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Technological pipelines rules recommendations. Rules for the design and safe operation of process pipelines

17.08.2023

A significant amount of construction of main facilities in the oil refining, metallurgical, and food industries is devoted to the arrangement of process pipelines. They play a critical role in the functioning of strategically important systems. Process pipelines are also used in agricultural complexes, heat supply systems and many other industries.

Basic Concepts

A pipeline is a device designed to transport a variety of substances. It consists of sections of pipes, connecting and shut-off valves, automation and fasteners.

What is the meaning of the concept of “process pipelines?” The definition designates them as supply systems for industrial enterprises through which semi-finished and finished products are transported, as well as substances that support the entire process.

Pipe location

During the installation process, you must follow these recommendations:

  • process pipelines must have a minimum length;
  • Sagging and stagnation are unacceptable in the system;
  • ensuring free access for technological control;
  • the possibility of locating the necessary lifting and transport equipment;
  • providing insulation to prevent moisture penetration and retain heat;
  • protection of pipelines from possible damage;
  • unhindered movement of fire extinguishing equipment and lifting mechanisms.

Slope angles

The operation of process pipelines involves forced stops. For this purpose, slopes are included in the project, which will ensure arbitrary emptying of the pipes. The design of process pipelines provides for the following slope angle depending on the medium being moved (values ​​are given in degrees):

  • gaseous medium: in the direction of movement - 0.002, against it - 0.003;
  • liquid, easily mobile substances - 0.002;
  • acidic and alkaline environment - 0.005;
  • substances of high viscosity or quick-hardening - up to 0.02.

The design may not provide for a slope, in which case special measures must be taken to empty the pipelines.

Preparatory work

Installation of process pipelines must first be accompanied by the following actions:


Route markings

This operation consists of transferring the mounting axes of fittings and compensators directly to the place where the process pipelines will be laid. Determining the marking location can be done with the following tools:

  • roulette;
  • plumb lines;
  • level;
  • hydraulic level;
  • templates;
  • squares.

If a large number of process pipelines are laid for a construction structure, the time allocated for marking is significantly reduced through the use of special layouts. They provide a visual representation of the location of pipeline lines in relation to the building structure. After marking, all applied elements are checked against the design, after which they begin fixing the supporting structures.

Installation of supports and fastenings

When arranging the foundation of a building, it must have holes for inserting bolts and fastening supports. They can be made using mechanized equipment. When installing supports, the following recommendations should be taken into account:

  1. Process pipelines that have fixed supports described above require the installation of fasteners in close proximity to the devices and fittings. on such supports must be tightly fixed, not allowing movement. The same requirements apply to clamps.
  2. Movable supports are mounted with the possibility of unhindered movement of the pipeline in order to freely extend it when the need arises. Thermal insulation must also be maintained during potential movement due to expansion.
  3. The process pipeline installer must check all installed supports for horizontal and vertical compliance. Possible deviations are provided for, which cannot exceed the following limits:
  • intra-shop pipelines - ± 5 mm;
  • external systems - ±10 mm;
  • slopes - 0.001 mm.

Plugging into existing systems

This requires special permits, and a process piping installer must be present at the work site to service these lines. The insertion is carried out when a new mounted component is connected to the existing system. Usually, for such cases, the installation of shut-off equipment is provided, but if the existing system does not have one, then they resort to tapping. There are several features here:

  1. The existing pipeline must be disconnected and emptied.
  2. Pipes through which flammable and explosive atmospheres were transported must be rendered harmless and washed.
  3. The welded fitting must pass preliminary tests. The steel grade is also determined according to the documentation.
  4. Welding work must be carried out by a highly qualified specialist who has special access to critical structures.
  5. Before installation of process pipelines begins, the connecting unit must pass all tests.

Blowing and flushing

The assembled pipeline is subjected to cleaning, the method of which depends on the size of the pipe:

  • diameter up to 150 mm - washed with water;
  • over 150 mm - blown with air;

The area to be cleaned must be isolated from other pipeline lines with plugs. Flushing with water is carried out until water begins to flow out of the pipe without contamination. Purge is carried out for 10 minutes. These methods are used if the technology does not provide for other cleaning standards. After the work has been completed, you can begin testing, which is performed in two ways: hydraulic and pneumatic.

Hydraulic tests

Before checking, process pipelines are divided into separate conditional sections and the following measures are carried out:

  • control by external inspection;
  • checking technological documentation;
  • installation of air valves, temporary plugs (the use of permanent equipment is prohibited);
  • turning off the tested segment;
  • connecting the test section to a hydraulic pump.

Thus, the strength and tightness of the pipeline is checked simultaneously. To establish the degree of strength, a special test pressure value is taken into account:

  • Steel pipelines operated at operating pressures up to 5 kgf/m². The value of the test parameter is 1.5 of the operating pressure, but not less than 2 kgf/m².
  • Steel pipes operating at a pressure exceeding 5 kgf/m². The parameter value for testing will be 1.25 working pressure;
  • Cast iron, polyethylene and glass - 2 kgf/m².
  • Pipelines made of non-ferrous metals - 1 kgf/m².
  • For pipes made of other materials - 1.25 working pressure.

The holding time under the set pressure value will be 5 minutes, only for glass pipelines it increases four times.

Pneumatic tests

For testing, either inert gas is used, which is taken from factory networks or from portable compressors. This option is preferred in cases where hydraulic tests are impossible for a number of reasons: lack of water, very low air temperature, and also when dangerous stresses can arise in the pipeline structure from the weight of water. The value of the maximum test pressure depends on the size of the pipeline:

  • for pipe diameters up to 200 mm - 20 kgf/m²;
  • 200-500 mm - 12 kgf/m²;
  • over 500 mm - 6 kgf/m².

