of the remarks set out in the Equipment Readiness Certificate (dissenting opinion). 3) In cases where the Certificate of Readiness (the conclusions of the commission, the dissenting opinion) indicates: violations whose presence, in the opinion of the members of the commission, adversely affects the operability and/or the safety of operation of the equipment - the measures for their elimination shall be taken by the operating organisation before the start-up of the equipment, and the commission shall be informed thereof; remarks on the completeness and content of the documentation submitted during the verification of the readiness of the equipment (production instructions, operating manual) that require its revision or reconsideration - then their elimination may be carried out within the time limits determined by the head of the operating organisation in agreement with the developer of the documentation. Information on the measures taken to eliminate the violations identified during the verification shall be sent to the organisations whose authorised representatives took part in the work of the commission, after receipt of which these organisations, in the event of disagreement with the sufficiency of the measures taken, notify the operating organisation thereof by any available means within 10 working days after receipt of the information in respect of violations affecting the safety of operation of the equipment, and no later than 30 working days for the other violations and remarks. 4) The decision to put the pressure equipment into operation shall be documented by an administrative document of the operating organisation in accordance with the conclusions of the Equipment Readiness Certificate. Information on the decision taken is recorded in the passport of the equipment and is certified by the signature of the responsible worker of the operating organisation upon whom the relevant official duties have been imposed by the administrative documents of the operating organisation, or by the signature of the chairman of the commission (where it is conducted).
218. In cases where it is necessary to conduct research tests of new experimental samples of pressure equipment at the site of their further use, and also where it is impossible to complete the adjustment of the pressure equipment in all operating modes of its work established by the design owing to the unreadiness of the consumer facilities or process equipment connected in stages, for joint operation with which as part of a process installation and (or) process it is intended, the head of the operating organisation may take a decision on the possibility of operating the pressure equipment in a trial operation mode (for a period of no more than six months). At the same time, as at the date of taking the decision on the possibility of operating the equipment in a trial operation mode, temporary operating documentation (instructions, operating charts and, in cases necessary under the conditions of the process, temporary process regulations) shall be developed and approved on the basis of the design documentation, the operating manual and other technical documentation of the design developer organisations and the equipment manufacturing organisation, and the availability of personnel and specialists of the appropriate qualification shall be ensured. The operating organisation shall notify Rostechnadzor or another federal executive authority in the field of industrial safety under whose supervision the given hazardous production facility falls of the decision taken on operating the pressure equipment in a trial operation mode, providing information on the time limits and measures for ensuring the safety of operation of the equipment in the trial operation mode. Upon completion of the operation of the equipment in the trial operation mode on the basis of the temporary operating documentation, taking into account the results obtained thereby, production instructions, operating charts and permanent process regulations (in cases necessary under the conditions of the process) shall be developed and approved, and the putting of the equipment into operation shall be carried out in the procedure established by these Federal Norms and Rules.
219. The start-up (switching on) into operation of equipment on the basis of the decision to put it into operation, and also the start-up (switching on) into operation and the routine shutdown of equipment in the course of its operation, are carried out on the basis of a written order of the person responsible for the sound condition and safe operation, in the procedure established by the administrative documents and production instructions of the operating organisation.
220. Before the start-up (switching on) into operation, on each unit of equipment (except for cylinders with a capacity of up to and including 100 litres), a plate shall be posted or an inscription applied indicating: (a) the number of the equipment according to the numbering system adopted in the operating organisation; (b) the registration number assigned by the territorial body of Rostechnadzor or another federal executive authority in the field of industrial safety in respect of the facilities and organisations under its supervision, which is applied after the receipt of the relevant information from the supervisory body, with the exception of the cases specified in paragraph 223 of the Federal Norms and Rules; (c) the permitted parameters (pressure, temperature of the working medium); (d) the date of the next external and internal inspection (EII) and hydraulic test (HT) of boilers and vessels, and external inspection (EI) of pipelines; (e) the date of expiry of the service life established by the manufacturing organisation or specified in the conclusion of the industrial safety expert review).
221. Pipelines, during operation, depending on their purpose and the parameters of the medium, shall be painted in the appropriate colour (identification colouring applied), have marking inscriptions and conventional symbols in accordance with the design documentation and the pipeline diagram, taking into account Appendix No. 4 to the Federal Norms and Rules.
222. No later than 10 working days after the date of taking the decision to put into operation and the start-up (switching on) into operation of the pressure equipment (with the exception of the equipment specified in paragraph 223 of the Federal Norms and Rules), the operating organisation sends to the territorial body of Rostechnadzor or another federal executive authority in the field of industrial safety, and also to the State Corporation Rosatom in the case specified in point "o" of paragraph 3 of the Federal Norms and Rules, the information in accordance with paragraph 224 of the Federal Norms and Rules for the registration of the pressure equipment, whereby: 1) Information on stationary equipment is sent to the location of the hazardous production facility as part of which it is installed and operated, to the relevant territorial body of Rostechnadzor or another federal executive authority in the field of industrial safety in respect of the hazardous production facility under its supervision. 2) Transported vessels (tanks) (with the exception of those subject to registration with another federal executive authority in the field of industrial safety) are registered with the bodies of Rostechnadzor at the location of the site (if any) of the operating organisation at which the work on repair, technical servicing and examination, the parking (storage) of the specified pressure equipment is carried out, or at the location (state registration) of the operating organisation. 3) Boilers of mobile (transportable) boiler installations (with the exception of those subject to registration with another federal executive authority authorised in the field of industrial safety) are subject to registration with the bodies of Rostechnadzor at the location (state registration) of the operating organisation. Information on the actual operating address of the boilers of mobile (transportable) boiler installations, including notification of a change of the address of their operation, is sent by the operating organisation to the territorial body of Rostechnadzor with which they are subject to registration (are registered), and also to the territorial body of Rostechnadzor on whose territory their operation is planned.
223. The following pressure equipment is not subject to registration with the bodies of Rostechnadzor and other federal executive authorities authorised in the field of industrial safety: (a) vessels operating with a group 1 medium (according to TR CU 032/2013) at a wall temperature of no more than 200 °C, in which the product of the values of the working pressure (MPa) and the capacity (m3) does not exceed 0.05, and also vessels operating with a group 2 medium (according to TR CU 032/2013) at the above-mentioned temperature, in which the product of the values of the working pressure (MPa) and the capacity (m3) does not exceed 1.0. Where two media having different states of aggregation and groups are simultaneously present in the working cavity of the vessel, the group (according to TR CU 032/2013) of the medium that creates an excess pressure of more than 0.07 MPa in the working cavity is taken into account; (b) the apparatus of air separation units and gas separation units located inside the thermal insulation casing (regenerators, columns, heat exchangers, condensers, adsorbers, separators, evaporators, filters, steam coolers and heaters); (c) drums for the transport of liquefied gases, cylinders with a capacity of up to and including 100 litres installed permanently, and also intended for the transport and (or) storage of compressed, liquefied and dissolved gases; (d) generators (reactors) for producing hydrogen used by the hydrometeorological service; (e) vessels included in a closed oil and gas production system (from the well to the main pipeline), which include vessels included in the process of preparation for the transport and utilisation of gas and gas condensate: separators of all separation stages, knock-out separators (on the gas line, on the flares), absorbers and adsorbers, degassing vessels for condensate, absorbent and inhibitor, condensate collectors, control and metering vessels for oil, gas and condensate, vessels located at booster compressor stations; (f) vessels for the storage or transport of liquefied gases, liquids and bulk solids that are under pressure periodically during their emptying; (g) vessels with compressed and liquefied gases intended for supplying fuel to the engines of the vehicles on which they are installed; (h) vessels installed in underground mine workings; (i) pipelines of steam and hot water of operational category Ie with an internal diameter of 70 mm or less; (j) pipelines of steam and hot water of operational categories IIe, IIIe, IVe with an internal diameter of 100 mm or less; (k) single-place medical pressure chambers; (l) sections of pipelines temporarily installed on the basis of: the design documentation of the hazardous production facility to ensure the pre-start purging of new pipeline systems and other equipment of the thermal power plant after installation; the documentation for repair in accordance with the paragraph of these Federal Norms and Rules to ensure the uninterrupted supply of the heat transfer medium bypassing the section disconnected for the period of repair or reconstruction as part of a pipeline in operation. The design and location of such pipelines shall comply with the design (engineering) documentation developed for them, taking into account the requirements of these Federal Norms and Rules, and their operation is carried out in accordance with paragraph 218 of the Federal Norms and Rules. The pressure equipment specified in this paragraph shall be registered by the operating organisation in accordance with its administrative documents.
224. For the registration of pressure equipment, the organisation operating this equipment submits to the territorial body of Rostechnadzor or another federal executive authority authorised in the field of industrial safety, if the pressure equipment is operated at a hazardous production facility under the jurisdiction of that body: (a) an application containing information on the operating organisation, indicating the place of installation of stationary equipment, the place of use of transportable equipment and the planned period of its operation at the specified place, and also the location of the production site for the repair and technical examination of tanks and the planned region of their use; (b) copies of the certificate of readiness of the pressure equipment for putting into operation and of the administrative document on putting it into operation, and also the details of the documentation confirming the conformity of the equipment with the requirements of the legislation of the Russian Federation on technical regulation and of Article 7 of Federal Law No. 116-FZ; (c) brief information on the equipment subject to registration, specified in the passport, including: the name or designation of the equipment, the year of manufacture, the manufacturing organisation, the factory number (according to the manufacturer's numbering system); the main technical characteristics, the design and operating (maximum, nominal, minimum) parameters and operating conditions of the equipment, information on the working medium, the design service life, the design resource (for pipelines, boilers and their main parts), the design number of start-ups (for pipelines and boilers), the maximum number of operating cycles (if established) of the vessel or of cylinder fillings; information on the date and results of the technical examination or the industrial safety expert review and on the time limits of the next technical examination and/or the period of safe operation (if any) specified in the conclusions of the expert review; (d) a set of technical documentation in the Russian language (the equipment passport with a drawing (set of drawings) attached to it, the operating manual (instructions), the certificate of installation quality (for permanently installed equipment), the passports of the valves or other documents identifying them, the passports of the safety devices of the equipment, the verification of the readiness of which was carried out in the cases provided for by paragraph 213 of these Federal Norms and Rules, without the participation of an authorised representative of Rostechnadzor or another federal executive authority in the field of industrial safety, if the pressure equipment is operated at a hazardous production facility under the supervision of that body). The specified set of technical documentation may be submitted in the form of copies certified by the operating organisation on paper or in electronic form.
225. In the event of failure by the operating organisation to submit the information and documents listed in paragraph 224 of the Federal Norms and Rules, of submission of the specified information and documents not in full, and also in the event of the impossibility of identifying the equipment and assessing its conformity with the established requirements in the field of industrial safety on the basis of the submitted information and documents, a registration number is not assigned to the equipment.
226. Pressure equipment is subject to deregistration with the bodies of Rostechnadzor or another federal executive authority in the field of industrial safety, if the pressure equipment was operated at a hazardous production facility under the jurisdiction of that body, in the cases of its disposal owing to the impossibility of further operation or the loss of the hazard characteristics necessitating the registration of such equipment, and also in the event of the transfer of the equipment for use by another operating organisation. The deregistration of the pressure equipment shall be carried out on the basis of an application of the operating organisation containing the reason for the deregistration, with copies of documents confirming the fact of disposal of the pressure equipment or the loss of the hazard characteristics necessitating the registration of such equipment, or the fact of the transfer of the equipment on legal grounds to another organisation, attached. Upon the transfer of pressure equipment to another operating organisation, the organisation transferring it: sends to the territorial body of Rostechnadzor or another federal executive authority in the field of industrial safety copies of documents containing the grounds for and confirmation of the fact of transfer of the equipment, and information on the organisation to which the equipment has been transferred (name, e-mail address, telephone number); makes an entry in the passport of the equipment (in the sections containing information on the registration number, on the location of the equipment, on the appointment of responsible persons, on the results of the technical examination) on the cessation of its use owing to the transfer to another organisation, with an indication of the necessity of complying with the requirements of these Federal Norms and Rules during the further operation of the equipment.
227. Where pressure equipment is present, the following shall be subject to registration in the State Register of Hazardous Production Facilities: (a) facilities incorporating pressure equipment subject to recording with the territorial bodies of Rostechnadzor or other federal executive authorities in the field of industrial safety, identified by the features specified in paragraph 3 of these Federal Norms and Rules and paragraph 2 of the Appendix to Federal Law No. 116-FZ; (b) facilities incorporating pressure equipment not subject to recording under paragraph 223 of these Federal Norms and Rules where there are features of hazard arising from the handling of the hazardous substances listed in paragraph 1 of Appendix No. 1 to Federal Law No. 116-FZ in a quantity exceeding that specified in Appendix No. 2 to Federal Law No. 116-FZ.
228. The organisation or individual entrepreneur operating pressure equipment (the operating organisation) shall ensure the maintenance of the pressure equipment in a serviceable (operable) condition and safe conditions for its operation. To this end, it is necessary to: (a) organise safe operation in accordance with the requirements of the legislation of the Russian Federation and ensure compliance therewith; (b) appoint, by an administrative document of the organisation, from among the engineering and technical personnel on the staff of the operating organisation, officials responsible for exercising production control during the operation of the equipment at the hazardous production facility, as well as those responsible for the serviceable condition and safe operation of the pressure equipment, who have undergone attestation in the field of industrial safety in accordance with the provisions of Article 14.1 of Federal Law No. 116-FZ; (c) appoint the necessary number of persons of the personnel servicing the equipment (specialists and workers) on the staff of the operating organisation who meet the qualification requirements, have no medical contraindications to that work and have been admitted to independent work in the procedure established by the administrative documents of the organisation. The number of personnel required for the safe operation of the equipment shall correspond to that specified in the design for the given hazardous production facility (where such data are available in the design); (d) establish, by administrative documents and instructions, a procedure ensuring the maintenance of the equipment in a serviceable condition and ensuring that the personnel (specialists and workers) on whom the duties of servicing the pressure equipment are placed carry out monitoring of the pressure equipment entrusted to them by means of its inspection, checking of the operation of the fittings, instrumentation, safety and interlocking devices, and alarm and protection means, with documentary recording (entry) of the results of the inspection and checking in the journal intended for this purpose or in another document; and also establish the types (forms) of documents kept in the organisation during the operation of the equipment and the procedure for maintaining (completing) them in paper or electronic form (provided that the preservation (backup) of the information stored in electronic form is ensured and that it is possible to identify the employee who entered the information into the electronic form of the document); (e) approve a list of the regulatory documents applied in the operating organisation, depending on the types of activity carried out, to ensure the industrial safety requirements established by the legislation of the Russian Federation and these Federal Norms and Rules; (f) develop and approve instructions for the person responsible for exercising production control and the person responsible for the serviceable condition and safe operation of the equipment; (g) develop and approve, on the basis of the operating manuals (instructions) for the specific type of equipment and taking into account the features of the technological process established by the design and technological documentation, production instructions for the personnel servicing and repairing the pressure equipment, defining their duties, the procedure for the safe conduct of work and their responsibility, taking into account what is specified in sub-clause "(d)" of this paragraph of the Federal Norms and Rules. Production instructions shall be issued to personnel before their admission to work, with confirmation of receipt by the signature of the employee in a journal or on the control copy of the production instruction, or by a mark in the electronic document management system, provided that this system ensures the storage of information and the ability to identify the employee and the actions performed by them; (h) ensure the timely conduct of attestation in the field of industrial safety of the engineering and technical personnel involved in the operation of the pressure equipment, in accordance with the provisions of Article 14.1 of Federal Law No. 116-FZ, as well as the checking of the knowledge of the servicing personnel (workers) to the extent of the production instructions and their admission to work in the procedure established by the administrative documents of the operating organisation drawn up in accordance with the requirements of the legislation of the Russian Federation and the Federal Norms and Rules; (i) ensure that work on technical examination, technical diagnosis, technical servicing and repair of the pressure equipment is carried out in accordance with the requirements of these Federal Norms and Rules, the technical documentation of the manufacturing organisation, and the regulatory documents and system for the conduct of work adopted for application in the operating organisation; (j) comply with the requirements of the manufacturing organisation established by the operating manual (instruction), as well as those specified in the copy of the safety justification of the equipment issued in accordance with TR CU 032/2013; (k) not permit the operation of unserviceable (inoperable) pressure equipment that does not meet the industrial safety requirements, in which defects (damage) affecting the safety of its operation have been identified, or in which the fittings, instrumentation, safety and interlocking devices, or alarm and protection means are unserviceable, and also without an industrial safety expert examination where the period of operation of the equipment has exceeded the service life specified in the equipment passport by the manufacturing organisation, or the safe operation period specified in the expert examination report; (k) monitor the condition of the pressure equipment (including the metal or other material from which the equipment is made) during its operation in accordance with the requirements of the operating manual (instruction), the regulatory documents adopted for application in the operating organisation and the Federal Norms and Rules; (l) upon detection of violations of industrial safety requirements, take measures to eliminate them and to prevent them in future; (m) ensure that an industrial safety expert examination is carried out in the cases provided for by the legislation of the Russian Federation in the field of industrial safety; (n) ensure the inspection, servicing, examination, industrial safety expert examination and repair of the buildings and structures intended for carrying out technological processes using pressure equipment, in accordance with the requirements of the technical regulations, these Federal Norms and Rules, and other federal norms and rules in the field of industrial safety; (o) ensure the availability and serviceability of the necessary set of direct-action and remote-action measuring instruments permanently installed on the pressure equipment and as part of the automated safety and control systems, as well as portable ones, for monitoring the parameters affecting the safety of the technological processes carried out at the hazardous production facility and the safety of the operation of the pressure equipment, and also the accuracy of their readings, in accordance with the provisions 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, Article 7814), the requirements of the Federal Norms and Rules, and the design, technical and operational documentation. To ensure these requirements, the operating organisation shall, on the basis of the design documentation and the technical documentation of the manufacturers of the equipment and systems and the technological regulations (where available), develop a list of the measuring instruments ensuring monitoring of the technological parameters affecting the safety of the technological processes carried out at the hazardous production facility and the safety of the equipment operating under excess pressure, which are subject to mandatory verification, and a list of the measuring instruments applied outside the sphere of state regulation of ensuring the uniformity of measurements, which are subject to calibration and the verification of which may be carried out in the cases established by the technological regulations (where available), the production instructions and the administrative documents of the operating organisation. (p) by an administrative document of the organisation, establish the procedure for the storage and maintenance of the technical (technological and operational) documentation for the pressure equipment, for the organisation of the recording of the pressure equipment and the recording of its examinations (in paper or electronic form), and ensure its implementation in accordance with the requirements of these Federal Norms and Rules.
229. Workers directly involved in the operation of pressure equipment shall: (a) engineering and technical personnel - undergo attestation in industrial safety, to the extent of the industrial safety requirements necessary for the performance of their work duties in accordance with Article 14.1 of Federal Law No. 116-FZ (depending on the type of the specific equipment to the operation of which they are admitted), know the provisions of the administrative documents, instructions and other regulatory documents adopted in the organisation to ensure industrial safety that relate to the duties performed, and comply with the requirements established therein in the course of performing the work; (b) servicing and repair personnel - meet the qualification requirements (depending on the type of the specific equipment to the operation of which they are admitted) and hold a document (protocol, certificate) issued in the procedure established by the administrative documents of the organisation entitling them to independent work in the relevant types of activity, know and comply with the requirements of the production, technological and other instructions (documents) defining the procedure and safe methods for performing the work to which the worker is admitted; (c) know the design, operating principle, technical characteristics, permissible operating parameters and operability criteria of the pressure equipment operated, monitor compliance with the technological process and suspend the operation of the equipment in the event of a threat of an emergency situation, informing their immediate supervisor thereof; (d) upon detection of damage to the pressure equipment that may lead to an emergency situation or indicates an inoperable condition of the equipment, not commence work until the pressure equipment is brought into an operable condition; (e) not commence work or cease work in conditions that do not ensure the safe operation of the pressure equipment, and in cases where deviations from the technological process and an impermissible increase (decrease) in the values of the operating parameters of the pressure equipment are detected; (f) in the event of accidents and incidents during the operation of the pressure equipment, act in accordance with the requirements of the relevant instructions and the action plans for the containment and elimination of the consequences of accidents (where available).
230. The number and qualification of the personnel required for the safe operation of the pressure equipment, taking into account its quantity, kinds (types) and operating conditions, shall correspond to the instructions of the design of the hazardous production facility and the operating manuals (instructions) for the equipment and may be changed where work on the reconstruction or technical re-equipment of the hazardous production facility is carried out that has led to an increase in the level of automation of the control of the technological process and equipment, on the basis of the instructions of the design documentation for the reconstruction or technical re-equipment of the hazardous production facility.
231. The number of engineering and technical personnel sufficient to ensure the safe operation of the hazardous production facility is determined by the operating organisation, taking into account the quantity and kinds (types) of the equipment operated, the conditions of its operation and the requirements of the design and operational documentation, and taking into account the time necessary for the timely and high-quality performance of the duties placed on the responsible persons by the job descriptions and the administrative documents of the operating organisation. The operating organisation shall create conditions for the performance by the engineering and technical personnel of the duties placed on them.
232. The person responsible for exercising production control over the safe operation of the pressure equipment shall have a technical education corresponding to the duties placed on them by the administrative documents of the organisation. The person responsible for exercising production control over the safe operation of the equipment may not combine the duties of the person responsible for the serviceable condition and safe operation of the pressure equipment.
233. The person responsible for exercising production control over the safe operation of the pressure equipment shall: (a) inspect the operating pressure equipment and check compliance with the established regimes during its operation at the frequency established by the job description and the schedule plan (where available); (b) exercise control over the preparation and timely presentation of the pressure equipment to a specialised organisation for examination and diagnosis; (c) exercise control over compliance with the requirements of the legislation of the Russian Federation in the field of industrial safety and the Federal Norms and Rules during the operation of the pressure equipment, and, upon detection of violations of industrial safety requirements, issue binding orders for the elimination of the violations and monitor their fulfilment, and also monitor the fulfilment of the orders issued by the representatives of Rostechnadzor and its territorial bodies and other bodies authorised in the field of industrial safety; (d) monitor the timeliness and completeness of the repair (reconstruction) performed, as well as compliance with the requirements of these Federal Norms and Rules during repair work; (e) check compliance with the established procedure for admitting workers to independent work, as well as the issuance to them of production instructions; (f) check the correctness of the maintenance of the technical and operational documentation during the operation and repair of the pressure equipment; (g) carry out examination of the equipment in the cases established by these Federal Norms and Rules, as well as participate in the examinations of the pressure equipment by a specialised organisation; (h) require the removal from work and the conduct of an extraordinary knowledge check for workers who violate industrial safety requirements; (i) monitor the conduct of emergency-response drills; (j) comply with the requirements of the documents defining their official duties.
234. Responsibility for the serviceable condition and safe operation of the equipment operating under pressure in a specific structural subdivision of the organisation shall be placed on an engineering and technical worker to whom the personnel ensuring the servicing and repair of this equipment are directly subordinate. Taking into account the structure of the operating organisation and its subdivisions, the following may be appointed: persons responsible for the safe operation of the equipment, from among the persons to whom the operational (shift) personnel (workers) are directly subordinate who prepare the equipment for operation, start it up and shut it down, including emergency shutdown, and also monitor and record the parameters and condition of the equipment, regulate the regimes of its operation, and eliminate deviations that have arisen in the course of operation and do not require shutdown of the equipment; a person responsible for the serviceable condition of the pressure equipment, who carries out functional interaction (in the procedure established by the administrative documents of the operating organisation) with the persons responsible for safe operation for the purpose of monitoring the current condition and eliminating defects arising during the operation of the equipment, who is responsible for the timely performance of technical servicing and of scheduled and unscheduled (according to the actual condition, for the purpose of eliminating defects) repairs by the in-house specialists and repair personnel subordinate to them or by a specialised organisation engaged under a contract. The number and date of the order of appointment, the surname, initials and position of the person responsible for the serviceable condition and safe operation of the equipment shall be recorded in the equipment passport. During leave, business trips, illness or in other cases of absence of the responsible persons, the performance of their duties is assigned, by an administrative document, to the workers deputising for them in their position who have the appropriate qualification and have undergone attestation in industrial safety in accordance with the established procedure.
235. Attestation of the persons responsible for the serviceable condition and safe operation of the pressure equipment, as well as of other workers whose activity is connected with the operation of the pressure equipment, is carried out in the procedure established in the operating organisation, to the extent of the industrial safety requirements necessary for the performance of work duties in accordance with Article 14.1 of Federal Law No. 116-FZ.
236. The person responsible for the serviceable condition and safe operation of the pressure equipment shall: (a) ensure the maintenance of the pressure equipment in a serviceable (operable) condition, the fulfilment by the servicing personnel of the production instructions, the performance of timely repairs, the preparation of the equipment for technical examination or diagnosis, and also control over the safety, completeness and quality of their conduct; (b) inspect the pressure equipment at the frequency determined by the job description (but not less than once a month) and ensure compliance with safe conditions and regimes of its operation; (c) check the entries of the personnel in the shift (operational) journal, the defects journal (where available) and other operational documents the maintenance of which is established by the administrative documents of the organisation, signing therein, and take measures to eliminate the observations regarding the operation of the equipment (defects) identified by the personnel; (d) keep the passports of the pressure equipment and the manuals (instructions) of the manufacturing organisations for installation and operation, unless a different procedure for storing the documentation is established by the administrative documents of the operating organisation; (e) carry out technical examinations in the cases established by the Federal Norms and Rules, participate in the technical examinations of the pressure equipment; (f) conduct emergency-response drills with the servicing personnel; (g) fulfil in a timely manner the orders for the elimination of the violations identified; (h) keep a record of the accumulated loading cycles of pressure equipment operated in a cyclic regime; (i) comply with the requirements of the documents defining their official duties.
237. Professional training and the issuance of a document on the education and (or) qualification of workers (workers and other categories of personnel (hereinafter - personnel (workers)) admitted to the servicing and repair of pressure equipment shall be carried out in organisations engaged in educational activity, in accordance with the requirements of the legislation of the Russian Federation in the field of education. The need for advanced training or for additional practical training (drills) in safe methods of work at the production site shall be determined by the operating organisation depending on the results of the knowledge check, the analysis of the causes of incidents, accident rate and injury rate, as well as in cases of reconstruction or technical re-equipment of the hazardous production facility involving the introduction of new technologies and equipment requiring a higher level of qualification.
238. The procedure for the knowledge check and the admission of a worker to independent work is determined by the administrative documents of the operating organisation and shall provide for the performance of the following procedures: (a) checking for the presence of a document confirming the qualification of the worker or the referral of the worker for professional training in accordance with the requirements of paragraph 237 of the Federal Norms and Rules; (b) conducting an introductory briefing; (c) conducting an initial briefing at the workplace; (d) conducting training in safe methods and techniques for performing work, with an on-the-job placement, providing for: the study of instructions, diagrams, the layout of the equipment, the actual arrangement of the instruments and controls, monitoring of the operation of the equipment, and the methods and frequency of their checking; safe methods of work, the procedure for handing over and taking over a shift, inspection, preparation for work, and the start-up and shutdown (scheduled and emergency) of the equipment, with the subsequent performance of work under the supervision of a mentor; (e) checking of the knowledge of the instructions and of the safe methods for performing work; (f) admission to independent work, with the issuance of a certificate. The admission of a worker to participate in the conduct of the activities specified in sub-clauses "(d)", "(e)", "(f)" of this paragraph of the Federal Norms and Rules is formalised in the procedure established by the administrative documents of the operating organisation. In this case, the duration of the conduct of the activities specified in sub-clause "(d)" of this paragraph of the Federal Norms and Rules is established depending on the complexity of the technological process, the level of qualification and the presence of work experience of the worker being admitted.
239. A periodic knowledge check of the personnel (workers) servicing the pressure equipment shall be carried out once every 12 months, and an extraordinary knowledge check shall be carried out: (a) upon transfer to another organisation; (b) upon replacement or reconstruction (modernisation) of the equipment, as well as the making of changes to the technological process and instructions, including upon conversion of the boiler serviced by them to the combustion of another type of fuel; (c) in the event of transfer of workers to the servicing of equipment of another type; (d) at the request of the person responsible for exercising production control.
240. The commission for checking the knowledge of the servicing and repair personnel (workers and specialists) shall be appointed by an administrative document of the operating organisation, which determines, among other things, the composition of the commission and the number of its members. In this case, not less than 3 persons from among the members included in the composition of the commission shall participate in the checking of the knowledge of a specific worker. The commission for checking the knowledge of the personnel includes the persons responsible for exercising production control over the safe operation of the equipment, the persons responsible for the serviceable condition and/or safe operation of the equipment, and also other engineering and technical personnel possessing the necessary qualification. Where it is impossible to ensure the necessary number of members of the commission from among the workers of the operating organisation, the following may be included in the composition of the commission for checking the knowledge of the servicing and repair personnel: the workers of educational organisations engaged in professional training (retraining) activity, the workers of specialised organisations, and public inspectors of the appropriate qualification who are attested in accordance with Article 14.1 of Federal Law No. 116-FZ.
241. The knowledge check of the personnel is carried out in the form of an interview and testing on control questions, and may also, where necessary, provide for the performance of practical tasks. The scope of the questions considered in this process shall ensure the possibility of checking knowledge of the requirements established by the production instructions and other administrative documents that define the list of work forming part of the duties of the person being checked and the safe methods for performing it, as well as the procedure of actions in emergency situations. The list of the instructions in force and other documents forming part of the scope of the knowledge check of the personnel, for a specific structural subdivision, workplace, profession (speciality) and the work performed by the worker, is approved and updated, in the event of their change, in the procedure established by the administrative documents of the organisation.
242. The results of the knowledge check of the servicing personnel (workers) are formalised, in the procedure established by the administrative documents of the operating organisation, by a protocol with a mark in the certificate of admission to independent work. The forms of the knowledge-check protocol and of the certificate of admission to independent work are determined by the administrative documents of the operating organisation, whereby: the protocol shall be signed by all members of the commission who carried out the knowledge check and shall contain information about the worker who underwent it to an extent sufficient for their identification, with an indication of the profession, information about the instructions and other documents (in the form of a listing of their titles and details (number, date) or an indication of the title (details) of the list of instructions approved for the specific worker or type of work) knowledge of which was checked, the results of the knowledge check, and a list of the types of work (and equipment) to the independent performance (servicing) of which the worker who has passed the knowledge check may be admitted; the certificate of admission to independent work shall contain brief information about the types of work (and equipment) to the independent performance (servicing) of which the worker who has passed the knowledge check is admitted and, in the event of positive results, a mark of the date of its conduct, signed by the chairperson of the commission or another official of the organisation whose duties determine the right to sign the certificate. The worker, after the knowledge check, shall be acquainted with its results against signature.
243. Before admission to independent work after professional training, after an extraordinary knowledge check provided for by paragraph 239 of these Federal Norms and Rules, and also where there is a break in work in the speciality of more than 12 months, the servicing personnel (workers) shall, prior to the knowledge check, undergo a placement to acquire (restore) practical skills. The placement programme is approved by the head of the operating organisation or an official authorised by them. The duration of the placement is determined depending on the complexity of the technological process and the pressure equipment.
244. The admission of personnel to the independent performance of work and the servicing of pressure equipment, where there is a document confirming the qualification, positive results of the placement and of the initial or unscheduled knowledge check, as well as the removal of personnel from work in the event of negative results of the periodic knowledge check of the worker, shall be formalised by the administrative documents of the organisation or its structural subdivision.
245. Where the set of technical documentation attached by the manufacturing organisation to the pressure equipment lacks documents (in the form of sections of the passport or separate record sheets, journals) providing for the possibility of entering information on the operating history of the pressure equipment (the place and conditions of operation and storage, the duration of operation or storage, information on technical examinations, repairs, replacement of elements, accidents and failures of the pressure equipment), such documents shall be developed and approved by the operating organisation (a recommended template is given in Appendix No. 5 to these Federal Norms and Rules).
246. The restoration of the passport and (or) the operating manual (instruction) of the pressure equipment in the event of loss, mislaying or the impossibility of further use owing to wear shall be carried out in accordance with Appendix No. 6 to these Federal Norms and Rules. The operational diagrams of pipelines, in the event of loss of the as-built diagram provided for by paragraph 198 of the Federal Norms and Rules, are restored by the operating organisation where there are workers of the qualification appropriate for this and a set of design (working) and as-built documentation, or by a specialised organisation during a technical examination, diagnosis or industrial safety expert examination. Passports of equipment manufactured, put into circulation and put into operation before the entry into force of the technical regulations and the Federal Norms and Rules do not require re-registration throughout the entire period of operation, except in the case where work is carried out on the reconstruction of such equipment with the drawing up of a new passport. Passports and other documents for steam and hot-water pipelines to which the requirements of TR CU 032/2013 do not apply are drawn up taking into account Appendix No. 7 to the Federal Norms and Rules.
247. To maintain pressure equipment in a serviceable (operable) condition and to prevent the risk of accident situations, the operating organisation shall ensure that maintenance, planned preventive repairs and unplanned repairs (where necessary, based on the technical condition of the equipment) are carried out by workers of its own subdivisions and (or) with the involvement of specialised organisations, whereby: 1) The scope and frequency of planned maintenance and repair work on pressure equipment and its elements is determined by a schedule approved by the technical manager of the operating organisation, taking into account the requirements set out in the operating manuals (instructions), as well as information on the current condition of the equipment obtained from the results of technical examinations (diagnostics) and operational monitoring during the operation of the pressure equipment. 2) For the performance of repair work on pressure equipment, the organisation carrying out such work shall develop work projects (programmes) and technological regulations (processes, instructions, maps), which, among other things, include: repair diagrams of the pressure equipment indicating the elements subject to repair or replacement, the locations for installing blanking plugs and their characteristics (diameter, thickness, length (extent), material), and the locations for installing locks on the drives of flangeless valves; organisational actions defining the requirements for the processes of preparing the equipment for repair and carrying out and completing the repair of the pressure equipment, including the requirements for the organisation of safe performance of work under the conditions of an operating hazardous production facility and of high-hazard work, for the admission of workers of the operating and (or) specialised organisation to perform repair work (where such organisation is involved in accordance with the requirements of Chapter III of the Federal Norms and Rules), as well as for the distribution of powers, responsibilities and the procedure for interaction of workers of the organisations when performing repair work on pressure equipment in accordance with the administrative documents of the operating organisation; the technology for performing repair work, the list of materials, machines and equipment, tools and fixtures necessary for their performance, as well as the sequence of technological operations established by the technological regulations (processes, instructions, maps) for the repair of pressure equipment, developed in accordance with the instructions of the operating manual (instruction) for the pressure equipment and the Federal Norms and Rules; a list of cases of the occurrence of conditions that do not ensure the safe performance of repair work, when it is necessary to suspend or terminate the performance of work, compiled on the basis of the results of the risk analysis and the hazard criteria of the pressure equipment. The developed work projects (programmes) and technological regulations (processes, instructions, maps) shall be approved by the technical manager or another authorised official of the organisation (or its separate subdivision) carrying out the repair, and agreed with the authorised representative of the specialised organisation (where such organisation is involved in accordance with the requirements of Chapter III of the Federal Norms and Rules). Where the executor of the repair is a specialised organisation, these documents are agreed with the customer organisation (the operating organisation). The developer of the work projects (programmes) and technological regulations (maps) is responsible for their quality and compliance with the requirements of industrial safety. The performance of repair work on pressure equipment with deviations from the requirements of the work projects (programmes) and technological regulations (processes, instructions, maps) shall not be permitted. The introduction of amendments to the work projects (programmes) and technological regulations (maps) shall be carried out by their developer.
248. An operating organisation performing installation work, repair work involving welding, reconstruction (modernisation) and commissioning of pressure equipment in operation shall have within its structure a specialised subdivision (subdivisions) meeting the relevant requirements set out in Chapter III of the Federal Norms and Rules.
249. The boiler room shall be provided with a clock and means of communication with the consumers of steam and hot water, the technical services and the administration of the operating organisation. During the operation of waste-heat recovery boilers, communication shall be established between the control panels of the waste-heat recovery boilers and the heat sources where these are located separately.
250. Persons not connected with the operation of boilers and of other main and auxiliary equipment interrelated with them shall not be admitted to the buildings and premises in which boilers are operated. Where there is a production necessity, unauthorised persons may be admitted to these buildings and premises only with the permission of the operating organisation and accompanied by its representative.
251. It shall be prohibited to assign to workers on duty for the servicing of boilers the performance, during the operation of a boiler, of any other work not provided for by the production instruction for the operation of the boiler and the technological auxiliary equipment.
252. It shall be prohibited to leave a boiler without constant supervision by the servicing personnel, both during the operation of the boiler and after its shutdown until the pressure in it drops to a value equal to atmospheric pressure, with the exception of boilers equipped with automation, alarm and protection systems ensuring the automatic maintenance of the design operating mode, the prevention of accident situations, and the shutdown of the boiler in the event of disturbances of the operating mode capable of causing damage to the boiler, where the design and the operating manual permit the operation of such boilers without constant supervision of their operation by the servicing personnel.
253. In the sections of boiler and pipeline elements with an elevated surface temperature with which direct contact by the servicing personnel is possible, the presence shall be ensured of thermal insulation provided for by the design (engineering) and technical documentation of the manufacturing organisation, ensuring an outer surface temperature of not more than 55 °C at an ambient temperature of not more than 25 °C.
254. During the operation of boilers with cast-iron economisers, it shall be ensured that the temperature of the water at the outlet of the cast-iron economiser is at least 20 °C below the temperature of the saturated steam in the steam boiler or the boiling temperature at the working water pressure in the hot-water boiler.
255. When burning fuel in boilers, the following shall be ensured: (a) uniform filling of the furnace with the flame without impingement of the flame on the walls; (b) prevention of the formation of stagnant and poorly ventilated zones within the volume of the furnace; (c) stable combustion of the fuel without flame lift-off and flashback within the specified range of operating modes; (d) prevention of the falling of drops of liquid fuel onto the floor and walls of the furnace, as well as of the separation of coal dust (unless special measures are provided for its afterburning within the volume of the furnace). When burning liquid fuel, trays with sand shall be installed beneath the nozzles to prevent fuel from reaching the floor of the boiler room. Furnace fuel oil or natural gas shall be used as the ignition fuel for the ignition devices of pulverised-coal burners. Other types of liquid fuel with a flash point of not less than 61 °C may be used. The use of highly flammable types of fuel as ignition fuel shall not be permitted.
256. During operation, the uniformity of load distribution shall be monitored and the condition of the elements of the suspension system shall be checked, and the adjustment of the tension of the suspensions after installation and during the operation of the boiler shall be ensured in the manner established by the operating manual (instruction).
257. The extraction of medium from the branch pipe or pipeline connecting the safety device with the protected element shall not be permitted.
258. The installation of shut-off devices on the steam supply line to safety devices and on the pipelines between the impulse valve and the main valve of impulse safety devices shall be prohibited.
259. The type and number of level indicators installed on the drum of the boiler during its operation shall comply with the instructions of the developer and the manufacturing organisation in the technical documentation of the boiler.