If the pressure limit is different, special test instructions must be developed for such conditions.

Pneumatic Test Requirements

Pneumatic testing is prohibited for above-ground cast iron and glass structures. For all other materials from which process pipelines can be made, there are special testing requirements:

  • the pressure in the pipeline increases gradually;
  • inspection can be carried out when the pressure reaches 0.6 of the operating value (increasing it during work is unacceptable);
  • checking for leaks is carried out by coating with a soap solution; tapping with a hammer is prohibited.

The results of hydraulic and pneumatic tests are considered satisfactory if during the test there was no pressure drop on the pressure gauge.

Transfer of pipelines into operation

At all stages of installation, appropriate documents are drawn up that record the types of work, approvals, tests, etc. They are transferred at the stage of pipeline commissioning as accompanying documentation, they include:

  • certificates of delivery of supporting structures;
  • certificates for welding materials;
  • protocol for internal pipeline cleaning;
  • certificates for checking the quality of welded joints;
  • conclusion on testing of shut-off valves;
  • acts and density;
  • a list of welders who performed the connections and documents confirming their qualifications;
  • pipeline diagrams.

Technological pipelines are put into operation along with industrial installations, buildings and structures. Only inter-shop systems can be rented separately.

Periodic monitoring should include the following operations:

  1. Checking technical condition during external inspection and non-destructive methods.
  2. Checking areas subject to vibration with special instruments that determine its frequency and amplitude.
  3. Troubleshooting problems that were identified during previous inspections.

Equally important is the safe operation of process pipelines, which is ensured by compliance with all established rules.

The monthly system health check should cover the following:

  • flange connections;
  • welds;
  • insulation and coating;
  • drainage systems,
  • support fastenings.

If leaks are detected, for safety reasons, the operating pressure must be reduced to atmospheric pressure, and the temperature of the heating lines must be lowered to 60ºC to carry out the necessary troubleshooting measures. The results of the inspection must be recorded in special journals.

Audit

This is used to determine the condition and operational capabilities of pipeline lines. It is advisable to carry out the inspection in areas where the operation of process pipelines is carried out in particularly difficult conditions. The latter include vibrations and increased corrosion.

Pipeline inspection includes the following operations:

  1. Checking the thickness of the structure using non-destructive methods.
  2. Measuring areas subject to creep.
  3. Inspection of welded joints that are in doubt.
  4. Examination
  5. Condition of support fastenings.

The first audit control should be carried out after a quarter of the period specified in the regulatory documents, but no later than 5 years after the launch of the facility. As a result of timely completion of all inspections, safe operation of process pipelines will be ensured.

Pipelines are designed to transport compressed air, water, steam, various gases and liquids. To quickly determine the contents of pipelines, and therefore ensure that workers comply with the relevant safety requirements when approaching them, ten groups of substances and the corresponding distinctive colors of the pipelines by which they are transported have been established: first - water (green), second - steam (red), third - air (blue), fourth and fifth - flammable and non-flammable gases, including liquefied (yellow), sixth - acids (orange), seventh - alkalis (purple), eighth and ninth - flammable and non-flammable liquids (brown), zero - other substances ( gray). Distinctive painting of pipelines is carried out along their entire length or in individual sections, depending on location, illumination, size, etc. In order to highlight the type of hazard, signal color rings are applied to pipelines: red - for flammable, explosive - and flammable substances; yellow - for harmful and dangerous substances (poisonous, toxic, radioactive) green - for safe and neutral substances. Sometimes, to specify the type of danger, in addition to the signal colored rings, warning signs, marking boards and inscriptions on pipelines in the most dangerous places of communications are used. The laying of pipelines on the territory of an enterprise can be underground (in channels and non-channel), above-ground (on supports) and above-ground (on overpasses, columns, walls of buildings, etc.). If possible, it is advisable to carry out ground and above-ground laying of pipelines, since then it is easy to inspect and check their condition. In addition, the service life of such pipelines is two to three times longer than underground ones. Pipelines are made from seamless pipes with welded joints. To facilitate installation and repair, flange connections are installed on the pipeline in convenient and accessible places. Pipelines are laid with a certain slope (1:500) in the direction of gas movement, and in low places separators with drain valves are installed to extract condensate and water. In order to prevent the occurrence of thermal stresses that can cause ruptures when cooling pipes or bends when they are heated, pipelines are provided with compensation elements: compensation loops, lyre-shaped pipes, stuffing box expansion joints, etc. The most common are U-shaped compensation loops, which allow thermal deformations to be evenly distributed throughout the pipeline. To ensure safety, serviceable and properly adjusted pressure reducing, check, shut-off and safety valves must be installed on the pipeline. Reducing valves (pressure regulators) maintain set pressure values ​​in the system regardless of changes in gas or liquid consumption by consumers. Check valves allow gas or liquid to pass through a pipeline in only one direction, therefore they prevent their reverse flow in the event of an emergency (for example, a fire in a flammable gas pipeline). When the permissible pressure is exceeded, check valves automatically open and part of the gas or liquid is released into the atmosphere or disposal channel. If poisonous, toxic, explosive or flammable gases or liquids are transported through the pipeline, then the safety valves must be of a closed type (when opened, gas or liquid is released into the closed system). Pipelines are periodically subject to external inspections and hydraulic tests. During external inspections, the condition of welded and flanged connections and seals is determined, slopes, deflections, and strength of load-bearing supports and structures are checked. During hydraulic tests, the tightness and strength of the pipeline is checked. If during the hydraulic test the pressure in the pipeline does not drop, and no cracks, ruptures, or leaks are found on the welds, flange connections, or housings of safety devices, then the test result is considered satisfactory. Thus, the safety of pipeline operation is ensured by their correct laying, high-quality installation, installation of compensation elements, necessary safety devices and fittings, monitoring their technical condition and timely repair. Natural gas is widely used in many enterprises and everyday life, most often as fuel. Considering that natural gas is an explosive substance, the gas pipeline, together with the installations that regulate the supply of gas and operate on it, is an object of increased danger, and therefore requires special care during operation. As a rule, the cause of accidents, explosions, and fires during the operation of gas facilities and gas pipelines is gas leakage. Since natural gas is odorless, to quickly detect its leak, an odorant is added to it - a substance with a strong odor (for example, ethyl mercaptan). To prevent the occurrence of induced currents of dangerous magnitude, which can cause explosions and fires, gas pipelines must be grounded and conductive jumpers installed at all flange connections.

GOSGOTEKHNADZOR OF RUSSIA

APPROVED
Resolution No. 11
Gosgortekhnadzor of Russia
from 03/02/95

DEVICE RULES
AND SAFE OPERATION
TECHNOLOGICAL PIPELINES

Mandatory for all enterprises and organizations
regardless of departmental affiliation and
organizational and legal forms

PB 03-108-96

Editorial committee: E. A. Malov (chairman), A. A. Shatalov (deputy chairman), L. N. Ganshina, B. M. Gusev, S. I. Zusmanovskaya, G. V. Kiryukhin, V. N. Konovalov, N. V. Martynov, Yu. S. Medvedev, E. Ya. Neiman, N. A. Potapov, V. B. Serebryany, R. A. Standrik, S. G. Starodub, G. M. Khazhinsky, N. V. Khimchenko, M. P. Elyash.

“Rules for the design and safe operation of technological pipelines” were developed by the State Gortekhnadzor of Russia, the Lower Volga District of the Gosgortekhnadzor of Russia, research and design institutes: VNIKTIneftekhimoborudovanie, NIIkhimmash, Giprokhimmontazh, IrkutskNIIkhimmash, GIAP, VNIIneftemash, VNIPIneft, YuzhNIIgiprogaz, OJSC "Sintezproekt", VNIImontazhspetsstroy with taking into account the comments of the Bashkir district of Gosgortekhnadzor of Russia, Angarsk Oil Company OJSC, Salavatnefteorgsintez OJSC, Kuibyshevazot CJSC, NIIPTkhimnefteapparatura, Nizhnekamskneftekhim OJSC and other interested organizations and enterprises.

These Rules establish general provisions and basic technical requirements for process pipelines: conditions for the selection and use of pipes, pipeline parts, fittings and basic materials for their manufacture, as well as requirements for welding and heat treatment, placement of pipelines, conditions of normal operation and repair, compliance with which is mandatory for all industries that have production facilities controlled by the Gosgortekhnadzor of Russia.

With the entry into force of these Rules, the “Rules for the construction and safe operation of pipelines for flammable, toxic and liquefied gases (PUG-69)”, approved by the USSR State Mining and Technical Supervision in 1969, become invalid.

All current industry normative and technical documents and instructions relating to the design, installation, operation and repair of steel in-plant and workshop process pipelines must be brought into compliance with these Rules.

The need and timing for bringing existing pipelines into compliance with these Rules are determined by the enterprise administration and agreed upon with the regional bodies of the State Mining and Technical Supervision Authority of Russia.

1. GENERAL PROVISIONS

1.1. Application area

1.1.1. Rules for the design and safe operation of process pipelines* apply to the design, installation, manufacture, installation, operation and repair of stationary steel process pipelines intended for transporting gaseous, vaporous and liquid media in the range of residual pressure (vacuum) 0.001 MPa (0.01 kgf /cm 2) up to a nominal pressure of 320 MPa (3200 kgf/cm 2) and operating temperatures from minus 196 to plus 700 ° C in chemical, petrochemical, oil refining, gas processing, chemical-pharmaceutical, pulp and paper, microbiological, coke-chemical, oil- and gas production enterprises.

* Rules for the design and safe operation of process pipelines hereinafter referred to as the Rules.

Notes 1. Process pipelines include pipelines within industrial enterprises through which raw materials, semi-finished and finished products, steam, water, fuel, reagents and other substances that ensure the conduct of the technological process and operation of equipment are transported, as well as inter-factory pipelines that are on the balance sheet of the enterprise .

2. The terms “pressure”, “conditional pressure”, except for specially specified cases, should be understood as excess pressure.

1.1.2. Along with these Rules, when designing, constructing and operating process pipelines, you should also be guided by the relevant sections of the Construction Norms and Rules (SNiP), the relevant rules of the State Technical Supervision Authority of Russia and other mandatory norms and rules.

In this case, it is necessary to take into account the requirements of fire and explosion safety, industrial sanitation and labor protection, set out in the relevant regulatory and technical documents (NTD), approved in the prescribed manner.

1.1.3. When designing and operating pipelines for liquid and gaseous chlorine, along with these Rules, one must be guided by the Safety Rules for the production, storage, transportation and use of chlorine (PBH-93).

1.1.4. When designing and operating air and gas pipelines for inert gas, along with these Rules, one should be guided by the requirements of the Rules for the Design and Safe Operation of Stationary Compressor Installations, Air and Gas Pipelines.

1.1.5. When designing and operating pipelines transporting gas containing hydrogen sulfide, along with these Rules, one should be guided by industry normative and technical documentation agreed with the State Technical Supervision Authority of Russia, and recommendations of specialized research organizations.