260. Direct-reading water level indicators shall be positioned (vertically or inclined forward at an angle of not more than 30° depending on the height of their location above the platform for observing their readings) and illuminated in such a way that the water level is visible from the workplace of the personnel servicing the boilers or from the platform from which the personnel observe the water level in the manner established by the production instruction.
261. On each direct-reading and indirect-reading water level indicator, the permissible upper and lower levels, established in accordance with the recommendations of the manufacturing organisation in the operating manual (instruction) for the boiler, shall be marked.
262. On direct-reading water level indicators of boilers with a working pressure of more than 4 MPa, during their operation, to protect the personnel, the presence and integrity of a protective casing against the destruction of the transparent plates shall be ensured.
263. If the distance from the platform from which the water level in the steam boiler is observed to the direct-reading water level indicators is more than 6 metres, and also in cases of poor visibility of the instruments, two lowered remote level indicators shall be installed. The lowered remote level indicators shall be connected to the boiler drum on separate fittings independently of the other water level indicators and shall have damping devices. For waste-heat recovery boilers, power boilers and power-technological boilers, the readings of the remote level indicators shall be displayed on the boiler control panel.
264. The height of the transparent element of the water level indicator shall exceed the permissible water level limits by not less than 25 mm on each side.
265. If, in justified cases, the boiler design provides, instead of direct-reading level indicators (with a water-level glass), for level indicators of a different design (a magnetic level indicator), or their installation has been carried out during the reconstruction (modernisation) of the boiler, then the production instruction shall include the instructions, provided for by the operating manual (instruction) for the boiler or by the design documentation for the reconstruction (modernisation), on the procedure for servicing the installed level indicator and taking its readings, taking into account corrections for the error of its readings.
266. The type, number and installation locations on the boiler of the instruments for monitoring pressure shall comply with the instructions of the design developer and the manufacturing organisation in the technical documentation of the boiler.
267. The scale of the pressure gauge is selected on the condition that at the working pressure the pointer of the pressure gauge shall be located within the second third of the scale. A red line shall be marked on the scale of the pressure gauge at the level of the graduation corresponding to the maximum permissible working pressure for the given element, taking into account the additional pressure from the weight of the liquid column. Instead of the red line, as an indicator of the value of the maximum permissible pressure, a plate (bracket) made of metal or another material of sufficient strength, painted red and fitting tightly against the glass of the pressure gauge, may be attached to the body of the pressure gauge.
268. The pressure gauge shall be installed in such a way that its readings are visible to the servicing personnel, whereby its scale shall be positioned vertically or inclined forward up to 30° to improve the visibility of the readings.
269. The nominal diameter of the body of pressure gauges installed: at a height of less than 2 metres from the level of the platform for observing the pressure gauge shall be not less than 100 mm; at a height of from 2 to 5 metres - not less than 160 mm; at a height of more than 5 metres - not less than 250 mm. When a pressure gauge is installed at a height of more than 5 metres, a lowered pressure gauge shall be installed as a duplicate.
270. During the operation of boilers with a working pressure of: not more than 2.5 MPa, pressure gauges with an accuracy class of not lower than 2.5 shall be used; more than 2.5 MPa up to 14 MPa inclusive - pressure gauges with an accuracy class of not lower than 1.5; more than 14 MPa - pressure gauges with an accuracy class of not lower than 1.
271. Before each pressure gauge, a three-way cock or another similar device shall be installed for blowing down, checking and disconnecting the pressure gauge. Before a pressure gauge intended for measuring steam pressure, in addition to the three-way cock or another similar device, a siphon tube with an internal diameter of not less than 10 mm shall be installed. On boilers with a working pressure of 4 MPa and more, shut-off devices shall be installed that allow the pressure gauge to be disconnected from the boiler, its communication with the atmosphere to be ensured, and the siphon tube to be blown down.
272. During the operation of boilers, the following shall be ensured: (a) the safety of operation of all the main and auxiliary equipment; (b) the possibility of achieving the rated steam output of the boilers, the parameters and quality of the steam and water; (c) the operating mode established on the basis of the start-up commissioning and mode tests and the operating manual (instruction); (d) the control range of loads determined for each type of boiler and type of fuel burned; (e) the change in the steam output of the boilers within the control range under the influence of the automation devices; (f) the minimum permissible loads.
273. Newly commissioned steam boilers with a working pressure of 10 MPa and more shall, after installation, be subjected to cleaning together with the main pipelines and other elements of the water-steam path. The cleaning method applied shall comply with the instructions of the manufacturing organisation in the operating manual (instruction). Steam boilers with a working pressure of less than 10 MPa and hot-water boilers shall, before commissioning, be subjected to alkaline treatment or other cleaning in accordance with the instructions of the operating manual (instruction).
274. Before the start-up of a boiler after repair, in the manner established by the production instructions, the serviceability and readiness for switching on of the main and auxiliary equipment, the instrumentation, the remote and automatic control means, the process protection devices, the interlocks, and the information and operational communication means shall be checked. Any faults identified in doing so shall be eliminated before the boiler is put into operation.
275. Before the start-up of a boiler after it has been in reserve for more than three days, the following shall be checked: (a) the operability of the equipment, the instrumentation, the remote and automatic control means, the process protection devices, the interlocks, and the information and communication means; (b) the passage of the commands of the process protections to all actuating devices; (c) the serviceability and readiness for switching on of those devices and equipment on which repair work was carried out during the downtime. Any faults identified in doing so shall be eliminated before the start-up of the boiler.
276. In the event of a fault in the protective interlocks and protection devices acting to shut down the boiler, its start-up shall not be permitted.
277. The start-up and shutdown of a boiler shall be carried out on the instruction of the person responsible for the serviceable condition and (or) safe operation, in the manner established by the production instructions and the mode charts, with a corresponding entry to this effect in the shift (operational) log or another operational document. All personnel connected with the operation of the boiler are notified of the planned time of the start-up and shutdown of the boiler before the actions and operations necessary for this are commenced.
278. The list of production instructions for the safe operation of boilers and auxiliary equipment, the development, approval and availability of which shall be ensured at the facility, is established by the administrative documents of the operating organisation. Production instructions are developed for each type of main and auxiliary equipment and (or) system as part of which it is operated. The number of instructions required is determined on the basis of the equipment specification and other sections of the design documentation containing information on the composition of the facility being operated, among them: the instruction(s) for the operation of boilers for the servicing personnel, developed (for each type of boiler among those installed at the hazardous production facility) on the basis of the manual (instruction) of the manufacturing organisation, taking into account the decisions determined by the design of the hazardous production facility on the arrangement (layout) of boilers, pipelines and auxiliary equipment, and the conditions and modes of operation; the mode charts compiled for each boiler based on the results of the start-up commissioning work after installation and the mode-commissioning (operational) tests during operation; the instructions for the maintenance, repair and checking of the automatic control system and safety instruments; the instructions for maintaining the water-chemistry mode of the boilers and for the operation of the installation(s) for the preparation (pre-boiler treatment) of water, with mode charts based on the results of commissioning; the instructions for the operation (servicing, checking of serviceability, adjustment) of safety devices; other instructions provided for by the list approved in the organisation.
279. Before firing up, a drum boiler shall be filled with chemically treated and deaerated feed water, whereby the quality of the water shall comply with the requirements of the operating manual (instruction) and of these Federal Norms and Rules. In the absence of a deaeration installation in the boiler room, cast-iron boilers may be filled with chemically treated water. A once-through boiler shall be filled with feed water, the quality of which shall comply with the operating instruction depending on the scheme of treatment of the feed water.
280. A drum boiler that has not cooled down may be filled at a metal temperature of the top of the emptied drum of not more than 160 °C (unless otherwise specified in the operating manual (instruction) of the boiler manufacturing organisation).
281. The filling of a once-through boiler with water, the removal of air from it, and also the operations during flushing to remove contaminants shall be carried out in the section up to the gate valves built into the boiler path in the separator mode of firing up, or throughout the entire path in the once-through mode of firing up. The firing-up water flow rate shall be equal to 30 per cent of the rated flow rate. Another value of the firing-up flow rate may be determined only by the operating manual (instruction) of the manufacturing organisation or by the operating instruction corrected on the basis of the results of commissioning tests.
282. The flow rate of the network water before the firing-up of a hot-water boiler shall be set and maintained in further operation at not lower than the minimum permissible value determined by the manufacturing organisation for each type of boiler.
283. When firing up once-through boilers of block units, the pressure before the gate valves built into the boiler path shall be maintained at a level of 12 - 13 MPa for boilers with a working pressure of 14 MPa and 24 - 25 MPa for boilers for supercritical pressure. A change in these values or firing up at sliding pressure is permitted subject to agreement with the manufacturing organisation on the basis of tests.
284. Before firing up and after the shutdown of a boiler, the furnace and the flue-gas ducts, including the recirculation ducts, shall be ventilated by the smoke exhausters, the forced-draught fans and the recirculation smoke exhausters with the dampers of the gas-air path open for not less than 10 minutes with an air flow rate of not less than 25 per cent of the rated value, unless other instructions are determined by the manufacturing organisation or the commissioning organisation. The ventilation of boilers operating under pressurisation and of hot-water boilers in the absence of smoke exhausters shall be carried out by the forced-draught fans and the recirculation smoke exhausters. Before firing up boilers from a state that has not cooled down, with excess pressure remaining in the steam-water path, the ventilation shall begin not earlier than 15 minutes before the ignition of the burners.
285. Before firing up a boiler operating on gas, the tightness of the closure of the shut-off valves before the burners shall be checked in accordance with the current instructions. Where there are signs of gas contamination of the boiler room, the switching on of electrical equipment, the firing up of the boiler, and also the use of open fire shall not be permitted.
286. When firing up boilers, the smoke exhauster and the forced-draught fan shall be switched on, and when firing up boilers whose operation is designed without smoke exhausters - the forced-draught fan.
287. From the moment of the start of firing up the boiler, monitoring of the water level in the drum shall be organised. The blowing down of the upper water-level indicators (unless otherwise specified in the operating manual (instruction) of the boiler manufacturing organisation) shall be carried out: (a) for boilers with a working pressure of 4 MPa and less - at an excess pressure in the boiler of 0.1 MPa and before connection to the main steam line; (b) for boilers with a working pressure of more than 4 MPa - at an excess pressure in the boiler of 0.3 MPa and at an excess pressure of from 1.5 to 3 MPa. The readings of the lowered water level indicators shall be verified against the water-level indicators during firing up (taking into account corrections).
288. The firing up of a boiler from various thermal states shall be carried out in accordance with the production instructions and the start-up schedules compiled on the basis of the operating manual (instruction) of the manufacturing organisation and the results of tests of the start-up modes.
289. During the firing up of a boiler from a cold state after repair, but not less than once a year, the thermal displacement of the screens, drums, steam lines and headers shall be checked against the benchmarks.
290. If, before the start-up of the boiler, work associated with the dismantling of flange connections and hatches was carried out on it, then at an excess pressure of 0.3 - 0.5 MPa the bolted connections shall be tightened. The tightening of bolted connections at a higher pressure shall not be permitted.
291. During the firing up and shutdowns of boilers, monitoring of the temperature mode of the drum shall be organised. The rate of heating and cooling of the lower generatrix of the drum and the temperature difference between the upper and lower generatrices of the drum shall not exceed the values established by the operating manual (instruction). For boilers with a working pressure of more than 10 MPa, the above parameters shall not exceed (unless otherwise specified in the operating manual (instruction) of the boiler manufacturing organisation) the following permissible values: (a) the rate of heating during firing up of the boiler, °C/10 min - 30; (b) the rate of cooling during shutdown of the boiler, °C/10 min - 20; (c) the temperature difference during firing up of the boiler, °C - 60; (d) the temperature difference during shutdown of the boiler, °C - 80. On all types of boilers, accelerated cooling down shall not be permitted.
292. The connection of a boiler to the common steam line shall be carried out after the draining and warming up of the connecting steam line. The steam pressure downstream of the boiler at the moment of connection shall be equal to the pressure in the common steam line.
293. The transition to the burning of solid fuel (the start of the supply of dust to the furnace) on boilers operating on fuel with a volatile yield of less than 15 per cent is permitted at a thermal load of the furnace on the ignition fuel of not lower than 30 per cent of the rated value. When operating on fuels with a volatile yield of more than 15 per cent, the supply of dust is permitted at a lower thermal load, which shall be established by the production instruction, on the basis of ensuring the stable ignition of the dust. When starting up a boiler after a short-term downtime (up to 30 minutes), the transition to the burning of solid fuel with a volatile yield of less than 15 per cent is permitted at a thermal load of the furnace of not lower than 15 per cent of the rated value.
294. The operating mode of a boiler shall comply with the mode chart compiled on the basis of testing of the equipment and the operating instruction. In the event of the reconstruction (modernisation) of a boiler and a change in the grade and quality of the fuel, start-up commissioning or mode commissioning shall be carried out with the drawing up of a report and a new mode chart.
295. During the operation of a boiler, the thermal modes ensuring the maintenance of the permissible steam temperatures in each stage and each flow of the primary and intermediate superheaters shall be observed.
296. During the operation of a boiler, the upper limit level of water in the drum shall be not higher, and the lower limit level not lower, than the levels established on the basis of the data of the operating manual (instruction) and of testing of the equipment.
297. The heating surfaces of boiler installations on the gas side shall be kept in an operationally clean condition by maintaining optimal modes and applying mechanised systems of integrated cleaning (steam, air or water apparatus, devices for impulse cleaning, vibration cleaning, shot cleaning). The devices intended for this, and also the means of remote and automatic control of them, shall be in constant readiness for action. The frequency of cleaning of the heating surfaces shall be regulated by a schedule or the operating manual (instruction).
298. During the operation of boilers, all the operating draught machines shall be switched on. Prolonged operation with part of the draught machines switched off (where this is established in the operating manual (instruction) and the mode chart) is permitted provided that a uniform gas-air and thermal mode is ensured on the sides of the boiler. In doing so, the uniformity of the distribution of air between the burners shall be ensured and the overflow of air (gas) through the stopped fan (smoke exhauster) shall be prevented.
299. On steam boilers burning, as the main fuel, fuel oil with a sulphur content of more than 0.5 per cent, within the control range of loads its burning shall be carried out at excess-air coefficients at the furnace outlet of not more than 1.03, unless otherwise established by the production instruction. In doing so, the performance of the established set of actions for the transfer of boilers to this mode (preparation of the fuel, application of appropriate designs of burner devices and nozzles, sealing of the furnace, equipping of the boiler with additional monitoring instruments and means of automation of the combustion process) is mandatory.
300. Fuel-oil nozzles, before installation in their working position, shall be tested on a water stand to check their capacity, the quality of atomisation and the angle of opening of the flame. The difference in the rated capacity of individual nozzles in the set installed on a fuel-oil boiler shall be not more than 1.5 per cent. Each boiler shall be provided with a spare set of nozzles. The operation of fuel-oil nozzles without an organised air supply to them, and also the use of uncalibrated nozzles, shall not be permitted. During the operation of the nozzles and the steam-fuel-oil lines of the boiler room, conditions shall be met that prevent fuel oil from entering the steam line.
301. The lining of boilers shall be in a serviceable condition, shall not have visible damage (cracks, deformations), and shall ensure the tightness of the furnace and a temperature on the surface of the lining not exceeding the value established by the developer of the boiler design and specified by the manufacturing organisation in the operating manual (instruction). Where signs of destruction of the boiler lining are identified that relate to the criteria of the limit state of equipment operating under pressure (Appendix No. 8 to these Federal Norms and Rules), measures shall be taken to withdraw the equipment from operation for repair
302. The furnace and the entire gas path of boilers shall be tight, the furnaces and flue-gas ducts of boilers with all-welded screens shall be free of infiltration, and in other cases, unless otherwise established by the operating manual: 1) the air infiltration into the furnace and into the gas path up to the outlet of the superheater for steam gas-and-fuel-oil boilers with a steam output of up to 420 t/h shall be not more than 5 per cent, with a steam output above 420 t/h - 3 per cent, for pulverised-coal boilers - 8 and 5 per cent respectively; 2) the infiltration into the gas path in the section from the inlet to the economiser (for pulverised-coal hot-water boilers - from the inlet to the air preheater) to the outlet from the smoke exhauster shall be (excluding ash-collecting installations) not more than 10 per cent with a tubular air preheater, and not more than 25 per cent with a regenerative one; 3) the infiltration into the furnace and gas path of hot-water gas-and-fuel-oil boilers shall be not more than 5 per cent, of pulverised-coal boilers (excluding ash-collecting installations) - not more than 10 per cent; 4) the air infiltration into electrostatic precipitators shall be not more than 10 per cent, and into ash-collecting installations of other types - not more than 5 per cent. The norms of infiltration are given as a percentage of the theoretically required quantity of air for the rated load of the boilers.
303. The tightness of the enclosing surfaces of the boiler and the flue-gas ducts, including the serviceability of the explosion valves (where present), shall be monitored by inspection and determination of the air infiltration in the manner and at the frequency established in the production instruction, but not less than once a month. The infiltration into the furnace shall also be determined instrumentally before and after repair, but not less than once a year, unless other requirements are established in the operating manual. Leaks of the furnace and flue-gas ducts of the boiler identified during operation shall be eliminated during the next scheduled repair of the equipment.
304. The checking of the serviceable action of pressure gauges, safety valves, water level indicators and feed pumps shall be carried out at the following intervals: (a) for boilers with a working pressure of up to 1.4 MPa inclusive - not less than once per shift; (b) for boilers with a working pressure of more than 1.4 MPa up to 4.0 MPa inclusive - not less than once per day (except for boilers installed at thermal power stations); (c) for boilers installed at thermal power stations, according to the instruction in accordance with the schedule approved by the technical manager (chief engineer) of the power station. A record of the results of the check is made in the shift (operational) log or another operational document, the form and procedure for maintaining which are established by the administrative documents of the operating organisation.
305. The checking of the serviceability of a pressure gauge is carried out by means of a three-way cock or the shut-off valves replacing it by setting the pointer of the pressure gauge to zero. Not less than once every 12 months (unless other intervals are established by the documentation for the specific type of pressure gauge), pressure gauges shall be verified in the manner established by the legislation of the Russian Federation.
306. Pressure gauges shall not be permitted for use in the following cases: (a) there is no information on the performance of verification (a seal or stamp, or a document on the performance of verification); (b) if the verification period of the pressure gauge has expired; (c) if the pointer of the pressure gauge, when it is switched off, does not return to the zero mark of the scale by an amount exceeding half of the permissible error for the given pressure gauge; (d) if the glass is broken or there are other damages to the pressure gauge that may affect the accuracy of its readings.
307. Direct-acting water level indicators are checked by blowing them down. The serviceability of remote level indicators is checked by comparing their readings with the readings of the direct-acting water level indicators.
308. The serviceability of safety valves is checked by their forced short-term opening (lifting). Safety valves shall protect boilers, superheaters, economisers and pipelines during their operation against a pressure increase in them of more than 10 per cent above the permitted pressure. A pressure increase upon full opening of the safety valve of more than 10 per cent above the permitted pressure may be permitted only where this is provided for by the strength calculation of the boiler, superheater and economiser and does not exceed the setting values of the actuation set points of the safety automation. During the operation of the boiler, checking of the setting and adjustment of the actuation value of the safety valves shall be carried out: periodically, after inspection and repair in accordance with the schedule of planned preventive repairs, not less than once every 12 months (unless otherwise established by the manufacturing organisation in the technical documentation of the valve); on an unscheduled basis, after the detection and elimination of a valve malfunction, including leakage (loss of tightness), failure of the safety valve to actuate when the pressure exceeds its setting value. The checking of the setting and the adjustment are carried out in the manner established by the production instruction, on a test bench ensuring the necessary accuracy of setting and adjustment. Checking of the setting and adjustment of the safety valve directly on the boiler may be permitted only in exceptional cases, where checking on a bench is structurally impossible, and in such case the production instruction shall provide for the technology for carrying out such work and additional safety measures. If the operation of the boiler is permitted at a reduced pressure, then the adjustment of the safety devices shall be performed taking into account the reduced pressure, with checking of the capacity of the safety devices by calculation. Work on checking the setting and adjustment of the safety valve may be performed, under the direction of the person responsible for the serviceable condition of the boiler, by the repair personnel of the operating organisation who hold the appropriate qualification and are authorised to carry out such work, or by a specialised organisation. The results of the checking of the setting and adjustment of the safety valve are documented by a report and (or) an entry in the log of checks in the manner established in the production instruction.
309. Checking of the serviceability of standby feed pumps is carried out by their short-term switching into operation in the manner established in the production instruction.
310. Checking of the serviceability of the alarm system and automatic protections shall be carried out in accordance with the schedule and instruction approved by the technical manager (chief engineer) of the operating organisation (separate subdivision).
311. On the handwheels of the valves, the preservation of the markings of the direction of rotation for opening and closing the valves shall be ensured.
312. Operational tests (regime commissioning) of the boiler to determine stable, optimal and safe modes of its operation within the limits of the minimum and maximum permissible parameters and load ranges established by the design and the technical documentation of the manufacturing organisation, with the drawing up of a regime chart and the adjustment (where necessary) of the production operating instruction, shall be carried out: upon commissioning of the boiler within the scope of start-up and commissioning work; after changes are made to its design; upon conversion of the boiler to another type or grade of fuel; in cases of deviation of the boiler operating parameters from the set values (to identify and eliminate the causes), and also periodically not less than once every 5 years. Boilers shall be equipped with the necessary devices for carrying out operational tests. After completion of the tests, the organisation that carried them out draws up and submits to the operating organisation a report with the results and recommendations (if any) and the regime charts for approval.
313. When the boiler is taken out into reserve or for repair, measures shall be taken for the preservation of the heating surfaces of the boiler and other elements. At the end of the heating season or upon shutdown, if there is no need for repair, and also after repair has been carried out, before the start of the heating season, the boilers and heat networks are preserved. The methods of preservation are established in the production instruction, taking into account the operating conditions of the equipment at the specific facility, on the basis of the design documentation and the operating manual (instruction). Upon start-up of hot-water boilers into operation, and also before the start of the heating season, the heat networks and internal heat-consumption systems are pre-flushed.
314. Internal deposits from the heating surfaces of boilers shall be removed during water washings at start-ups and shutdowns or during cleanings. The cleaning methods are applied in accordance with the instructions of the operating manual (instruction). The frequency of chemical cleanings shall be determined by the operating manual (instruction), taking into account the results of the quantitative analysis of internal deposits.
315. Feeding a shut-down boiler with draining of water to accelerate the cooling of the drum shall not be permitted.
316. Draining of water from a shut-down steam boiler with natural circulation is permitted after reducing the pressure in it: (a) to 1 MPa - for power boilers operated at thermal power plants; (b) to atmospheric pressure - for the remaining boilers. Where there are rolled joints in a shut-down boiler, draining of water from it is permitted at a water temperature not higher than 80 °C. From a shut-down once-through boiler, it is permitted to drain water at a pressure above atmospheric; the upper limit of this pressure shall be established by the operating manual (instruction) depending on the system of drains and expanders. Draining of water from a hot-water boiler is permitted after cooling the water in it to a temperature equal to the temperature of the water in the return pipeline, but not higher than 70 °C. Upon shutdown of the boilers of unit-type power plants, steam removal of the intermediate superheater into the turbine condenser shall be performed.
317. When the boiler is shut down into reserve, after ventilation of the furnace and gas ducts for not less than 10 minutes but not more than 15 minutes, the draught and blast machines shall be stopped, and all shut-off gates on the gas-air ducts, manholes and inspection hatches, and also the guide vanes of the draught and blast machines, shall be tightly closed, unless other instructions for shutting down the boiler are specified by the manufacturing organisation in the operating manual (instruction) of the boiler.
318. In the winter period, on a boiler that is in reserve or under repair, monitoring of the air temperature shall be established. When the value of the air temperature in the boiler house (or the outdoor temperature in the case of an open layout) is below 0 °C, measures shall be taken to maintain positive air temperatures in the furnace and gas ducts, in the enclosures at the drum, in the areas of the blow-down and drainage devices, air heaters, impulse lines and sensors of the measuring instruments, and also the heating of the water in the boilers or its circulation through the screen system shall be arranged.
319. The cooldown mode of boilers after shutdown, when they are taken out for repair, shall be determined by the operating manual (instruction). Cooldown of boilers with natural circulation by means of the draught and blast machines is permitted where the permissible difference in metal temperatures between the upper and lower generatrices of the drum is ensured. Modes with and without maintaining the water level in the drum are permitted. Cooldown of once-through boilers may be carried out directly after shutdown.
320. Supervision by the duty personnel of a shut-down boiler shall be organised until the pressure in it is fully reduced and the voltage is removed from the electric motors; monitoring of the temperature of the gas and air in the area of the air preheater and of the flue gases may be discontinued not earlier than 24 hours after shutdown.
321. When boilers operate on solid or gaseous fuel, where fuel oil is the reserve or start-up fuel, the schemes of the fuel oil facilities and fuel oil pipelines shall be in a condition ensuring the immediate supply of fuel oil to the boilers.
322. In the event of a rupture of the fuel oil pipeline or gas pipeline within the boiler house premises or of heavy leaks of fuel oil (gas), all measures shall be taken to prevent the outflow of fuel through the damaged sections, up to shutting down the fuel oil pumping station and closing the shut-off valves at the gas distribution point, and also to prevent fire or explosion.
323. To prevent, during the operation of the boiler and the feed path, the formation of damage to their elements as a result of scale and sludge deposits, an increase in the relative alkalinity of the boiler water to dangerous limits, or as a result of corrosion of the metal, the operating organisation shall ensure the maintenance of the water-chemical regime of the boilers, comprising pre-boiler and in-boiler water treatment and regulation of the quality of the boiler water, and shall also ensure chemical monitoring of compliance with the water-chemical regime. Steam boilers with natural and multiple forced circulation with a steam output of 0.7 t/h and more, once-through steam boilers regardless of steam output, and also hot-water boilers, shall be equipped with installations for pre-boiler water treatment. Other effective methods of water treatment that guarantee the operation of the boiler and the feed path without the above-mentioned damage may also be applied. To ensure the safety of boilers with a steam output of less than 0.7 t/h, such a period between cleanings shall be established that the thickness of the deposits on the most heat-stressed sections of the boiler heating surface, by the time of its shutdown for cleaning, does not exceed 0.5 mm. The technology and methods of pre-boiler and in-boiler water treatment are determined by the design documentation on the basis of the recommendations of the design developer and the boiler manufacturing organisation, as established by the operating manual (instruction) of the boiler, and also taking into account the features of the technological process for which the boiler is used.
324. Make-up feeding with raw water of boilers equipped with devices for pre-boiler water treatment shall not be permitted. In cases where the design provides for make-up feeding of the boiler with raw water in emergency situations, on the raw water lines connected to the lines of softened make-up water or condensate, and also to the feed tanks, two shut-off devices each and a control valve between them shall be installed. During normal operation, the shut-off devices shall be in the closed position and sealed, and the control valve - open. Each case of make-up feeding of the boilers with raw water shall be recorded in the water treatment (water-chemical regime) log, indicating the duration of the make-up feeding and the quality of the feed water during this period. In such case, hot-water boilers shall operate at reduced temperature parameters, with the temperature of the heat carrier at the boiler outlet not exceeding 60 °C.
325. Pre-boiler and in-boiler water treatment and regulation of water quality are carried out in accordance with the instructions and regime charts for maintaining the water-chemical regime, developed by the commissioning organisations during start-up and commissioning work after installation or during regime commissioning work in the course of operation, and shall ensure the quality of the feed, boiler, make-up and network water in accordance with the norms established by the design documentation, the boiler manufacturing organisation and Appendix No. 9 to the Federal Norms and Rules. The operation of pre-boiler water treatment installations is carried out in accordance with the production instructions developed on the basis of the operating manuals (instructions) of the installation manufacturing organisations, taking into account the requirements of the design and technological documentation. The instructions and regime charts shall be approved by the head of the operating organisation and be located at the workplaces of the personnel.
326. Chemical monitoring during the operation of boilers shall ensure: (a) the timely detection of violations of the operating modes of the water treatment, heat-and-power and heat-network equipment leading to corrosion, scale formation and deposits; (b) the determination of the quality (composition) of water, steam, condensate, deposits, reagents, preserving and washing solutions, fuel, slag, ash, gases, oils and waste water.
327. The frequency of sampling of the source, chemically purified, boiler, network, feed and make-up water, condensate and steam is established by the commissioning organisation during start-up and commissioning (after installation) or regime commissioning (in the course of operation) work, depending on the type of boiler equipment, its operating mode, the quality of the source and feed water, and the water treatment scheme.
328. On the basis of internal inspections of boilers and auxiliary equipment, sampling of deposits, and cutting out of tube samples (where necessary), reports are drawn up on the condition of the internal surface, on the need to carry out operational cleaning and to take other measures preventing corrosion and the formation of deposits.
329. The operating organisation shall ensure the timely repair of boilers in accordance with the approved schedule of planned preventive repair, and also unscheduled repair, where necessary, according to the actual condition of the boiler. For each boiler, a repair log shall be kept, into which the person responsible for the serviceable condition and safe operation of the boiler enters information on the repair work performed, the materials used, the welding and the welders, and on the shutdown of the boilers for cleaning and washing. The replacement of tubes and rivets and the re-rolling of the joints of tubes with drums and headers shall be marked on the layout diagram of the tubes (rivets) attached to the repair log. The repair log also reflects the results of the inspection of the boiler before cleaning, indicating the thickness of the scale and sludge deposits, and all defects identified during the repair period.
330. Before the commencement of work inside the drum or header of a boiler connected to other operating boilers by pipelines (steam line, feed, drainage, drain lines), and also before an internal inspection or repair of elements operating under pressure, the boiler shall be disconnected from all pipelines by blanks, if flanged valves are installed on them. In the event that the valves of the steam and water pipelines are flangeless, the disconnection of the boiler shall be performed by two shut-off devices, provided there is between them a drainage device with a nominal diameter of not less than 32 mm having a direct connection to the atmosphere. The drives of the gate valves, and also of the shut-off valves of the open drains and of the emergency water discharge line from the drum, shall be locked with a lock in such a way that the possibility of loosening their tightness while the lock is locked is excluded. The keys to the locks shall be kept by the person responsible for the serviceable condition and safe operation of the boiler, unless another procedure for their storage is established at the enterprise.
331. The thickness of the blanks used for disconnecting the boiler is established on the basis of a strength calculation. A blank shall have a projecting part (a tang) by which its presence is determined. When gaskets are installed between the flanges and the blank, the gaskets shall be without tangs.
332. The admission of people inside the boiler, and also the opening of the shut-off valves after the removal of people from the boiler, shall be performed only under a written permission (permit to work) issued in the manner established by the administrative documents of the operating organisation.
333. The operation of pressure vessels shall be carried out in accordance with the production instruction on the operating mode and safe servicing of vessels developed and approved by the operating organisation. The instruction shall, in particular, regulate: (a) the vessels to which the instruction applies, their purpose, with a description of the design of the vessels and the scheme of their connection; (b) the duties of the personnel during duty for observation and monitoring of the operation of the vessel; (c) the procedure for checking the serviceability of the serviced vessels and the equipment related to them in working condition; (d) the procedure, time limits and methods for checking the valves, safety devices, protection automation and alarm instruments; (e) the procedure for starting up into operation and stopping (ceasing operation) of the vessel; (f) safety measures when taking equipment out for repair, and also additional safety measures for vessels with a working medium of group 1 (in accordance with TR CU 032/2013); (g) cases requiring the immediate stopping of the vessel, provided for by these Federal Norms and Rules, and also other cases determined by the specifics of the operation of the vessel. The procedure for emergency stopping and reduction of pressure to atmospheric is established depending on the specific connection scheme of the vessel and the technological process; (h) the procedure for the actions of the personnel in the event of an accident or incident; (i) the procedure for maintaining the shift (operational) log (including the recording of the taking over and handing over of duty, and the checking of the entries by the person responsible for the serviceable condition and safe operation of the vessel) or other operational documents established for this by the administrative documents of the organisation. The description of the design and the connection scheme of the vessel, of the procedure for starting up and stopping (including emergency stopping) of the vessel and of other work during the performance of which action is exerted on the valves, instruments and other devices (switching (opening, closing), checking of serviceability, regulation of the parameters of the medium), the installation of blanks and other technological operations, in the production instruction shall contain the sequence of performance of specific actions, indicating the ordinal numbers (according to the connection scheme) or the names (ensuring identification) of the above-listed devices in respect of which the specified actions are performed. The development of a separate instruction in respect of a vessel (vessels) operating as part of a technological installation or other system of an interconnected complex of machines and equipment is not required, if all the requirements necessary to ensure its safe operation and servicing are established in the production instruction for their operation.
334. In the production instruction on the operating mode and safe servicing of autoclaves with quick-release covers, in addition to what is established by paragraph 333 of these Federal Norms and Rules, instructions shall be included on: (a) the procedure for using the key-tally and the lock; (b) the permissible heating and cooling rates of the autoclave and the methods of their monitoring; (c) the procedure for observing the thermal movements of the autoclave and monitoring the absence of pinching of the movable supports; (d) the monitoring of the continuous removal of condensate.
335. In the operating organisation, the connection scheme of the vessel (vessels) shall be approved, indicating: the source of pressure; the parameters; the working medium; the valves, measuring instruments, automatic control means (if any), safety and interlocking devices, including the place of their installation (location) (vessel nozzle, pipeline) and the ordinal number (according to the numbering of the operating organisation). The connection schemes of the vessels shall be at the workplaces of the personnel.
336. During the operation of vessels heated by hot gases, reliable cooling of the walls under pressure shall be ensured, not allowing the wall temperature to exceed the permissible values.
337. To exclude the possibility of putting into operation vessels (autoclaves) with quick-release covers when the cover is incompletely closed, and of opening it when there is pressure in the vessel, such vessels shall be equipped with locks with a key-tally. The procedure for the storage and use of the key-tally shall be reflected in the production instruction on the operating mode and safe servicing of vessels.
338. During the operation of a vessel with a working pressure of up to 2.5 MPa inclusive, direct-acting pressure gauges having an accuracy class of not lower than 2.5 shall be used, and at a working pressure of more than 2.5 MPa the accuracy class of the pressure gauges used shall be not lower than 1.5.
339. On the scale of the vessel's pressure gauge, a red line shall be applied indicating the permitted working pressure in the vessel; instead of the red line, it is permitted, as an indicator of the value of the maximum permissible pressure, to attach to the body of the pressure gauge a plate (bracket) of metal or other material of sufficient strength, painted red and fitting tightly against the glass of the pressure gauge. The pressure gauge shall be selected with such a scale that the measurement limit of the working pressure is in the second third of the scale.
340. The installation of the pressure gauge on the vessel shall ensure the distinct visibility of its readings to the attending personnel. The nominal diameter of the body of pressure gauges installed at a height of less than 2 metres from the level of the platform for observing them shall be not less than 100 mm; at a height from 2 to 3 metres inclusive - not less than 160 mm. The installation of pressure gauges at a height of more than 3 metres from the level of the platform is not permitted.
341. For the periodic checking of the working pressure gauge, a three-way cock or a device replacing it shall be installed between the pressure gauge and the vessel. In necessary cases, the pressure gauge, depending on the operating conditions and the properties of the medium in the vessel, shall be provided with either a siphon tube, or an oil buffer, or other devices protecting it from the direct action of the medium and temperature and ensuring its reliable operation. The pressure gauges and the pipelines connecting them to the vessel shall be protected against freezing.
342. Instead of a three-way cock on vessels operating under a pressure of more than 2.5 MPa or at a medium temperature of more than 250 °C, and also with a medium classified as group 1 (in accordance with TR CU 032/2013), the installation of a separate nozzle with a shut-off device for connecting a second pressure gauge is permitted. The installation of a three-way cock or a device replacing it is not obligatory where there is the possibility of checking the pressure gauge within the established time limits by removing it from the stationary vessel.
343. Pressure gauges shall not be permitted for use on vessels in the following cases, if: (a) there is no information on the performance of verification (a seal or stamp, or a document on the performance of verification); (b) the verification period of the pressure gauge has expired; (c) the pointer of the pressure gauge, when it is switched off, does not return to the zero mark of the scale by an amount exceeding half of the permissible error for the given pressure gauge; (d) the glass is broken or there are other damages to the pressure gauge that may affect the accuracy of its readings.
344. Verification of pressure gauges with their sealing or stamping shall be performed not less than once every 12 months, unless other time limits are established in the documentation for the pressure gauge. The attending personnel shall carry out checking of the serviceability of the pressure gauge by means of the three-way cock or the shut-off valves replacing it, by setting the pointer of the pressure gauge to zero. The procedure and time limits for checking the serviceability of pressure gauges by the attending personnel during the operation of vessels shall be determined by the production instruction on the operating mode and safe servicing of vessels, approved by the management of the operating organisation.
345. During the operation of vessels operating at a changing wall temperature, monitoring of compliance with the permissible heating and cooling rates of the vessels shall be carried out, the requirements for which (where such monitoring is necessary) are established in the operating manual (instruction).
346. Checking of the serviceability of the operation of a spring safety valve is carried out by: (a) inspection and forced opening of it during the operation of the equipment, at the frequency established in the production instruction for the operation of safety valves (if any) or in the instruction on the operating mode and servicing of vessels; (b) checking of the actuation of the safety valve on a test bench, where forced opening of the valve on an operating vessel is impermissible taking into account the properties of the working medium (explosive, combustible, toxic) or the conditions of the technological process, and also for all cases among those specified in sub-clauses "a", "b" of this paragraph of the Federal Norms and Rules, after a scheduled repair (inspection) of the valve with its disassembly and after an unscheduled repair to eliminate a malfunction, at the frequency established in the production instruction on the basis of the operating manual, the design and technological documentation.
347. During the operation of the safety valve, the possibility of arbitrary change of its actuation set point shall not be allowed: lever-load safety valves shall have on the lever devices excluding arbitrary movement of the load; on a spring safety valve, the screw regulating the tension of the spring shall be covered with a cap, and the screws fastening the cap shall be sealed. During the operation of a spring safety valve on a vessel with a working medium that may have a harmful effect on the material of the spring, protection of the spring against impermissible heating (cooling) and direct action of the working medium shall be ensured.
348. The installation of a pressure gauge and a safety valve is not obligatory on a vessel whose working pressure established by the manufacturing organisation in the passport is equal to or greater than the pressure of the feeding source, and provided that in this vessel the possibility of a pressure increase from a chemical reaction or the action of elevated temperature is excluded.
349. On the supply pipeline of a vessel designed for a pressure lower than the pressure of its feeding source, an automatic reducing device shall be installed with a pressure gauge and a safety device installed on the side of the lower pressure after the reducing device. In the event of the installation of a bypass line, it shall also be equipped with a reducing device. The installation of one reducing device with a pressure gauge and a safety valve is permitted on the supply pipeline common to a group of vessels operating at one and the same pressure, up to the first branch to one of the vessels. In such case, the installation of safety devices on the vessels themselves is not obligatory, if the possibility of a pressure increase is excluded in them. If, owing to the physical properties of the working medium, reliable operation of the automatic reducing device is not ensured, then the installation of a flow regulator is permitted and protection against a pressure increase is provided for.