1.1.6. These Rules do not apply to pipelines:

trunk (gas pipelines, oil pipelines and product pipelines);

acetylene and oxygen;

power plants, boiler houses, mines;

heating networks, water supply and sewerage lines;

lined with non-metallic materials;

gases containing explosive dust and fibers;

temporary, constructed for the period of construction, installation or reconstruction of an enterprise or workshop, with a service life of no more than 1 year;

special purpose (nuclear installations, mobile units, lubrication systems that are an integral part of equipment, etc.);

steam and hot water of category I with a diameter of 51 mm or more, as well as all other categories with a diameter of 76 mm or more, which are subject to the requirements of the Rules for the construction and safe operation of steam and hot water pipelines;

fuel gas, which is subject to the Safety Rules in the gas industry, when using gas from main and city gas pipelines or liquefied gases as fuel.

1.1.7. Depending on the operating pressure, technological pipelines covered by these Rules are divided into low-pressure technological pipelines with a nominal pressure of up to 10 MPa (100 kgf/cm2) inclusive, and high-pressure technological pipelines with a nominal pressure of over 10 MPa (100 kgf/cm2) cm 2) up to 320 MPa (3200 kgf/cm 2).

1.1.8. It is allowed to develop industry-specific regulatory documents regulating the conditions and requirements of a specific industry, within the framework of the basic provisions and requirements of these Rules.

1.2. Basic provisions

1.2.1. These Rules establish the basic technical requirements for the design, design, manufacture, installation, operation and repair of technological steel pipelines, as well as the conditions for the selection and use of pipes, pipeline parts, fittings and basic materials. Compliance with these Rules is mandatory for all enterprises and organizations involved in the design, manufacture, installation and operation of process pipelines, regardless of departmental subordination and organizational and legal forms.

1.2.2. For pipes, fittings and connecting parts of pipelines, conditional ( R y) and the corresponding trial ( R etc.), as well as workers ( R slave) pressures are determined according to GOST 356. At a negative operating temperature of the environment, the conditional pressure is determined at a temperature of plus 20 °C.

1.2.3. The wall thickness of pipes and pipeline parts must be determined by strength calculations depending on the operating (design) parameters, corrosion and erosion properties of the medium according to regulatory and technical documents in relation to the current range of pipes. When choosing the wall thickness of pipes and pipeline parts, the features of their manufacturing technology (bending, assembly, welding) must be taken into account.

The maximum operating (calculated) pressure in the pipeline is taken to be:

permitted pressure for the device to which the pipeline is connected;

for pressure pipelines (after pumps, compressors, gas blowers) - the maximum pressure developed by the centrifugal machine with the valve closed on the discharge side; and for piston machines - the response pressure of the safety valve installed at the pressure source;

for pipelines with safety valves installed on them - the response pressure of the safety valve.

Pipelines that are tested for strength and density together with the apparatus must be designed for strength taking into account the testing pressure of the apparatus.

1.2.4. When calculating the wall thickness of pipelines, the addition to compensate for corrosive wear to the calculated wall thickness must be selected based on the condition of ensuring the required service life of the pipeline in accordance with current standards for the use of materials in technological processes and corrosion rates.

Depending on the rate of corrosion of carbon steels, the media are divided into:

non-aggressive and low-aggressive - with a corrosion rate of up to 0.1 mm/year;

moderately aggressive - with a corrosion rate of 0.1-0.5 mm/year;

highly aggressive - with a corrosion rate of over 0.5 mm/year.

1.2.5. When choosing materials and products for pipelines, you should be guided by the requirements of these Rules, as well as the instructions of industry and interindustry normative and technical documentation establishing their range, nomenclature, types, main parameters, conditions of use, etc. The following should be taken into account:

operating pressure and operating temperature of the transported medium;

properties of the transported and environment (aggressiveness, explosion and fire hazard, harmfulness, etc.);

properties of materials and products (strength, cold resistance, corrosion resistance, weldability, etc.);

ambient air temperature for pipelines located outdoors or in unheated rooms. When choosing materials and products for pipelines, the average temperature of the coldest five-day period should be taken as the design air temperature in accordance with SNiP 2.01.01-82.

1.2.6. The organizations or enterprises that performed the relevant work are responsible for the selection of the pipeline layout, the correctness of its design, strength calculations and choice of material, for the accepted service life, quality of manufacture, installation and repair, as well as for the pipeline’s compliance with the requirements of rules, standards and other normative and technical documentation.

1.2.7. All design changes that arise during the manufacturing, installation and repair of the pipeline, including the replacement of materials, parts and changes in the category of pipelines, must be carried out by an organization licensed by the Gosgortekhnadzor of Russia for the right to design pipelines.

1.2.8. The organization operating the pipeline (pipeline owner) bears full responsibility for the correct and safe operation of the pipeline, control over its operation, for the timeliness and quality of inspection and repair in accordance with these Rules, as well as for coordination with the author of the project of all changes made into the object and design documentation.

1.2.9. For pipelines and fittings that are in contact with explosive and fire hazardous and harmful environments, the design organization establishes an estimated service life, which must be reflected in the design documentation and included in the pipeline passport.

The operation of pipelines that have expired their design service life is permitted upon receipt of a technical conclusion on the possibility of its further operation and permission in the manner established by regulatory documents.

1.2.10. Organizations carrying out the design, manufacture, installation, repair, operation and technical diagnostics of pipelines must have a license from the Gosgortekhnadzor of Russia for the work performed.