350. The capacity of safety valves is determined in accordance with the normative documentation, taking into account the discharge coefficient for each valve (for compressible and incompressible media) and the cross-sectional area of the valve to which it is assigned, indicated in the passport of the safety valve. With the safety valves in operation, a pressure exceeding the permitted pressure shall not be permitted in the vessel: (a) by more than 0.05 MPa - for vessels with a pressure of less than 0.3 MPa; (b) by more than 15 per cent - for vessels with a pressure from 0.3 to 6 MPa inclusive; (c) by more than 10 per cent - for vessels with a pressure of more than 6 MPa. With the valves in operation, a pressure increase in the vessel of not more than 25 per cent of the permitted pressure is permitted, provided that this increase is provided for by the operating manual (instruction) of the vessel. If, during operation, the working pressure of the vessel is reduced, then a calculation of the capacity of the safety valves for the new operating conditions shall be carried out.
351. To ensure the safe operation of vessels, the connecting pipelines of safety valves (supply, discharge and drainage) shall be protected against freezing of the working medium in them. The extraction of the working medium from the branch pipes (and on the sections of the connecting pipelines from the vessel to the valves) on which safety devices are installed shall not be permitted.
352. When several safety devices are installed on one branch pipe (pipeline), the cross-sectional area of the branch pipe (pipeline) shall be not less than 1.25 of the total cross-sectional area of the valves installed on it. When determining the cross-section of connecting pipelines with a length of more than 1000 mm, the value of their resistances shall also be taken into account.
353. The installation of shut-off valves between the vessel and the safety device, and also after it, shall be prohibited. For a group of safety devices (two or more), valves before (after) the safety device (devices) may be installed, provided that the safety devices are equipped with an interlock made in such a way that, under any variant of disconnection of the valves (valve) provided for by the design, the safety devices remaining in operation have a total capacity ensuring compliance with the requirements of paragraph 350 of these Federal Norms and Rules. When two safety devices are installed, the interlock shall exclude the possibility of their simultaneous disconnection.
354. The medium leaving the safety devices shall be discharged to a safe place. The discharged toxic, explosion- and fire-hazardous process media shall be directed into closed systems for further utilisation or into systems of organised combustion. In cases justified by the design documentation, the discharge of non-toxic explosion- and fire-hazardous media into the atmosphere through discharge pipelines is permitted, provided that their design and locations ensure the explosion- and fire-safe dispersion of the discharged medium. It shall be prohibited to combine discharges containing substances that are capable, when mixed, of forming explosive mixtures or unstable compounds.
355. To ensure the removal of condensate, the discharge pipelines of safety devices and the impulse lines of pilot-operated safety valves shall be equipped with drainage devices at points where condensate may accumulate. Condensate shall be discharged from the drainage pipelines to a safe place. The installation of shut-off elements or other fittings on drainage pipelines shall not be permitted.
356. Bursting disc safety devices shall be installed on the branch pipes or pipelines directly connected to the vessel at points that are open and accessible for inspection and for installation and removal. The discs shall be placed only in the fastening assemblies intended for them. The connecting pipelines shall be protected against freezing of the working medium within them.
357. Where a bursting disc safety device is installed in series with a safety valve (upstream or downstream of the valve), the cavity between the valve and the disc shall, to enable monitoring of its serviceability, communicate through a branch tube with a pressure gauge showing the absence of pressure (when the disc is in serviceable condition) or the presence of pressure (in the event of loss of tightness (rupture) of the disc). The installation of a switching device upstream of bursting disc safety devices may be permitted where a doubled number of bursting disc devices is provided, thereby ensuring protection of the vessel against overpressure in any position of the switching device.
358. The procedure and time limits for checking the serviceability of operation, for repair, and for checking the trip set-point on a test bench of safety devices, depending on the conditions of the process, shall be specified in the operating instruction for safety devices approved by the management of the operating organisation. In accordance with the procedure established by the operating instructions: the results of checking the setting of safety devices are documented in reports and recorded in the relevant log; the results of checking the serviceability of safety devices and information on their setting are entered in the shift (operational) log or other operational documents, the forms and the procedure for maintaining which are established by the administrative documents in the operating organisation.
359. When operating vessels having a medium interface, for which monitoring of the liquid level is required, the following shall be ensured: (a) visibility of the readings of the liquid level indicator by installing it in its design position; (b) monitoring of the level by means of two direct-reading indicators on vessels heated by flame or hot gases where the liquid level may fall below the permissible level; (c) the presence on the liquid level indicator of markings of the permissible upper and lower levels, the height of the transparent liquid level indicator being not less than 25 mm below the lower and above the upper permissible liquid levels respectively, unless otherwise established in the operating manual of the vessel; (d) where the vessel is equipped with several level indicators by height, their arrangement in such a way that they ensure continuity of the liquid level readings; (e) discharge of the working medium to a safe place when blowing down the fittings (cocks, valves) installed on the level indicator; (f) the use of a protective device to protect personnel against injury in the event of rupture of the transparent element used on the level indicator, made of glass or mica; (g) the operable condition of the audible, visual and other level alarms and interlocks provided by the design in addition to the direct-reading level indicators, by checking their operation and rectifying the violations identified, in accordance with the procedure established by the operating instruction.
360. To keep vessels in serviceable condition, the operating organisation shall organise and ensure the timely repair of vessels, on a planned basis in accordance with the schedule and on an unplanned basis upon the detection of defects affecting the safety of the vessel and/or of personnel (visually visible defects (cracks) of the elements of the pressure vessel, leakage of the working medium through through-defects of its elements (cracks, fistulas) and leaking detachable joints, malfunction of the level indicators, fittings, safety and other devices ensuring the safe operation of the vessel). The repair of vessels and their elements while under pressure shall not be permitted. To ensure safety during work carried out inside a vessel, before such work begins a vessel connected to other operating vessels by a common pipeline shall be separated from them by blanks or disconnected. Disconnected pipelines shall be blanked off. Only blanks whose thickness is determined by a strength calculation, installed between flanges and having a projecting part (tang) by which the presence of the blank is identified, may be used for isolating the vessel. Where gaskets are installed between flanges, they shall be without tangs.
361. When working inside a vessel (internal inspection, repair, cleaning), safe luminaires with a voltage not exceeding 12 V shall be used, and in explosive media - of explosion-proof design. Before commencing work inside vessels that have operated with hazardous and inert media, without personal breathing protection, an analysis of the air medium shall be carried out for the absence of harmful or other substances exceeding the maximum permissible concentrations. Work inside a vessel shall be carried out under a permit to work drawn up in accordance with the procedure established by the administrative documents of the operating organisation.
362. At a negative ambient air temperature, the start-up, shutdown or tightness test of vessels operated in the open air or in unheated premises shall be carried out in accordance with the winter start-up regulations established in the operating instruction, developed on the basis of the requirements of the operating manual (instruction) and the design documentation. Taking into account the dependence of the strength characteristics of the material from which the vessel is made on temperature, as well as the minimum temperature at which the steel (or other material) and the welded joints of the given vessel are permitted for operation under pressure, the winter start-up regulations for the vessel (or group of vessels of the same design operating under identical conditions) shall determine: (a) the minimum values of the working medium pressure and the air temperature at which the vessel may be started up; (b) the procedure (schedule) for raising the pressure (from the minimum start-up pressure to the operating pressure) in the vessel during start-up and for reducing it during shutdown; (c) the permissible rate of increase of the vessel wall temperature during start-up and of decrease during shutdown.
363. At the workstations of the personnel servicing the pipeline (pipelines), the operating organisation shall ensure the availability, in a form accessible for constant use, of a set of the operating instructions for the pipeline (pipelines) necessary for safe operation (servicing, repair and testing), as well as of the as-built diagrams of the pipelines (in accordance with paragraph 198 of the Federal Norms and Rules) or of the operational (process) diagrams of the pipelines developed on their basis, which, in addition to the directions of the operating instructions, ensure the possibility of safe performance of work during operation of the pipeline (start-up, shutdown, repair, testing). The procedure for ensuring the availability at specific workstations of the set of documents necessary for the safe operation of the pipeline and of other equipment technologically interconnected with it is determined by the administrative documents of the operating organisation. In the absence (loss during operation) of the as-built documentation of the pipelines, the operational (process) diagrams may be developed on the basis of the data on the pipeline specified in the passport and in the design (design-engineering, working) documentation, based on the results of a field inspection and measurements during technical examination (diagnostics) or an industrial safety expert review.
364. The operating instruction for the pipeline (system of pipelines and equipment) shall, in particular, regulate: (a) the pipeline (pipeline system) and the equipment included in it (if any) to which the instruction applies, its purpose, with a description of the composition of the pipeline diagram; (b) the duties of the personnel during duty (shift) in observing and monitoring the operation of the pipeline and of the equipment included in it; (c) the procedure, time limits and methods for checking the instrumentation and control devices, fittings, safety devices, and protection and alarm automation devices; (d) the procedure for preparing the pipeline for start-up (filling, warming-up), for start-up (connection) and for shutdown (disconnection) of the pipeline; (e) the safety measures when taking equipment out for repair, draining the working medium; (f) the cases requiring immediate shutdown of the pipeline and of the equipment operating together with it, provided for by these Federal Norms and Rules, as well as others determined by the specifics of the diagram. The procedure for emergency shutdown and reduction of the pressure to atmospheric is established depending on the specific diagram and the features of the process; (g) the procedure of action of the personnel in the event of an accident or incident; (h) the procedure for maintaining the shift (operational) log and/or other forms of documentation established in the operating organisation, in which are recorded the documentation of the handing over and taking over of the shift (duty), the results of monitoring the operating modes, inspections of the equipment and checks of the pressure gauges, safety and other devices carried out by the personnel, and the verification of the personnel's records by the person responsible for the sound condition and safe operation of the pipeline). The description of the pipeline system diagram, of the procedure for preparation for operation, start-up and shutdown (including emergency shutdown) of the pipeline, and of other work during the performance of which actions are taken on the fittings, instruments and other devices (switching (opening, closing), checking serviceability, adjusting the medium parameters), the installation of blanks and other process operations, in the operating instruction shall contain the sequence of performance of the specified actions, indicating the ordinal numbers (according to the diagram) of the above-listed devices in respect of which they are carried out.
365. To prevent accidents of pipelines operating at a temperature causing creep of the metal, the operating organisation shall ensure the performance of systematic observations (monitoring) of the growth of residual deformations in accordance with the requirements of the design documentation, the operating manuals, the operating instructions and the methodologies determining the frequency and criteria of monitoring. This requirement applies to steam lines made of carbon, manganese and silicon-manganese steel operating at a steam temperature of 420 °C and above, as well as to steam lines made of chromium-molybdenum and chromium-molybdenum-vanadium steels operating at a steam temperature of 500 °C and above, and made of chromium and chromium-nickel (austenitic) steels at a steam temperature of 540 °C and above. The need to install means for observing the growth of residual creep deformations of the metal in the sections of the above-mentioned pipelines with an internal diameter of less than 100 mm shall be determined by the pipeline design. Such pipelines shall also undergo technical diagnostics, non-destructive and destructive testing, including before they exhaust their assigned service life (service period), in accordance with the requirements established in the operating manual (instruction), the operating instructions and other administrative documents adopted in the operating organisation.
366. After a capital repair, as well as a repair involving the cutting-out and re-welding of pipeline sections, replacement of fittings, adjustment of supports and replacement of thermal insulation, before putting the equipment into operation, the following shall be checked in accordance with the procedure established by the operating instructions: (a) the absence of temporary erection and repair braces, structures and devices, and scaffolding; (b) the serviceability of the fixed and sliding supports and spring fastenings, of the ladders and servicing platforms of the pipelines and fittings; (c) the amount of tightening of the springs of the hangers and supports in the cold state; (d) the serviceability of the thermal-movement indicators; (e) the possibility of free movement of the pipelines during their warming-up and other operating modes; (f) the condition of the drains and air vents, and of the safety devices; (g) the values of the gradients of the horizontal sections of the pipelines and their conformity with the provisions of these Federal Norms and Rules; (h) the ease of movement of the moving parts of the fittings; (i) the conformity of the readings of the extreme positions of the shut-off fittings (open-closed) on the control panels with their actual position; (j) the serviceability of the thermal insulation as regards its presence at the points provided for by the design, as well as the absence of defects (cracks, failures in individual sections), signs of wetting indicating leakage of the medium (damage to the pipeline).
367. During the operation of pipelines and fittings, in accordance with the procedure established by the operating instructions in accordance with the directions of the operating manual and the design documentation, the following shall be monitored: (a) the values of the thermal movements of the pipelines and their conformity with the calculated values, according to the readings of the indicators (benchmarks); (b) the absence of pinching and increased vibration of the pipelines; (c) the tightness of the safety devices, fittings and flanged joints; (d) the temperature regime of operation of the metal during start-ups and shutdowns; (e) the degree of tightening of the springs of the hangers and supports in the operating and cold state - not less than once every two years; (f) the tightness of the gland seals of the fittings; (g) the conformity of the readings of the position indicators of the control fittings on the control panels with their actual position; (h) the presence of lubrication of the bearings, of the assemblies of the drive mechanisms, of the screw pairs spindle - threaded bush, in the reduction gears of the electric drives of the fittings in the cases provided for by the operating manual.
368. When filling steam lines that have not cooled down with the medium, the difference between the temperatures of the pipeline walls and of the working medium shall be monitored, and this difference shall be maintained within the calculated values.
369. The drainage system shall ensure the complete removal of moisture during the warming-up, cooling and emptying of the pipelines. When replacing parts and elements of pipelines, the design position of the pipeline axis shall be maintained. When laying drainage lines, the direction of thermal movements shall be taken into account to avoid pinching of the pipelines. When combining the drainage lines of several pipelines, shut-off fittings shall be installed on each of them.
370. The names and numbers according to the process diagrams of the pipelines, as well as indicators of the direction of rotation of the handwheel (flywheel), shall be applied to the fittings or to a special tag. Control valves shall be provided with indicators of the degree of opening of the regulating element, and shut-off fittings - with indicators of the position of their shut-off element (in the open and closed state). The fittings shall be accessible for servicing. At the points of installation of the fittings and of the thermal-movement indicators of the steam lines, servicing platforms shall be installed. The fittings shall be used in accordance with their functional purpose specified in the technical documentation.
371. The checking of the serviceability of operation of the pressure gauges and safety valves shall be carried out within the following time limits: (a) for pipelines with an operating pressure of up to 1.4 MPa inclusive - not less than once per shift; (b) for pipelines with an operating pressure of over 1.4 to 4.0 MPa inclusive - not less than once per day; (c) for pipelines with an operating pressure of over 4 MPa, as well as for all pipelines installed at thermal power stations, - within the time limits established by an instruction approved by the technical manager (chief engineer) of the organisation. A record of the results of the check is entered in the shift (operational) log in accordance with the procedure established by the operating instructions and the administrative documents of the operating organisation.
372. When operating pipelines with an operating pressure of not more than 2.5 MPa, pressure gauges with an accuracy class of not lower than 2.5 shall be used. When operating pipelines with an operating pressure of over 2.5 to 14 MPa inclusive, pressure gauges with an accuracy class of not lower than 1.5 shall be used. When operating pipelines with an operating pressure of over 14 MPa, pressure gauges with an accuracy class of not lower than 1 shall be used. The scale of the pressure gauges is selected on the condition that, at the operating pressure, the pointer of the pressure gauge is in the second third of the scale. A red line indicating the permitted operating pressure shall be applied to the scale of the pressure gauge; instead of the red line, as an indicator of the value of the maximum permissible pressure, it is permitted to attach to the body of the pressure gauge a plate (bracket) made of metal or other material of sufficient strength, painted red and fitting closely against the glass of the pressure gauge.
373. The pressure gauge shall be installed in such a way that its readings are visible to the servicing personnel, with its scale positioned vertically or inclined forward by up to 30° to improve the visibility of the readings. The nominal diameter of the body of pressure gauges installed at a height of less than 2 metres from the level of the observation platform shall be not less than 100 mm; at a height of 2 to 3 metres - not less than 160 mm; at a height of over 3 to 5 metres - not less than 250 mm. Where a pressure gauge is located at a height of over 5 metres, a lowered pressure gauge shall be installed as a duplicate.
374. Upstream of each pressure gauge there shall be a three-way cock or another similar device for blowing down and disconnecting the pressure gauge. Upstream of a pressure gauge intended for measuring steam pressure there shall be a siphon tube with an internal diameter of not less than 10 mm.
375. The servicing personnel, during the operation of the pipeline, carry out the checking of the serviceability of the pressure gauge at the frequency established in the operating instruction, taking into account the requirements of paragraph 370 of the Federal Norms and Rules, by means of the three-way cock or of the shut-off devices replacing it, by setting the pointer of the pressure gauge to zero. Not less than once every 12 months (unless other time limits are established by the documentation for the pressure gauge), the pressure gauges shall be verified, and a stamp or seal shall be applied to each of them.
376. Pressure gauges shall not be permitted for use in the following cases: (a) there is no information on the performance of verification (a seal or stamp, or a document confirming verification); (b) the verification period of the pressure gauge has expired; (c) upon disconnection, the pointer of the pressure gauge does not return to the zero mark of the scale by an amount exceeding half of the permissible error for the given pressure gauge; (d) the glass is broken or there are other damages to the pressure gauge that may affect the correctness of its readings.
377. The serviceability of safety valves is checked by their forced short-term lifting (opening) or by checking the operation of the valve on test benches, if forced opening of the valve is undesirable owing to the conditions of the process. Safety devices shall be calculated and adjusted so that the pressure in the protected element does not exceed the permitted pressure by more than 10 per cent, and, at a permitted pressure of up to 0.5 MPa - by not more than 0.05 MPa. An excess of the permitted pressure by more than 10 per cent upon full opening of the safety valve may be allowed only in the event that this is provided for by the strength calculation of the pipeline. If operation of the pipeline is permitted at a reduced pressure, then the adjustment of the safety devices shall be carried out to this pressure, and the throughput capacity of the devices shall be checked by calculation.
378. The extraction of the medium from the branch pipe on which a safety device is installed shall not be permitted. The installation of shut-off devices on the supply line of the working medium to the safety device and on the pipelines between the pilot valve and the main valve of pilot-operated safety devices shall be prohibited.
379. Safety valves shall have discharge pipelines protecting personnel against burns when the valves operate. The installation of shut-off devices on the discharge pipelines shall not be permitted. These pipelines shall be protected against freezing and equipped with drains for draining off the condensate accumulating in them. The installation of shut-off devices on the drains shall be prohibited.
380. When operating a pipeline whose design pressure and permitted operating pressure are less than the pressure of the source feeding it, a pressure-reducing device or a pressure-reducing and desuperheating unit (where regulation of pressure and temperature is required) shall be used to ensure safety, with a pressure gauge and a safety device installed on the lower-pressure side downstream of the pressure-reducing device. The pressure-reducing devices shall ensure automatic regulation of pressure, and the pressure-reducing and desuperheating devices, in addition, - automatic regulation of temperature. The boundary separating the lower-pressure pipeline from the higher-pressure pipeline is the shut-off fitting on the section of the pipeline downstream of the pressure-reducing unit (pressure-reducing and desuperheating unit) and the safety device, which shall have a strength equivalent to that of the pipeline upstream of the pressure-reducing unit (pressure-reducing and desuperheating unit) and shall undergo testing together with it.
381. In an organisation operating pipelines, a repair log (repair logs) shall be maintained in paper or electronic form (provided that the safekeeping (backing-up) of the information stored in electronic form is ensured and that the possibility of identifying the person who entered the information into the electronic form of the log is ensured), into which, under the signature of the person responsible for the sound condition and safe operation of the pipelines, information on all repair work carried out, including work that does not give rise to the need for an extraordinary technical examination, shall be entered. Information on repair work giving rise to the need for an extraordinary examination of the pipeline, on the materials used in the repair, as well as information on the documents confirming the quality of the welding, shall be entered in the passport of the pipeline.
382. Before the commencement of repair work on a pipeline, it shall be separated from all other pipelines by blanks or disconnected from the operating equipment. If the fittings of steam and hot-water pipelines are flangeless, then disconnection of the pipeline shall be carried out by two shut-off devices, with a drainage device having a nominal diameter of not less than 32 mm and a direct connection to the atmosphere between them. The drives of closed gate valves, as well as of the shut-off fittings of open drains, shall be locked by a locking device so that the possibility of their opening or closing is excluded. The keys to the locking devices shall be kept by the person responsible for the sound condition and safe operation of the pipeline. The thickness of the blanks and flanges used when disconnecting the pipeline shall be determined by a strength calculation. A blank shall have a projecting part (tang) by which its presence is identified. The gaskets between the flanges and the blank shall be without tangs.
383. The repair of pipelines, fittings and elements of remote control of fittings, the installation and removal of the blanks separating the pipeline section being repaired, shall be carried out under a permit to work in accordance with the procedure established in the operating organisation.
384. Fittings after repair shall be tested for tightness at a pressure equal to 1.25 of the operating pressure - for fittings removed from their place, and at the operating pressure - for fittings repaired without removal from their place of installation.
385. During the operation of pipelines and fittings, in accordance with the procedure established by the operating instructions, monitoring of the condition of the thermal insulation as regards its conformity with the design documentation and with paragraphs 93, 94, 95 of these Federal Norms and Rules, and identification of the presence or absence of defects (cracks, failures in individual sections), signs of wetting indicating leakage of the medium (damage to the pipeline), as well as the taking of measures for rectification, shall be ensured.
386. At hazardous production facilities where pressure equipment is used, instructions establishing the actions of workers in emergency situations (including in the event of an accident) shall be developed and approved. The instructions shall be issued to the workplace against a signature confirming their receipt by the workers involved in the operation of the pressure equipment. The procedure for checking knowledge of the instructions and for training exercises (where necessary) to practise actions in emergency situations is determined by the administrative documents of the operating organisation. The scope of the instructions depends on the features of the process and the type of pressure equipment operated. For hazardous production facilities in respect of which paragraph 2 of Article 10 of Federal Law No. 116-FZ provides for the mandatory development and approval of action plans for the containment and elimination of the consequences of accidents, it is not required to develop separate instructions establishing the actions of workers in emergency situations during operation of pressure equipment, if such actions are provided for by the approved action plan for the containment and elimination of the consequences of accidents. For other hazardous production facilities, where there is no need to develop a separate instruction, in the event that, apart from the risks arising from a specific unit of pressure equipment, there are no risks of further development of the emergency situation to the equipment and production processes interconnected with it, as well as no other risks of an accident at the hazardous production facility, the establishment of the procedure for the actions of workers in emergency situations by the operating instructions for the equipment may be permitted. Emergency situations, among other cases determined by the administrative documents of the operating organisation taking into account the features of the process of the specific hazardous production facility, the presence of hazardous substances, and the types and characteristics of the equipment used at it, shall include deviations from the normal course of the process, of the operating mode of the equipment, power supply cut-off and other situations whose further development may lead to injury of workers, the occurrence of an incident or accident, including cases requiring emergency shutdown of the equipment. Cases of unplanned cessation of operation of the equipment by shutting it down and disconnecting it by the action of protections or by the personnel to prevent an accident, upon deviation of the operating parameters of the equipment from the normal modes established by the operating instructions, operating charts, design, technical and process documentation, or upon the occurrence of defects, damage (failure) of the equipment or of the devices installed on it (hereinafter - emergency shutdown (disconnection)), and the procedure of actions of the personnel, shall be established in the operating instruction for the specific equipment, taking into account the directions of the operating manual, the design and process documentation of the hazardous production facility, as well as the requirements of paragraphs 389, 390, 391 of the Federal Norms and Rules, which determine the standard list of cases of emergency shutdown of a boiler, vessel, pipeline.
387. In the instructions establishing the actions of workers in emergency situations (including in the event of an accident), alongside the requirements determined by the specifics of the hazardous production facility, the following information for workers engaged in the operation of pressure equipment shall be specified: (a) operational actions to prevent and contain accidents; (b) the ways and methods of eliminating accidents; (c) evacuation schemes in the event of the occurrence of an emergency situation, explosion, release of toxic substances in the premises or on the site where the equipment is operated, if the emergency situation cannot be contained or eliminated; (d) the procedure for bringing the pressure equipment into a safe position in the non-operating state, or a reference to the operating instructions establishing such requirements; (e) the places for disconnecting the power supply inputs and the list of persons entitled to disconnect them; (f) the locations of the first-aid kits; (g) the methods of rendering first aid to workers who have come under electrical voltage, sustained burns, or been poisoned by combustion products; (h) the procedure for notifying the workers of the hazardous production facility and the specialised services engaged in carrying out actions to contain accidents. The availability of these instructions is ensured by the officials of the organisation operating the hazardous production facility whose duty this is, and their implementation in emergency situations - by each worker of the hazardous production facility.
388. The procedure of actions in the event of an incident during the operation of pressure equipment is determined and established by the operating organisation in the operating instructions.
389. The boiler shall be immediately shut down and disconnected by the action of emergency protection systems or by personnel in the cases provided for by the instruction, in particular in the event of: (a) detection of a malfunction of the safety valve; (b) an increase in pressure in the boiler drum above the permitted value by 10 per cent with its continued rise; (c) a fall in the water level in the boiler below the lowest permissible level; (d) a rise in the water level above the highest permissible level; (e) cessation of the operation of all feed pumps; (f) cessation of the operation of all direct-acting water level indicators; (g) detection of cracks, bulges, leaks (weeps) in the metal and welded joints of the boiler elements (drum, header, chamber, steam-water bypass and water-drain pipes, steam and feed pipelines, flame tube, firebox, furnace casing, tube plate, external separator, fittings), breakage of an anchor bolt or stay; (h) an impermissible increase or decrease in pressure in the path of a once-through boiler up to the built-in gate valves; (i) extinction of the flames in the furnace during chamber combustion of fuel; (j) a reduction in the water flow through the hot-water boiler below the minimum permissible value; (k) a reduction in the water pressure in the path of the hot-water boiler below the permissible value; (l) a rise in the water temperature at the outlet of the hot-water boiler to a value 20 °C below the saturation temperature corresponding to the working pressure of water in the outlet header of the boiler; (m) a malfunction of the safety automatics or the emergency alarm, including the disappearance of voltage on these devices; (n) the occurrence of a fire threatening the operating personnel, the boiler and the equipment technologically interconnected with it.
390. The vessel shall be immediately shut down in the cases provided for by the instruction on the operating regime and safe servicing, in particular: (a) if the pressure in the vessel has risen above the permitted value and does not fall despite the measures taken by personnel; (b) upon detection of a malfunction of the safety device against pressure increase; (c) upon detection in the vessel and its elements operating under pressure of cracks, leaks, bulges, rupture of gaskets; (d) in the event of a malfunction of the pressure gauge and the impossibility of determining the pressure by other instruments; (e) in the event of a fall in the liquid level below the minimum permissible or a reduction in the heat-carrier flow below the minimum permissible value in vessels with fire heating; (f) in the event of failure of all liquid level indicators; (g) in the event of a malfunction of the safety interlocking devices; (h) in the event of a fire directly threatening the vessel under pressure.
391. The pipeline shall be immediately shut down and disconnected by the action of protection systems or by personnel in the cases provided for by the instruction, in particular: (a) upon detection of a malfunction of the safety device against pressure increase, a malfunction of the reducing device; (b) if the pressure in the pipeline has risen above the permitted value and does not fall despite the measures taken by personnel; (c) if cracks, bulges, weeps in the base metal and welded joints, breakage of an anchor bolt or stay are detected in the main elements of the pipeline; (d) in the event of a malfunction of the pressure gauge and the impossibility of determining the pressure by other instruments; (e) in the event of a malfunction of the safety interlocking devices; (f) in the event of pinching and increased vibration of the pipeline; (g) in the event of a malfunction of the drainage devices for the continuous removal of liquid; (h) in the event of a fire directly threatening the pipeline.
392. The time and reasons for the emergency shutdown of equipment operating under pressure shall be recorded in shift (operational) logs or other operational documents intended for this purpose, the procedure for maintaining which in paper or electronic form (provided that the preservation (backup) of information stored in electronic form is ensured and that the possibility of identifying the employee who entered the information into the electronic form of the log is ensured) is determined by the administrative documents of the organisation.
393. The operation of buildings and structures at a hazardous production facility intended for carrying out technological processes using equipment operating under pressure as part of it, for the purpose of preventing accidents and injury to people, shall be carried out in accordance with the requirements of the legislation of the Russian Federation in the procedure established by the administrative documents of the operating organisation on the basis of the instructions of the design documentation. Operational monitoring of the condition (inspection and monitoring of the technical condition) of buildings and structures is carried out in accordance with the Interstate Standard GOST 31937-2011 "Buildings and structures. Rules for inspection and monitoring of technical condition", put into effect by the order of the Federal Agency for Technical Regulation and Metrology of 27 December 2012 No. 1984-st as a national standard of the Russian Federation from 1 January 2014 (Moscow: Standartinform, 2014). In the event of loss at a hazardous production facility of the design documentation for a building or structure, the preparation of documentation containing information about the building or structure and instructions for their operation to the extent of the corresponding sections of the lost design documentation is carried out by a specialised organisation based on the results of the inspection of the building or structure in accordance with the requirements of paragraph 462 of these Federal Norms and Rules.
394. Equipment operating under pressure listed in paragraph 3 of the Federal Norms and Rules shall, during operation, be subjected to: (a) technical examination (a set of periodically carried out works to determine the actual condition of equipment operating under pressure for the purpose of determining its operability and compliance with industrial safety during use within the period of safe operation): initially before commissioning after installation (initial technical examination); periodically during operation (periodic technical examination); before the term of the periodic technical examination in the cases established by these Federal Norms and Rules (extraordinary technical examination); (b) technical diagnosis for the purpose of monitoring the condition of the equipment or its individual elements during technical examination to establish the nature and dimensions of the defects revealed thereby, as well as in the cases established by the operating manual (instruction) of the equipment and in the cases specified in sub-clause "c" of this paragraph of the Federal Norms and Rules; (c) industrial safety expert examination in the cases established by Article 7 of Federal Law No. 116-FZ. Technical diagnosis includes a set of operations using methods of non-destructive and destructive testing, performed in respect of the equipment or its individual elements as part of operational monitoring during operation of the equipment within the service life, in the cases established by the operating manual, and during technical examination to clarify the nature and dimensions of the revealed defects, as well as upon expiry of the design service life of equipment operating under pressure or after exhaustion of the design resource of safe operation, as part of the industrial safety expert examination for the purpose of determining the possibility, parameters and conditions of the further operation of this equipment. Operational monitoring of the metal of the main elements of boilers and pipelines of thermal power plants is carried out in accordance with the federal norms and rules in the field of industrial safety.
395. The scope of works, procedure and frequency of technical examinations within the service life of equipment operating under pressure is determined by the operating manual (instruction) and the requirements of these Federal Norms and Rules.
396. Technical examinations of equipment operating under pressure subject to registration with the territorial bodies of Rostechnadzor or other federal executive bodies authorised in the field of industrial safety shall be carried out by an authorised specialised organisation, as well as by the person responsible for carrying out production control together with the person responsible for the sound condition and safe operation of the equipment in the cases established by these Federal Norms and Rules. The specialised organisations authorised to carry out technical examination of equipment operating under pressure include organisations having within their composition non-destructive testing units (laboratories) conforming to the federal norms and rules in the field of industrial safety "Basic Requirements for Carrying Out Non-Destructive Testing of Technical Devices, Buildings and Structures at Hazardous Production Facilities", approved by order of Rostechnadzor of 1 December 2020 No. 478 (registered by the Ministry of Justice of the Russian Federation on 24 December 2020, registration No. 61795), and possessing, on the basis of ownership rights and other lawful grounds, the methodologies necessary for carrying out technical examination of specific types of equipment and a set of measuring and diagnostic instruments and devices, staffed with employees of appropriate qualification in the field of non-destructive testing, certified in visual and measurement testing, as well as other methods of non-destructive testing (where their application is necessary during technical examination), including: the manufacturer of the specific type of equipment (its legal successor in the event of reorganisation or an organisation continuing to produce similar types of equipment and possessing a set of design, technological and operational documentation of the manufacturer on lawful grounds); an expert organisation holding a licence of Rostechnadzor for carrying out industrial safety expert examination of technical devices used at hazardous production facilities; organisations authorised by the manufacturer and other specialised organisations meeting the above criteria. An organisation performing work on the technical examination of equipment operating under pressure shall, to ensure that organisations operating the equipment are informed and that control (supervision) can be exercised, submit to Rostechnadzor information on the types of equipment operating under pressure in respect of which it has the organisational and technical capability to carry out technical examination, indicating the information confirming its compliance with the above requirements for a specialised organisation authorised to carry out technical examination of equipment operating under pressure, including with regard to the availability of employees of appropriate qualification, a set of measuring and diagnostic instruments and devices, as well as the methodologies necessary for the high-quality performance of technical examination works on specific types of equipment.
397. Technical examination of equipment subject to registration with the territorial bodies of Rostechnadzor or other federal executive bodies in the field of industrial safety (in respect of organisations subject to their supervision), beyond the design service life during the period of safe operation established in the conclusion of the industrial safety expert examination, shall be carried out by a specialised organisation holding a licence to carry out activities in industrial safety expert examination of technical devices used at hazardous production facilities, as well as by the person responsible for carrying out production control over the safe operation of the equipment together with the person responsible for the sound condition and safe operation of the equipment, to the extent and with the frequency determined by the conditions of safe operation of the equipment established in the conclusion of the industrial safety expert examination (but no less frequently than the terms established by the operating manual (instruction) and these Federal Norms and Rules).
398. In the event of the detection during technical examination of impermissible defects preventing the further operation of the equipment within the design service life, based on the results of technical diagnosis it shall be ensured that an analysis (investigation) of the reasons for their occurrence and an assessment of the residual resource (where necessary) is carried out, with the determination of the technology for eliminating the defects and (or) the actions for monitoring their condition and preventing the further development of defects and the formation of new ones similar to those revealed, by the forces of the manufacturer of the equipment or an expert organisation holding a licence to carry out activities in industrial safety expert examination of technical devices used at hazardous production facilities. Further operation of such equipment is possible after establishing and eliminating the causes of the impermissible defects, as well as their elimination by carrying out repair.
399. An extraordinary technical examination of equipment operating under pressure is carried out in the cases where: (a) boilers, vessels have not been operated for more than 12 months, and pipelines - for more than 24 months; (b) the equipment was dismantled and installed at a new location, with the exception of transportable equipment operated by one and the same organisation; (c) repair of the equipment has been carried out using welding, surfacing, heat treatment (where necessary) of elements operating under pressure, with the exception of works after which an industrial safety expert examination is required in accordance with the legislation of the Russian Federation in the field of industrial safety. When carrying out an extraordinary technical examination, the previously appointed terms for carrying out technical examination do not change.
400. The results of the technical examination, indicating the maximum permitted parameters (Appendix No. 1 to these Federal Norms and Rules) of operation (pressure, temperature of the working medium) and the terms of the next examination, shall be recorded in the passport of the equipment operating under pressure by the persons who carried out the technical examination. The term of the next periodic technical examination shall not exceed the service life of the equipment established by the manufacturer or by the conclusion of the industrial safety expert examination drawn up based on the results of technical diagnosis upon extension of the service life of the equipment. When carrying out an extraordinary technical examination, the previously appointed terms for carrying out technical examination do not change.
401. If defects are detected during examination, then to establish their nature and dimensions, technical diagnosis using non-destructive testing methods shall be carried out in the procedure provided for by these Federal Norms and Rules. If, based on the results of the technical diagnosis carried out, defects are revealed that reduce the strength of the equipment operating under pressure below the values established in the technical documentation, the possibility of its operation at reduced parameters (pressure, temperature) recorded in the passport based on the results of technical diagnosis is permitted until the defects are eliminated at the nearest scheduled repair or the equipment is replaced, provided that the possibility of safe operation of the equipment at reduced parameters: is permitted by the technological process in which the equipment is used and does not contradict the minimum permissible values of the parameters of its operation established by the manufacturer (where such instructions exist) in the operating manual (instruction) and operating charts; is confirmed by a strength calculation carried out taking into account the actual technical condition (nature and dimensions of defects) of the equipment, with determination (where necessary) of the residual resource and with the mandatory establishment, based on the results thereof, of a limited operating period until the defects are eliminated at the nearest repair. When transferring the equipment to the mode of operation at reduced parameters, the following shall be done: appropriate changes shall be introduced into the production instructions and operating diagrams; the installation and adjustment of an automatic reducing device shall be provided for in the cases established by the Federal Norms and Rules; a check of the throughput capacity of the safety valves by an appropriate calculation shall be carried out, as well as their readjustment (taking into account the reduced parameters) or replacement (in the event of negative results of the throughput capacity calculation).
402. For vessels intended for the storage and transportation of liquefied gases, the pressure of which changes depending on the ambient air temperature, the establishment of a permitted pressure less than the value of the working pressure specified by the manufacturer in the passport shall not be permitted, this value being determined on the basis of the decisions taken during design by the developer of the vessel on its structural design (including the materials used in manufacture, the arrangement and type of thermal insulation), the results of the strength calculation taking into account the properties of the working medium, static, dynamic (inertial) loads and other hazardous factors characteristic of this type of equipment. Upon detection of impermissible defects, the operation of such vessels shall be immediately terminated.
403. If it is established during technical examination that equipment operating under pressure, owing to existing defects or violations, is in a condition dangerous for its further operation, then the operation of such equipment shall be prohibited. The actual (operable/inoperable) condition of equipment operating under pressure, depending on the type and nature of the defects, shall be established in accordance with the instructions of the operating manual (instruction). In the absence in the operating manual (instruction) of criteria for the limit state of equipment operating under pressure, their establishment shall be carried out in accordance with Appendix No. 8 to the Federal Norms and Rules.
404. In the event that, during the analysis (assessment of the nature, dimensions and causes of occurrence) of defects revealed during the technical examination of equipment operating under pressure, it is established that their occurrence is due to the operating regime of the equipment at the given operating organisation or to the features (deficiencies) of the design of this type of equipment, then the person who carried out the technical examination shall send to the head of the operating organisation information on the need to carry out an extraordinary technical examination of all equipment operating under pressure that is operated in a similar regime, or of equipment of similar design used at the given operating organisation. In doing so, the operating organisation shall be obliged to ensure that the specified works are carried out, with subsequent informing of Rostechnadzor (or another federal executive body in the field of industrial safety, if the equipment operating under pressure is operated at a hazardous production facility subordinate to that body) of the results of their performance. Of the fact of detection of defects the occurrence of which is due to the features (deficiencies) of the design of the equipment, the organisation that carried out the technical examination shall notify (with the attachment of supporting documents) the manufacturer of this equipment or the person authorised by the manufacturer, Rostechnadzor, and the organisation that drew up the document confirming the conformity of this equipment with the requirements of TR CU 032/2013.
405. Technical examination of boilers, as well as of the metal structures of their frames (where present), includes: (a) external and internal inspection of the boiler and its elements; (b) inspection of the metal structures of the boiler frame (where present); (c) hydraulic tests; (d) tests of the electrical part (for electric boilers). During technical examination of a boiler, it is permitted to use the non-destructive testing methods specified in Chapter III of these Federal Norms and Rules in the cases established by the operating manual (instruction) of the boiler and the requirements of the Federal Norms and Rules.
406. The external and internal inspection of a boiler has the purpose: (a) at the initial examination, to verify that the boiler is installed and equipped in accordance with the requirements of these Federal Norms and Rules, the design and the operating manual (instruction), as well as that the boiler and its elements have no damage arising during their transportation and installation; (b) at periodic and extraordinary examinations, to establish the operability of the boiler and the possibility of its further operation.
407. The initial and extraordinary technical examination of boilers shall be carried out by an authorised specialised organisation. The initial technical examination of boilers which have undergone internal inspection and hydraulic testing by the manufacturer and have been delivered to the installation site in assembled form, provided that the preservation period established by the manufacturer has not expired and the preservation conditions established by the manufacturer have not been violated, is permitted to be carried out at the installation site by specialists of the operating organisation (the person responsible for carrying out production control (technical supervision) over the safe operation of the equipment and the person responsible for the sound condition and safe operation of the equipment).
408. The periodic technical examination of boilers is carried out by an authorised specialised organisation, as well as by the person responsible for the sound condition and safe operation of the equipment together with the person responsible for carrying out production control over the safe operation of the equipment, to the extent and with the frequency established by the Federal Norms and Rules, unless otherwise provided for by the operating manual (instruction) of the boiler.
409. An authorised specialised organisation carries out the periodic technical examination of boilers no less frequently than: (a) once every four years - external and internal inspections; (b) once every eight years - hydraulic testing.
410. The person responsible for the sound condition and safe operation of the equipment shall: participate, together with the person responsible for carrying out production control over the safe operation of the equipment, in the technical examination carried out by the authorised specialised organisation; carry out, together with the person responsible for carrying out production control over the safe operation of the equipment, external and internal inspections of the boiler before the commencement and after the completion of the scheduled repair, but no less frequently than once every 12 months (if there are no other instructions on the timing in the operating manual (instruction)); carry out hydraulic testing at working pressure each time after the opening of the drum, header or repair of the boiler, if the nature and scope of the repair do not necessitate an extraordinary technical examination. To improve the quality of the inspection of boilers of thermal power plants, employees of the metal control service (laboratory) (where present) may be involved by the person responsible for the sound condition and safe operation of the equipment in the procedure provided for by the administrative documents of the operating organisation.
411. An extraordinary technical examination of a boiler, provided for by sub-clause "c" of paragraph 399 of these Federal Norms and Rules, is carried out: (a) if more than 15 per cent of the anchor stays of any wall have been replaced; (b) after replacement of the drum, screen header, superheater, steam cooler or economiser; (c) if more than 50 per cent of the total number of screen and boiler or fire tubes, or 100 per cent of superheater tubes and economiser tubes, have been simultaneously replaced; (d) if such examination is necessary by decision of the person responsible for the sound condition and safe operation of the boiler based on the results of the inspection carried out and the analysis of the operational documentation.
412. During the external and internal inspections of a boiler, attention shall be paid to the detection of possible cracks, tears, bulges, buckles and corrosion on the internal and external surfaces of the walls, traces of steaming and weeps in welded, riveted and rolled joints, as well as damage to the lining that may cause a danger of overheating of the metal of the boiler elements.
413. Boilers being installed at thermal power plants may be provided with lining before being presented for technical examination, provided that all installation blocks are thoroughly inspected before the lining is applied to them. For this purpose, a commission shall be established, composed of authorised representatives of the engineering and technical personnel of the power plant, the metals laboratory (service) and the installation organisation. During the inspection, the following shall be checked: compliance with tolerances on the relative positioning of parts and assembly units, displacement of edges and misalignment of the axes of the joined pipes, structural elements of welded joints, the presence on the boiler elements of factory marking and its correspondence with the passport data, the absence of damage to parts and assembly units during transportation. Where the results of the inspection and of the check of the performed testing of welded joints (factory and installation) are positive, an act shall be drawn up by the commission for each installation block and approved by the technical manager of the power plant. This act is an integral part of the boiler installation quality certificate and the basis for performing the lining before the technical examination of the boiler. The fully installed boiler shall be presented for internal inspection (in accessible places) and hydraulic testing. If, during the inspection of the boiler, damage to the lining is detected that gives rise to suspicion that the blocks were subjected to impacts during installation, then the lining shall be partially opened to check the condition of the pipes and to eliminate the damage.
414. Before the periodic external and internal inspections, the boiler shall be cooled and thoroughly cleaned of scale, soot, ash and slag deposits. The internal devices in the drum shall be temporarily dismantled and removed (if they hinder the inspection) in the procedure provided for by the operating manual (instruction). In case of doubt as to the sound condition of the walls or joints, the person who carries out the examination has the right to require the opening of the lining or the removal of the insulation in full or in part, and during the internal inspection of a boiler with fire tubes - the full or partial removal of the tubes.
415. Hydraulic testing of boilers is carried out only where the results of the external and internal inspections are satisfactory. When carrying out hydraulic testing of a boiler, the corresponding requirements of the section "Hydraulic (Pneumatic) Testing" of Chapter III of these Federal Norms and Rules shall be complied with. The boiler shall be presented for hydraulic testing with the fittings installed on it. In the event of a reduction of the working pressure relative to that specified in the passport, the test pressure during hydraulic testing is determined on the basis of the permitted pressure established based on the results of the technical examination.
416. When carrying out technical examinations of electric boilers, tests of the electrical part of the electric boiler are additionally carried out to check the condition of the electrical insulation.
417. If, during the examination of a boiler, mechanical tests of the metal of the drum or other elements were carried out and, as a result of the tests of carbon steel, the presence of one of the following indicators is revealed: (a) tensile strength below 320 MPa (32 kgf/mm2); (b) a ratio of the conventional yield strength at a residual deformation of 0.2 per cent to the tensile strength of more than 0.75; (c) elongation of less than 14 per cent; (d) impact toughness on specimens with a sharp notch of less than 25 J/cm2, then the further operation of this element shall be prohibited. The permissible values of the specified characteristics for alloy steels are established in each specific case by the manufacturer.
418. If, during the examination of a boiler, surface cracks or leaks (leakage, traces of steaming, salt deposits) are detected, then before their elimination by means of welding-up, investigations of the defective joints for the absence of corrosion shall be carried out. The areas affected by corrosion shall be removed.
419. The technical examination of the metal structures of a boiler frame shall be carried out in accordance with the operating manual (instruction) of the boiler. In the absence of instructions in the operating manual (instruction), the technical examination of the metal structures shall be carried out within the following terms: initial - before the boiler is put into operation after installation; periodic - no less frequently than once every 8 years simultaneously with the examination of elements operating under pressure; upon expiry of the service life of the boiler, during its technical diagnosis as part of the industrial safety expert examination upon expiry of the service life. An extraordinary technical examination of the metal structures of a boiler shall be carried out: in the event of explosions (pops) in the furnace and (or) gas ducts; as a result of the effect of high temperatures on the metal structures owing to a malfunction of the lining or in the event of a fire; after natural or man-made emergencies, the negative effect of which could have had an influence on the condition and load-bearing capacity of the metal structures of the boiler.
420. The following are subject to technical examination as part of the frame: the load-bearing elements of the frame and the ceiling covering ensuring the strength and rigidity of the structure (columns, cross-bars, ties, ridge beams, framing beams of the ceiling covering); critical design elements, damage to one of which may cause an emergency situation; other design elements, damage to one of which does not affect the safe operation of the boiler as a whole; stiffening belts, cladding elements and hoppers, truss gusset plates. In boilers without a load-bearing frame (self-supporting), the supporting structures (assemblies) of the heating surfaces, headers and drums are subject to technical examination.
421. The scope, methods and frequency of technical examinations of vessels (with the exception of cylinders with a capacity of up to and including 100 l manufactured before the entry into force of TR CU 032/2013) shall be determined in accordance with the instructions of the manufacturer (design developer) in the operating manual (instructions). The technical examination of cylinders manufactured before the entry into force of TR CU 032/2013 shall be carried out in accordance with the procedure approved by the developer of the cylinder design, which specifies the frequency of examination and the rejection standards. In the absence of such instructions, the scope, methods and frequency of technical examinations within the service life of vessels shall be adopted in accordance with Appendix No. 10 to the Federal Norms and Rules.
422. The primary, periodic and extraordinary technical examination of vessels subject to registration with the territorial body of Rostechnadzor or with other federal executive authorities in the field of industrial safety (in respect of vessels of organisations subject to their supervision) is carried out by the authorised specialised organisation, as well as by the person responsible for exercising production control over the operation of vessels operating under pressure, jointly with the person responsible for the sound condition and safe operation, within the periods established in the operating manual (instructions) or in Appendix No. 10 to these Federal Norms and Rules.
423. The primary, periodic and extraordinary technical examination of vessels not subject to registration with the territorial body of Rostechnadzor is carried out by the person responsible for the sound condition and safe operation within the periods established in the operating manual (instructions) or in Appendix No. 10 to these Federal Norms and Rules. The need for the participation of the person responsible for production control over the safe operation of the equipment is determined by the administrative documents of the operating organisation.
424. The minimum scope of the primary technical examination of vessels includes: (a) visual and measuring inspection from the internal (where accessible) and external surfaces of the vessel; (b) monitoring of the wall thickness of elements of vessels operating under the pressure of corrosive and aggressive media, if this is established in the operating manual (instructions) and/or provided for in the design documentation of the hazardous production facility, taking into account the specifics of the process in which the vessels are used; (c) verification of the compliance of the installation, the pipework, the fitting with measuring and control instruments and safety devices of the vessel, with the requirements of the design and technical documentation; (d) hydraulic testing. During the technical examination of vessels, other methods of non-destructive testing may be used, including the acoustic emission method.
425. During the primary technical examination, the inspection of the internal surface and the hydraulic testing of a vessel supplied in assembled form may be omitted, if this is established in the requirements of the operating manual (instructions) and the periods and preservation conditions specified therein have not been violated.
426. The scope of the extraordinary technical examination is determined by the reasons that gave rise to it. When an extraordinary examination is carried out, the passport of the vessel shall state the reason that gave rise to the need for such examination.
427. Before the inspection (visual and measuring inspection) of the internal surface of the vessel, other work inside the vessel and its hydraulic testing are carried out, the vessel shall be stopped, cooled (warmed up), freed of the working medium filling it, with ventilation (purging) and neutralisation and degassing (where necessary) carried out, disconnected from power sources and from all pipelines connecting the vessel with pressure sources or other vessels and process equipment. The procedure for carrying out the specified work, depending on the properties of the working medium, the design of the vessel, the features of its connection scheme and the process, and the requirements set out in this section of Chapter IV of the Federal Norms and Rules, shall be established in the production instruction or in other documentation on the safe conduct of work (process regulations, instruction) approved by the operating and/or authorised specialised organisation performing the specified work.
428. Purging of a vessel operating under the pressure of air or inert gases, before work inside its shell begins, is carried out with air; purging of a vessel operating under the pressure of combustible gases is carried out with inert gas and/or air. The completion of purging, in necessary cases taking into account the properties of the working medium, is determined by the results of the analysis of the medium inside the vessel after purging. Vessels operating with toxic substances, before work inside them begins, including before the visual and measuring inspection, shall be subjected to thorough treatment (neutralisation, degassing).
429. The disconnection of the vessel from all pipelines connecting it with pressure sources or other vessels and process equipment is carried out by installing blanks in the detachable joints or by directly disconnecting them from the supply and discharge pipelines at the detachable joints, with blanks installed on the pipeline flanges.
430. The surfaces of vessels, before the inspection begins, shall be cleaned of deposits and dirt for the visual and measuring inspection to be carried out. At the request of the person carrying out the examination, the lining, insulation and other types of protection shall be removed if there are signs indicating the possible presence of defects affecting the safety of use of the vessel (visually visible mechanical damage; deformation; violations of the integrity of the lining, insulation and protective shell of the body; loss of tightness of the vessel body or its protective shell according to instrument readings). Where the design of the vessel and/or a feature of the process does not provide for the possibility of removing the insulation and other protective devices of the body with subsequent restoration, the diagnosis of the possible presence of defects in places inaccessible for inspection, by removal of the protective coating or by other methods, shall be carried out in accordance with the procedure and technology of the design developer and/or the manufacturer of the vessel, involving, where necessary, a specialised organisation and/or the manufacturer of the vessel to perform the work. When an extraordinary technical examination is carried out after repair involving welding and heat treatment, for the inspection and the strength and tightness tests of the vessel, the external insulation may be removed partially only at the place subjected to repair.
431. The hydraulic testing of a vessel shall be carried out in accordance with the approved diagrams and instructions on the operating mode and safe servicing of vessels, developed at the operating organisation taking into account the requirements of the operating manual (instructions). When the hydraulic testing of a vessel is carried out, the relevant requirements of the section "Hydraulic (pneumatic) testing" of Chapter III of these Federal Norms and Rules shall be met. The value of the test pressure is determined on the basis of the permitted pressure for the vessel. The holding time of the vessel under the test pressure (unless other instructions are given in the operating manual) shall be not less than: (a) 10 min - for a wall thickness of up to and including 50 mm; (b) 20 min - for a wall thickness of over 50 and up to and including 100 mm; (c) 30 min - for a wall thickness of over 100 mm.
432. The hydraulic testing of vessels shall be carried out only where there are satisfactory results of their external and internal inspection (visual and measuring inspection) and of other methods of non-destructive testing and investigations provided for by the operating manual (instructions).
433. During the hydraulic testing of vertically installed vessels, the test pressure shall be monitored by a pressure gauge installed on the upper cover (head) of the vessel, and where such installation of the pressure gauge is structurally impossible, the value of the test pressure shall be determined taking into account the hydrostatic pressure of the water depending on the level at which the pressure gauge is installed.
444. In cases where hydraulic testing cannot be carried out (large loads from the weight of the water on the foundation, the inter-floor ceilings or on the vessel itself; difficulty of removing the water; the presence of lining inside the vessel), it may be replaced with pneumatic testing in accordance with the requirements of the section "Hydraulic (pneumatic) testing" of Chapter III of these Federal Norms and Rules.
445. Vessels operating under the pressure of media classified in the 1st group according to TR CU 032/2013 shall be subjected to a tightness test with air or inert gas at a pressure equal to the working pressure. The tests shall be carried out in accordance with the instruction approved by the operating organisation, before start-up, after the completion of the technical examination and other work provided for by the instruction.
446. Steam and hot water pipelines, during the technical examination (primary, periodic and extraordinary), shall be subjected to: (a) external inspection and hydraulic testing - before the start-up of a newly installed pipeline, after reconstruction and repair of a pipeline involving welding and heat treatment, and also before the start-up of a pipeline after it has been in a state of preservation for more than two years; (b) external inspection - at the frequency established in this section of the Federal Norms and Rules. During the technical examination of pipelines, methods of non-destructive testing may also be used.
447. The primary, periodic (within the periods established in paragraph 448 of the Federal Norms and Rules) and extraordinary technical examination of steam and hot water pipelines subject to registration with the territorial bodies of Rostechnadzor or with other federal executive authorities in the field of industrial safety (in respect of pipelines of organisations subject to their supervision) is carried out by the authorised specialised organisation.
448. The periodic examination of steam and hot water pipelines subject to registration with the territorial bodies of Rostechnadzor or other federal executive authorities authorised in the field of industrial safety (in respect of organisations subject to their supervision) is carried out by: (a) the authorised specialised organisation at least once every three years, unless other periods are established in the operating manual (instructions); (b) the person responsible for the sound condition and safe operation of the equipment jointly with the person responsible for production control over the safe operation of the equipment, by inspecting the pipeline before the start and after the completion of scheduled repair, but at least once every 12 months (unless other instructions on the timing are given in the operating manual (instructions)), and also if the nature and scope of the repair do not give rise to the need for an extraordinary examination. Where the design of the pipelines of heat networks provides for the presence of a system of operational remote monitoring (ORM) of their condition during operation, the frequency of their technical examination by a specialised organisation may be increased for a period of no more than 5 years, provided that the ORM system is maintained in sound condition and the technical examination is carried out by specialists of the operating organisation in accordance with the requirements of sub-clause "b" of this paragraph of the Federal Norms and Rules.
449. The technical examination of pipelines not subject to registration with the bodies of Rostechnadzor or with other federal executive authorities in the field of industrial safety is carried out by the person responsible for the sound condition and safe operation of the pipelines. The need for the participation of the person responsible for production control over the safe operation of the equipment is determined by the administrative documents of the operating organisation.
450. The technical examination (primary, periodic, extraordinary) of pipelines is carried out in accordance with the requirements of the design and process documentation and the operating manual (instructions).
451. During the technical examination of pipelines, attention shall be paid to the sections operating under particularly difficult conditions, where the maximum wear of the pipeline is most likely due to corrosion, erosion, vibration and other causes. Such sections include those where the direction of flow changes (bends, tees, tie-ins, drainage devices, as well as pipeline sections before and after fittings) and where an accumulation of moisture or of substances causing corrosion is possible (dead-end and temporarily idle sections).
452. The external inspection in the cold state and the hydraulic testing of a pipeline during the primary technical examination are carried out before the application of thermal insulation to the sections where welded and detachable joints are located, and during an extraordinary examination (after repair involving welding) before the application of insulation to the sections subjected to repair. The procedure for carrying out non-destructive testing, inspection and hydraulic testing of pipelines assembled from pipes and other assembly elements supplied by the manufacturer with thermal insulation applied to them, the material properties of which require the sealing of the welded joint zone after it is made, is determined in accordance with the instructions of the design (engineering) and process documentation and of the manufacturer in the operating manual (instructions).
453. The external inspection of pipelines is carried out in two stages, in the cold and hot states, to check the absence of pinching of the pipeline that impedes movement during thermal expansion: during the technical examination in the cases specified in sub-clause "a" of paragraph 446 of these Federal Norms and Rules; during operation after the repair (adjustment) of the elements of the support-and-suspension system of the pipeline and before each start-up from the cold state in the manner established by the production instruction.
454. The external inspection of pipelines laid by the open method or in walk-through and semi-walk-through ducts may be carried out without removing the insulation; however, if the person carrying out the inspection has doubts about the condition of the walls or welds of the pipeline, the person carrying out the inspection may require partial or complete removal of the insulation. The external inspection of pipelines laid in non-walk-through ducts or by ductless laying is carried out by excavating the soil of individual sections and removing the insulation at least every two kilometres of the pipeline, unless otherwise provided in the design documentation and the operating manual (instructions) of the pipeline.
455. When the hydraulic testing of a pipeline is carried out, the relevant requirements of the section "Hydraulic (pneumatic) testing" of Chapter III of the Federal Norms and Rules shall be met, taking into account the requirements of paragraphs 456 - 460 of the Federal Norms and Rules.
456. Steam bypass pipelines within turbines and steam extraction pipelines from the turbine to the gate valve are not subjected to hydraulic testing, provided that their condition is assessed using at least two methods of non-destructive testing to the extent established in the operating manual (instructions).
457. Vessels which are an integral part of a pipeline (having no shut-off devices - not capable of being disconnected from the medium) are tested at the same pressure as the pipelines.
458. For the duration of the hydraulic testing, instead of measuring and other devices, the loading of which with the test pressure shall not be permitted according to the instructions of the technical documentation, transition spools are installed, the material and strength of which correspond to the characteristics of the pipeline.
459. For testing pipelines located at a height of over 3 metres from ground (floor) level and from stationary platforms, scaffolding, staging, other devices and equipment ensuring the possibility of safe inspection of the pipeline shall be used.
460. The hydraulic test may be replaced by two types of testing (radiographic and ultrasonic) in cases of quality control of the connecting welded joint of a pipeline with a pipeline of an operating main line, with pipelines within a boiler or other process equipment (if there is only one shut-off gate valve between them), and also in the control of no more than two permanent welded joints made during repair.
461. During the operation of hazardous production facilities at which pressure equipment is used, in accordance with the requirements of the legislation of the Russian Federation in the field of industrial safety, the conduct of the industrial safety expert examination of the documentation, buildings and structures of the hazardous production facility and the pressure equipment, as well as of the testing, technical diagnostics and technical examinations of pressure equipment in the cases provided for by the regulatory legal acts of the Russian Federation, shall be ensured.
462. When the industrial safety expert examination is carried out, compliance shall be ensured with the mandatory requirements for the procedure for conducting the industrial safety expert examination, for the drawing up of the expert examination conclusion and for experts in the field of industrial safety, established by the provisions of the federal norms and rules in the field of industrial safety "Rules for Conducting Industrial Safety Expert Examination" (hereinafter - the FNP EPB), approved by Order No. 420 of the Federal Environmental, Industrial and Nuclear Supervision Service of 20 October 2020 (registered by the Ministry of Justice of the Russian Federation on 11 December 2020, registration No. 61391).
463. Technical diagnostics with non-destructive and destructive testing (where necessary) of pressure equipment during its operation within the service life (resource) established by the manufacturer shall be carried out: (a) during the technical examination in the cases established by the operating manual of the pressure equipment, and also by decision of a specialist of the operating or specialised organisation performing the technical examination, to clarify the nature and dimensions of defects identified as a result of visual testing; (b) during operational control of the metal or other material of the pressure equipment or of its individual elements in the cases established for the relevant equipment by the operating manuals (instructions), and, in the case of heat power equipment (boilers and pipelines), also in accordance with the federal norms and rules in the field of industrial safety determining the procedure for carrying out operational control of the metal and extending the service life of the main elements of boilers and pipelines of thermal power stations; (c) to establish the causes of an incident that occurred with the equipment as a result of defects formed during its operation, to determine the nature, dimensions and causes of their occurrence. Technical diagnostics of pressure equipment (within its service life) is performed by employees of the specialised subdivision (laboratory) of the operating organisation (where available) or of a specialised organisation, equipped with equipment for non-destructive and/or destructive testing, and by employees of the appropriate qualification.
464. Based on the results of the non-destructive and destructive testing performed during the technical diagnostics of pressure equipment (within its service life), primary documents (protocols, reports, conclusions) are drawn up (for each testing method) in the manner established by the administrative documents of the specialised organisation, which are signed by the specialists who performed the specified work. On the basis of the primary documents, a report (technical report) on the technical diagnostics and the non-destructive and destructive testing is drawn up, with the documents on non-destructive and destructive testing attached to it. The report (technical report) on the technical diagnostics and the non-destructive and destructive testing is signed by the head of the organisation that carried them out and is attached to the passport of the pressure equipment. Information on the results and reasons for the technical diagnostics and the non-destructive and destructive testing is recorded in the passport of the equipment by the authorised representative of the organisation that carried them out, or by a specialist of the operating organisation responsible for the sound condition and safe operation of the equipment. 465 Technical diagnostics performed within the scope of the industrial safety expert examination to establish the actual condition of the equipment as at the date of its performance, carried out by an organisation holding a licence to conduct industrial safety expert examination of technical devices used at hazardous production facilities, shall be performed in the cases established by paragraph 23 of the FNP EPB, and also in other cases determined by the head of the organisation conducting the expert examination, in agreement with the operating organisation.
466. The conduct of technical diagnostics in the cases specified in paragraphs 463 and 465 of the Federal Norms and Rules, for equipment installed in an open area outside a building, shall be planned for a period at positive ambient air temperatures. In cases of restorative repair after an accident at a hazardous production facility of pipelines of heat networks under conditions of negative ambient air temperatures, immediately after the completion of the repair, non-destructive testing of the quality of the work performed is carried out in the manner established by Chapter III of the Federal Norms and Rules, with the subsequent conduct of an industrial safety expert examination (technical diagnostics) during a period of positive ambient air temperatures.
467. The industrial safety expert examination of pressure equipment, the requirements for which are not established by TR CU 032/2013 and other technical regulations, before the start of its use at a hazardous production facility shall include: (a) analysis of the design (engineering), technical and process documentation containing information on the purpose, design and technical characteristics of the equipment, on the materials used in its manufacture, on the scope, methods and results of the non-destructive and destructive testing and tests of the equipment carried out during manufacture; (b) external and internal inspection, visual and measuring inspection of the equipment and its elements to determine their compliance with the documentation submitted; (c) non-destructive and, where necessary, destructive testing carried out to provide indirect confirmation of the testing results indicated in the documentation of the manufacturer, selectively to the extent established by the expert organisation on the basis of the analysis of the documentation submitted, the inspection and the measurements. When testing is carried out, methods from among those listed in Chapter III of these Federal Norms and Rules shall be used, as well as other methods analogous to those applied by the manufacturer, and also spectral analysis of the metal of the main elements (where it is necessary to verify the reliability of information on the grade of the material used); (d) assessment of the sufficiency and results of the calculations of equipment of foreign manufacture in relation to the methods used in the Russian Federation for calculating analogous equipment and the strength margins established therein, with verification calculations carried out (where necessary); (e) hydraulic or pneumatic testing at test pressure, if this test was not carried out by the manufacturer of the equipment (there is no information on its performance) or the value of the test pressure and/or the holding time under it adopted by the manufacturer are less than the corresponding values provided for in Chapter III of these Federal Norms and Rules; (f) assessment of the compliance of the equipment with the requirements of the regulatory documents based on the results of the work carried out within the framework of the expert examination, with a determination of the possibility of its safe operation under the parameters and conditions indicated in the technical documentation.
468. When the industrial safety expert examination of pressure equipment is carried out, the work specified in paragraph 24 of the FNP EPB is performed, and the technical diagnostics carried out in this connection includes the activities provided for by paragraph 25 of the FNP EPB. The scope of the work carried out and of the testing methods applied is determined depending on the specific type of equipment subjected to technical diagnostics, on the case that gave rise to the need for the industrial safety expert examination, taking into account the instructions of the technical documentation of the manufacturer and the standard diagnostic procedures for analogous types of equipment (where available), and is refined in the course of the work on the basis of the analysis of the documentation relating to the equipment. In this case, in addition to the analysis of the documentation, for pressure equipment the following are mandatory: visual and measuring inspection, the application of non-destructive testing methods, the investigation of the structure and properties of the metal for equipment operating under creep conditions, the performance of calculation procedures, and hydraulic or pneumatic testing at test pressure in accordance with the requirements established in Chapter III of these Federal Norms and Rules.
469. Hydraulic or pneumatic testing at test pressure is permitted where there are positive results of the technical diagnostics and positive results of the strength calculation. Where inadmissible defects have been identified, a change in the characteristics of the material of the equipment elements that are under the action of excess pressure during its operation has been established, and also where the strength of the equipment has not been confirmed by the results of the calculation, its testing at test pressure shall not be permitted.
470. Within the service life (resource) established by the manufacturer or by the expert organisation based on the results of the industrial safety expert examination, for pressure equipment whose design contains elements operating under conditions of metal creep, element-by-element technical diagnostics, that is, by groups of elements of the same type (by product range, steel grade and operating parameters), is permitted to extend their resource. The results of such diagnostics shall be drawn up in the form of a technical conclusion (technical report), in which an assessment of the technical condition of the diagnosed elements shall be given and the conditions and periods for extending their operation are substantiated. The primary documents on non-destructive and destructive testing shall be attached to the conclusion (report), and it shall be signed by the head of the organisation that carried out the diagnostic work.
471. Based on the results of the technical diagnostics and the determination of the residual resource (service life) of the equipment, carried out within the scope of the industrial safety expert examination in accordance with the FNP EPB, an industrial safety expert examination conclusion is drawn up, containing conclusions on the compliance of the object of the expert examination with the requirements of industrial safety and on the possibility of extending the period of safe operation, establishing: (a) the period of further safe operation of the equipment; (b) the conditions of further safe operation of the equipment, including the permitted parameters and operating modes, as well as the scope, methods and frequency of the technical examination and element-by-element technical diagnostics in the cases established by these Federal Norms and Rules.
472. Information on the results of the industrial safety expert examination is recorded in the passport of the equipment by the authorised representative of the organisation that carried it out or by a specialist of the operating organisation and shall contain: the name of the organisation that carried out the industrial safety expert examination; the date of signing of the industrial safety expert examination conclusion; the registration number in the register of industrial safety expert examination conclusions; the finding of the industrial safety expert examination conclusion.
473. The use of heat carriers other than those specified in the boiler passport shall be agreed with the boiler manufacturer.
474. Outside the boiler room, a special tank shall be installed for draining the heat carrier from the system and the boilers. The drain lines shall ensure the unimpeded draining of the heat carrier by gravity and its complete removal from the boiler.
475. To ensure excess pressure that precludes the possibility of the heat carrier boiling in the boiler and at the highest point of the external circulation system, pressurisation of the heat carrier with inert gas or the installation of an expansion vessel at the required height shall be used.
476. The fittings shall be selected depending on the operating parameters and properties of the heat carrier. The fittings used on boilers shall be connected to the branch pipes and pipelines by welding. In this case, bellows-type fittings shall be used. The use of gland-packed fittings for a pressure of no more than 1.6 MPa is permitted. Shut-off fittings installed on boilers on the inlet and outlet sides of the heat carrier shall either be located in a place that is easily accessible and safe for servicing, or be controlled remotely. Flanged joints, fittings and pumps shall not be installed near inspection openings, manholes, pressure relief devices and ventilation openings of furnaces and gas ducts. On the drain line of the heat carrier in the immediate vicinity of the boiler (at a distance of no more than 1 metre), two shut-off devices shall be installed in series.
477. The elements of the level indicator that come into contact with the heat carrier, in particular its transparent element, shall be made of non-combustible materials resistant to the action of the heat carrier at the operating temperature and pressure. In direct-acting liquid level indicators, the internal diameter of the fittings serving to disconnect the level indicator from the boiler shall be not less than 8 mm. The bore of the shut-off fittings shall be not less than the bore of the openings in the body of the level indicator. The installation of test cocks or valves instead of liquid level indicators in a steam boiler shall not be permitted.
478. On a liquid boiler, pressure gauges shall be installed at the inlet to the boiler and at the outlet from it.
479. On the pipeline conveying steam or heated liquid away from the boiler, immediately at the boiler before the shut-off device, temperature-indicating and temperature-recording instruments shall be installed, and on the supply pipeline - an instrument indicating temperature.
480. At least two safety valves shall be installed on each boiler. The total throughput capacity of the safety valves installed on a liquid boiler shall be sufficient to discharge the increase in volume of the expanded heat carrier at the boiler's rated heat output. The use of lever-and-weight safety valves shall not be permitted. Only fully enclosed-type safety valves may be used. The nominal diameter of a safety valve shall be not less than 25 mm and not more than 150 mm. Safety devices may be installed on an expansion vessel that is not shut off from the boiler. A three-way valve or another device that precludes the possibility of simultaneously shutting off all safety valves may be installed between the boiler (vessel) and the safety valves. When one or more safety valves are shut off, the remaining ones shall provide the required throughput capacity. The total throughput capacity of the safety valves installed on the expansion vessel shall be not less than the mass flow of inert gas entering the vessel in an emergency. The discharge from the safety valves of steam or of liquid heated to boiling temperature or above shall be effected through condensation devices connected to the atmosphere, the back pressure not exceeding 0.03 MPa. The shut-off and supply pipelines shall have heating devices to prevent solidification of the heat carrier.
481. Liquid boilers and heating systems shall have expansion vessels or a free volume to receive the heat carrier that has expanded upon heating. The geometric volume of the expansion vessel shall be not less than 1.3 times greater than the increase in volume of the liquid heat carrier contained in the boiler and the installation when it is heated to the operating temperature. The expansion vessel shall be placed at the highest point of the installation. The expansion vessel shall be fitted with a liquid level indicator, a pressure gauge and a safety device against pressure rising above the permissible value.
482. Boilers shall be equipped with process protections that shut off heating in the following cases: (a) a drop in the heat carrier level below the lowest permissible level; (b) a rise in the heat carrier level above the highest permissible level; (c) an increase in the heat carrier temperature above the value specified in the design; (d) an increase in the heat carrier pressure above the value specified in the design; (e) a drop in the heat carrier level in the expansion vessel below the permissible value; (f) reaching the minimum value of the heat carrier flow rate through the liquid boiler and the minimum steam output (heat output) of the steam boiler specified in the data sheet; (g) an impermissible rise or fall of the gaseous fuel pressure before the burners; (h) an impermissible fall of the liquid fuel pressure before the burners, except for rotary burners; (i) an impermissible reduction of the draught in the furnace; (j) an impermissible fall of the air pressure before forced-air-supply burners; (k) extinction of the burner flames. When the maximum permissible parameters of the boiler are reached, audible and visual alarms shall be activated automatically.
483. For each steam boiler with an individual feed arrangement, at least two feed pumps shall be installed, of which one is the working pump and the other the standby pump. The electrical supply of the pumps shall be from two independent sources. With a group feed arrangement, the number of feed pumps is selected so that, if the most powerful pump stops, the total delivery of the remaining pumps is not less than 110 per cent of the rated steam output of all working boilers. For steam boilers into which condensate returns by gravity, the installation of feed pumps is not mandatory. For liquid boilers, at least two circulation pumps with an electric drive shall be installed, of which one shall be the standby pump. The delivery and head of the circulation pumps shall be selected so that the required circulation rate of the heat carrier in the boiler is ensured. Liquid boilers shall be equipped with a recirculation line with an automatic device that maintains a constant flow rate of the heat carrier through the boilers upon partial or full disconnection of the consumer. Steam boilers with forced supply of the heat carrier and liquid boilers shall be equipped with automatic devices that stop the fuel supply upon a power failure, and, where there are two independent supply sources for the pump motors, with a device that switches from one supply source to the other. To make up for losses of the heat carrier circulating in the system, a device to ensure make-up of the system shall be provided.
484. Steam and liquid boilers shall be installed in free-standing boiler houses or on open sites. Where boilers are installed on open sites, measures precluding the possibility of the heat carrier cooling down are mandatory. In the room for the boilers, in the zone where the pipelines and vessels containing the heat carrier are located, a temperature at which solidification of the heat carrier is precluded shall be maintained. A service tank with liquid heat carrier for periodic make-up of the boilers and regeneration of the heat carrier may be installed in the boiler room. The tanks shall be provided with heating. The placement of tanks above the boilers shall not be permitted. Depending on the duration of operation, the temperature conditions, the specific thermal loads of the heating surfaces and the operating conditions, the heat carriers shall be subjected to periodic regeneration. The duration of boiler operation between regenerations and the methodology for determining the degree of decomposition of the heat carrier are established by a production instruction. The content of decomposition products in the heat carrier shall not exceed 10 per cent. For each boiler, a schedule for technical inspection of the heating surfaces and a schedule for cleaning the heating surfaces of deposits shall be established. Technical inspection and cleaning of the heating surfaces shall be carried out systematically, but not less frequently than every 8000 hours of boiler operation, with an entry in the repair log.
485. The use of soda recovery boilers (hereinafter - SRB) at operating parameters (pressure above 4 MPa and superheated steam temperature above 440 degrees C) may be permitted where special measures to prevent high-temperature corrosion of the heating surfaces are ensured. The SRB shall provide for the combustion of liquors and of auxiliary fuel - fuel oil or natural gas. The number and delivery of feed devices for an SRB shall be selected as for boilers with the layer combustion method. In this case, the capacity of the standby pumps (with a steam drive or an electric drive from an independent source) shall be selected according to the conditions of normal cooling of the SRB upon an emergency shutdown of the electrically driven pumps. A standby cooling system for the smelt spouts (a standby pump, service water intermediate tanks) shall also be provided.
486. SRBs shall be installed in a separate building, and the control panel - in a room separate from the boiler shop, having an exit other than through the SRB room. The arrangement of an SRB in a single common block together with power, hot-water and heat-recovery boilers, as well as with the liquor evaporation and oxidation units inseparably connected with the SRB, is permitted.
487. The arrangement of the auxiliary equipment and pipelines shall preclude the possibility of water entering the furnace.
488. During operation of the SRB, the operable condition of the smelt spout cooling system using chemically treated deaerated water shall be ensured.
489. The operating organisation shall establish a system for monitoring the condition of the metal and of the welded joints of the SRB components which, depending on the stage of the life cycle, provides for: (a) incoming, in-process and acceptance inspection during erection, repair and reconstruction; (b) technical diagnostics and monitoring within the design service life (service resource); (c) inspection upon reaching the design or assigned service life. The procedure, scope and frequency of the work are determined by the production and process instructions approved within the operating organisation, developed with regard to the requirements of the operation manuals (instructions) and the actual condition of the equipment.
490. During erection, repair and reconstruction, all welded butt joints of the furnace chamber shall be subjected to continuous radiographic inspection.
491. Operation of the SRB on liquors with a dry-solids content in the black liquor before the nozzles of less than 55 per cent shall not be permitted.
492. The SRB shall be switched to the combustion of auxiliary fuel in the following cases: (a) the arising of a hazard of water or diluted liquor entering the furnace; (b) failure of half of the smelt spouts; (c) cessation of the water supply for cooling the spouts; (d) failure of all green-liquor transfer pumps; (e) failure of all transfer pumps, or of one of the induced-draught fans, or of one of the fans.
493. The SRB shall be immediately stopped and shut down by the action of the protections or by the personnel in the event of: (a) water entering the furnace; (b) loss of voltage at the remote and automatic control devices and at all instrumentation; (c) a leak of smelt other than through the spouts or through leaks in the furnace and the impossibility of eliminating it; (d) cessation of operation of the devices for breaking up the smelt jet and stopping of the agitators in the smelt dissolving tank; (e) failure of all induced-draught fans and fans; (f) failure of all smelt spouts; (g) in other cases provided for by the operation manual (instruction) and the production instruction.
494. Fire-tube boilers shall be equipped with automatic protections that stop their operation when the parameters established by the production instructions are exceeded. When the maximum permissible parameters of the fire-tube boiler are reached, audible and visual alarms shall be activated automatically.
495. A steam fire-tube boiler shall be shut down in the following cases: (a) an impermissible increase in the steam pressure; (b) an impermissible drop in the water level; (c) an impermissible rise in the water level; (d) an impermissible increase or decrease in the gaseous fuel pressure before the burner; (e) an impermissible decrease in the liquid fuel pressure before the burner; (f) an impermissible decrease in the air pressure before the burner; (g) an impermissible decrease in the draught in the furnace (for boilers operating under draught); (h) extinction of the burner flame; (i) cessation of the electricity supply to the boiler house.
496. A hot-water fire-tube boiler shall be shut down in the following cases: (a) an impermissible increase or decrease in the water pressure at the boiler outlet; (b) an impermissible increase in the water temperature at the boiler outlet; (c) an impermissible decrease in the water flow rate through the boiler; (d) an impermissible increase or decrease in the gaseous fuel pressure before the burner; (e) an impermissible decrease in the liquid fuel pressure before the burner; (f) an impermissible decrease in the air pressure before the burner; (g) an impermissible decrease in the draught in the furnace (for boilers operating under draught); (h) extinction of the burner flame; (i) cessation of the electricity supply to the boiler house.