2. TECHNOLOGICAL PIPELINES WITH CONDITIONAL PRESSURE UP TO 10 MPa (100 kgf/cm2)

2.1. Pipeline classification

2.1.1. All pipelines with pressure up to 10 MPa (100 kgf/cm 2) (inclusive), depending on the hazard class of the transported substance (explosion, fire hazard and harmfulness) are divided into groups (A, B, C) and depending on the operating parameters of the environment ( pressure and temperature) - into five categories (I, II, III, IV, V).

The classification of pipelines is given in table. .

Table 2.1

Pipeline classification R at £ 10 MPa (100 kgf/cm 2)

Transported substances

III

R slave, MPa (kgf/cm 2)

t slave, °С

R slave, MPa (kgf/cm 2)

t slave, °С

R slave, MPa (kgf/cm 2)

t slave, °С

R slave, MPa (kgf/cm 2)

t slave, °С

R slave, MPa (kgf/cm 2)

t slave, °С

Substances with toxic effects

a) extremely and highly hazardous substances of classes 1, 2 (GOST 12.1.007 )

Regardless

Regardless

b) moderately hazardous substances of class 3 (GOST 12.1.007 )

Over 2.5 (25)

Above +300 and below -40

-40 to +300

Vacuum below 0.08 (0.8) (abs)

Regardless

Explosive and fire hazardous substancesGOST 12.1.044

a) flammable gases (GG), including liquefied gases (LPG)

Over 2.5 (25)

Above +300 and below -40

Vacuum from 0.08 (0.8) (abs) to 2.5 (25)

-40 to +300

Vacuum below 0.08 (0.8) (abs)

Regardless

b) flammable liquids (flammable liquids)

Over 2.5 (25)

Above +300 and below -40

Over 1.6 (16) to 2.5 (25)

+120 to +300

Up to 1.6 (16)

-40 to +120

Vacuum below 0.08 (0.8) (abs)

Regardless

Vacuum above 0.08 (0.8) (abs)

-40 to +300

c) flammable liquids (FL)

Over 6.3 (63)

Above +350 and below -40

Over 2.5 (25) to 6.3 (63)

Over +250 to +350

Over 1.6 (16) to 2.5 (25)

Over +120 to +250

Up to 1.6 (16)

-40 to +120

Vacuum below 0.003 (0.03) (abs)

Same

Vacuum below 0.08 (0.8) (abs)

Same

Vacuum up to 0.08 (0.8) (abs)

Over +350 to +450

Over 2.5 (25) to 6.3 (63)

+250 to +350

Over 1.6 (16) to 2.5 (25)

Over +120 to +250

Up to 1.6 (16)

-40 to +120

Notes 1. The designation of a group of a specific transported medium includes the designation of the general group of the environment (A, B, C) and the designation of a subgroup (a, b, c), reflecting the hazard class of the transported substance.

2. The designation of the pipeline group in general corresponds to the designation of the group of the transported medium. The designation “pipeline of group A(b)” means a pipeline through which a medium of group A(b) is transported.

3. The group of a pipeline transporting media consisting of various components is established according to the component that requires the pipeline to be assigned to a more responsible group. Moreover, if the mixture contains hazardous substances of hazard classes 1, 2 and 3, the concentration of one of the components is lethal, the group of the mixture is determined by this substance.

If the most dangerous component in terms of physical and chemical properties is included in the mixture in insignificant quantities, the issue of assigning the pipeline to a less responsible group or category is decided by the design organization (the author of the project).

4. The hazard class of harmful substances should be determined in accordance with GOST 12.1.005 and GOST 12.1.007, the values ​​of fire and explosion hazard indicators of substances - according to the relevant technical documentation or methods set out in GOST 12.1.044.

6. For vacuum pipelines, it is not the nominal pressure that should be taken into account, but the absolute operating pressure.

7. Pipelines transporting substances with an operating temperature equal to or exceeding their auto-ignition temperature or an operating temperature below minus 40 ° C, as well as incompatible with water or air oxygen under normal conditions, should be classified as category I.

2.1.2. Categories of pipelines determine a set of technical requirements for the design, installation and scope of control of pipelines in accordance with these Rules.

2.1.3. The hazard class of technological environments is determined by the project developer based on the hazard classes of substances contained in the technological environment and their ratios in accordance with GOST 12.1.007.

2.1.5. By decision of the developer, it is allowed, depending on operating conditions, to accept a more responsible (than determined by the operating parameters of the environment) category of pipelines.

2.2. Requirements for materials used for pipelines

2.2.1. Pipes, shaped connecting parts, flanges, gaskets and fasteners used for steel process pipelines must meet the requirements of these Rules and relevant regulatory and technical documents in terms of quality, technical characteristics and materials.

The quality and technical characteristics of materials and finished products used for the manufacture of pipelines must be confirmed by the manufacturing plants with the appropriate passports or certificates. Materials and products that do not have passports or certificates are allowed to be used only for pipelines of categories II and below and only after they have been checked and tested in accordance with standards, technical specifications and these Rules.

The material of the pipeline parts, as a rule, must match the material of the pipes being connected. When using and welding dissimilar steels, one should be guided by the instructions of the relevant regulatory and technical documents.

Based on the conclusion of specialized research organizations, the use of pipes and pipeline parts made from materials not specified in these Rules is allowed.

2.2.2. Pipes and fittings of pipelines must be made of steel with technological weldability, with a ratio of yield strength to tensile strength of no more than 0.75, a relative elongation of the metal at break on five-fold samples of at least 16% and an impact strength of not less thanKCU = 30 J/cm 2 (3.0 kgf · m/cm 2) at the minimum permissible temperature of the wall of the pipeline element during operation.

2.2.3. The use of imported materials and products is permitted if the characteristics of these materials meet the requirements of domestic standards and are confirmed by the conclusion of a specialized research organization.

Approved

by order of the Minister of Emergency Situations of the Republic of Kazakhstan


Industrial safety requirements for

operation of process pipelines

Chapter 1. General provisions
1. These Requirements apply to designed, newly manufactured and modernized steel process pipelines intended for transporting gaseous, vaporous and liquid media in the range from a residual pressure (vacuum) of 0.001 MPa (0.01 kgf/cm) to a nominal pressure of 320 MPa (3200 kgf/cm) and operating temperatures from -196 ° C to 700 ° C and operated at hazardous production facilities.

2. The wall thickness of pipes and pipeline parts is determined by strength calculations depending on the design parameters, corrosion and erosion properties of the medium according to regulatory and technical documents in relation to the current range of pipes. When choosing the wall thickness of pipes and pipeline parts, the features of their manufacturing technology (bending, assembly, welding) are taken into account.

The following are taken as the design pressure in the pipeline:

1) design pressure for the apparatus to which the pipeline is connected;

2) for pressure pipelines (after pumps, compressors, gas blowers) - the maximum pressure developed by the centrifugal machine when the valve on the discharge side is closed; and for piston machines - the response pressure of the safety valve installed at the pressure source;

3) for pipelines with safety valves installed on them - the pressure of the safety valve setting.

Pipelines that are tested for strength and density together with the apparatus are designed for strength taking into account the testing pressure of the apparatus.3. When calculating the wall thickness of pipelines, the increase to compensate for corrosive wear to the calculated wall thickness should be selected based on the condition of ensuring the required design service life of the pipeline and the corrosion rate.

Depending on the corrosion rate of steels, media are divided into:

1) non-aggressive and low-aggressive - with a corrosion rate of up to 0.1 mm/year (resistant steel);

2) moderately aggressive - with a corrosion rate of 0.1-0.5 mm/year;

3) highly aggressive - with a corrosion rate of over 0.5 mm/year.

At a corrosion rate of 0.1-0.5 mm/year and above 0.5 mm/year, steel is considered to be of low resistance.

4. When choosing materials and products for pipelines, consider:

1) design pressure and design temperature of the transported medium;

2) properties of the transported medium (aggressiveness, explosion and fire hazard, harmfulness, etc.);

3) properties of materials and products (strength, cold resistance, corrosion resistance, weldability, etc.);

4) negative ambient temperature for pipelines located in the open air or in unheated rooms. When choosing materials and products for pipelines, the following should be taken as the calculated negative air temperature:

the average temperature of the coldest five-day period in the region with a probability of 0.92, if the operating temperature of the pipeline wall under pressure or vacuum is positive;

the absolute minimum temperature of a given area if the operating temperature of the pipeline wall under pressure or vacuum becomes negative due to the influence of ambient air.

5. For pipelines and fittings, the design organization establishes a service life in the design documentation.

Chapter 2. Process pipelines with nominal pressure

up to 10 MPa (100 kgf/cm)

Paragraph 1. Classification of pipelines
6. Pipelines with pressure up to 10 MPa (100 kgf/cm) inclusive, depending on the hazard class of the transported substance (explosion, fire hazard and harmfulness) are divided into groups A, B, C and depending on the operating parameters of the medium (pressure and temperature) - into five categories (I, II, III, IV, V).

The classification of pipelines is given in Appendix 1 of these Requirements.

8. The hazard class of technological environments is determined by the project developer based on the hazard classes of substances contained in the technological environment and their ratios.

10. It is allowed, depending on operating conditions, to accept a higher (than determined by the operating parameters of the environment) category of pipelines.

The designation of a group of a certain transported medium includes the designation of the medium group (A, B, C) and the designation of the subgroup (a, b, c), reflecting the hazard class of the substance.

The designation of the pipeline group in general corresponds to the designation of the group of the transported medium. The designation “pipeline of group A(b)” means a pipeline through which a medium of group A(b) is transported.

The group of a pipeline transporting media consisting of various components is determined by the component that requires the pipeline to be assigned to a more responsible group. If the mixture contains hazardous substances of hazard classes 1, 2 and 3 and if the concentration of one of them is the most dangerous, the group of the mixture is determined by this substance.

If the most dangerous component in terms of physical and chemical properties is included in the mixture in an insignificant amount, the issue of assigning the pipeline to a less responsible group or category is decided by the design organization.

For vacuum pipelines, it is not the conditional pressure that is taken into account, but the absolute operating pressure.

Pipelines transporting substances with an operating temperature equal to or exceeding their auto-ignition temperature or an operating temperature below -40°C, as well as incompatible with water or air oxygen under normal conditions, are classified as category I.

Paragraph 2. Requirements for materials used for pipelines
11. Pipes, shaped connecting parts, flanges, gaskets and fasteners used for pipelines comply with the relevant regulatory and technical documentation in terms of quality, technical characteristics and materials.

The quality and technical characteristics of materials and finished products used for the manufacture of pipelines are confirmed by manufacturer certificates. Materials and products that do not have certificates may be used only for pipelines of categories II and below and after their inspection and testing, in accordance with regulatory and technical documentation.

The material of the pipeline parts corresponds to the material of the connected pipes. When using dissimilar pipes and welding them, they are guided by the instructions of the relevant regulatory and technical documents.

12. Pipes and shaped parts of pipelines are made of steel with technological weldability, with a ratio of yield strength to tensile strength of no more than 0.75, a relative elongation of the metal at break on five-fold samples of at least 16% and an impact strength of not less than 30 J/cm ( 3.0 kgf m/cm) at the minimum design temperature of the wall of the pipeline element.