497. As safety devices during the operation of electric boilers, alongside direct-acting safety valves (lever-and-weight, spring-loaded), safety devices with rupturing membranes (membrane safety devices) may also be used.
498. Membrane safety devices are installed: (a) instead of lever-and-weight and spring-loaded safety valves, where such valves cannot be used, for example, because of their inertia; (b) in parallel with safety valves to increase the throughput capacity of the pressure-relief system.
499. On boilers with an electrical power of more than 6 MW, the installation of a recording pressure gauge or of other types of measuring instruments recording the water pressure at the points determined by the design is mandatory.
500. Each boiler shall be equipped with the necessary switching apparatus, and also with automatic control, monitoring, protection and alarm devices structurally arranged as a remote or built-in control panel. The current of each boiler shall be measured in each of the three phases. Where protection against phase imbalance is provided, the current may be measured in one phase.
501. Electric boiler houses with electric boilers shall be equipped with means for determining the specific electrical resistivity of the feed (network) water. In boiler houses with hot-water electric boilers with a total electrical power of more than 1 MW, recording instruments for measuring the water temperature shall be installed at the points determined by the design.
502. Each steam boiler with resistance electric heating elements shall be provided with automatic disconnection of the power supply when the water level falls below the maximum permissible position.
503. Each boiler shall be provided with electrical and process protections ensuring timely automatic shutdown of the boiler in the event of impermissible deviations from the specified operating modes. The types and values of the protection set-points are determined by the organisation that developed the boiler design.
504. Electrode boilers with a voltage above 1 kV and an earthed or earth-insulated casing shall have protective devices that shut down the boiler in the following cases: (a) multi-phase short circuits in the line supplying the boiler, at its inputs and inside it (the protective devices shall operate without time delay); (b) single-phase earth faults in the line, at the inputs and inside the boiler (the protective devices shall operate without time delay for boilers with an earthed casing and on a signal - for boilers with an earth-insulated casing); (c) current overload above the rated value (the protective devices shall operate with a time delay); (d) a rise in the pressure in the boiler above the design value (the protective devices shall operate without time delay); (e) a rise in the temperature of the outgoing water above the maximum specified in the boiler data sheet (the protective devices shall operate with a time delay); (f) a fall in the pressure in the hot-water boiler below the minimum operating value; (g) reaching the minimum permissible water flow rate (upon a decrease in or cessation of the water flow through the boiler); (h) a fall in the water level in the steam boiler to the minimum permissible (the protective devices shall operate without time delay); (i) an impermissible rise in the water level in the steam boiler.
505. Boilers with a voltage up to 1 kV shall have protective devices ensuring shutdown of the boiler in the following cases: (a) multi-phase short circuits in the line supplying the boiler, at the inputs and inside the boiler (the protective devices shall operate without time delay); (b) single-phase earth faults in the line supplying the boiler, at the inputs and inside the boiler (the protective devices for boilers with an earthed casing shall operate without time delay, and the protective devices for boilers with an earth-insulated casing shall operate on a signal); (c) current overload above the rated value (the protective devices shall operate with a time delay). Protective devices are not required for boilers with resistance electric heating elements; (d) a rise in the temperature of the outgoing water above the maximum specified in the boiler data sheet (the protective devices shall operate with a time delay); (e) an impermissible rise in the water level in the steam boiler (the protective devices shall disconnect the water and electricity supply to the boiler); (f) load current asymmetry above 25 per cent of the rated current of the boiler (the protective devices shall operate with a time delay). Protective devices are not required for boilers with resistance electric heating elements; (g) stopping of the circulation (network) pumps (the protective devices shall operate with a time delay); (h) an impermissible fall in the water level in the steam boiler.
506. In boiler houses with electrode boilers of a voltage above 1 kV with an earthed casing, protection against single-phase earth fault shall be provided on the sections supplying the boilers, or in the transformer winding, operating with a time delay to disconnect the section circuit-breaker or to disconnect all boilers supplied from that transformer, observing the time selectivity steps. Boilers with a voltage up to 1 kV shall have residual-current devices preventing electric shock to persons.
507. In boiler houses with electrode boilers of a voltage above 1 kV with an insulated casing, protection shall be provided: (a) against single-phase earth faults on the sections supplying the boilers, or in the transformer winding (the protection shall operate on a signal). If such protection is made directional, then a zero-sequence current protection with action to disconnect the boiler without time delay shall also be provided. This protection is intended for cases of an earth fault outside the given boiler under conditions of a breakdown of the insulation of its casing. The arrangement of the protection shall ensure its selectivity in the event of an earth fault outside the given boiler while the insulation of its casing is intact; (b) an excess of the leakage current - the protection shall operate with a time delay of not more than 0.5 seconds to disconnect all electrode boilers of the given installation in the event that the total current flowing through the insulating inserts of the electrode boilers exceeds 20 A. If several electric boiler houses are supplied from one electrically connected section of the network, then for each electric boiler house the operating current of the protection is calculated taking into account the total permissible current flowing through the insulating inserts of the electrode boilers of the given electric boiler house in the event of a single-phase earth fault in the network. , (8) where Uph - the phase voltage of the supply network; Iperm - the total permissible current through the insulating inserts in the event of a single-phase earth fault; - the resistance of all insulating inserts of the electrode boilers of the given electric boiler house. The total operating current of the protections of the individual electric boiler houses shall be 20 A. It is permitted to provide only one earth-fault protection, operating without time delay to disconnect all electrode boilers of the given installation in the event of a single-phase earth fault in the network supplying them. In this case, earth-fault protection is not provided on each electrode boiler.
508. In boiler houses with electrode boilers of a voltage up to 1 kV with an insulated casing, protection shall be provided that acts to disconnect all boilers from a current-leakage relay. The conductivity of the water columns located inside the insulating inserts on the pipelines shall not cause the current-leakage relay to operate.
509. Each protection shall have devices signalling its operation.
510. After the erection or major overhaul of an electrode boiler, the operation of the power regulator shall be checked for ease and smoothness of travel, the limit switches shall be adjusted, and the automatic stops of the boiler power regulator at the extreme positions under remote control shall be checked.
511. After erection, major overhaul, routine repair or during preventive tests not associated with taking the electrical equipment out for repair, electrical tests of the electrical equipment of electric boilers shall be carried out in accordance with the standards specified in Appendix No. 11 to these Federal Norms and Rules.
512. The periods between descaling of the boiler, as well as between replacements of the electrodes or the electric heating elements owing to impermissible scale deposits on them, shall coincide with the scheduled inspections of the boiler.
513. The boiler shall operate on water having a specific electrical resistivity within the limits specified in the data sheet.
514. The frequency of measurement of the specific electrical resistivity of the water entering the boiler shall comply with the requirements of Appendix No. 11 to these Federal Norms and Rules. In the event of a sharp change in the power of the boilers (by 20 per cent or more from the normal), an extraordinary determination of the specific resistivity of the water is carried out.
515. The required value of the specific electrical resistivity of the boiler water during operation of the steam boiler shall be maintained by means of continuous and periodic blowdowns. The continuous blowdown of the boilers shall be automated.
516. The design of the water-treatment plant shall provide for the possibility of adding to the water entering the boiler readily soluble salts that do not increase the scale-forming ability and corrosive activity of the boiler water, steam and condensate, to reduce the specific electrical resistivity of the water to the standardised values. The choice of the salt and its concentration shall be made on the basis of calculation and experimental verification, taking into account the technical characteristics of the boiler, the heat-consuming systems and the equipment forming part of them. The reduction of the specific electrical resistivity of the water by introducing readily soluble salts into the feed water and boiler water is applied for: (a) hot-water boilers with a voltage up to 1 kV operating on a closed heat-supply scheme (without water intake); (b) steam boilers at their start-up to accelerate the build-up and maintenance of the power.
517. Tanks filled with liquid ammonia at a temperature not exceeding minus 25 degrees C at the moment of completion of filling shall have thermal insulation or shade protection. The thermal insulation casing of a tank for cryogenic liquids shall be provided with a serviceable bursting membrane.
518. In the upper part of railway tanks, the presence of a serviceable platform near the manhole with metal ladders on both sides of the tank, provided with handrails, shall be ensured. On railway tanks for liquefied oxygen, nitrogen and other cryogenic liquids, it is permitted not to install a platform near the manhole.
519. During operation, tanks shall be equipped with serviceable: (a) valves with siphon tubes for draining and filling the medium; (b) a valve for releasing vapours from the upper part of the tank; (c) a spring-loaded safety valve; (d) a fitting for connecting a pressure gauge; (e) a liquid level indicator.
520. A safety valve installed on a tank shall communicate with the gas phase of the tank and have a cap with openings for releasing gas in the event of the valve opening. The area of the openings in the cap shall be not less than one and a half times the working cross-sectional area of the safety valve.
521. Each filling and drain valve of a tank and barrel for liquefied gas shall be provided with a blanking plug.
522. During operation, on each barrel, except barrels for chlorine and phosgene, the presence and serviceability of a valve for filling and draining the medium installed on one of the ends shall be ensured. Where the valve is installed on the concave end of the barrel, it shall be covered by a cap, and where it is installed on the convex end, in addition to the cap, the serviceability of the encircling band (skirt) shall be ensured. For barrels for chlorine and phosgene, the presence and serviceability of filling and drain valves with siphons shall be ensured.
523. Tanks intended for the transport of media classified in group 1 in accordance with TR CU 032/2013 shall have on the siphon tubes for draining an excess-flow valve that precludes the escape of gas in the event of rupture of the pipeline.
524. The throughput capacity of the safety valves installed on tanks for liquefied oxygen, nitrogen and other cryogenic liquids shall be determined as the sum of the design evaporation rate of the liquids and the maximum capacity of the device for creating pressure in the tank during its emptying. The design evaporation rate is taken as the quantity of liquid oxygen or nitrogen (cryogenic liquid) in kilograms that may evaporate within one hour under the action of the heat received by the tank from the surrounding environment at an outdoor air temperature of 50 degrees C. The maximum capacity of the device for creating pressure in the tank during its emptying is taken as the quantity of gas in kilograms that may be introduced into the tank within one hour when the evaporator or other pressure source operates at full load.
525. Organisations carrying out filling and filling stations shall keep a filling log in the form established by the organisation (filling station), in which, in particular, the following shall be indicated: (a) the date of filling; (b) the name of the manufacturing organisation of the tank and barrels; (c) the works and registration numbers for tanks and the works number for barrels; (d) the signature of the person who carried out the filling. Where the filling station fills tanks and barrels with different gases, a separate filling log is kept for each gas.
526. Tanks and barrels may be filled only with the gas for the transport and storage of which they are intended.
527. Before filling tanks and barrels with gases, the responsible person shall carry out a thorough inspection of the outer surface, shall check the serviceability and tightness of the fittings, the presence of residual pressure and the correspondence of the gas contained in them to the intended purpose of the tank or barrel. The results of the inspection of the tanks and barrels and the conclusion on the possibility of filling them shall be recorded in a log.
528. It shall be prohibited to fill defective tanks or barrels with gas, and also if: (a) the data-sheet data applied by the manufacturing organisation are absent; (b) the period of the assigned examination has expired; (c) the fittings and instrumentation are absent or defective; (d) the proper painting or markings are absent; (e) the tanks or barrels contain gas other than that for which they are intended.
529. The consumer, when emptying tanks and barrels, shall leave in them an excess gas pressure of not less than 0.05 MPa. For liquefied gases whose vapour pressure in winter time may be less than 0.05 MPa, the residual pressure is established by the production instruction of the organisation carrying out the filling.
530. The filling and emptying of tanks and barrels with gases shall be carried out in accordance with an instruction drawn up and approved in accordance with the established procedure. The filling standards for tanks and barrels are determined by their manufacturer. In the absence of such information, the filling standards are determined in accordance with Appendix No. 12 to these Federal Norms and Rules.
531. During storage and transport, filled barrels shall be protected from the action of the sun's rays and from local heating.
532. The amount of filling of tanks and barrels with liquefied gases shall be determined by weighing or by another reliable method of control established by the operation manual and the process documentation of the filling organisation.
533. If a gas leak is detected during the filling of tanks or barrels, the filling shall be stopped and the gas removed from the tank or barrel; the filling may be resumed only after the existing damage has been rectified. After filling tanks or barrels with gas, blanking plugs shall be installed on the side fittings of the valves, and the fittings of the tanks shall be closed with a protective cap, which shall be sealed.
534. During the operation of tanks and barrels, the preservation of the following data-sheet data of the manufacturing organisation, applied by stamping (on tanks around the circumference of the manhole flange, on barrels - on the ends), shall be ensured: (a) the name of the manufacturing organisation or its trademark; (b) the number of the tank (barrel); (c) the year of manufacture and the date of examination; (d) the capacity; (e) the mass in the empty state (for tanks without a running gear); (f) the values of the working and test pressures; (g) the stamp of the technical control department; (h) the date of the examination carried out and of the next examination.
535. During the operation of transport tanks, only those facilities of operating organisations at which the storage and use of tanks under gas pressure in the process are carried out, including during loading and unloading operations, shall be subject to registration in the state register of hazardous production facilities (on the basis of the use of equipment operating under excess pressure). The transport of tanks, as well as the carriage of barrels under gas pressure on public roads by road (rail) transport, does not relate to activity in the field of industrial safety and is carried out in accordance with the requirements of other regulatory legal acts and international agreements in force on the territory of the Russian Federation.
536. Degassing (purging) of transport tanks shall be carried out at a hazardous production facility having a system for collecting and utilising the residues of liquefied hydrocarbons, as well as process equipment for carrying out steaming or purging with inert gas, by personnel of the appropriate qualification.
537. The requirements of this Chapter apply to cylinders intended for the storage and transport of gases and do not apply to cylinders permanently installed on a foundation (with the exception of paragraphs 540 and 546 of these Federal Norms and Rules).
538. Cylinders shall be fitted with shut-off fittings (valves) tightly screwed into the openings of the neck or into the discharge-and-filling fittings of special cylinders that do not have a neck.
539. Monoblocks (bundles of cylinders) shall have manifolds connecting their valves or fittings, tightly screwed into the openings of the necks of the cylinders.
540. Cylinders with a capacity of more than 100 litres shall be equipped with safety valves. With a group installation of cylinders, the installation of a safety valve for the entire group of cylinders is permitted. The throughput capacity of the safety valve is confirmed by calculation.
541. The side fittings of valves for cylinders filled with hydrogen and other combustible gases shall have a left-hand thread, and for cylinders filled with oxygen and other non-combustible gases - a right-hand thread.
542. Shut-off valves in cylinders for oxygen shall be screwed in using sealing materials whose ignition in an oxygen environment is precluded.
543. When cylinders are used, the following data shall be present on the spherical part of each cylinder, unless another location is specified in the operating manual (instructions): (a) the information subject to application in accordance with the requirements of TR CU 032/2013, and on cylinders used as a fuel tank for motor vehicles, also in accordance with the requirements of the Technical Regulations of the Customs Union "On the Safety of Wheeled Vehicles" (TR CU 018/2011), approved by Decision of the Customs Union Commission No. 877 of 9 December 2011 (official website of the Customs Union Commission http://www.tsouz.ru/, 15 December 2011), which is binding on the Russian Federation in accordance with the Treaty on the Eurasian Economic Union, ratified by Federal Law No. 279-FZ of 3 October 2014 "On Ratification of the Treaty on the Eurasian Economic Union" (Collection of Legislation of the Russian Federation, 2014, No. 40, Article 5310); (b) the date of the technical examination carried out and of the next technical examination of the cylinder; (c) the stamp of the organisation (individual entrepreneur) that carried out the technical examination. The location and method of applying the marking, depending on the material used in the manufacture of the cylinder, shall be selected in accordance with the instructions of the operating manual (instructions). The mass of cylinders, with the exception of acetylene cylinders, shall be indicated taking into account the mass of the applied paint, the cap ring and the shoe, if these are provided for by the design, but without the mass of the valve and the cap.
544. Cylinders for dissolved acetylene shall be filled with an appropriate quantity of porous mass and solvent. The organisation (individual entrepreneur) filling the cylinder with porous mass is responsible for the quality of the porous mass and for the correctness of the filling of the cylinders. The organisation (individual entrepreneur) carrying out the filling of cylinders with solvent bears responsibility for the quality of the solvent and its correct dosage. After the filling of cylinders for dissolved acetylene with porous mass and solvent, the tare mass (the mass of the cylinder without the cap, but with the porous mass and solvent, the shoe, the ring and the valve) is stamped on its neck.
545. The painting of cylinders and the application of inscriptions during operation is carried out by manufacturers, filling stations (filling points) or testing points (checking points) in accordance with the requirements of TR CU 032/2013. The colour of the painting and the text of the inscriptions for cylinders used in special installations or intended for filling with special-purpose gases, the requirements for the painting and inscriptions of which are not defined by TR CU 032/2013, are established by the design documentation and/or the technical specifications for the product for the storage of which these cylinders are intended, and are indicated in administrative documents.
546. Permanently installed cylinders with a capacity of more than 100 l may be painted in other colours with the application of inscriptions and marking in accordance with the design documentation and the operating manual (instructions).
547. Inscriptions on cylinders are applied around the circumference over a length of not less than 1/3 of the circumference, and the bands over the entire circumference, whereby the height of the letters on cylinders with a capacity of more than 12 litres shall be 60 mm, and the width of the band 25 mm. The dimensions of the inscriptions and bands on cylinders with a capacity of up to 12 litres shall be determined depending on the area of the cylinders' side surface.
548. Where the technical documentation does not contain information on the cylinder's service life determined during its design, the service life shall be established as 20 years. The possibility, conditions and period of operation of special-purpose cylinders whose design is defined by an individual project and does not correspond to standard cylinder designs, upon expiry of the service life established by the manufacturer, and also in the cases established by the operating manual (instructions) for the equipment of which they form part, shall be determined on the basis of the results of an industrial safety expert examination (technical diagnostics). An industrial safety expert examination for the purpose of extending the service life of transportable mass-application cylinders with a capacity of 100 litres or less is not carried out; their operation beyond the assigned service life, provided that the results of the technical examination and diagnostics are satisfactory, may be permitted by the person who carried out the examination, but no longer than until the expiry of the maximum permissible period of time established by the manufacturer or the developer of the design of the specific type of cylinder and specified in the operating manual (instructions) and/or the methodology for carrying out the technical examination (diagnostics). Extension of the operating period of cylinders whose actual service life has exceeded 20 years, installed in the systems of special mobilisation-purpose facilities and their infrastructure facilities, shall be carried out in accordance with the methodology for technical diagnostics of the cylinders installed in the said systems, agreed with Rostechnadzor.
549. The examination (testing) of cylinders is carried out by manufacturers, and also by specialised organisations having filling stations (filling points) and/or testing points (checking points), provided that they have: (a) production premises, in accordance with a project developed by a specialised organisation, and also technical means ensuring the possibility of carrying out the examination of cylinders in full accordance with the methodologies of the developer of the construction design and/or the manufacturer of the specific type of cylinders; (b) persons responsible for carrying out the examination appointed by order, from among specialists certified in accordance with the established procedure, and workers of the appropriate qualification; (c) a stamp with an individual code; (d) a production instruction for carrying out the technical examination of cylinders, establishing the scope and procedure for carrying out the work, drawn up on the basis of the methodologies of the developer of the cylinder construction design.
550. The stamp code is assigned by the territorial body of Rostechnadzor or another federal executive authority empowered in the field of industrial safety (in respect of the organisations subject to its supervision). An organisation planning to carry out activities involving the examination of cylinders submits an application for the assignment of a stamp code, indicating therein information on its organisational and technical readiness for this type of activity in accordance with the requirements of these Federal Norms and Rules, with an indication of the characteristics of the cylinders whose examination the organisation is ready to carry out (the type or make of the cylinders, the capacity of the cylinders, the name and purpose of the gases for which they are intended). In the event of changes to the composition of the equipment, the technological process, the expansion of the types (nomenclature) of cylinders subject to technical examination, in the event of liquidation or reorganisation of a legal (natural) person in the form of transformation, a change of its name or location, or a change of the name or place of residence of the individual entrepreneur, and also in the event of a change of the addresses of the places where the said type of activity is carried out, and also upon expiry of five years from the moment of registration of the stamp code, the organisation shall send the relevant information to the territorial body of Rostechnadzor or another federal executive authority empowered in the field of industrial safety (in respect of the organisations subject to its supervision) for re-registration for the purpose of expanding the area of validity or confirming the currency of the assigned stamp code where there are no changes. The procedure for re-registration of the stamp code is identical to the registration procedure.
551. In organisations carrying out the examination of cylinders, the maintenance of a log of the issue and return of coded stamps to the specialists entrusted with carrying out the examination of cylinders shall be ensured. A coded stamp is issued to a person who has undergone training and certification in industrial safety in accordance with the established procedure and has been appointed by an order (instruction) of the head of the organisation to carry out the examination of cylinders. Stamps of one code are assigned to one person for the entire duration of that person's performance of the examination of cylinders. One-off or temporary transfers of stamps for the stamping of cylinders to other persons without a corresponding order (instruction) of the head of the organisation (individual entrepreneur) shall not be permitted. The procedure ensuring the safekeeping of the stamps and of the log of the issue and return of coded stamps is determined by an order of the head of the organisation (individual entrepreneur).
552. Upon cessation by an organisation (individual entrepreneur) of the examination of cylinders, the remaining coded stamps are destroyed by the organisation (individual entrepreneur) under a report, one copy of which is submitted to the territorial body of Rostechnadzor that assigned the stamp code or another federal executive authority empowered in the field of industrial safety (in respect of the organisations subject to its supervision),
553. Stamp codes shall consist of a numerical part - Arabic numerals in the form of numbers from 01 to 98 - and an alphabetical part using capital letters of the Russian alphabet (except the letters "Z", "E", "I", "O", "Kh", "Ch", the hard sign, "Y", the soft sign), and also the capital letters of the Latin alphabet "F", "L", "N", "R", "S", "U", "V", "W", "Z". A stamp code has three characters of the same size (6 mm high), arranged in a row within a circle 12 mm in diameter, and consists of two digits (the numerical part of the code) and one capital letter (the alphabetical part of the code). The inclusion in the code of any other characters (including dashes, dots), their fractional arrangement or the use of codes not provided for, and also the transposition of digits (for example, replacing the numerical part of the code 12 with the number 21), shall not be permitted. For the rejection of cylinders, organisations shall use round stamps 12 mm in diameter bearing the letter "X". The location for applying the rejection stamp "X" is to the right of the cylinder number at a distance of not more than 10 mm. Stamp codes assigned to an organisation planning to carry out activities involving the examination of cylinders and subordinate to another federal executive authority in the field of industrial safety shall include an alphabetical part of two capital letters of the Russian and Latin alphabets (for example, "FW") and a numerical part of digits from 1 to 9 (example of a code: FW1), allocated by Rostechnadzor individually to the specific executive authority in the field of industrial safety.
554. The distribution (assignment) of the numerical, alphanumeric and alphabetical parts of stamp codes among the territorial bodies of Rostechnadzor and other federal executive authorities in the field of industrial safety is carried out by Rostechnadzor. The territorial body of Rostechnadzor for each organisation, or another federal executive authority in the field of industrial safety for each subordinate organisation, establishes an individual stamp code and maintains a record of the assigned codes in a log of stamp codes within the unified register of stamp codes in circulation on the territory of the Russian Federation.
555. Control over compliance with the requirements of these Federal Norms and Rules during the technical examination, repair and filling of cylinders, for the purpose of ensuring industrial safety and reducing the risk of accidents (explosions) of cylinders used on the territory of the Russian Federation, is carried out by Rostechnadzor within the powers established by the Government of the Russian Federation to supervise compliance with industrial safety requirements during the servicing and repair of technical devices used at hazardous production facilities, by carrying out inspections in accordance with the provisions of the legislation in the field of protection of the rights of legal entities and individual entrepreneurs in the exercise of state control (supervision) and municipal control.
556. The examination of cylinders, with the exception of cylinders for acetylene dissolved under pressure (hereinafter - acetylene), comprises: (a) inspection of the internal (with the exception of cylinders for liquefied hydrocarbon gas (propane-butane) with a capacity of up to 55 litres) and external surfaces of the cylinders; (b) checking of the mass and capacity of the cylinders; (c) hydraulic testing of the cylinders. The checking of the mass and capacity of seamless steel cylinders of up to 12 litres inclusive and over 55 litres, and also of welded cylinders regardless of capacity, is not carried out. For cylinders equipped with shut-off and safety devices (SSD), safety valves, membrane safety devices (MSD), upon expiry of the service life of the SSD, safety valve, MSD, an extraordinary examination shall be carried out with the replacement of the SSD, safety valve, MSD that have exhausted their service life.
557. Where the results are satisfactory, the organisation in which the examination was carried out stamps (applies) on the cylinder its round stamp 12 mm in diameter, the date of the examination carried out and of the next examination (on the same line as the stamp). The results of the technical examination of cylinders with a capacity of more than 100 litres are entered in the cylinder passport. In this case, stamps are not placed on the cylinders.
558. The results of the examination of cylinders, with the exception of acetylene cylinders, are recorded by the person who examined the cylinders in a test log having, in particular, the following columns: (a) the trademark or name of the manufacturer; (b) the cylinder number; (c) the date (month, year) of manufacture of the cylinder; (d) the date of the examination carried out and of the next examination; (e) the mass stamped on the cylinder, kg; (f) the mass of the cylinder established during the examination, kg; (g) the capacity of the cylinder stamped on the cylinder, litres; (h) the capacity of the cylinder determined during the examination, litres; (i) the working pressure, MPa; (j) a note on the fitness of the cylinder; (k) the surname, initials and signature of the representative of the organisation (individual entrepreneur) that carried out the examination; (l) information on the owner of the cylinder.
559. The examination of acetylene cylinders shall be carried out at acetylene filling stations within the periods established by the manufacturer (but not less frequently than every 5 years), and comprises: (a) inspection of the external surface; (b) checking of the porous mass; (c) pneumatic testing.
560. The condition of the porous mass in cylinders for dissolved acetylene shall be checked at acetylene filling stations not less frequently than every 24 months. Where the condition of the porous mass is satisfactory, the following shall be stamped on each cylinder: (a) the year and month of the checking of the porous mass; (b) the individual stamp of the filling station; (c) a stamp 12 mm in diameter bearing the letters "Pm", certifying the checking of the porous mass.
561. Acetylene cylinders filled with porous mass are tested during the examination with nitrogen at a pressure of 3.5 MPa. The purity of the nitrogen used for testing the cylinders shall be not lower than 97 per cent by volume.
562. The results of the examination of cylinders for dissolved acetylene are entered in a test log having, in particular, the following columns: (a) the cylinder number; (b) the trademark of the manufacturer; (c) the date (month, year) of manufacture of the cylinder; (d) the surname, initials and signature of the representative of the organisation (individual entrepreneur) that carried out the examination; (e) the date of the examination carried out and of the next examination of the cylinder.
563. The inspection of cylinders shall be carried out for the purpose of detecting on their walls traces of corrosion, cracks, dents and other damage capable of affecting safety during further operation of the cylinders (to establish the fitness of the cylinders for further operation until the date of the next technical examination). Composite and metal-composite cylinders shall be inspected for damage and delamination of the composite winding. Before inspection, cylinders shall be thoroughly cleaned and washed with water, and cylinders intended for media classified in group 1 in accordance with TR CU 032/2013 shall be washed with an appropriate solvent or degassed (decontaminated).
564. Cylinders in which, during the inspection of the external and internal surfaces, impermissible defects specified in the production instruction for examination are detected (in particular, cracks, laminations, dents, bulges, cavities and scratches more than 10 per cent of the nominal wall thickness in depth; tears and chippings; wear of the neck thread), shall be rejected. Loosening of the ring on the neck of the cylinder cannot serve as a reason for rejecting the latter. In this case, the cylinder may be permitted for further examination after securing the ring or replacing it with a new one. Cylinders in which a skewed or loose fitting of the shoe is detected shall not be permitted for further examination until the shoe has been refitted. The securing or replacement of a loosened ring on the neck or shoe shall be performed before the examination of the cylinder.
565. The rejection of cylinders based on the results of the external and internal inspection shall be carried out in accordance with the production instruction and the technical documentation of the cylinder manufacturer. The operation of cylinders on which the data have been re-stamped or on which not all of the data provided for by paragraph 543 of these Federal Norms and Rules have been stamped (applied) shall be prohibited.
566. In the absence of instructions from the manufacturer on rejection, standard seamless steel cylinders with a capacity of from 12 to 55 litres are rejected and withdrawn from operation where the mass decreases by 7.5 per cent or more, and also where their capacity increases by more than 1 per cent. The actual capacity of the cylinder is determined: from the difference between the mass of the cylinder filled with water and the mass of the empty cylinder; by means of measuring tanks or by another method established in the production instruction ensuring the necessary measurement accuracy.
567. Hydraulic tests of cylinders shall be carried out on specially equipped stands ensuring safety during testing. The magnitude of the test pressure and the holding time of cylinders under test pressure shall be indicated by the manufacturer in the technical documentation for the cylinders (in the operating manual and/or the methodology for carrying out the technical examination (diagnostics)), whereby the test pressure shall be not less than one and a half times the working pressure. The test pressure for cylinders made from a material the ratio of whose tensile strength to yield strength is more than 2 may be reduced to 1.25 times the working pressure.
568. The examination, rejection and marking of cylinders made from metal-composite and composite materials are carried out in accordance with the rejection requirements and standards established by the design developer and/or the cylinder manufacturer and specified in the operating manual (instructions).
569. Specialised organisations for the checking (testing) of cylinders shall render rejected cylinders unusable, regardless of their purpose, by any method excluding the possibility of their further use. Rejected cylinders shall be disposed of in accordance with the requirements of the operating manual (instructions).
570. The examination of cylinders shall be carried out in separate rooms specially equipped for carrying it out in accordance with the project. The air temperature in these rooms shall be not lower than 12 °C. For the internal inspection of cylinders, a portable source of electric lighting and other devices ensuring the possibility of visual inspection, with a voltage not exceeding 12 V, may be used. During the inspection of cylinders filled with explosive gases, the fittings of the hand lamp and its plug connection shall be of explosion-proof design.
571. Gas-filled cylinders held in long-term warehouse storage, upon the arrival of the scheduled periods of periodic examination, are subjected to examination on a selective basis in a quantity of not less than 5 units from a batch of up to 100 cylinders, 10 units from a batch of up to 500 cylinders and 20 units from a batch of over 500 cylinders. Where the results of the examination are satisfactory, the storage period of the cylinders is established by the person who carried out the examination, but for no more than two years. The results of the selective examination are documented in a corresponding report. Where the results of the examination are unsatisfactory, a repeat examination of the cylinders is carried out in the same quantity. In the event of unsatisfactory results in the repeat examination, further storage of the entire batch of cylinders shall not be permitted; the gas shall be removed from the cylinders within the period specified by the person who carried out the examination, after which the cylinders shall be subjected to technical examination each individually.
572. The operation (filling, storage, transportation and use) of cylinders shall be carried out in accordance with the requirements of the instruction of the organisation (individual entrepreneur) carrying out the said activity, approved in accordance with the established procedure. Responsibility for non-compliance with the requirements for the safe operation of cylinders, including the use of cylinders with the violations specified in sub-clauses "a" to "d" and "g" of paragraph 587 of these Federal Norms and Rules, is borne by their owner.
573. Workers servicing cylinders shall undergo a check of their knowledge of the instruction and shall have a certificate of admission to independent work, issued in accordance with the established procedure.
574. The placement (installation) of gas cylinders at points of consumption (use) as an individual cylinder installation (not more than two cylinders (one working, the other standby) of each type of gas used in the technological process), as a group cylinder installation, and also at points of storage of the technological stock of cylinders, shall be carried out in accordance with the equipment placement plan (project), taking into account the requirements of these Federal Norms and Rules.
575. During the use and storage of cylinders, their installation in places of passage of people, movement of goods and passage of vehicles shall not be permitted.
576. Cylinders (in the case of individual installation) shall be located at a distance of not less than 1 metre from heating radiators and other heating appliances, stoves, and not less than 5 metres from heat sources with an open flame.
577. The placement of group cylinder installations and the storage of cylinders with combustible gases shall be carried out in rooms specially equipped in accordance with the project or in an open area, whereby the location of group cylinder installations and the storage of cylinders with combustible gases in a room where the technological process of using the combustible gas contained in them is carried out shall not be permitted.
578. A gas cylinder at the place of application, before the start of use, shall be set in a vertical position and reliably secured against falling in the manner established by the production operating instruction. During the performance of repair or installation work, a cylinder with compressed oxygen may be laid on the ground (floor, platform), previously fully cleaned of spills of fuel and oils, ensuring: (a) the location of the valve above the shoe of the cylinder and the prevention of rolling of the cylinder; (b) the placement of its upper part on a spacer with a cut-out, made of wood or another material that excludes spark formation. The use of cylinders with gases liquefied and dissolved under pressure (propane-butane, acetylene) in a horizontal position shall not be permitted.
579. During the operation of cylinders, the gas contained in them shall not be permitted to be used up completely. For a specific type of gas, taking into account its properties, the residual pressure in the cylinder is established in the operating manual (instructions) and shall be not less than 0.05 MPa, unless otherwise provided for by the technical specifications for the gas.
580. The release (supply) of gases from cylinders into a vessel, and also into process equipment with a lower working pressure, shall be carried out through a reducer intended for the given gas and painted in the corresponding colour. At the inlet to the reducer, a pressure gauge shall be installed with a scale ensuring the possibility of measuring the maximum working pressure in the cylinder; and on the low-pressure chamber of the reducer, a spring-loaded safety valve shall be installed, adjusted to the corresponding permitted pressure in the vessel or process equipment into which the gas is released, and also a pressure gauge corresponding to that pressure. The type of pressure gauge and safety valve is determined by the design developer and the manufacturer of the reducer.
581. For the purpose of preventing ignition and explosion of cylinders with combustible gases and oxygen, the equipment connected to them, and also the pipelines and/or flexible hoses used for its connection, shall be in good working order and shall correspond (in terms of materials and strength) to the gas used in them.
582. Where it is impossible, owing to a malfunction of the valves, to release the gas from the cylinders at the place of consumption, the latter shall be returned to the filling station separately from the empty cylinders, with a corresponding temporary inscription (marking) applied to them by any available method that does not damage the integrity of the cylinder body. The release of gas from such cylinders at the filling station shall be carried out in accordance with the instruction approved in accordance with the established procedure.
583. The filling of cylinders shall be carried out by organisations (individual entrepreneurs) having filling stations (filling points) whose production premises (sites), in accordance with the project and the requirements of these Federal Norms and Rules: are equipped for filling cylinders with a specific type of gases; provide for the possibility of the acceptance-issue and separate storage of empty and filled cylinders; are fitted with technical means and equipment ensuring the filling, emptying (including the draining of non-evaporated residues, in the case of liquefied gases, the release of gas from cylinders with faulty fittings), repair and painting of cylinders. The release of gas from cylinders with faulty fittings and the repair of cylinders shall be carried out by organisations (individual entrepreneurs) meeting the requirements of paragraph 549 of these Federal Norms and Rules.
584. The organisation filling the cylinders shall ensure the availability of the necessary number of specialists certified in accordance with the provisions of Article 14.1 of Federal Law No. 116-FZ within the scope of the industrial safety requirements necessary for the performance of labour duties, and of workers with a qualification corresponding to the nature of the work performed, and also of production instructions defining the procedure for the acceptance, issue, storage, filling, emptying and repair of cylinders.
585. Filling stations carrying out the filling of cylinders with compressed, liquefied and soluble gases shall maintain a cylinder filling log, in which, in particular, the following shall be indicated: (a) the date of filling; (b) the cylinder number; (c) the date of examination; (d) the mass of the (liquefied) gas in the cylinder, kg; (e) the signature, surname and initials of the person who filled the cylinder. If cylinders are filled with different gases, a separate filling log shall be maintained for each gas. The procedure for keeping records of the filling (refuelling) of cylinders (fuel tanks) of motor vehicles at vehicle refuelling stations is established by production instructions, taking into account their specific features, determined by the requirements of the design documentation and other regulatory legal documents establishing requirements for the said facilities, provided that the requirements of paragraph 587 of the Federal Norms and Rules are met.
586. The filling of cylinders with gases shall be carried out in accordance with an instruction developed and approved by the filling organisation (individual entrepreneur), taking into account the properties of the gas determined by the project of the filling station, local conditions and the filling technology, and also the requirements of the operating manual (instructions) and other documentation of the cylinder manufacturer, whereby: 1) Cylinders arriving for filling shall be checked and inspected for the absence of violations that do not permit their filling, including those specified in paragraph 587 of these Federal Norms and Rules. 2) Before the filling of oxygen cylinders, a check for the absence in them of an admixture of combustible gases shall be carried out with a gas analyser in the manner established by the instruction. 3) Cylinders being filled with gas shall be firmly secured and tightly connected to the filling manifold. 4) When cylinders are filled with medical oxygen, they shall be purged with the pressure of the medium being filled in the manner established by the instruction. 5) The filling of cylinders with liquefied gases shall comply with the standards established by the cylinder manufacturer and/or the technical specifications for liquefied gases. In the absence of such information, the filling standards are determined taking into account the permitted pressure of the cylinder in accordance with Appendix No. 12 to the Federal Norms and Rules. 6) The filling of cylinders in which there is no excess pressure of gases is carried out after their preliminary checking in accordance with the instruction of the filling station.
587. The filling with gas and the use for the intended purpose of cylinders shall not be permitted where: (a) the period of the assigned examination, the service life (number of refuellings) established by the manufacturer has expired; (b) the period for checking the porous mass has expired; (c) the cylinder body is damaged; (d) the valves are faulty; (e) proper painting or inscriptions are absent; (f) there is no excess pressure of gas; (g) the established stamps are absent.
588. The refitting of shoes and cap rings, the replacement of valves, cleaning, restoration of the painting and inscriptions on cylinders shall be carried out at cylinder examination points. A valve, after a repair involving its disassembly, shall be checked for tightness at working pressure. The fitting of shoes onto cylinders may be carried out only after the release of gas, the unscrewing of the valves and the appropriate degassing of the cylinders. The cleaning and painting of gas-filled cylinders, and also the securing of rings on their neck, shall be prohibited.
589. Cylinders containing gases (with the exception of cylinders containing toxic gases) may be stored either in special premises or in the open air; in the latter case they shall be protected from atmospheric precipitation and sunlight. The warehouse storage of oxygen cylinders and combustible-gas cylinders in the same premises shall be prohibited.
590. Cylinders containing toxic gases shall be stored in special enclosed premises.
591. Filled cylinders with shoes fitted on them, as well as cylinders of a special design with a concave bottom, shall be stored in a vertical position. To prevent them from falling, cylinders shall be placed in specially equipped sockets or cages, or shall be enclosed by a barrier.
592. Cylinders that do not have shoes may be stored in a horizontal position on wooden frames or racks. When stored on open areas, cylinders with shoes may be stacked with spacers of rope, wooden bars, rubber or other non-metallic materials having cushioning properties placed between the horizontal rows. When cylinders are stacked, the height of the stacks shall not exceed 1.5 metres, and the cylinder valves shall face the same direction.
593. Warehouses for the storage of cylinders filled with gases shall conform to a design developed in accordance with the established procedure taking into account the requirements of these Federal Norms and Rules. The warehouse building shall be single-storey with lightweight-type roofing and shall have no attic spaces. The walls, partitions and roofing of warehouses for the storage of gases shall be of non-combustible materials conforming to the design; windows and doors shall open outwards. Window and door glass shall be frosted or painted with white paint. The height of warehouse premises for cylinders shall be not less than 3.25 metres from the floor to the lowest projecting parts of the roof covering. Warehouse floors shall be level with a non-slip surface, and those of warehouses for cylinders containing combustible gases shall have a surface of materials that preclude spark formation when struck by any objects.
594. The equipping of warehouses for cylinders containing combustible gases that are hazardous in respect of explosions is determined by the design.
595. In warehouses, instructions, rules and posters on the handling of cylinders held in the warehouse shall be posted.
596. Warehouses for cylinders filled with gas shall have natural or mechanical ventilation.
597. Warehouses for cylinders containing explosion- and fire-hazardous gases shall be located within a lightning protection zone.
598. The warehouse premises for the storage of cylinders shall be divided by non-combustible walls into compartments, in each of which the storage of no more than 500 cylinders (40 litres) containing combustible or toxic gases and no more than 1000 cylinders (40 litres) containing non-combustible and non-toxic gases is permitted. Compartments for the storage of cylinders containing non-combustible and non-toxic gases may be separated by non-combustible partitions not less than 2.5 metres high with open openings for the passage of people and openings for mechanisation equipment. Each compartment shall have its own exit to the outside.
599. The separation distances between warehouses for cylinders filled with gases, between warehouses and adjacent production buildings, public premises and residential houses are determined by the design and shall conform to town-planning norms.
600. The movement of cylinders at the facilities where they are used (the places where work is performed) shall be carried out on trolleys specially adapted for this purpose or by means of other devices ensuring the safety of transportation.
601. The transport of cylinders filled with gases within the boundaries of a hazardous production facility, the production site of an enterprise and at other facilities where installation and repair work is carried out shall be carried out on spring-mounted vehicles or on motor carts in a horizontal position, necessarily with spacers between the cylinders. Wooden bars with cut-out sockets for the cylinders may be used as spacers, as well as rope or rubber rings not less than 25 mm thick (two rings per cylinder) or other spacers protecting the cylinders from striking one another. During transport, all cylinders shall be laid with their valves facing the same direction. The transport of cylinders in special containers is permitted, as well as without containers in a vertical position, necessarily with spacers between them and guarding against possible falling. The transport of cylinders filled with gas on public roads by road (rail) transport does not fall within the scope of activity in the field of industrial safety and is carried out in accordance with the requirements of other regulatory legal acts and international agreements in force in the territory of the Russian Federation.
602. The transportation and storage of cylinders shall be carried out with the caps screwed on, unless the cylinder design provides other protection for the cylinder's shut-off device. The storage of filled cylinders prior to their issue to consumers is permitted without protective caps.
603. During the operation, filling, storage and transportation of cylinders made of metal-composite and composite materials, the additional requirements established by the design developer and/or the cylinder manufacturing organisation and set out in the operating manual (instructions) and other documentation of the manufacturing organisation shall be complied with.
604. This Chapter of the Federal Norms and Rules establishes the industrial safety requirements for medical stationary pressure chambers operating under an excess pressure of more than 0.07 MPa used in medical and other organisations irrespective of their form of ownership and departmental affiliation (hereinafter - MO) to provide a therapeutic or adaptive effect on the persons placed in them.
605. Medical stationary pressure chambers are special pressure vessels which, depending on the number of persons placed in them and the working medium, are subdivided into single-occupancy and multi-occupancy chambers operating under an excess pressure of air or gaseous medical oxygen (or other gas mixtures).
606. Single-occupancy medical pressure chambers shall be manufactured in accordance with the requirements of these Federal Norms and Rules.
607. Multi-occupancy medical pressure chambers placed on the market for the first time shall conform to the requirements of TR CU 032/2013. During the operation of pressure chambers manufactured and put into operation before the entry into force of TR CU 032/2013, their conformity to the requirements of the design and technical documentation of the design developer enterprises and the manufacturing organisation shall be ensured.
608. The safety of use of medical stationary pressure chambers, which are medical technology equipment, shall be ensured by compliance with the requirements of these Federal Norms and Rules, as well as the legislation of the Russian Federation in the field of industrial safety, healthcare and the licensing of certain types of activity.
609. The operation of pressure chambers, including installation, adjustment, putting into operation, maintenance and repair, shall be carried out in accordance with the design, the operating manual (instructions) and other technical documentation of the manufacturing organisation, as well as the requirements of these Federal Norms and Rules and the relevant regulatory documents.
610. The installation, adjustment, maintenance and repair of a pressure chamber and of the devices, pipelines and other systems that ensure its operation shall be carried out by specialised organisations conforming to the requirements of Chapter III of these Federal Norms and Rules and holding a licence for the maintenance of this type of medical technology.
611. The acceptance of a pressure chamber following installation and putting into operation shall be carried out in accordance with the requirements of Chapter V of these Federal Norms and Rules.
612. The design of single-occupancy pressure chambers and the materials (metallic and non-metallic) of the main elements of the pressure chamber body shall ensure the reliability and safety of its operation during the service life (operating life) established by the design developer and/or the manufacturing organisation on the basis of a calculation. The design pressure shall be 10 per cent higher than the working pressure. The test pressure for testing the pressure chamber shall be 1.5 times the working pressure.
613. The design of pressure chambers, the materials (metallic and non-metallic) of the main elements of the pressure chamber body and those used for their finishing and internal equipment, the devices and utilities placed in them (buttons, connectors, switches and other equipment), as well as the patient medical monitoring systems used during their operation, shall ensure explosion and fire safety, taking into account the properties of the working medium, especially when pure gaseous oxygen is used.
614. The gas supply system of a pressure chamber shall provide the rate of compression (pressure increase) and decompression (pressure reduction) necessary to ensure the safe conduct of the therapeutic processes for which it is intended, in accordance with the requirements of regulatory documents.
615. The pressure chamber shall be equipped with a safety valve set to an actuation pressure of no more than 10 per cent of the working pressure.
616. The geometric dimensions of a single-occupancy pressure chamber shall ensure the safe presence of the person placed inside the chamber. The length of the pressure chamber shall be not less than 2000 mm, the internal diameter of the body of newly manufactured pressure chambers shall be not less than 700 mm; for pressure chambers manufactured and put into operation before the adoption of these Federal Norms and Rules, an internal diameter of 600 mm is permitted. The geometric dimensions (width, length) of the place (couch) for positioning the patient in the internal cavity of the pressure chamber shall ensure the patient's free and safe placement in the pressure chamber.
617. Where a pressure chamber is manufactured in the form of a metal base with a transparent dome or portholes, the design, arrangement and material used in manufacturing the dome (porthole) shall provide sufficient visibility for observing the patient's condition, good visibility of the patient, as well as the necessary strength meeting the requirements of paragraph 612 of these Federal Norms and Rules.
618. In the pressure chamber hall, in the immediate vicinity of the pressure chamber, shut-off valves shall be installed that provide the possibility of rapid (instantaneous) shut-off of the supply of the working medium to the pressure chamber. Directly on the pressure chamber body, fittings (a valve) shall be installed that provide the possibility of rapid (instantaneous) release of the working medium from it in emergency and abnormal situations.
619. The controls of the gas supply system of a pressure chamber shall be mounted on a single control panel. All controls and monitoring devices shall have clear and unambiguously legible marking.
620. The pressure chamber shall be equipped with a pressure gauge for monitoring the pressure in it. The accuracy class of the pressure gauge shall be not lower than that established by the pressure chamber manufacturing organisation and shall provide the necessary pressure measurement error, taking into account the operating modes determined by the therapeutic process.
621. The control panel of the pressure chamber shall be fitted with a time-monitoring device.
622. The pressure chamber shall be fitted with a communication system providing transmission of the operator's speech into the pressure chamber in "Push-to-talk" mode, and of the patient's speech to the operator in a continuous (background) mode. The communication system shall ensure speech intelligibility.
623. A pressure chamber operating with a compressed-air medium shall be equipped with visual and audible alarm devices indicating that the oxygen concentration by volume exceeds 23 per cent. The device shall have the capability to switch off the audible alarm.
624. A pressure chamber fitted with units and/or components that require an electric power supply for their operation shall be equipped with an uninterruptible power supply system (source).
625. The manufacture of single-occupancy medical pressure chambers shall be carried out by specialised organisations that ensure compliance with the requirements of these Federal Norms and Rules and the legislation in the field of licensing the manufacture of medical technology; that have equipment for the quality manufacture of these pressure chambers, as well as specialists trained and certified in accordance with the established procedure, and workers of the appropriate qualification.
626. Multi-occupancy medical pressure chambers, depending on the operating modes for which they are intended, are used with an excess working pressure of up to 1 MPa.
627. A multi-occupancy medical pressure chamber shall consist of at least two compartments - the main chamber for accommodating patients during the treatment session and an antechamber to enable specialists from among the medical personnel to enter the chamber while it is under pressure and to remove a patient from the chamber if necessary before the end of the treatment session. Multi-occupancy pressure chambers may also be multi-compartment and consist of prefabricated sections forming hyperbaric complexes that provide for the conduct of hyperbaric oxygenation sessions (hereinafter - HBO) for patients, as well as the conduct of surgical operations under excess pressure in cases where this is necessary on medical grounds.
628. Multi-occupancy medical pressure chambers used in an MO shall, by their design and dimensions, ensure the possibility of safely accommodating patients in them and conducting the relevant course of treatment for which they are intended, and shall have internal space dimensions (by diameter or height, depending on the geometric shape of the body) of not less than 1800 mm; in cases justified by the design, depending on the purpose of the pressure chamber and the number of persons accommodated, other dimensions may be provided for.
629. The entrance doors (hatches) of pressure chambers are made in the form of flat doors mounted on hinges or equipped with a sliding mechanism, while the doors (hatches) shall provide the necessary strength and tightness of the pressure chamber compartments. The door openings of pressure chambers made in the form of flat doors shall have a minimum height of not less than 1.55 metres and a width of not less than 0.7 metres and shall provide the possibility of carrying a patient into the pressure chamber on a stretcher. Hatches of circular shape shall have a minimum internal diameter of not less than 0.6 m. The closing mechanisms of doors and hatches shall be made of spark-safe materials. In cases where the doors or hatches have an automatic drive, they shall additionally be equipped with manual opening devices that make it possible to open (close) the doors in the event of an emergency or absence of electric power.
630. The equipment of pressure chambers shall provide the possibility of creating the working pressure in the pressure chamber, monitoring the pressure, maintaining the pressure within the required range and reducing the pressure in accordance with the selected treatment mode. Control of the air supply to the pressure chamber is provided for both manually and automatically (remotely). Where automatic (remote) control is used, valve systems shall be provided that make it possible to manually control the supply (release) of air. Pressure chambers shall be equipped with manual shut-off valves installed on the pressure chamber body, in the supply (release) lines for air and medical oxygen. The valves shall provide rapid (instantaneous) closing of the valves in the event of a fault (loss of tightness) of the pressure chamber or of the gas supply (release) lines and shall prevent loss of pressure in the pressure chamber. During normal operation of the pressure chamber, the valves shall be open and the handles (handwheels) shall be sealed.
631. The equipping of a pressure chamber with the necessary equipment is carried out in accordance with the design, depending on its purpose, including with life-support systems and special breathing units, through which the supply of medical oxygen to the breathing masks and the removal of the gas exhaled by the patient beyond the pressure chamber are provided. The control devices for the breathing units shall be located outside the pressure chamber.
632. Each compartment of a pressure chamber shall be fitted with a safety valve that actuates in the event of a pressure increase of 10 per cent above the working pressure and provides closing when the pressure falls by no more than 15 per cent. The safety valve (valves) shall be installed outside the pressure chamber in a place protected from mechanical damage or accidental actuation in the event of unauthorised access.
633. All devices for supplying air to the pressure chamber or releasing air from the pressure chamber shall be protected by pneumatic silencers, protective screens or other devices that prevent injury to the patient during the supply of air and the suction of the patient's clothing or body parts during the release of pressure or the actuation of the safety valve.
634. The compartments of a pressure chamber shall be equipped with pressure gauges that provide for measurement of the pressure inside the pressure chamber.
635. Non-combustible materials and coatings, or materials and coatings that do not support combustion, shall be used in the equipment of pressure chambers. The electrical equipment and the equipment for active heating of the pressure chamber shall be protected from overheating and spark formation during operation and in emergency situations. The electrical equipment used inside the pressure chamber shall have a maximum voltage of no more than 42 V.
636. The gas supply control console shall be located outside the pressure chamber. The gas supply control devices shall have clear marking that does not permit ambiguous interpretation or operator error. The pressure chamber shall be equipped with gas-analysis instruments for the breathing gas medium. Instruments for monitoring the content of oxygen and carbon dioxide shall be installed as a mandatory requirement, providing continuous monitoring of the percentage content of the gas and an alarm in the event of exceedance of or reduction below the threshold values.
637. The installation of medical pressure chambers is carried out on a stationary basis in buildings intended and equipped for accommodating patients, as well as in special transportable containers.
638. The requirements for the placement of a pressure chamber in transportable containers mounted on various chassis or on a stationary basis, as well as for the design of the container, are determined by the design developer and the manufacturing organisation of such complexes on the basis of the requirements for ensuring maximum safety.
639. Stationary medical pressure chambers are installed in specially equipped premises (pressure chamber halls) of HBO subdivisions, in the buildings of an MO on the basis of a design developed in accordance with the requirements of the legislation on town-planning activity and in the field of industrial safety. The relocation of an HBO subdivision to other premises of the same MO or to another MO, during the performance of technical re-equipment and/or reconstruction work of the HBO department, shall be carried out on the basis of design documentation developed in accordance with the requirements of the legislation on town-planning activity and in the field of industrial safety. The operation of medical pressure chambers installed in breach of the design documentation shall not be permitted.
640. The placement of pressure chambers in basement floors shall not be permitted.
641. The placement of multi-occupancy medical pressure chambers shall ensure the convenience of their installation and mounting on the ground floor of the building, with the exception of cases justified by the technology of their use and the design documentation, in which case a calculation of the foundations, floor slabs and columns for the possibility of installing the pressure chamber in the premises shall be carried out, taking into account the subsequent performance of technical examination of the pressure chambers, including the performance of hydraulic tests.
642. The spatial-planning solutions for the arrangement of the pressure chamber hall and the placement in it of single-occupancy and/or multi-occupancy pressure chambers, as well as of the systems ensuring their operation, life-support devices and other equipment, shall be determined by design documentation developed by design organisations taking into account the requirements of these Federal Norms and Rules and the design norms for medical institutions in force at the time of development.
643. The area and volume of the pressure chamber hall premises are determined by the design depending on the number of pressure chambers and other equipment placed in it, to ensure the possibility of the safe presence, at the pressure chamber installation location, of medical personnel and the accommodation of patients awaiting treatment, on the basis of the capacity of the pressure chamber and the staffing schedule of the servicing (medical) personnel, in which case the following shall be ensured: (a) the presence of evacuation exits from the pressure chamber hall premises in the number established by the design, but not less than two exits - for pressure chamber halls in which the placement of more than two single-occupancy pressure chambers is provided for, and for pressure chamber halls with multi-occupancy pressure chambers. The presence of one evacuation exit is permitted in cases justified by the design, if the layout of the pressure chamber hall premises provides for the presence of two or more passages to the evacuation exit that eliminate the need for people to move past equipment that has undergone an emergency loss of tightness or has caught fire; (b) the width of the door openings of the evacuation exits from the pressure chamber halls, as well as of the passages in the pressure chamber hall between the installed equipment, shall provide the possibility of unimpeded movement of single-occupancy pressure chambers, including for their evacuation with patients in the event of an emergency situation; (c) all doors in the pressure chamber hall shall open outwards, in which case the area of the windows and doors is determined by calculation during design and shall provide for the release of the maximum possible quantity of compressed gas during its emergency discharge in the event of a pressure chamber accident; (d) the placement of pressure chambers in the pressure chamber hall premises shall be determined by the design and shall ensure the convenience and safety of their servicing, the possibility of free and unimpeded movement, and the evacuation of patients and personnel. The minimum distance from the projecting parts of the pressure chamber to a wall or to stationary-mounted medical apparatus shall be 1 metre. The minimum distance between pressure chambers shall be 1.5 metres. The minimum distance from heating appliances and other heat sources to pressure chambers shall be 1 metre.
644. The fitting-out of the pressure chamber hall shall take into account the requirements of the design norms for medical institutions with regard to finishing materials, power supply and earthing systems, ventilation, lighting and heating, including: (a) materials conforming to the requirements of the design documentation, taking into account the conditions of their use, shall be used in the construction of the walls separating the pressure chamber hall from other premises, as well as in the finishing of the pressure chamber hall premises; the floor in the pressure chamber hall shall have an antistatic covering, which shall be confirmed by a certificate for the floor-covering material used or by a resistance-measurement report; (b) the pressure chamber hall shall be equipped with supply and exhaust ventilation; (c) pressure chamber halls shall be fitted with communication systems, emergency alarm systems and gas-analysis systems (detectors) for monitoring the temperature, humidity and oxygen content in the atmosphere of the pressure chamber hall; (d) the electrical equipment and power supply systems of the pressure chamber halls shall conform to electrical safety norms; (e) the following shall be provided in the pressure chamber hall: a protective earthing system for the electrical equipment and a system, independent of it, for protecting the pressure chambers and personnel from the accumulation of static electricity; (f) for the discharge of gases from the pressure chamber, special pipelines shall be provided in the pressure chamber hall that carry the gases beyond the pressure chamber hall. Combining the discharge pipelines for air and oxygen shall be prohibited. The end part of the discharge pipeline shall be located beyond the outer wall of the building, positioned in height and at a distance from window openings and ventilation (air-conditioning) devices at a distance determined by the design and ensuring the safe dispersal into the atmosphere of the discharged oxygen. The pipelines shall be securely fixed and have appropriate marking; (g) in the pressure chamber hall premises in which multi-occupancy pressure chambers are installed, an individual isolating breathing apparatus or self-rescuer apparatus (or apparatus in accordance with the staffing schedule and the design) for the pressure chamber operator shall be placed in case of fire, smoke or exceedance of the concentration of hazardous gases in the pressure chamber hall and to enable people to be brought out of the pressure chamber; (h) the oxygen and air supply pipelines shall provide the necessary strength at the working pressure and be routed in such a way as to avoid mechanical damage. The type of pipelines, the material and the diameter are determined during design, on the basis of the volume of the pressure chamber and the oxygen pressure. The pipelines shall be earthed, and the pipelines shall not be used for the earthing of other equipment; (i) the supply of oxygen to the pressure chambers shall be carried out either from the general oxygen supply system of the medical organisation or from an autonomous source. When oxygen is supplied to the pressure chambers from the general oxygen supply system, operational communication shall be ensured with the duty personnel of the service providing the oxygen supply. Shut-off valves shall be installed on the oxygen supply pipeline at the inlet outside the pressure chamber hall premises, and, on the sections of the pipeline immediately before each pressure chamber, shut-off valves with a pressure gauge located before them. The design of the connection assembly of the pressure chamber inlet fitting to the shut-off valves shall provide the possibility of quickly disconnecting the pressure chamber for its evacuation with a patient in the event of an emergency situation in the pressure chamber hall premises; (j) the compressed-air supply system for the pressure chamber shall consist of compressed-air sources (high-pressure air compressors, not less than two in number) and an air reservoir providing storage of air in the volume required according to the design to ensure the raising and maintenance of the pressure in the pressure chamber; (k) the heating of pressure chamber halls shall be carried out using a water heat-transfer medium whose temperature does not exceed 95 °C.
645. An MO operating medical pressure chambers shall, to ensure their maintenance in good working order and safe working conditions: (a) appoint, by order, a person responsible for exercising production control over the operation of pressure equipment in all subdivisions of the MO, a person responsible for the safe operation of the pressure chamber (the head of the HBO subdivision), and a person responsible for the sound technical condition of the pressure chamber (from among the technical specialists of the HBO subdivision or a specialised subdivision of the MO); (b) staff the HBO subdivision with personnel trained and admitted, in accordance with the established procedure, to independent work on the pressure chamber; (c) ensure the development and availability of instructions for the operation and maintenance of the pressure chambers and the technical systems of the HBO department in accordance with the requirements of the regulatory documentation and the operating manuals (instructions) for the equipment; (d) establish a procedure for the safe admission of patients to the pressure chamber hall premises and their presence directly in the pressure chamber, for which purpose ensure the provision of information on the rules of conduct and the necessary safety measures, taking into account the existing hazardous factors (pressure equipment and the physical and chemical properties of oxygen), and ensure the availability of a change set of cotton clothing for the safety of persons placed in the pressure chamber for the purpose of conducting a treatment session using gaseous oxygen. The presence of a patient in the pressure chamber in synthetic, spark-generating clothing shall not be permitted.
646. The person responsible for the safe operation of the pressure chamber shall: (a) ensure the safe operation of the pressure chamber, the pressure chamber halls and the technical life-support systems of the HBO subdivision, and their maintenance in good working order; (b) ensure the development, keeping and storage of the operational documentation, its issue to the personnel directly working on the pressure chamber, and its availability at the workplaces; (c) ensure the organisation and conduct of the testing of the knowledge of the personnel directly working on the pressure chamber; (d) check daily the entries of the personnel in the HBO session registration log, entering in it a record of the results of the check; (e) take part in the conduct of periodic (scheduled) monitoring of the pressure chamber, the pressure chamber halls and the technical life-support systems of the HBO subdivisions; (f) monitor the timeliness of the performance of the scheduled works for the maintenance, repair and technical examination of the equipment; (g) ensure the fulfilment of prescriptions; (h) upon the detection of violations of the requirements of the operational documentation, issue instructions for their elimination to the personnel directly working on the pressure chamber; (i) stop the operation of the pressure chamber upon the detection of violations of the safe operation requirements; (j) not permit to work on the pressure chamber persons (medical personnel of the HBO department, technical specialists of the MO and of external organisations) who do not have the appropriate admission, who have not passed the knowledge test or who violate the requirements for the safe operation of the pressure chamber and the regime for conducting treatment sessions.
647. The person responsible for the sound technical condition of the pressure chamber shall: (a) ensure the safe operation of the pressure chamber, the chamber halls and the life-support technical systems of the HBO unit by keeping them in sound condition; (b) keep the design and acceptance documentation for the premises, equipment and technical systems of the HBO unit; (c) ensure the storage and maintenance of the operational documentation (data sheets, operating manuals and other technical documentation of the manufacturers, work instructions and logs) for the pressure chambers and technical systems of the HBO unit; (d) carry out a daily check of the operational readiness of the chamber hall and of the equipment and process life-support systems of the HBO unit installed therein, in accordance with the procedure established by the instructions and other administrative documents of the medical organisation; (e) periodically (at least once a week) monitor the conduct of the daily technical session on the pressure chamber; (f) carry out periodic (scheduled) monitoring of the pressure chamber, the chamber halls and the life-support technical systems of the HBO unit; (g) draw up plans for preventive scheduled work (maintenance) of the pressure chamber and of the technical systems supporting its operation, in accordance with the requirements of the operating manuals (instructions) and other technical documentation of the manufacturing organisations; (h) arrange the maintenance and repair of the pressure chamber and of the technical systems supporting its operation, by the personnel of the technical services of the medical organisation or by specialised organisations; (i) keep records of the operating cycles accumulated by the pressure chamber; (j) ensure the preparation of the pressure chamber for technical examination and (or) technical diagnosis. The person responsible for the sound technical condition of the pressure chamber shall stop the operation of the pressure chamber in cases of detection of faults, both of the pressure chamber and of other technical systems of the HBO units, and also where the pressure chamber has exhausted its service life or service term in the absence of a positive conclusion based on the results of technical diagnosis. The person responsible for the sound technical condition of the pressure chamber shall record in the pressure chamber operation log all identified remarks on the operation of the pressure chamber, the oxygen supply system and the technical support of the safe operation of the chamber hall, and shall report them to the head of the HBO department.
648. The responsible persons of the HBO department shall, in accordance with the established procedure, undergo attestation to the extent of the industrial safety requirements necessary for the performance of their work duties in accordance with the provisions of Article 14.1 of Federal Law No. 116-FZ.
649. Medical and technical personnel of the organisation who hold qualifications corresponding to the work performed by them may be admitted to servicing the pressure chamber by order of the head of the medical organisation. The knowledge check, training and admission of medical personnel to the work of servicing the pressure chamber and conducting sessions using it are carried out in accordance with the procedure established by the administrative documents of the medical organisation in accordance with the requirements of these Federal Norms and Rules. The commission for checking the knowledge of personnel includes the person responsible for carrying out production control, the responsible persons of the HBO department and of the centralised technical services (subdivisions) of the medical institution, and also other specialists at the decision of the head. The initial knowledge check of medical personnel is carried out after training, before admission to the work of servicing the pressure chamber and conducting sessions using it. The periodic knowledge check is carried out once every 12 months. An extraordinary knowledge check shall be carried out in the following cases: installation of a new type of pressure chamber; transfer of medical personnel to work in another unit equipped with a pressure chamber; upon revision of the operational documentation; upon violations by personnel of the requirements of the operational documentation; on the instruction of the person responsible for carrying out production control in cases of detection of violations of safety requirements.
650. The operation of pressure chambers is carried out in accordance with the operating instructions, developed on the basis of the requirements of the technical documentation for each specific type of pressure chamber, taking into account local conditions. The operating instructions for the pressure chamber are developed by the responsible persons of the HBO unit in accordance with the procedure established by the administrative documents of the medical organisation. The operating instructions for the pressure chamber shall establish requirements for personnel, including the procedure for checking serviceability, preparation for operation, starting and stopping the pressure chamber and the systems supporting its operation, the procedure for admitting patients to the chamber hall and placing them in the pressure chamber, and also safety requirements during the operation of the pressure chamber and the oxygen supply system.
651. The technology and procedure for conducting a treatment session shall be determined by the instructions and (or) other administrative documents of the medical organisation. Information on the conduct of a treatment session shall be entered in the session registration log. The medical personnel directly working with the pressure chamber and the responsible persons of the HBO unit shall keep a separate log for each pressure chamber. The log shall be kept at the workplace.
652. Where two or more pressure chambers are in operation at the medical organisation, a pressure chamber registration log is kept in the form approved by the medical organisation, in which are indicated the data-sheet particulars of the pressure chamber, the time and place of its installation, the periods of technical diagnosis, the exhausted service life, the service terms and other information relating to the operation of the pressure chamber.
653. In the chamber hall, in a place convenient for consultation, a special board is installed, on which the following information is placed: the names of the persons responsible for the HBO service; a list of persons authorised to work independently on the pressure chamber, indicating the periods of the next knowledge check; extracts from the labour protection instructions for work on the pressure chamber and for the operation of the pressure chamber, including a list of personnel actions in the event of emergency and abnormal situations (disconnection of the oxygen supply, of the power supply, depressurisation of the pressure chamber or of the oxygen pipelines and other), an emergency evacuation plan in the event of an emergency situation; the approved oxygen and power supply diagrams, indicating the points of emergency shut-off of the gas and power supply, and also information (a memo) for patients on the rules for being in the chamber hall and on the safety measures when undergoing treatment procedures in the pressure chamber. The instructions shall be kept at the workplaces of the personnel.
654. Every day, before conducting the first treatment session with a patient, the medical worker shall carry out a technical check of the operational readiness of the pressure chamber (routine monitoring) in accordance with the operating instructions, which includes: (a) checking the records in the HBO session registration log; (b) inspection of the pressure chamber; (c) checking the initial condition of the pressure chamber; (d) conducting a technical session without a patient at the isopression pressure and for the time specified in the operating instructions, with a check of the serviceability of the safety valve for the absence of jamming; (e) checking the serviceability of the communication system with the pressure chamber cover open. Based on the results of the check carried out, a record of the readiness of the pressure chamber for operation shall be made in the HBO session registration log, and the signature of the person who carried out the check shall be provided.
655. The operation of the pressure chamber shall not be permitted where there is a record of faults in the HBO session registration log. The main criteria of faults for which the operation of the pressure chamber shall not be permitted are: (a) the presence of gas leaks due to leaktightness failure of the pressure chamber, hoses, fittings or docking units; (b) a failure of the earthing; (c) a fault in the communication system with the patient; (d) the absence, damage or malfunction of the instrumentation; (e) a fault or incorrect adjustment of the safety valve; (f) a fault in the life-support systems (control, monitoring, communication); (g) a fault in the emergency alarm; (h) the presence of mechanical damage that may lead to a reduction in the strength of the units that are under pressure during operation; (i) a fault in the oxygen supply system, including the absence of the standard pressure in the supply pipeline. When faults are detected, a corresponding record shall be made in the HBO session registration log, with mandatory notification of the specialists responsible for the safe operation and for the sound technical condition of the pressure chamber.
656. During the operation of the pressure chamber, continuous monitoring of the gas environment in the pressure chamber by the concentration of carbon dioxide (CO2), and also by temperature and humidity, is required. The monitoring of these characteristics shall be carried out in accordance with the operating instructions by means of the standard instruments forming part of the pressure chamber, or by means of autonomous monitoring instruments permitted for use in single-place medical pressure chambers.
657. During the operation of the pressure chamber, continuous monitoring of the leaktightness of the elements and units under pressure is required. The factors characterising a leaktightness failure are: sounds (hissing) when the gas environment penetrates from the pressure chamber or the supply pipelines into the surrounding atmosphere, a reduction in the compression rate (below the set value), a pressure drop in the pressure chamber in the isopression mode, increased oxygen consumption per session, an increase in the percentage content of oxygen in the atmosphere of the chamber hall and other visually observable signs of a leaktightness failure and destruction of the pressure chamber.
658. To prevent leaktightness failure and destruction of the pressure chamber, the following are ensured: (a) a daily preventive check of the quality of the connections and hoses by visual inspection before the start of work and by the pressure gauge readings during work; (b) continuous monitoring of the oxygen pressure in the supply line before the start of each treatment session; (c) continuous monitoring of the percentage content of oxygen in the chamber hall in cases where the design of the chamber hall provides for the installation of an automatic gas analyser, and by the use of portable gas analysers in the order and with the frequency established by the administrative documents of the medical organisation; (d) checking the conformity of the leaktightness of the pressure chamber with the indicator specified in the technical documentation for the pressure chamber, during periodic monitoring and technical examination; (e) continuous instrument monitoring of the pressure of the gas environment in the pressure chamber; (f) routine and periodic monitoring of the technical condition of the pressure chamber; (g) maintenance of the pressure chamber; (h) inspection of the condition of the glazing of the pressure chamber body before a session to detect defects, including "silvering" of the pressure chamber portholes; (i) protection of the transparent elements of the pressure chamber body from the effects of direct solar radiation (it is necessary to use curtains or blinds on the windows), radiation from operating germicidal lamps, local heating and organic solvents; (j) compliance with safety requirements.
659. Pressure gauges installed on the supply pipelines to the pressure chamber shall have an accuracy class of not less than 2.5. A red line indicating the working pressure in the pressure chamber shall be marked on the scale of the pressure gauge; instead of a red line, it is permitted, as an indicator of the value of the maximum permissible pressure, to attach to the body of the pressure gauge a plate (bracket) made of metal or another material of sufficient strength), painted red and fitting tightly to the glass of the pressure gauge. When selecting a pressure gauge for the pressure chamber, it is permitted for the measurement limit of the maximum working pressure to be in the third quarter of the scale.
660. The verification of pressure gauges, with their sealing or stamping, shall be carried out at least once every 12 months, unless other periods are established in the documentation for the pressure gauge. The results of verification are entered in the register of the periodic verification of pressure gauges. The maintenance and storage of the register is assigned to the person responsible for the sound technical condition of the pressure chamber.
661. A pressure gauge shall not be permitted for use in cases where: (a) there is no information on the verification carried out (a seal or stamp, or a document on the verification carried out); (b) the verification period has expired; (c) when it is switched off, the pointer does not return to the zero reading of the scale by an amount exceeding half of the permissible error for the given instrument; (d) the glass is broken or there is damage that may affect the accuracy of the readings of the pressure gauge.
662. Pressure chambers undergo preventive maintenance. The types and scope of maintenance, its frequency, and also the norms for the consumption of materials used in carrying it out (degreasing solutions, lubricants, alcohol), shall comply with the requirements set out in the documentation of the manufacturing organisation of the pressure chamber. The maintenance of the pressure chamber shall be carried out by a technical specialist of the HBO unit or of a specialised subdivision of the medical organisation and (or) by specialised organisations holding a licence for the maintenance of this type of medical equipment.
663. Scheduled repair and the elimination of faults of the pressure chamber detected during operation and during routine and scheduled checks, technical examination or diagnosis, shall be carried out in accordance with the technical documentation by specialists of the medical organisation servicing the pressure chamber and (or) by specialised organisations holding a licence for the maintenance of this type of medical equipment. During repair, it shall not be permitted to change the design and process diagram of the pressure chamber without the permission of the manufacturing organisation or the design organisation. The replacement of units and parts is permitted only with identical ones having documents confirming the quality of manufacture. During restorative painting of the internal surface and internal elements of pressure chambers, the old coating shall be removed and the standard thickness of the coating shall be ensured.
664. At least once a month, the person responsible for the sound technical condition, in the presence of the person responsible for the safe operation of the pressure chamber, shall carry out scheduled (periodic) monitoring of the technical condition and serviceability of the pressure chamber. The scheduled monitoring shall be carried out on the basis of the technical documentation of the manufacturing organisation of the pressure chamber and shall include: (a) checking the leaktightness of the pressure chamber and the serviceability of its systems and units, including the shut-off and shut-off-and-control fittings and the instrumentation (pressure gauges); (b) a technical session with the pressure chamber held without a patient at the working pressure for 30 to 60 minutes and with a short-term increase of the pressure to the value at which the safety valve operates, with measurement of the actual pressures at the start of its opening and at its full closing. The assessment of the technical condition shall be carried out taking into account the number of sessions accumulated by each pressure chamber on the basis of the criteria of malfunction, operability and limit state established in the technical documentation. The accounting of the accumulated sessions, with a record in the record card, shall be carried out by means of the operating-hour (cycle) counter sealed by the manufacturing organisation, and where a counter is not provided for on the given type of pressure chamber, then by the HBO session registration log.
665. The scheduled periodic monitoring of the technical condition and serviceability of the process systems and equipment of the chamber hall, carried out simultaneously with the monitoring of the technical condition of the pressure chamber, includes a check of: (a) the equipment of the chamber hall; (b) the oxygen supply system of the pressure chamber (within the chamber hall); (c) other technical systems (telephone communication, alarm, water supply, heating, air conditioning and ventilation systems); (d) diagnostic and other medical apparatus.
666. Information on the conduct of preventive maintenance, repair, monitoring of the technical condition, technical examination and diagnosis of the pressure chamber, the equipment and the process systems of the chamber hall, and on the faults that arose during their operation, is recorded in the maintenance and repair log. The maintenance and storage of the maintenance and repair log is carried out by the person responsible for the sound technical condition of the pressure chamber. The conclusion on the possibility of continued operation or the need for repair of the pressure chamber is entered in the session registration log.
667. The results of the technical examination of the pressure chamber and (or) its technical diagnosis are drawn up in accordance with Chapter VI of these Federal Norms and Rules.
668. The pressure chamber shall undergo technical examination before being put into operation and periodically during operation.
669. The initial technical examination of a pressure chamber supplied as an assembly shall be carried out by the manufacturing organisation before installation at the place of its use, or by a specialised organisation. The initial technical examination shall include a check of the quality of manufacture, inspection, hydraulic strength tests and pneumatic tests for leaktightness and tightness. A record of the results of the initial technical examination is made in the data sheet of the pressure chamber. After the installation of the pressure chamber at the place of its use in the chamber hall, the specialised organisation that carried out the installation of the pressure chamber together with the technical specialists of the medical organisation shall carry out a check of the technical documentation, of the correctness of the installation and connection of the pressure chamber to the life-support systems, an inspection of the pressure chamber and a check of its operation and leaktightness at the working pressure of the environment. The results shall be recorded in the data sheet of the pressure chamber.
670. An extraordinary technical examination of the pressure chamber is carried out: (a) before start-up, if the pressure chamber has not been operated for more than 12 months; (b) if the pressure chamber has been dismantled and installed in a new place; (c) at the request of the responsible persons of the operating organisation.
671. The scope, methods and frequency of the work performed when carrying out the technical examination of the pressure chamber are established by the operating manual (instructions) of the pressure chamber and shall, as a minimum, provide for the conduct of a visual inspection of the pressure chamber, a check of it in operation and of the operation of the life-support systems, and also a check of the leaktightness of the pressure chamber at the working pressure of the environment.
672. The industrial safety expert examination (technical diagnosis) of the pressure chamber shall be carried out in accordance with the requirements of Chapter VI of these Federal Norms and Rules after the exhaustion of the assigned (design) service life or the assigned (design) service term, to determine the conformity of the pressure chamber with the industrial safety requirements, and also the possibility and the periods for the extension of safe operation.
673. Technical diagnosis is carried out according to special methods for the specific type of pressure chamber, developed by the manufacturing organisations of the pressure chamber.
674. An extraordinary technical diagnosis is carried out: (a) after the installation of a pressure chamber not previously in operation, where the periods and conditions of storage established by the manufacturing organisation have been violated; (b) after reconstruction or repair with replacement of the main elements of the pressure chamber; (c) where there is damage sustained during transportation or during operation that affects the safety of operation of the pressure chamber. The reasons for the extraordinary technical diagnosis are recorded in the data sheet of the pressure chamber.
675. Technical diagnosis is carried out directly at the place of installation of the pressure chamber or, if necessary, at a specialised organisation carrying out this work.
676. The person responsible for the sound condition of the pressure chamber shall submit to the specialists of the organisation carrying out the technical diagnosis the following documents: (a) a complete set of technical documentation for the pressure chamber; (b) the design of the installation and layout of the pressure chamber; (c) the operational documentation.
677. The results of the industrial safety expert examination (technical diagnosis) of the pressure chamber are drawn up in accordance with the requirements of Chapter VI of these Federal Norms and Rules.
678. In the event of negative results of the technical diagnosis, the pressure chamber shall be subject to repair with subsequent repeated technical diagnosis, or to disposal.
679. In the case of the use of diving pressure chambers as multi-place medical pressure chambers, their installation, re-equipment and the features of operation in modes differing from those established by the manufacturing organisation shall be determined by the design documentation. Where necessary (in cases of insufficiency of the requirements of these Federal Norms and Rules and other applicable regulatory legal acts), the organisation developing the design documentation shall, in addition to these Federal Norms and Rules, determine requirements for ensuring the safe operation of such pressure chambers, with the development of a safety justification in accordance with the legislation in the field of industrial safety.