13. Pipes, depending on the parameters of the transported medium, are selected in accordance with regulatory and technical documentation.

14. Seamless pipes made from ingots and shaped parts for these pipes may be used for pipelines of groups A and B of the first and second categories, subject to their inspection by ultrasonic flaw detection (hereinafter referred to as ultrasonic testing) in a volume of 100% over the entire surface.

15. For pipelines transporting liquefied hydrocarbon gases (hereinafter referred to as LPG), as well as substances belonging to group A (a), seamless hot- and cold-deformed pipes should be used. In accordance with the instructions of the regulatory and technical documentation, it is allowed to use electric-welded pipes with a nominal diameter of more than 400 mm for pipelines transporting substances belonging to group A (a) and liquefied hydrocarbon gases with a metal corrosion rate of up to 0.1 mm/year, with an operating pressure of up to 2.5 MPa (25 kgf/cm) and temperatures up to 200°C, heat treated, 100% control of welds (ultrasound or transmission) with positive results of mechanical tests of samples from welded joints in full, including impact strength .

It is allowed to use shells made of sheet steel as pipes in accordance with the requirements of the design and safe operation of pressure vessels for a nominal pressure of up to 2.5 MPa (25 kgf/cm).

16. For pipelines, pipes with standardized chemical composition and mechanical properties of the metal (group B) are used.

17. The pipes are tested by the manufacturer with a test hydraulic pressure specified in the normative and technical documentation for the pipes, or have an indication in the certificate of the guaranteed value of the test pressure.

It is allowed not to carry out hydrotesting of seamless pipes if they have been subjected to non-destructive testing over the entire surface.

18. Electric-welded pipes with a spiral seam may only be used for straight sections of pipelines.

19. Electric-welded pipes used for transporting substances of groups A(b), B(a), B(b) (Appendix 1), with the exception of liquefied gases with pressure over 1.6 MPa (16 kgf/cm) and groups B(c) ) and B pressure over 2.5 MPa (25 kgf/cm), with an operating temperature over 300°C in the heat-treated state, and their welds are subjected to 100% non-destructive testing (ultrasound or radiography) and bending or impact strength testing.

It is allowed to use non-heat-treated pipes with a ratio of the outer diameter of the pipe to the wall thickness equal to or more than 50 for transporting media that do not cause corrosion cracking of the metal.

20. Electric-welded pipes in contact with a medium that causes corrosion cracking of the metal, regardless of pressure and wall thickness in the heat-treated state, and their welds are equal in strength to the base metal and are subjected to 100% testing by non-destructive methods (ultrasound or radiography).

21. Pipes made of carbon semi-quiet steel can be used for environments of group B with a wall thickness of no more than 12 mm in areas with a design outside air temperature of not lower than -30°C, while ensuring the temperature of the pipeline wall during operation is not lower than -20°C.

Pipes made of carbon boiling steel can be used for environments of group B with a wall thickness of no more than 8 mm and a pressure of no more than 1.6 MPa (16 kgf/cm) in areas with a design air temperature of not lower than -10°C.

22. The design of flanges and materials for them should be selected taking into account the parameters of the working media according to the regulatory and technical documentation.

23. Flat welded flanges are used for pipelines operating at a nominal pressure of no more than 2.5 MPa (25 kgf/cm) and a medium temperature of no higher than 300°C. For pipelines of groups A and B with a nominal pressure of up to 1 MPa (10 kgf/cm), flanges are used that are designed for a nominal pressure of 1.6 MPa (16 kgf/cm).

24. For pipelines operating at a nominal pressure of over 2.5 MPa (25 kgf/cm), regardless of temperature, as well as for pipelines with an operating temperature above 300°C, regardless of pressure, butt-welded flanges are used.

25. Butt weld flanges are made from forgings or banding blanks.

It is allowed to manufacture butt-welded flanges by rolling blanks along the sheet plane for pipelines operating at a nominal pressure of no more than 2.5 MPa (25 kgf/cm), or by bending forged strips for pipelines operating at a nominal pressure of no more than 6.3 MPa (63 kgf/cm), subject to 100% control of welds by radiographic or ultrasonic methods.

26. When choosing the type of sealing surface of the flanges, be guided by Appendix 2 of these Requirements.

27. For pipelines transporting substances of groups A and B of technological objects of the 1st explosion hazard category, the use of flange connections with a smooth sealing surface is not allowed, with the exception of cases of using spirally wound gaskets with a restrictive ring.

28. Select fasteners for flange connections and materials for them depending on the operating conditions and steel grades of the flanges.

To connect flanges at temperatures above 300°C and below -40°C, regardless of pressure, use studs.

29. When manufacturing studs, bolts and nuts, the hardness of the studs or bolts is at least 10 - 15 HB higher than the hardness of the nuts.

30. It is not allowed to manufacture fasteners from boiling, semi-calm, Bessemer and automatic steel.

31. Material blanks or finished fasteners made of high-quality carbon, heat-resistant and heat-resistant alloy steels are heat-treated.

For fasteners used at pressures up to 1.6 MPa (16 kgf/cm) and operating temperatures up to 200°C, fasteners made of carbon steel with threads up to 48 mm in diameter are not allowed to undergo heat treatment.

32. In the case of using fasteners made of austenitic steels at an operating temperature of the environment above 500°C, it is not allowed to produce threads by rolling.

33. Select materials for fasteners with a coefficient of linear expansion close in value to the coefficient of linear expansion of the flange material with a difference in the values ​​of the linear expansion coefficients of materials not exceeding 10%.