680. This Chapter of the Federal Norms and Rules establishes additional industrial safety requirements for diving pressure chambers used in specialised institutions (organisations engaged in carrying out diving work, training centres, diving schools, treatment and prevention institutions and other organisations), for carrying out decompression, training and treatment of divers.
681. Depending on the purpose and conditions of operation, diving pressure chambers may be located: (a) stationary pressure chambers - in the premises of permanent, prefabricated and other buildings (structures) intended for the stationary installation of pressure chambers, or in non-residential buildings specially re-equipped (with technical re-equipment, repair or major repair carried out), provided that their conformity with the design documentation, developed in accordance with the legislation of the Russian Federation on urban development activities and in the field of industrial safety, is ensured, and that the requirements of these Federal Norms and Rules are fulfilled; (b) transportable pressure chambers - in containers of various designs installed (transported) on the chassis of vehicles or in a stationary manner.
682. During the installation of diving pressure chambers and other equipment, the fitting-out (arrangement) of buildings and premises (chamber halls) for their placement, and also during their operation in institutions subordinate to the Ministry of Defence of the Russian Federation or to other ministries and departments of the Russian Federation, the requirements of the guiding documents on the diving service and on the design and operation of diving pressure chambers, approved by the relevant federal bodies and departments within the scope of their powers, shall be taken into account.
683. During the stationary installation of diving pressure chambers, in accordance with the design documentation, the following shall be ensured: (a) the room for the installation of the pressure chambers shall provide the possibility for divers and servicing personnel to be present in it, based on the capacity of the pressure chamber and the staffing schedule of the servicing personnel, whereby the necessary evacuation exits shall be provided; (b) all windows and doors in the room of the pressure chamber (chamber hall) shall open outwards, whereby it is necessary to calculate the area of the windows and doors providing for the release of compressed gas in cases of depressurisation of the equipment and pipelines during an accident; (c) chamber halls shall be equipped with communication systems and the necessary gas analysis systems (alarms) for monitoring the increase in the concentration of oxygen and oxygen-containing mixtures in the room in cases of their leaks; (d) chamber halls shall have a power supply system of reliability category 1 in accordance with the requirements of the Rules for the Construction of Electrical Installations; (e) for the discharge of gases from the pressure chamber, special pipelines shall be laid in the chamber hall to ensure the removal of gases beyond the chamber hall, whereby it shall not be permitted to combine the air and oxygen discharge pipelines; (f) an individual isolating breathing apparatus (or apparatuses - in accordance with the staffing schedule) of the pressure chamber operator shall be placed in the chamber hall in case of fire, smoke or exceedance of the concentration of hazardous gases in the chamber hall, to ensure the safe removal of people from the pressure chamber; (g) the chamber hall shall be equipped with supply and exhaust ventilation systems; (h) the laying of high-pressure pipelines for oxygen and other gases with an increased oxygen content in the chamber hall shall be prohibited; the maximum pressure of gases in such pipelines is permitted to be no more than 7.0 MPa; (i) the requirements for the finishing technology of the chamber hall room and for the materials shall be determined during design, whereby the use of antistatic materials that do not accumulate static electricity and do not create preconditions for its accumulation shall be ensured; (j) the placement of multi-place pressure chambers shall ensure the convenience of their assembly and installation on the ground floor of the building, except in cases justified by the technology of their use and the design documentation, whereby, in any case, a calculation of the foundations, floors and columns for the possibility of installing the pressure chamber in the room shall be carried out, taking into account the subsequent technical examination of the pressure chambers, including the conduct of hydraulic tests. The installation of pressure chambers on the semi-basement and basement floors shall not be permitted; (k) the number of evacuation exits from the room where the pressure chamber is located shall be not less than two; (l) if the design specification for the design of the hazardous production facility and the installation of a stationary pressure chamber on it provides for the process of transferring (moving) a diver from a transportable pressure chamber to a stationary pressure chamber, then in this case the stationary pressure chambers shall be equipped with a docking unit for connecting transportable pressure chambers (with the possibility of placing a transportable pressure chamber inside a stationary one intended for treatment), and the placement of the pressure chambers shall ensure unimpeded approach with a transportable pressure chamber and shall ensure the possibility of transferring (moving) a diver to the stationary pressure chamber.
684. The requirements for the installation and operation of pressure chambers in containers of various designs, transported on various chassis or installed in a stationary manner, are determined by the manufacturing organisation of such complexes, on the basis of the requirements for ensuring maximum safety, and are specified in the operating manual (instructions) and other technical documentation. At the same time, the possibility and procedure for conducting decompression (recompression) sessions during the movement of the vehicle shall be determined by the manufacturing organisation of the complexes. The system for storing the air (breathing gas mixtures) reserves of the pressure chamber shall ensure the supply of air (BGM) to the pressure chamber throughout the entire period of a person's stay in the pressure chamber.
685. Pressure chambers with a diameter of 1200 mm and more shall be equipped with shut-off fittings installed directly on the body of the pressure chamber, both on the outside and inside the pressure chamber, which shall ensure the possibility of shutting off the supply (discharge) pipelines of the gas supply system of the pressure chamber in emergency cases or where it is necessary for the divers to carry out decompression independently. The fittings shall be sealed in the working position. The list of the pressure chamber fittings and the chamber hall pipelines subject to sealing, and their working position (open - closed), shall be specified in the operational documentation.
686. All fittings of high-pressure oxygen supply systems (with the exception of the bodies of pressure gauges and other items not having direct contact with oxygen) used for the supply of oxygen shall be made of materials that exclude their ignition and combustion in an oxygen environment (of increased oxygen content).
687. Valves installed on oxygen pipelines shall ensure a smooth increase of pressure after they are opened. The use of ball valves is permitted only at the points of emergency shut-off of the supply or discharge of oxygen from the compartments of the pressure chamber.
688. All bypass valves shall have handles of a distinctive red colour or be marked with a red square on the mnemonic diagram of the panel, to prevent accidental opening.
689. The connection of equipment and life-support systems to the pressure chamber shall be carried out by means of shut-off valves installed on the body of the pressure chamber.
690. The safety valves of the compartments of the pressure chamber shall be connected by means of a shut-off valve that ensures the instantaneous closing of the pressure chamber in the event of a failure of the safety valve (incorrect operation); the handles of the valves shall be sealed in the open position and be red.
691. During the operation of the pressure chamber, the possibility for divers to monitor the pressure in the pressure chamber shall be ensured by installing a pressure gauge - pneumatic depth gauge inside its compartment (compartments).
692. The pressure gauges (pneumatic depth gauges) of the pressure chamber shall have an accuracy class of not less than 0.6 and shall ensure the possibility of taking readings over the entire range of the scale of the pressure gauge.
693. The valves of the pressure gauges (pneumatic depth gauges) shall provide the possibility of connecting a control pressure gauge used to check the accuracy of the readings of the technical (working) pressure gauges at the places of their installation.
694. All inlets and outlets inside the pressure chamber shall have silencers or diffusers (grilles) preventing the suction of body parts of the people located in the chamber.
695. The equipment used for heating the pressure chamber shall comply with the electrical safety norms.
696. The supply of pure medical (100 per cent) oxygen to the pressure chamber shall be carried out for the breathing of divers through special oxygen masks (BIBS masks), and also to maintain the percentage content of oxygen (metered supply of oxygen) in the breathing gas environment of the pressure chamber (with closed and semi-closed ventilation cycles). The metered supply of oxygen is carried out only through a metering - small-capacity cylinder (with a volume of no more than 100 l). At the same time, interlock devices shall be provided for the oxygen supply valves from the line (transport cylinder) to the small-capacity cylinder, which do not allow the possibility of simultaneous opening of these valves. The metered supply of oxygen by other means shall be prohibited. When supplying oxygen to the breathing masks, the possibility of exhaling oxygen outside the pressure chamber shall be ensured; the exhalation of oxygen into the atmosphere inside the pressure chamber shall be prohibited. When supplying oxygen to the breathing masks, quick-disconnect devices for connecting the masks shall be provided in the pressure chamber. These devices shall be of various sizes, which exclude errors when connecting the masks for the inhalation and exhalation of oxygen.
697. The life support systems of pressure chambers shall have gas analysers with a threshold for actuation of the audible alarm when the oxygen concentration reaches more than 23 per cent. The pressure chamber shall have a gas analyser for determining the concentration of carbon dioxide (CO2) in the compartments.
698. Where breathing masks operating at a pressure in the pressure chamber above 0.2 MPa are used in pressure chambers (including masks for the supply of an artificial breathing mixture), a device (regulator) shall be provided that ensures sufficient back-pressure (resistance) on exhalation to prevent injury to divers. The magnitude of the back-pressure (resistance) to exhalation shall be regulated automatically depending on the pressure in the pressure chamber.
699. During operation of the pressure chamber, the serviceability of the mechanical interlocking device (the presence of which shall be provided for by the design of the medical lock) that prevents the opening of the external hatch cover in the event of incomplete release of the pressure from the lock cavity shall be ensured.
700. Automatic or semi-automatic control systems may be used for the supply and discharge of air and oxygen. Where these systems are used, all pressure chambers shall be equipped with a backup manual system for the supply and discharge of air and oxygen from the compartments of the pressure chamber.
701. The supply of gases into the compartments of the pressure chamber to build up pressure shall be carried out through pressure-reducing devices. The pressure-reducing devices shall have a backup. The connection of high-pressure gas supply lines directly to the pressure chamber, bypassing the pressure-reducing devices, shall be prohibited. Safety valves shall be installed after all pressure-reducing devices to prevent the pressure of the supplied gases from rising above the value established by the operational documentation.
702. During operation of a pressure chamber equipped with a sanitary sewage system with a damper vessel for the removal of waste products, the serviceability of the valves installed on the damper vessel, with an interlocking device that prevents the release of pressure from the pressure chamber through the damper cylinder into the atmosphere, shall be ensured.
703. In all pressure chambers, the presence and operability of a carbon dioxide (CO2) absorber shall be ensured.
704. The compartment hatches shall be equipped with valves for equalising the pressure between compartments.
705. During operation of the pressure chamber, the presence and also the serviceability of the main and backup (emergency) communication systems, which shall be of the induction type or operate from replaceable power cells, shall be ensured in the compartments.
706. The compartments of the pressure chamber shall be equipped with portholes, which shall have protective covers or transparent screens to protect the glass from accidental mechanical impact.
707. The installation and assembly of the pressure chamber are carried out by specialised organisations in accordance with the design and the technical documentation of the manufacturing organisation.
708. After the installation of the pressure chamber, an inspection of its shell, devices, fittings and pipelines, as well as tests, shall be carried out. After this, the commissioning of the pressure chamber is carried out in accordance with Chapter IV of these Federal Norms and Rules.
709. The organisation of the operation of diving pressure chambers shall comply with the requirements of these Federal Norms and Rules and is determined by the administrative documents of the operating organisation, taking into account the specifics of their use and the requirements of these Federal Norms and Rules. 710 Diving pressure chambers manufactured before the entry into force of these Federal Norms and Rules and TR CU 032/2013 are used until the end of the service life specified by the manufacturing organisation. Upon expiry of the period they shall be modernised in accordance with the requirements of these Federal Norms and Rules.
711. For safe operation of the pressure chamber, the operating organisation shall ensure the performance of primary, periodic and extraordinary technical examination, as well as technical diagnostics. The scope and procedure for carrying them out shall comply with the requirements of the operating manual or other technical documentation for the pressure chamber of the specific type and of these Federal Norms and Rules.
712. The primary technical examination of the pressure chamber (unless there are other instructions in the technical documentation) includes: (a) verification of the technical documentation; (b) external and internal inspection of the pressure chamber shell; (c) hydraulic strength tests; (d) pneumatic leak-tightness and tightness tests; (e) an operational check of the pressure chamber.
713. The primary technical examination of pressure chambers transported in parts and assembled at the installation site outside the manufacturing organisation shall be carried out to the scope specified in paragraph 712 of these Federal Norms and Rules, after their assembly at the installation site. The primary technical examination of pressure chambers supplied fully assembled after manufacture may be carried out at the manufacturing enterprise. In this case, after assembly of the pressure chamber at the installation site in the operating organisation, the following are carried out: verification of the technical documentation, inspection, testing of the pipelines and an operational check of the pressure chamber.
714. The periodic technical examination is carried out in the manner and at the frequency established in the operating manual or other technical documentation of the manufacturing organisation for the specific type of pressure chamber, but no later than 10 years from the start of operation. The periodic technical examination shall include: (a) internal and external inspections of the shell, systems and devices; (b) hydraulic (strength) and pneumatic (tightness and leak-tightness) tests; (c) an operational check of the pressure chamber life support systems and other devices.
715. The extraordinary technical examination is carried out in the following cases: (a) upon detection of a defect that reduces the strength of the pressure chamber (bulges, dents, scoring, cracks, corrosion wear); (b) in the event of a breach of the operating regimes owing to the occurrence of malfunctions of the pressure chamber or its elements affecting the safety of the persons inside the pressure chamber and of the service personnel. The extraordinary technical examination is carried out to the scope of the periodic technical examination.
716. Hydraulic tests of pressure chambers are carried out at a test pressure equal to 1.25 of the working pressure. During the hydraulic tests at test pressure, the shell, bulkheads, locks, doors and the hatch and lock covers of the pressure chamber are checked for strength. Hydraulic tests of pressure chambers transported in parts and assembled at the installation site outside the manufacturing organisation are carried out after their assembly at the installation site. For a pressure chamber supplied in assembled form, after installation at the operating facility only those sections and welded joints of the supply pipelines of the systems that were not subjected to hydraulic testing before the installation of the pressure chamber are subject to hydraulic testing. Sections of pipelines that form a single functional circuit with the pressure chamber and that are subjected to assembly welding after their manufacture or to brazing during assembly at the operating facility are tested for strength at a test pressure equal to one and a half times the working pressure of the pressure chamber. For similar tests during the examination (during operation) of pressure chambers, the test pressure for the pipelines of the pressure chamber systems shall correspond to 1.25 of the working pressure. Instead of hydraulic tests during operation of the pressure chamber, pneumatic tests of the equipment and pipelines of the pressure chamber systems that are loaded with air or gas pressure may be carried out. The possibility of such a substitution is permitted where the design of the equipment and pipelines is non-detachable and where there are stringent requirements for the degreasing and sanitary treatment of the internal surfaces. The decision to replace hydraulic tests with pneumatic tests is taken by the operating organisation together with the organisation carrying out the technical examination, after performing the corresponding strength calculation and carrying out inspection (before the tests begin) of the welds by ultrasonic flaw detection or the radiographic method and by surface flaw detection methods. The test pressure for pneumatic tests of the equipment and pipelines of the pressure chamber systems, as well as the scope of non-destructive testing of the welded joints, shall be determined in the technical examination programme drawn up taking into account the recommendations of the design developer and (or) the manufacturing organisation of the pressure chamber. When hydraulic or pneumatic strength tests of the pressure chamber are carried out, compliance with the requirements of Chapter III of these Federal Norms and Rules shall be ensured. The test results are documented in a protocol and recorded in the passport of the pressure chamber.
717. Pneumatic tests of the pressure chamber and its elements for leak-tightness and tightness are carried out at a gas medium pressure equal to the working pressure, after the hydraulic strength tests have been carried out. Pneumatic tests for leak-tightness and tightness are carried out with air (nitrogen) and with gas of the type for which the pressure chamber is intended, observing the following sequence: (a) testing with air (nitrogen); (b) elimination of defects; (c) testing with helium; (d) elimination of defects. The helium testing of the pressure chamber shall be carried out initially after manufacture.
718. A fully assembled pressure chamber, with the portholes, pressure-tight penetrations (glands), safety valves and pipelines with the shut-off valves nearest to the pressure chamber shell (or the shut-off valves on the control panel) installed, is subjected to pneumatic tests for leak-tightness and tightness before the thermal insulation is applied.
719. The operational check of the pressure chamber at the working pressure of the gas medium is carried out to the scope provided for in the test programme at the final stage of the primary technical examination of the pressure chamber, after the hydraulic and pneumatic tests have been carried out, to confirm its compliance with the requirements of the technical documentation and the safety requirements, in the following cases: after assembly of the pressure chamber on the test bench of the manufacturing organisation; after assembly of the pressure chamber at the operating facility.
720. During the operational check of the pressure chamber, the following is monitored: (a) the condition and serviceability of the pressure chamber, the fittings, the pipelines, the pressure-reducing valves, the connecting flanges, the electrical equipment, the earthing, the instrumentation, the life support systems and means, the serviceability of the pressure-tight penetrations, the portholes and their glass. The serviceability of the life support systems and means is checked at the working pressure in the pressure chamber during their operation for their intended purpose; (b) the operability of the long-stay pressure chamber and of its life support systems and means during operation for their intended purpose: in air at normal atmospheric pressure; in air under a gas medium pressure corresponding to the working pressure in the pressure chamber; with a gas medium (oxygen-helium) at the working pressure in the pressure chamber; (c) the operability of the safety valves (for lifting and reseating) by raising the pressure in the pressure chamber or on a test bench for testing safety valves; (d) the preparedness of the service personnel and their knowledge of the operating instructions.
721. The operational check of the pressure chamber after assembly is carried out by a commission (to the scope of the readiness verification work established by the requirements of Chapter IV of the Federal Norms and Rules), which may, where necessary, include representatives of the manufacturing organisation, the operating organisation (the customer) and the specialised organisation. The composition of the commission for the operational check of the pressure chamber during periodic and extraordinary examinations is determined by the administrative documents of the operating organisation.
722. The results of the technical examination are documented in the manner established by Chapter VI of these Federal Norms and Rules.
723. To ensure safe operation, pressure chambers shall be subjected to the following types of technical diagnostics: (a) scheduled technical diagnostics, carried out upon expiry of the assigned service life or exhaustion of the assigned service resource, to assess the technical condition of the pressure chamber with a view to determining the parameters and conditions of its further safe operation; (b) unscheduled technical diagnostics, carried out to assess the technical condition of the pressure chamber after an accident or detected damage, with a view to determining the possible parameters and conditions of the further operation of the pressure chamber. The technical diagnostics of pressure chambers is carried out by an organisation authorised in accordance with the established procedure, in accordance with a developed programme and methodology. The scope, methods and procedure for carrying out the technical diagnostics and the documentation of its results are determined in accordance with the technical documentation for the pressure chamber and the requirements of Chapter VI of these Federal Norms and Rules.
1. The maximum values of the parameters (pressure and temperature) of the working medium taken as the basis for classifying equipment within the scope of these Federal Norms and Rules, and also indicated in the equipment passport following the technical examination: (a) for a once-through steam boiler and a hot-water boiler or a boiler with organic and inorganic heat carriers - the maximum parameters of the working medium at the boiler outlet; (b) for a steam boiler with a drum - the maximum parameters of the steam in the drum and at the outlet of the superheater header (where present); (c) for a vessel - the maximum working parameters of temperature and pressure of the working medium under normal flow, determined taking into account its physico-chemical properties and the operating conditions of the vessel; (d) for pipelines from boilers - the maximum working parameters at the boiler outlet; (e) for steam pipelines from turbines operating with back-pressure - the maximum possible pressure in the back-pressure provided for by the technical specifications for the supply of the turbine, and the maximum possible steam temperature in the back-pressure when the turbine is running at no load; (f) for steam pipelines from the non-controlled and controlled steam extractions of the turbine (including steam pipelines of intermediate superheating) - the maximum possible values of pressure and temperature of the steam in the extraction (according to the data of the turbine manufacturing organisation); (g) for pipeline sections of pressure-reducing and pressure-reducing-and-cooling installations (RU, ROU) and fast-acting pressure-reducing-and-cooling installations (BROU), including the inlet and outlet gate valves - the pipeline parameters on the high-pressure side; (h) for steam pipelines from pressure-reducing and pressure-reducing-and-cooling installations - the maximum possible values of pressure and temperature of the reduced steam adopted in the design of the installation; (i) for feedwater pipelines after high-pressure deaerators - the nominal water pressure taking into account the hydrostatic pressure of the liquid column, and the saturation temperature in the deaerator; (j) for feedwater pipelines after feed pumps and high-pressure heaters (PVD) - the highest pressure created in the pressure pipeline by the feed electric pump with the gate valve closed and at the maximum pressure on the pump suction line (where feed pumps with a turbine drive and electric pumps with a fluid coupling are used - 1.05 of the nominal pump pressure), and the maximum design temperature of the water after the last PVD; (k) for the supply and return pipelines of water heat networks - the highest possible pressure and the maximum water temperature in the supply pipeline of the heat source, taking into account the operation of pumping substations along the route and the terrain relief. The pipeline parameters determined from the working parameters of the medium at its inlet (in the absence of devices on it that change these parameters) apply to the whole pipeline, regardless of its extent, are indicated in the operational documentation and are taken as the basis as the working parameters among the initial data when performing strength calculations and carrying out hydraulic tests.
2. During operation of pressure equipment, as the value of the maximum permissible (authorised) working pressure indicated in the record of the results of the technical examination of the equipment, the maximum value of the excess working pressure that corresponds to the conditions for safe conduct of the technological process, is permissible for the equipment or its element and is established on the basis of the primary assessment of its conformity after manufacture (reconstruction), as well as of the periodic assessment of the actual technical condition during operation based on the results of technical examination and (or) diagnostics and a control strength calculation, is adopted. The value of the authorised pressure of equipment that is in serviceable condition corresponds to the working pressure indicated by the manufacturing organisation in the passport, or may be less than the passport value where it is incorporated into a technological complex (system) at a specific hazardous production facility for which, taking into account the technical characteristics of the equipment incorporated into it (technological units, pumps, compressors, pipelines and other devices) and the operating regimes, the design documentation establishes a value of the maximum working pressure under normal flow of the technological process that is less than the working pressure indicated in the passport of the equipment used within such a complex (system). To ensure the requirements of these Federal Norms and Rules, where the value of the authorised pressure is reduced on the basis of the design following the primary technical examination, or during operation following the periodic technical examination (or) diagnostics and a control strength calculation, this value of the authorised pressure is taken as the basis as the working pressure when setting the safety devices and safety instruments and when establishing the value of the test pressure during testing. In cases where the consumers (equipment, installations) connected to the pressure equipment are temporarily unable to accept the maximum load owing to detected defects, the authorised working pressure established in this case is taken into account when setting the actuation of the safety devices (with mandatory calculation of their throughput capacity) and the safety instruments of the pressure equipment, but shall not be taken as the basis in place of the working pressure indicated in the passport when selecting the elements and materials used for its repair, and also when determining the test pressure for testing. Operation of the equipment shall be carried out within the values (no more than) of the maximum authorised working parameters indicated above, which, among other things, shall be taken into account when monitoring the operating regimes of the equipment, when setting the safety devices, safety instruments and emergency alarm devices installed separately or forming part of automated process control systems, so as to prevent and reduce the risk of accidents and incidents during operation of the equipment, which, in accordance with the definitions established in Article 1 of Federal Law No. 116-FZ, in relation to the equipment listed in paragraph 3 of the Federal Norms and Rules, are as follows: 1) The following shall be classified as an accident of equipment during its operation under pressure at a hazardous production facility: destruction of the equipment or of its main (one or more) elements (see paragraph 103 of these Federal Norms and Rules), accompanied by the opening (rupture) of the walls of the shell and other elements of the equipment, with the release of a medium expanding in volume and possible scattering of fragments, occurring as a result of an impermissible rise in the excess pressure of the working medium or owing to the loss of the strength properties of the structural materials of the equipment as a result of the development of defects during its operation, because of which restoration of the equipment to an operable condition is impossible or restorative repair or replacement of the destroyed main elements of the equipment is required; destruction (deformation) of the supporting steel structures (frame) with full or partial loss by them of load-bearing capacity, occurring during the destruction of the equipment elements or leading to their destruction, after which restoration of the equipment to an operable condition is impossible or restorative repair or replacement of the destroyed main elements of the equipment and parts of the steel structures is required; destruction of the equipment or of its main elements during operation under pressure and of the supporting steel structures (frame) with full or partial loss of load-bearing capacity under the action of external factors: mechanical impact on the external surface of an element or an uncontrolled explosion and (or) fire that led to an accident of the equipment. 2) The following shall be classified as an incident during operation of equipment under pressure at a hazardous production facility: damage (including a breach of tightness) to the covers and closures of the manholes or hatches of the pressure equipment; the formation of bulges and dents on the walls of the pressure equipment and (or) its main elements, of cracks and fistulas in the base metal and (or) in the welded joints of the pressure equipment and (or) its main elements; damage to and ruptures of individual parts, tubes or assemblies of the main elements that have not led to an accident of the pressure equipment but have made it necessary to shut it down (cease operation) to carry out repair or replacement of the damaged section (part, assembly) of the main element of the equipment, or to temporarily plug the damaged tube within the element until the next scheduled repair of the equipment is carried out, in cases where this is permitted by the operating manual (instructions); explosions (pops) of fuel vapours or of a pulverised-coal mixture with air in the furnaces and gas ducts of boilers that have not led to an accident and that require shutting down and checking the condition of the boiler to determine the possibility of its operation or the need to repair the damaged elements and the lining of the boiler.
3. Steam and hot (superheated) water pipelines, to which, among other kinds (types) of equipment operating under excess pressure, the Federal Norms and Rules apply, forming a system (structure) consisting of pipeline fittings, assembly units, tubes, flanges and other parts and elements of the pipeline interconnected with the use of permanent and (or) detachable joints, as well as of the parts of the supporting-and-suspension system attached to them that ensure the safe operation of the pipeline, intended for transporting water steam at an excess pressure of more than 0.07 MPa or water at a temperature of more than 115 °C (including pipelines of heat networks and of other purposes), for the transfer of thermal energy from a source (boiler, turbine, water heater, vessel and other technical devices) to a consumer (technological installation (unit), vessel, steam turbine, building heating system and other consuming installations), are subdivided, depending on temperature and pressure, into operational categories Ie, IIe, IIIe, IVe, the alphanumeric designation (identifier, index) of which has been adopted as equivalent (analogous) to the numerical designations of pipeline categories I, II, III, IV established by the previously in-force rules for the construction and safe operation of steam and hot-water pipelines (hereinafter - PB), so as to ensure: the unambiguous interpretation and correct application of the requirements of these Federal Norms and Rules, including in respect of pipelines whose technical documentation was drawn up during the period of the previously in-force PB; the possibility of the error-free application of the recommendations of normative and technical documents establishing the scopes of quality control of welding by non-destructive methods during assembly and repair in the course of operation, and other recommendations containing references to pipeline categories under the previously in-force PB. The correlation of the operational categories under the Federal Norms and Rules with the categories under the previously in-force PB is given in Table 1.
To determine the category of a pipeline, the values of the working parameters of the transported medium shall be taken in accordance with paragraph 1 of this Appendix to the Federal Norms and Rules. If the values of the parameters of the medium (pressure and temperature) fall within different categories, the pipeline shall be assigned to the category corresponding to the maximum value of the parameter of the medium. Given the direct interrelation of the operational category with the parameters of the pipeline, the entry of categories into the design and operational documentation of pipelines developed and approved before the entry into force of these Federal Norms and Rules is not required until the need for its revision arises.
4. When pressure equipment is used at a hazardous production facility, the requirements of Federal Law No. 116-FZ and of these Federal Norms and Rules apply to buildings and structures intended for carrying out technological processes with the use of pressure equipment, the destruction of which owing to an inoperable (emergency) condition may cause an accident of the equipment and injury to people, including: (a) buildings, where they contain the equipment listed in paragraph 3 of these Federal Norms and Rules: of production purpose of industrial enterprises; of thermal power stations and boiler houses; of central heating points and pumping stations forming part of pipeline systems. (b) structures: chimneys standing separately on their own foundation, and gas ducts from the boilers to the chimneys; metal chimneys mounted on the metal frame of shaft-layout boilers; the boiler frame - a load-bearing metal structure that takes the load from the mass of the boiler, taking into account temporary and special loads, and that ensures the required mutual arrangement of the boiler elements; trestles for steam and hot-water pipelines; free-standing pipeline supports with a foundation; structures of the supporting-and-suspension system of pipelines; ducts (non-passable, semi-passable, passable) for laying pipelines, together with the building structures forming part of them (trays, foundation (block) supports), chambers and pavilions for installing fittings and other devices; load-bearing foundations that take the load from the equipment installed on them and ensure its stable position.
1. This Appendix, in accordance with Chapter III of the Federal Norms and Rules, establishes the basic requirements for the norms for assessing the quality of welded joints operating under pressure and made by arc, electroslag, electron-beam and gas welding, under visual, measurement, capillary, magnetic-particle, radiographic and ultrasonic testing, as well as under mechanical tests and metallographic examination.
2. The quality assessment norms are adopted according to the following dimensional indicators (RP): according to the nominal thickness of the welded parts - for butt welded joints of parts of equal thickness (where the ends of the parts are pre-machined by boring, expanding, calibration or compression - according to the nominal thickness of the welded parts in the machining zone); according to the nominal thickness of the thinner part - for butt welded joints of parts of different nominal thickness (where the end of the thinner part is pre-machined - according to its nominal thickness in the machining zone); according to the design height of the fillet weld - for corner, tee and lap welded joints (for corner and tee welded joints with full penetration, the nominal thickness of the thinner part may be taken as the dimensional indicator); according to twice the nominal thickness of the thinner part (of the two welded) - for edge welded joints (except joints of the welding-in of tubes into tube sheets); according to the nominal thickness of the tube wall - for welded joints of the welding-in of tubes into tube sheets. In radiographic testing of welded joints through two walls, the quality assessment norms shall be taken according to the same dimensional indicator as in testing through one wall.
3. The extent (length, perimeter) of welded joints is determined along the external surface of the welded parts at the edges of the weld (for joints of branch pipes, and also for corner and tee joints - along the external surface of the part being welded on, at the edge of the fillet weld).
4. The number and total reduced area of individual inclusions and clusters revealed by the non-destructive testing methods applied shall not exceed the values specified in these norms on any section of a welded joint 100 mm long. For welded joints with an extent of less than 100 mm, the norms for the number and total reduced area of individual inclusions and clusters are reduced in proportion to the reduction in the extent of the joint being tested. If a fractional value is obtained in this case, it is rounded to the nearest whole number.
5. Visual and measurement testing (VIK) is carried out in respect of all surfaces of semi-finished products, blanks, parts, assembly units and articles that are accessible for this purpose. Visual and measurement testing is performed before the testing of materials and welded joints (weld overlays) by other non-destructive testing methods, and also after the elimination of defects. Before testing, the surfaces of materials and welded joints (weld overlays) are cleaned of moisture, slag, metal spatter, rust and other contaminants that impede the testing. Measurements are carried out after visual testing or simultaneously with it. Measurements of parts prepared for welding are carried out before their assembly. Visual and measurement testing of materials and welded joints (weld overlays) that are subject to heat treatment is carried out before and after that operation. If the part, structure or assembly being tested is subject to full heat treatment (normalising or quenching with subsequent tempering), testing is carried out after it has been performed. Visual and measurement testing of materials and welded joints that are subject to mechanical machining, including the removal of the weld reinforcement bead, or to deformation, is carried out before and after those operations.
6. During the assembly of elements to be welded, visual and measurement control is carried out to identify and verify that the permissible dimensions of gaps, edge offsets, the shape and dimensions of the edges and the geometric position (break or perpendicularity) of the axes and surfaces of the assembled elements are ensured, and the following is performed. 6.1. When preparing parts for welding, the following shall be controlled: the presence of marking and (or) documentation confirming the acceptance of semi-finished products, parts, assembly units and articles during incoming control; the presence of the marking of the material's manufacturing organisation on the parts prepared for welding; the mechanical removal of the heat-affected zone at the location of thermal (flame) cutting of the workpieces (the need for which shall be specified in the design or process documentation); the geometric shape of the machined edges, including when preparing parts with different nominal wall thicknesses; the geometric shape of the machined internal surfaces of annular parts; the shape of the backing plates (rings) and consumable inserts; the presence of a seal weld at the split of the backing plate (ring), the quality of the seal weld of the backing plate (ring), and also the presence of dressing of the seal weld at the split of the backing plate (ring); the cleanliness (the absence of visually observable contamination, dust, corrosion products, moisture, oil and the like) of the edges to be welded (surfaced) and the surfaces adjacent to them, and also of the areas of material to be subjected to non-destructive control. 6.2. During the assembly of parts for welding, the following shall be controlled visually: the correctness of the installation of the backing plates (rings); the correctness of the installation of temporary process attachments; the correctness of the assembly and fastening of the parts in the assembly fixtures; the correctness of the arrangement and the number of tack welds and their quality; the correctness of the installation of fixtures for back-purging with shielding gas; the correctness of the application of the activating flux and the protective flux paste; the presence of a protective coating against spatter of molten metal on the surface of parts made of austenitic steels welded by manual arc welding and by semi-automatic (automatic) gas-shielded consumable-electrode welding; the cleanliness of the edges and the adjacent surfaces of the parts. 6.3. Measurement control during the preparation of parts for welding is carried out to check: the dimensions of the edge preparation (the bevel angles of the edges, the thickness and width of the root face of the prepared edges); the dimensions (diameter, length, tool exit angle) of the boring (expansion) of the pipe ends along the internal diameter; the dimensions of the backing plates (rings) and consumable inserts (width, thickness, bevel angles, diameter); the dimensions of the elements of segment bends; the perpendicularity of the ends of cylindrical parts prepared for welding to their generatrices; the minimum actual wall thickness of the cylindrical part after boring along the internal diameter; the dimensions of the holes for the branch pipe (nozzle) and the machining of the edges in the pipe (header, shell); the thickness and width of the backing in the lock joint; the width of the zone of mechanical dressing of the external and internal surfaces of the parts and the roughness of the surfaces of the edges and the adjacent surfaces of the parts, including the location of the dressing of the weld at the split of the remaining backing plate (ring). 6.4. Measurement control of the joints assembled for welding includes a check of: the dimensions of the welds attaching the temporary process attachments; the distance of the process attachment from the edge of the preparation and the arrangement of the attachments along the length (perimeter) of the joint (where necessary, if the technical documentation stipulates the distance between adjacent attachments); the magnitude of the gap in the joint, including between the part and the backing plate (ring); the amount of edge offset (internal and external) of the assembled parts; the amount of overlap of the parts in the lap joint; the dimensions (length, height) of the tack welds and their arrangement along the length (perimeter) of the joint (where necessary, if this is stipulated in the technical documentation, also the distance between adjacent tack welds); the amount of the gap in the lock of the consumable wire insert; the amount of the break of the axes of cylindrical pipe parts and of the planes of flat parts (sheets); the amount of non-coaxiality of the axes of the branch pipe and the hole in the shell (pipe); the amount of misalignment (deviation) of the axes in corner joints of pipes; the dimensions of the width of the zone of application of the protective coating on the surfaces of the parts; the geometric (linear) dimensions of the assembly assembled for welding (in the cases stipulated by the project and design documentation). 6.5. Not less than 20 per cent of the parts and joints from among those submitted for acceptance shall be subject to visual and measurement control of the preparation and assembly of parts for welding. The break of the axes of circumferential joints of cylindrical elements assembled for welding is measured in 2 - 3 cross-sections (in the zone of maximum break identified during visual control) at a distance of 200 mm from the centre of the joint. In the absence of a straight section of the part 200 mm long, the measurement of the dimension may be carried out on a section of shorter length with subsequent recalculation to a length of 200 mm using the formula k = 200k1 / L, where k1 and L are the amount of the break of the axes and the distance from the joint at which the measurement was performed. In the case where measurements by this method do not ensure the required accuracy, the measurements shall be carried out by a special method. The asymmetry in the cross-section of the branch pipe of the pipe being welded in a corner joint is determined by performing not less than two measurements in one cross-section. The measurement control of the asymmetry of the hole for the branch pipe of the pipe being welded in a corner joint may be performed at the stage of control of the preparation of parts for welding. If deviations are identified from the requirements of the working drawings and (or) the production and process documentation which may lead to a deterioration in the quality of the welded joints, the scope of the sampling control shall be doubled for the group of parts (joints) of the same type. If, during the additional control, deviations from the requirements of the design documentation and (or) the production and process documentation are identified a second time, the scope of control for the group of parts prepared for acceptance shall be increased to 100 per cent. Parts rejected during control shall be corrected. Joints of parts assembled for welding that are rejected during control shall be disassembled with subsequent re-assembly after the elimination of the causes that led to their initial defective assembly.
7. Visual and measurement control of the quality of welded joints (surfacings) during welding (surfacing) and of the finished welded joint (surfacing) is carried out to confirm their conformity with the requirements of the design documentation, the production and process documentation and (or) the regulatory documentation and the Federal Norms and Rules. 7.1. In the completed welded joint, the following shall be controlled visually: the absence (presence) of surface cracks of all types and directions; the absence (presence) on the surface of the welded joints of defects (pores, inclusions, clusters of pores and inclusions, delaminations, burn-throughs, worm-holes, overlaps, shrinkage cavities, undercuts, incomplete penetration, spatter of molten metal, depressions between the beads, coarse ripple, and also places where the welding arc has contacted the surface of the base material); the quality of the dressing of the metal at the places of attachment of temporary process attachments, inductor combs and bosses for fastening thermoelectric converters (thermocouples), and also the absence of surface defects at the places of dressing; the quality of the dressing of the surface of the welded joint of the article (the weld and the adjacent areas of the base metal) for subsequent control by non-destructive methods (if such control is provided for by the production and process documentation); the presence of marking (stamping) of the weld and the correctness of its execution. 7.2. In the completed welded joint, the following shall be controlled by measurements: the dimensions of the surface defects (pores, inclusions) identified during visual control; the height and width of the weld, and also the concavity and convexity of the reverse side of the weld where the reverse side of the weld is accessible for control; the height (depth) of the depressions between the beads (inter-bead depressions) and the ripple of the weld surface; the undercuts (depth and length) of the base metal; the absence of incomplete penetration (with the exception of design-intended incomplete penetration) on the external and internal side of the weld; the dimensions of the leg of the fillet weld; the absence of breaks of the axes of the welded cylindrical elements. 7.3. During visual and measurement control of welded joints, the controlled zone shall include the surface of the weld metal and also the adjacent areas of material on both sides of the weld, of a width: not less than 5 mm - for butt joints made by arc and electron-beam welding, flash butt resistance welding, or heated-element butt welding, where the nominal thickness of the welded parts is up to 5 mm inclusive; not less than the nominal wall thickness of the part - for butt joints made by arc and electron-beam welding, flash butt resistance welding, or heated-element butt welding, where the nominal thickness of the welded parts is over 5 up to 20 mm; not less than 20 mm - for butt joints made by arc and electron-beam welding, flash butt resistance welding, or heated-element butt welding, where the nominal thickness of the welded parts is over 20 mm, and also for butt and corner joints made by gas welding, regardless of the nominal wall thickness of the welded parts, and when repairing defective areas in welded joints; not less than 5 mm (regardless of the nominal thickness of the welded parts) - for corner, T, edge and lap welded joints and joints of welding of tubes into tube sheets, made by arc and electron-beam welding; not less than 50 mm (regardless of the nominal thickness of the welded parts) - for welded joints made by electroslag welding. 7.4. The roughness of the surfaces of parts and welded joints dressed for control, and also the surface of the edge preparation of parts (assembly units, articles) prepared for welding, shall be not more than Ra 12.5 (Rz 80). 7.5. The roughness of the surfaces of articles and welded joints for carrying out subsequent methods of non-destructive control depends on the control method and shall be not more than: Ra 3.2 (Rz 20) - for penetrant control; Ra 10 (Rz 63) - for magnetic particle control; Ra 6.3 (Rz 40) - for ultrasonic control. 7.6. Visual control of the removal of material subjected to heat influence during cutting by thermal methods (gas, air-arc, gas-flux, plasma and others) is carried out on each part that has been subjected to cutting. 7.7. Each tack weld in the joint shall be subject to visual control. Tack welds whose dimensions raise doubts based on the results of visual control are subjected to measurement control. The measurement of the welds attaching the temporary process attachments and of the distance from the attached fastening element to the edge of the preparation is performed in one place. Each attachment shall be subject to control. 7.8. Layer-by-layer visual control during welding is carried out to identify impermissible surface defects (cracks, pores, inclusions, burn-throughs, worm-holes, shrinkage cavities, lack of fusion, coarse ripple, depressions between the beads, overlaps) in each layer (bead) of the weld. Defects identified during control shall be corrected before the start of welding of the subsequent layer (bead) of the weld. At the request of the Customer or in accordance with the production and process documentation, welded joints made with layer-by-layer visual control shall additionally be subject to control by penetrant or magnetic particle flaw detection on accessible areas.
8. Defects identified during visual and measurement control shall be eliminated before the performance of the subsequent process operation or before the acceptance of the object of control. The elimination of the identified defects shall be carried out in accordance with the requirements of the production and process documentation. If the defects identified during visual and measurement control do not prevent the further application of other types (methods) of non-destructive control, these defects may be eliminated after the completion of control by other types (methods) of control.
9. Visual and measurement control of the quality of the correction of defective areas in the material, welded joints and surfacings is carried out to confirm the completeness of the removal of the defect, to check the conformity of the shape and dimensions of the excavation of the defective area and the quality of the welding-up of the excavations (in cases where the excavation is subject to welding-up) with the requirements of the production and process documentation, the regulatory documentation and the Federal Norms and Rules, and the following shall be performed. 9.1. When repairing defective areas, the following shall be controlled visually: the completeness of the removal of the defect identified during visual control and control by other methods of non-destructive control; the shape of the excavation of the defective area; the shape of the machining of the edges of the excavation; the cleanliness (the absence of visually observable contamination, dust, corrosion products, oil and the like) of the surface of the excavation and the surfaces adjacent to it; the width of the zone of mechanical dressing of the material surfaces adjacent to the edges of the excavation; the absence (presence) of defects (cracks, pores, inclusions, clusters of pores and inclusions, worm-holes, burn-throughs, overlaps, shrinkage cavities, undercuts, incomplete penetration, spatter of molten metal, depressions between the beads, coarse ripple and the like) on the surface of the weld filling the excavation and on the areas of material adjacent to the excavation. 9.2. When repairing defective areas in the material and welded joints, the following shall be controlled by measurement: the dimensions of the excavation of the defective area; the dimensions of the edge preparation of the excavation (the bevel angle, the radii of the start and the end of the excavation, the thickness of the metal web when correcting cracks and the like); the width of the zone of mechanical dressing of the material areas adjacent to the edges of the excavation; the dimensions of the defects on the surface of the weld filling the excavation and on the areas of material adjacent to it, identified during visual control; the roughness of the surfaces of the excavation and the adjacent areas of material in the zone of their dressing (before welding up the excavation), and also of the material surfaces before carrying out subsequent methods of non-destructive control.
10. Visual and measurement control during the operation of equipment within the scope of technical examination, diagnostics and industrial safety expert review is carried out to determine its actual condition and to assess the condition of the material and welded joints in accordance with the requirements of the Federal Norms and Rules, the Federal Norms and Rules on industrial safety expert review, the technical documentation and the regulatory documentation. To ensure the quality of visual and measurement control, maps (diagrams) of visual and measurement control are drawn up, in which are indicated the places of control on the specific technical device or structure, the control diagrams, the measuring instruments for the controlled parameter and the quality assessment standards.
11. Visual and measurement control of technical devices and structures during operation is carried out to identify changes (deformation) in their shape and surface defects in the base material, welded joints and repair surfacings (cracks, corrosion and erosion damage, deformations, external wear of elements) that have arisen during operation, and the following shall be performed. 11.1. During visual control of the material and welded joints, the following is checked: the absence (presence) of mechanical damage to the surfaces; the absence (presence) of shape change of the structural elements (deformed areas, warping, sagging and other deviations from the initial arrangement); the absence (presence) of cracks and other surface defects that have arisen (developed) during operation; the absence of corrosion and mechanical wear of the surfaces. 11.2. Measurement control of the material and welded joints is performed to determine the conformity of the geometric dimensions of the structures and the permissibility of the damage to the material and welded joints identified during visual control with the requirements of the working drawings, technical specifications, standards and passports. 11.3. During measurement control of the condition of the material and welded joints, the following is determined: the dimensions of the mechanical damage to the material and welded joints; the dimensions of the deformed areas of the material and welded joints, including the length, width and depth of dents, bulges and blisters; the ovality of cylindrical elements, including pipe bends; the straightness (deflection) of the generatrix of the structure (element); the actual wall thickness of the material (where direct measurements can be carried out); the depth of corrosion pits and the dimensions of the zones of corrosion damage, including their depth.
12. When assessing quality, the following shall be ensured. 12.1. During visual and measurement control of welded joints, the following shall not be permitted: cracks of all types and directions; incomplete penetration (lack of fusion) between the base metal and the weld, and also between the weld beads; incomplete penetration in the root of the weld (except in the cases stipulated in the regulatory documentation); overlaps (sags) and metal spatter; unfilled craters; worm-holes; burn-throughs; clusters; undercuts (except in the cases stipulated in the regulatory documentation); deviations of the dimensions of the weld and of the mutual arrangement of the elements to be welded beyond the established standards. On the prepared edges there shall be no traces of cutting (for parts made of low-carbon, manganese and silicon-manganese steels) and no traces of marking-out (centre-punching) applied on the external surface of the parts after cutting. The maximum permissible gap between the end of the straightedge and the surface of the pipe shall be not more than 1.5 mm at a distance of 200 mm from the joint, and in the welded joint - not more than 3 mm. The standards for permissible defects identified during visual and measurement control are given in Table 12.1.
12.2. During penetrant control of a welded joint by indicator traces, elongated and non-single indicator traces shall not be permitted. The number of single rounded indicator traces shall not exceed the standards specified in Table 12.1 for single inclusions, and the largest dimension of each indicator trace shall not exceed three times the values of these standards. The defects identified during this control are assessed by their actual indicators after the removal of the reagent. In doing so, the requirements of paragraphs 5, 12.1 and Table 12.1 of this Appendix shall be followed. The results of this assessment are final.
12.3. When magnetic particle control is applied, the quality assessment standards shall conform to the standards for visual control (paragraphs 5, 12.1 and Table 12.1). The defects identified during this control are assessed by their actual dimension after the removal of the emulsion or powder. The results of this assessment are final.
12.4. During radiographic control, the quality of welded joints is considered satisfactory if the radiographic image does not record cracks, incomplete penetration (with the exception of the cases stipulated in the regulatory documentation), burn-throughs, worm-holes, or impermissible convexity and concavity of the weld root (Table 12.1), and the dimension, number and total reduced area of single inclusions and clusters do not exceed the standards given in Table 12.2 and the regulatory documentation.
The required sensitivity level of the image is established by the regulatory documentation.
12.5. During ultrasonic control, the quality of welded joints is considered satisfactory if the following conditions are observed:
the discontinuities identified are not extended (the conditional length of the discontinuity shall not exceed the conditional length of the corresponding reference reflector);
the distance along the scanning surface between two adjacent discontinuities is not less than the conditional length of the discontinuity with the larger value of this indicator (the discontinuities are single);
the equivalent areas and the number of single discontinuities do not exceed the standards established in the regulatory documentation.
12.6. The quality of welded joints, based on the results of mechanical tests, is considered satisfactory subject to the fulfilment of the following requirements:
(a) the tensile strength shall be not lower than the minimum permissible for the base metal, and when testing welded joints of elements with different standard values of tensile strength, this indicator shall be not lower than the minimum permissible for the less strong base metal.
(b) the bend angle in the static bending test and the gap between the compressed surfaces in the flattening test of welded joints of pipes with an external diameter of less than 108 mm and a wall thickness of less than 12 mm shall conform to the requirements of Table 12.3.
(c) the impact toughness in the impact bending test of type VI specimens with a notch along the weld shall be not less than:
49 J/cm (5 kgf·m/cm) - for welded joints of elements made of pearlitic-class steels and high-alloy steels of the martensitic-ferritic class;
69 J/cm (7 kgf·m/cm) - for welded joints of elements made of chromium-nickel steels of the austenitic class.
12.7. The standards for assessing the quality of welded joints, based on the results of metallographic examinations, shall conform to the requirements of the regulatory documentation. In doing so, the impermissible defects are the defects specified in paragraph 12.1.
____________________________ "__" __________ 20__
The Commission appointed by order ________________________________, comprising:
1. Brief information about the equipment operating under excess pressure _____________________________________________________ (the information provided for by sub-clause "c" of paragraph 224 of the Federal Norms and Rules on equipment operating under excess pressure is indicated)
2. During the check of the readiness of ___________________________ for start-up (name of the equipment) into operation, the following has been established: (a) the following documents are included in the set of documentation of the equipment manufacturing organisation, the documentation certifying the quality of installation (the completeness and quality of repair or reconstruction works), the documents confirming the acceptance of the equipment after the completion of commissioning works, and also the documentation confirming the conformity of the equipment with the requirements of the legislation of the Russian Federation on technical regulation and Article 7 of Federal Law No. 116-FZ: [table - reproduced in the Russian original] (b) the technical examination of ____________________________ has been carried out (name of the equipment) ______________________________________________, based on the results of the technical (name of the organisation and date of the technical examination) examination, _________________________________________ has been drawn up (name and details of the document) with a conclusion on the possibility of operating the equipment; (c) based on the results of the commissioning tests and integrated testing of the equipment, carried out by ________________________________________________, (name of the organisation and date of performance) _________________________________________ has (have) been drawn up. (name and details of the document(s))
3. During the check of the arrangement of supervision over the operation of _____________________________, it has been established: (name of the equipment) (a) the equipping of the equipment with fittings, monitoring and measuring instruments, safety devices and process protection systems ________________________ (conforms/does not conform) to the design; the serviceability of the fittings, monitoring and measuring instruments, safety devices and process protection systems is confirmed by ______________________________________________________; (names and details of the supporting documents) (b) _________________________ has been installed __________________________________ (name of the equipment) (in accordance with the requirements/ in violation of the requirements) of industrial safety; the connection scheme of the equipment ________________________ (conforms/does not conform) to the requirements of the equipment manufacturer set out in the operating manual (instruction); (c) to ensure the safe operation of the equipment, _______________________________________ the following specialists have been appointed: (name and details of the document) ____________________________________________________________. (positions, surnames, first names, patronymics (if any) of the appointed specialists, details of the attestation records) The servicing of the equipment is carried out by the following personnel: ____________________________________________________________ (occupation, actual number of personnel of the given occupation, details of the document on admission to independent work) ____________________________________ (conforms/does not conform) to the requirements of the project documentation, the operating manual (instruction) of the equipment manufacturer and the Federal Norms and Rules; (d) for the responsible persons and specialists carrying out the operation of the equipment, job instructions have been developed: ___________________________________________________________; (names and dates of approval of the job instructions) (e) for the servicing personnel, production instructions have been developed _____________________________________, and to ensure control over the operation of (names and dates of approval of the production instructions) the equipment, __________________________________________________ have been developed (names and dates of approval of the operational _________________________________; documents provided for by the Federal Norms and Rules on equipment operating under excess pressure) (f) the feed devices of the boiler _________________________________ (conform/do not conform) to the design and are in a ____________________________ condition, which is confirmed by (serviceable/unserviceable) ___________________________________________________________________ (name and details of the documents) (completed when a check of the boiler is carried out); (g) the water chemistry regime of the boiler ______________________ (conforms/does not conform) to the requirements of the Federal Norms and Rules on equipment operating under excess pressure (completed when a check of the boiler is carried out); (h) additional information provided for by the Federal Norms and Rules on equipment operating under excess pressure and the operating instructions _______________________________________________________________
4. Dissenting opinion of the member (members) of the Commission (if any) ___________________________________________________________________________ CONCLUSIONS AND RECOMMENDATIONS: _______________________ _________________________ (conforms/does not conform) to the established requirements (name of the equipment, factory No.) and _______________________ be admitted into operation. (may/may not) Recommendations ______________________________________________________________
1. The colouring, symbols, dimensions of letters and arrangement of inscriptions are adopted on the basis of the project documentation and the regulatory documentation applied in accordance with the legislation of the Russian Federation on standardisation.
2. The following inscriptions shall be applied to the pipelines: (a) on the main lines - the number of the main line (a Roman numeral) and an arrow indicating the direction of movement of the working medium. If, under the normal regime, its movement in both directions is possible, two arrows directed in both directions are given; (b) on the branches near the mains - the number of the main line (a Roman numeral), the number of the unit (Arabic numerals) and arrows indicating the direction of movement of the working medium; (c) on the branches from the mains near the units - the number of the main line (a Roman numeral) and arrows indicating the direction of movement of the working medium.
3. The number of inscriptions on the same pipeline is not standardised. The inscriptions shall be visible from the places of control of the fittings and other devices within the specific pipeline. At the places where pipelines exit and enter another room, inscriptions are mandatory.
4. Where the surface of the pipeline insulation is covered with metal cladding (sheets of aluminium, galvanised iron and other corrosion-resistant metals), the colouring of the cladding along its entire length may be omitted. In this case, depending on the medium being conveyed, the corresponding symbols shall be applied.
5. The following inscriptions shall be applied to the valves, gate valves and their drives: (a) the number or symbol of the shut-off or control element corresponding to the operational diagrams and instructions; (b) an indicator of the direction of rotation towards closing (C) and towards opening (O).
6. The inscriptions on the fittings and drives listed in paragraph 5 of this Appendix are made in the following places: (a) where the handwheel is located near the body of the valve (gate valve) - on the body or insulation of the valve (gate valve) or on an attached plate; (b) where remote control is by means of a handwheel - on the column or bracket of the handwheel; (c) where remote control is by means of a chain - on a plate fixedly connected to the bracket of the chain wheel and secured in a position ensuring the best visibility from the control platform; (d) where remote control of a valve or gate valve located under the floor of the servicing platform is by means of a removable handwheel (the end of the shaft is recessed in the floor and covered with a lid) - on the lid on the internal and external sides; (e) where remote control is by means of an electric drive - at the starting switch; (f) in the case of remote control, in addition to the inscriptions provided for by sub-clauses "b", "c", "d", "e", inscriptions shall also be applied to the handwheels of the controlled fittings.
1. Information on the location of ___________________________________________________________ (the kind (type) of pressure equipment (boiler, vessel, pipeline), the date of manufacture (production)/commissioning/the safe operation period are indicated [table - reproduced in the Russian original]
2. The person responsible for the serviceable condition and safe operation of ___________________________________________________________ (the kind (type) of pressure equipment (boiler, vessel, pipeline) is indicated [table - reproduced in the Russian original]
3. Information on the installed fittings (not specified in the passport by the equipment manufacturing organisation, if they are not part of the equipment delivery set, and also in the case of their replacement during repair or reconstruction) [table - reproduced in the Russian original]
1. In the case of loss, misplacement or the impossibility of further use owing to wear of the passport and (or) the operating manual (instruction) of pressure equipment in operation, their duplicates shall be issued by the manufacturing organisation of this equipment, by its legal successor or by an organisation that continues to produce similar equipment and lawfully possesses a set of technical (process, operational, repair) documentation of the manufacturing organisation (hereinafter in the text of this Appendix - the manufacturer).
2. In the absence of the manufacturing organisation, the restoration of the passport (the drawing-up of an operational passport) of pressure equipment shall be carried out by the organisation performing the industrial safety expert review of the technical device used at a hazardous production facility (hereinafter in the text of this Appendix - the expert organisation), in accordance with this Appendix to the Federal Norms and Rules.
3. Instead of a duplicate of the operating manual (instructions) for the pressure equipment, a copy of the operating manual (instructions) for identical equipment of the same manufacturing organisation, installed at the operating organisation or operated by another organisation, may be used.
4. The operating organisation shall submit to the preparer of the passport (the manufacturer or the expert organisation) all documents and information available to it that are necessary for the preparation of the passport. The application (request) of the operating organisation for the issue (preparation) of a duplicate or the restoration of the passport shall contain the reasons giving rise to such a need, information (the name of the equipment, type, model, grade, factory (serial) number, date of manufacture) and materials (a photograph of the nameplate or of the manufacturing organisation's marking on the body, copies of drawings (if any)) that make it possible to identify the specific unit of equipment in respect of which the duplicate of the passport or its restoration is requested, information on the actual technical condition of the equipment (including on the modes and cycles of its operation, on technical examinations, diagnostics and (or) industrial safety expert reviews and their results, and repairs carried out during the period of operation, on the absence or presence of changes made (introduced) to the design of the equipment in the process), and also information confirming the lawfulness of the use of the equipment concerned by the organisation that ordered the preparation of the duplicate of the passport or its restoration.
5. Where there is an application (request) from the operating organisation, the manufacturer may issue a duplicate of the passport on the basis of the set of technical (design, process, operating and repair) documentation held by it and certify the duplicate of the passport with a seal (if any) and the signature of the official responsible for the preparation of passports for the equipment manufactured. Where the equipment has been produced by a foreign manufacturer, the duplicate of the passport may be certified with a seal (if any) and the signature of a representative of an organisation (a legal entity or an individual entrepreneur) authorised by the manufacturing organisation, provided that there are appropriate documents confirming that it holds the powers granted by the foreign manufacturer for responsibility for its products in the territory of the Russian Federation.
6. The form of the duplicate of the passport and the scope of the information indicated in it shall correspond to the design of the pressure equipment and to the requirements of the regulatory documents (regulatory legal acts, standards and (or) technical specifications and other regulatory and technical documentation (hereinafter in the text of this Appendix - regulatory documents) that were in force in respect of the equipment concerned during the period of its release and commissioning. For equipment to which TR CU 032/2013 applies and which was manufactured after its entry into force, the duplicate of the passport, depending on the type of equipment, shall comply with the requirements of paragraphs 19, 20, 21, 22, 23 of Section IV of TR CU 032/2013 or with the requirements of the standards containing the forms of passports for certain types of pressure equipment that are included in the list of standards through the voluntary application of which compliance with the requirements of TR CU 032/2013 is ensured. On the title page of the duplicate of the passport, information shall be indicated to the effect that it is not an original but a duplicate of the passport, with a brief indication of the reasons (grounds) for its preparation and of information on the organisation that carried out its preparation (the name and particulars of the organisation (the address of the legal entity, OGRN) or of the individual entrepreneur (surname, first name, patronymic (if any), INN), and also the particulars of the document confirming its powers). The manufacturer shall, where necessary, attach to the duplicate of the passport a general-arrangement drawing (a set of drawings), calculations and other technical documentation at the request of the operating organisation. The operating organisation shall attach to the duplicate of the pressure-equipment passport prepared by the manufacturing organisation the technical documentation of the manufacturing organisation that is available or that has been obtained on request from the manufacturing organisation together with the duplicate of the passport, and also operating documentation in accordance with the recommended templates set out in Appendix No. 5 to these Federal Norms and Rules or, in the event of its absence, documents based on the results of the work carried out in accordance with paragraph 7 of this Appendix.
7. Where the operating organisation lacks information on the modes and cycles of operation of the equipment, on technical examinations, diagnostics and (or) industrial safety expert reviews and their results, and repairs previously carried out during the period of its operation, after receipt of the duplicate of the passport and of the set of drawings from the manufacturing organisation, the equipment shall, before its start-up, be subjected to an extraordinary technical examination, with diagnostics carried out within its scope where necessary (where its design service life has not expired) or to an industrial safety expert review, for the purpose of verifying its conformity with the documentation submitted by the manufacturing organisation, as regards the absence or presence of changes to the design of the equipment, of establishing the actual condition and of taking a decision on the possibility and period of further operation of the pressure equipment.
8. Where there is no manufacturing organisation, the restoration of the passport (the preparation of an operating passport) shall be carried out on the basis of the technical documentation of the manufacturing organisation available (if any) at the operating organisation, the operating documentation and the repair documentation maintained at the operating organisation, and also on the basis of the results of a survey of the pressure equipment carried out by the expert organisation to assess its actual condition at the time of restoration of the passport and to clarify the information set out in the documentation submitted, or to restore the missing information where there is an insufficient volume of information on the equipment for the restoration of its passport.
9. In restoring the passport, the expert organisation shall perform the following main work: 9.1. Carry out an analysis (study) of the materials submitted by the operating organisation, and a check of the completeness and sufficiency of the information provided in them for the preparation (restoration) of the passport. 9.2. Carry out a survey (diagnostics) of the equipment using non-destructive and, where necessary, destructive testing methods to establish the actual condition of the equipment, to confirm or clarify the information submitted about it, and also to restore the missing information about the equipment. The scope and types of methods applied during the survey are determined by the expert organisation depending on the completeness of the information submitted (selectively where there is information on the grades and characteristics of the materials used or, where such information is absent, element by element in full in respect of each element, including welded joints and the parts attached to it, valves and other devices forming part of the equipment), including: where the operating organisation has drawings and other documents of the manufacturing organisation reflecting information on the design of the equipment and its elements, on the base and welding materials used in manufacture, and also on the methods and scope of the inspection and tests carried out, the scope of the survey performed by the expert organisation in restoring the passport shall be determined on the basis of the need to establish the actual condition of the equipment and to confirm (clarify) the data set out in the documentation submitted; where there is no technical documentation containing the necessary information about the equipment, in the course of the survey the necessary measurements and studies shall be carried out using non-destructive and destructive testing methods that make it possible, in addition to the above, to determine the grade and characteristics (chemical composition and mechanical properties) of the materials used. 9.3. Based on the results of the work specified in paragraphs 9.1 and 9.2 of this Appendix to the Federal Norms and Rules, it is necessary to: prepare general-arrangement drawings of the equipment and its main elements (where they are absent); perform a strength calculation for the equipment taking into account its actual condition established on the basis of the results of the survey (where a strength calculation is present in the set of technical documentation of the manufacturing organisation, the need to carry out a verification strength calculation for the equipment or its individual elements is determined depending on its actual condition by the expert organisation); perform, where necessary, a calculation of the discharge capacity of the safety valves taking into account the requirements established by these Federal Norms and Rules; carry out an analysis of the design of the equipment as a whole and of its main elements, and also of the strength characteristics of the base and welding materials (including a comparison of the data set out in the technical documentation submitted (if any) with the actual results of the survey, and also a comparison of the materials of foreign-made equipment with domestic analogues) for the purpose of establishing their conformity with the requirements of the regulatory documents that were in force during the period of release and commissioning of the equipment, and also a comparison of them with the requirements of the regulatory documents in force at the time of restoration of the passport; prepare the passport in accordance with the recommended template and indicating in it the necessary information about the equipment and its elements to the extent set out in paragraph 6 of this Appendix, including: the name, factory (serial) number, date of manufacture, technical characteristics of the equipment, the name and geometric dimensions of the elements, the type, grade and characteristics of the base and welding materials, the scope and methods of inspection and tests, and other information in the sections falling within the competence of the manufacturing organisation, and also information on the valves, safety, instrumentation and other devices actually installed on the equipment at the time of preparation (restoration) of the passport. Where there is no manufacturer's technical documentation containing the information necessary for entry in the passport, data obtained on the basis of the results of measurements, inspection and tests carried out by the expert organisation are entered in the relevant sections of the passport. When information about the equipment and its elements is entered in the relevant sections of the passport, the source of its determination shall be indicated (the particulars of the drawing or other document of the manufacturer and, in their absence, the particulars of the document based on the results of measurements, inspection and tests carried out by the expert organisation).
10. The restored passport shall be signed by the head of the expert organisation and the technical manager of the operating organisation, with the following attached to it: the opinion of the industrial safety expert review, the drawings and calculations performed by the expert organisation, the operating manual (instructions) and other technical documentation of the manufacturing organisation, and also operating documentation (containing information on technical examinations, diagnostics and repairs previously carried out), where the operating organisation has them. On the title page of the passport, information shall be indicated to the effect that the passport is not an original but has been restored in the course of operation, with a brief indication of the reasons for restoration and of information on the organisation that performed the specified work (the name and particulars of the licence for the right to carry out the industrial safety expert review).
11. The preparation of a duplicate or the restoration of the passport of pressure equipment shall not be permitted where there is no marking on the equipment that makes it possible to identify it, and no information on the manufacturer of the equipment, the date of its manufacture and commissioning.
12. The organisation operating the equipment shall notify in writing the Federal Environmental, Industrial and Nuclear Supervision Service (Rostechnadzor) or another federal executive authority in the field of industrial safety of the fact of the preparation of a duplicate or the restoration of the passport of pressure equipment subject to registration with the territorial body of Rostechnadzor or with another federal executive authority in the field of industrial safety, indicating the reasons that gave rise to the need for the preparation of a duplicate or the restoration of the passport, indicating information on the organisation that performed the work, attaching a copy of the document confirming the right to perform the functions of the manufacturing organisation of the equipment (where the duplicate of the passport has been prepared by the manufacturing organisation) or to carry out activities involving the industrial safety expert review of technical devices used at a hazardous production facility, information on the actual condition of the equipment (including how (examination, diagnostics, expert review) and by whom it was established (the name and particulars of the organisation (the address of the legal entity, OGRN) or of the individual entrepreneur (surname, first name, patronymic (if any), INN)), and also the particulars of the opinion of the industrial safety expert review (the registration number, the date of registration in the register of industrial safety expert review opinions, where it has been carried out) of the pressure equipment in respect of which the preparation of a duplicate or the restoration of the passport was carried out.
Name of the pipeline in accordance with the design documentation:
(b) Information on the main valves and shaped parts (cast and forged).
(c) Information on the flanges and fasteners.
5. Information on stiloscopy _____________________________
6. Results of the hydraulic test of the pipeline. List of technical documents attached to the passport (diagrams, drawings, certificates and other documents for the pipeline, sections of the pipeline, and also documents of the manufacturers for elements and devices supplied separately for use as part of the pipeline) ________________________________________________________________________ L.S. Signature of the head (or the technical manager) of the owner enterprise of the pipeline "__" __________ 20__ L.S. Signature of the head (or the technical manager) of the enterprise that carried out the installation (fabrication) of the pipeline or of the head of the expert organisation that prepared the passport for the pipeline in operation in the event of its absence or loss "__" __________ 20__ L.S. Signature of the authorised representative of the enterprise that developed the design of the pipeline and carried out the designer's supervision of the installation (fabrication) of the pipeline (in the case provided for by the contract (agreement)) "__" __________ 20__
1. Data on installation (fabrication). The pipeline (section) has been installed (fabricated) in full compliance with the design, ___________________ developed by _______________________________ (particulars of the design) (name of the design organisation) ___________________________________________________________________________ (particulars of the design and name of the design organisation) From elements and parts manufactured by: ___________________________________________________________________________ (name and designation (code) of the elements in accordance with the design and the technical documentation of their manufacturer, names and addresses of the manufacturing plants) according to working drawings ________________________________ ___________________________________________________________________________ (number of the assembly drawings)
2. Information on welding. Type of welding used in the installation of the pipeline: _______________________ Data on the filler material ____________________________________ (specify the type, grade, GOST or TU) ___________________________________________________________________________ Methods, scope and results of inspection of the welded joints ____________________ ___________________________________________________________________________ The welding of the pipeline has been performed by certified welders in accordance with the requirements of ___________________________________________________________________________ (name of the Norms and Rules, standards and other regulatory and technical documentation in accordance with which, as directed by the design and the agreement, the welding work was carried out) ___________________________________________________________________________ (information on the welders, indicating the surname, first name, patronymic (if any), the particulars of the documents confirming their qualification and certification, and also the stamp code assigned to them)
3. Information on the heat treatment of the welded joints (type and mode) ___________________________________________________________________________
4. Information on the materials from which the pipeline was fabricated: ___________________________________________________________________________ (a) Information on the pipes. [table - reproduced in the Russian original] (b) Information on the main valves and shaped parts (cast and forged). [table - reproduced in the Russian original] (c) Information on the flanges and fasteners. [table - reproduced in the Russian original]
5. Information on stiloscopy _______________________________________
6. Results of the hydraulic test of the pipeline. 6.1. The pipeline shown in the attached diagram has been tested with a test pressure of ____________________________ for _______ min in accordance with ___________________________________________________________________________ (name of the documents establishing the requirements for carrying out tests) 6.2. At a pressure of __________ the pipeline was inspected, and the following was found: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________
7. Conclusion. The pipeline has been fabricated and installed in accordance with the design and ___________________________________________________________________________ (name of the technical regulations, standards and other regulatory and technical documentation) has been recognised as fit for operation at a pressure of not more than ________ and a temperature of ___ °C "__" _________ 20__ Inventory of the attached documents: As-built documentation (diagrams, drawings), certificates (passports) of the elements, parts and valves, certificates for the materials, documents confirming the performance of quality control of the work based on the results of incoming inspection, destructive and non-destructive testing of the materials and welding, and other documents specified by the contract (agreement for the performance of the work). ____________________________________ ____________________________________ L.S. Person in charge of the installation work (the head (technical manager) of the organisation that carried out the installation (fabrication) of the pipeline (section of the pipeline), or another official holding the appropriate rights and powers established by the administrative documents of that organisation) L.S. Signature of the head (technical manager) or authorised representative of the organisation of the final manufacturer that monitored the progress of the work and accepted the set of documentation for the section of the pipeline from the organisation that carried out the installation of the section (where the agreement provides for the performance of the work by the forces of several organisations)
1. Information on the pipes from which the elements of the pipeline are fabricated. [table - reproduced in the Russian original]
2. Information on the main valves and shaped parts (cast, welded or forged) of the pipeline. [table - reproduced in the Russian original]
3. Information on the flanges and fasteners. [table - reproduced in the Russian original]
4. Information on welding. Type of welding used in the fabrication of the elements ______________________ ___________________________________________________________________________ Data on the filler material ____________________________________ ___________________________________________________________________________ The welding of the pipeline has been performed by certified welders in accordance with the requirements of ______________________________________________________________ ___________________________________________________________________________ (name of the norms and rules, standards and other regulatory and technical documentation in accordance with which, as directed by the design and the agreement, the welding work was carried out) ___________________________________________________________________________ (information on the welders, indicating the surname, first name, patronymic (if any), the particulars of the documents confirming their qualification and certification, and also the stamp code assigned to them)
5. Information on the heat treatment of pipes, bends and welded joints (type, mode) ___________________________________________________________________________
6. Information on the inspection of the welded joints (scope and methods of inspection) ___________________________________________________________________________
7. Information on stiloscopy ___________________________________________________________________________
8. Information on the hydraulic test ___________________________________________________________________________
9. Conclusion. The elements of the pipeline: ________________________________________________ (name of the elements, their quantity) ___________________________________________________________________________ have been fabricated and tested in full compliance with ____________________________ (name and particulars of the ___________________________________________________________________________ technical regulations, standards, design and technical documentation for fabrication) and have been recognised as fit for operation at the design parameters: at a pressure of __________________, at a temperature of __________________________. Inventory of the attached documents ____________________________________ ___________________________________________________________________________ "__" _________ 20__ Head (technical manager) of the manufacturing organisation Head of the department (service) of technical control or of another subdivision carrying out quality control of the products manufactured
1. Reduction of the wall thickness of pressure equipment as a result of corrosion or erosion wear beyond the minimum value established by the strength calculation.
2. The presence of deposits on the heated elements of pressure equipment leading to overheating (burnout) of the metal of the elements, the thickness of which exceeds the permissible value established during the development (design) of the equipment. This defect is detected during inspections of the pressure equipment, and its presence may also be indirectly indicated by an increase in hydraulic resistance in the path of the pressure equipment and a decrease in the temperature of the working medium at the outlet from the pressure equipment as a result of deterioration of heat exchange.
3. The presence of cracks of all kinds and directions (fatigue, thermal, corrosion), and also of other operational defects in the base metal, welded, rolled, detachable and riveted joints of pressure equipment, the magnitude of which exceeds the values established by the design developer (the manufacturing organisation) set out in the technical and regulatory documentation for the specific type of equipment, including: tears, laminations, blisters, bulges, dents on the internal and external surfaces of the walls of the pressure equipment; ovality of the elements of the pressure equipment; deviation from straightness (deflection) of the tubular and cylindrical elements of the pressure equipment; displacement of the heating-surface tubes out of alignment; cracks, ruptures, leaks (leakage, weeping, sweating, traces of steaming and seepage), traces of corrosion, laminations, scabs, undercuts or laps, dents in the welded, rolled, detachable and riveted joints; reduction in the length of the protruding tube ends in the rolled joints ("bell-mouths"); the presence of residual deformation of the metal of the elements of the pressure equipment operating under creep conditions. defects of welded joints exceeding the permissible magnitude established by the regulatory documents on welding; corrosion cracking of the metal of the pressure equipment in the zone of the welds, and also in places of corrosion pits and pitting.
4. The presence of damage to the lining of pressure equipment that may cause a danger of overheating of the metal of its elements, and also creates a threat of injury to the operating personnel, including through cracks, complete or partial destruction (collapse) of the lining of the boiler furnace, of the fire-protective lining (gunite) and of the refractory lining of the heated elements of the pressure equipment.
5. The presence of damage (cracks, deformations) to the supporting metal structures (framework) of pressure equipment affecting their load-bearing capacity.
1. The quality indicators of the feed water for boilers with natural and forced multiple circulation with a steam capacity of 0.7 t/h and more (except water-tube boilers with natural circulation and a working steam pressure of 14 MPa) shall not exceed the indicated values: (a) for steam fire-tube boilers: [table - reproduced in the Russian original] (b) for water-tube boilers with natural circulation (including boiler-heaters) and a working steam pressure of up to 4 MPa: [table - reproduced in the Russian original] (c) for water-tube boilers with natural circulation and a working steam pressure of 10 MPa: [table - reproduced in the Russian original] (d) for power-technological boilers and waste-heat boilers with a working steam pressure of up to 5 MPa: [table - reproduced in the Russian original] (e) for power-technological boilers and waste-heat boilers with a working steam pressure of 11 MPa: [table - reproduced in the Russian original] (f) for high-pressure boilers of combined-cycle plants: [table - reproduced in the Russian original]
2. The quality indicators of the feed water for water-tube boilers with natural circulation and a working steam pressure of 14 MPa and for power once-through boilers shall not exceed the indicated values: (a) for water-tube boilers with natural circulation and a working steam pressure of 14 MPa: [table - reproduced in the Russian original] Where losses of steam and condensate are made up with chemically treated water, an increase in the pH value to 10.5 is permitted. The content of sodium compounds for boilers with a pressure of 14 MPa shall be not more than 50 µg/dm3. Adjustment of the norms for the sodium content in the feed water is permitted at a CHP plant with a process steam extraction where no gas-tight boilers or other boilers with increased local thermal loads of the water walls are installed at it and the superheating of the steam is controlled by injection of its own condensate. The specific electrical conductivity of the H-cationised sample for boilers with a pressure of 14 MPa shall be not more than 1.5 µS/cm. A corresponding adjustment of the norm for the specific electrical conductivity is permitted in cases of adjustment of the norm for the sodium content in the feed water. The content of hydrazine (where the water is treated with hydrazine) shall be from 20 to 60 µg/dm3; during the period of start-up and shutdown of the boiler a hydrazine content of up to 3000 µg/dm3 is permitted (with discharge of steam into the atmosphere). The content of ammonia and its compounds shall be not more than 1000 µg/dm3; in individual cases agreed with the regional dispatching unit of the power system (in the case of equipment under the management (control) of the dispatcher), an increase in the ammonia content is permitted to values that ensure the maintenance of the required pH value of the steam but do not lead to exceeding the norms for the content of copper compounds in the feed water. The content of free sulphite (during sulphitation) shall be not more than 2 mg/dm3. The total content of nitrites and nitrates for boilers with a pressure of 14 MPa shall be not more than 20 µg/dm3; (b) for power once-through boilers: [table - reproduced in the Russian original]
3. The quality indicators of the make-up and network water for hot-water boilers (except hot-water boilers installed at thermal power plants and thermal stations) shall not exceed the indicated values: [table - reproduced in the Russian original]
4. The quality indicators of the network water for hot-water boilers installed at thermal power plants and thermal stations shall not exceed the following values: [table - reproduced in the Russian original]
5. The quality indicators of the make-up water for hot-water boilers installed at thermal power plants and thermal stations shall not exceed the following values: (a) closed heat-supply systems: [table - reproduced in the Russian original] (b) in open heat-supply systems (with direct water draw-off) the quality of the make-up water shall also satisfy the norms in force for drinking water. The make-up water for open heat-supply systems shall be subjected to removal of organic impurities from it if the colour of the water sample, when it is boiled for 20 minutes, increases beyond the norm indicated in the regulatory documents in force for drinking water. In the silicate treatment of water for making up heat networks with direct draw-off of hot water, the content of silicate in the make-up water shall be not more than 50 mg/dm3 calculated as SiO2. In the silicate treatment of the make-up water, the limiting concentration of calcium shall be determined taking into account the total concentration not only of sulphates (to prevent the precipitation of CaSO4) but also of silicic acid (to prevent the precipitation of CaSiO3) for the given heating temperature of the network water, taking into account its excess in the near-wall layer of the boiler tubes by 40 °C. The direct addition of hydrazine and other toxic substances into the make-up water of heat networks and the network water shall not be permitted.
6. The quality norms for the boiler water, the required mode of its corrective treatment, and the modes of continuous and periodic blowdowns are adopted on the basis of the instructions of the manufacturing organisation of the boiler, standard instructions on maintaining the water-chemistry regime or on the basis of the results of thermal-chemical tests. In doing so, for steam boilers with a pressure of up to 4 MPa inclusive that have riveted joints, the relative alkalinity of the boiler water shall not exceed 20 per cent; for boilers with welded drums and attachment of the tubes by the rolling method (or by rolling with sealing welding), the relative alkalinity of the boiler water is permitted up to 50 per cent; for boilers with welded drums and welded-on tubes, the relative alkalinity of the boiler water is not regulated. For steam boilers with a pressure of over 4 to 10 MPa inclusive, the relative alkalinity of the boiler water shall not exceed 50 per cent; for boilers with a pressure of over 10 to 14 MPa inclusive, it shall not exceed 30 per cent.
7. The quality indicators of the feed water of steam electric boilers shall not exceed the following values: [table - reproduced in the Russian original]
8. The quality indicators of the make-up and network water of hot-water electric boilers shall not exceed the following values: [table - reproduced in the Russian original]