It is allowed to use materials of fasteners and flanges with linear expansion coefficients, the values ​​of which differ by more than 10%, in cases justified by strength calculations or experimental studies, for flange connections at an operating temperature of no more than 100°C.

34. Gaskets and gasket materials for sealing flange connections are selected depending on the transported medium and its operating parameters in accordance with the project, regulatory and technical documentation.

35. Shaped parts of pipelines, depending on the parameters of the transported medium and operating conditions, should be selected according to the regulatory and technical documentation.

36. Shaped parts of pipelines should be made from steel seamless and straight-seam welded pipes or sheet metal, the metal of which meets the requirements of the project, regulatory and technical documentation, and the conditions of weldability with the material of the connected pipes.

37. Pipeline parts for environments that cause corrosion cracking of metal, regardless of design, steel grade and manufacturing technology, are subject to heat treatment.

Local heat treatment of welded joints of sectional bends and welded tees from pipes is allowed if heat-treated pipes are used for their manufacture.

38. When choosing welded parts of pipelines, depending on the aggressiveness of the environment, temperature and pressure, be guided by the regulatory and technical documentation.

39. Welding of fittings and quality control of welded joints should be carried out in accordance with the requirements of regulatory, technical and design documentation.

40. Branching from the pipeline is carried out using one of the methods set out in Appendix 3 of these Requirements. Strengthening tee connections with stiffeners is not allowed.

41. Connecting branches according to method “a” (Appendix 3) is used in cases where the weakening of the main pipeline is compensated by the existing strength reserves of the connection.

42. When choosing a method for connecting branches to the main pipeline, give preference to methods “b”, “c”, “e” (Appendix 3).

43. An overlay on the branch pipeline (connection according to method “e” in Appendix 3) is installed when the ratio of the diameters of the branch and main pipelines is at least 0.5.

44. Welded tees are used at pressure Py - up to 10 MPa (100 kgf/cm).

45. Welded bends with a nominal bore D y = 150÷400 mm should be used for process pipelines at a pressure P y of no more than 6.3 MPa (63 kgf/cm).

Welded bends with a nominal bore D y = 500÷1400 mm can be used for process pipelines at a pressure P y of no more than 2.5 MPa (25 kgf/cm 2).

46. ​​Welded concentric and eccentric reducers with nominal diameter D у =250÷400 mm can be used for process pipelines at pressure Р у up to 4 MPa (40 kgf/cm), and with D у 500÷1400 mm - at Р у up to 2 .5 MPa (25 kgf/cm).

The limits of use of steel transitions, depending on temperature and aggressiveness of the environment, correspond to the limits of use of connected pipes for similar steel grades.

Welded seams of transitions are subject to 100% control by ultrasonic or radiographic methods.

47. It is allowed to use petal transitions for process pipelines with a nominal pressure P y of no more than 1.6 MPa (16 kgf/cm) and a nominal diameter D y = 100÷500 mm.

It is not allowed to install petal transitions on pipelines intended for transporting liquefied gases and substances of group A(a) (Appendix 1).

48. Weld petal transitions, followed by 100% control of the welds using an ultrasonic or radiographic method.

After manufacturing, the petal transitions are subjected to high-temperature tempering.

49. Welded crosses may be used on pipelines made of carbon steel at an operating temperature not exceeding 250°C.

Crosspieces made of electric-welded pipes can be used at a pressure P of no more than 1.6 MPa (16 kgf/cm 2), while they are made of pipes recommended for use at a pressure P of at least 2.5 MPa (25 kgf/cm 2 ).

Crosspieces made of seamless pipes may be used at a pressure P of no more than 2.5 MPa (25 kgf/cm2), provided they are made from pipes recommended for use at a pressure Py of at least 4 MPa (40 kgf/cm2).

50. For process pipelines, use steeply curved bends made from seamless and welded straight-seam pipes by hot stamping or broaching, bent and stamp-welded bends.

51. Bent bends made from seamless pipes are used instead of steeply bent and welded bends in cases where it is necessary to minimize the hydraulic resistance of the pipeline, on pipelines with a pulsating flow of the medium (to reduce vibration), on pipelines with a nominal bore D y less than 25 mm.

The limits of application of smooth-bent bends with a bend radius R≥2D n from pipes of the current range correspond to the limits of application of the pipes from which they are made.

52. When choosing the bending radius of smooth-bent bends, be guided by the design and normative-technical documentation.

The minimum length of the straight section from the end of the pipe to the beginning of the rounding should be taken equal to the diameter Dn of the pipe, but not less than 100 mm.

54. The temperature limits for the use of materials for flange plugs or plugs installed between flanges should be taken into account the temperature limits for the use of flange materials.

55. Quick-release plugs are produced and installed in accordance with the project.

Welded, flat and ribbed plugs can be used for process pipelines transporting substances of groups A and B at pressure P up to 2.5 MPa (25 kgf/cm2).

56. Plugs installed between flanges, quick-release plugs should not be used to separate two pipelines with different media, the mixing of which is unacceptable.

57. The quality and material of the plugs are confirmed by a certificate.

On each removable plug (on the shank, and in its absence - on the cylindrical surface), indicate the plug number, steel grade, nominal pressure P y and nominal bore D y.

58. Installation and removal of plugs are noted in the log.

Chapter 3. High pressure process pipelines

over 10 MPa (100 kgf/cm 2) up to 320 MPa (3200 kgf/cm 2)

Paragraph 1. General provisions
59. The design of the pipeline ensures safety during operation and provides for the possibility of its complete emptying, cleaning, washing, purging, external and internal inspection, control and repair, removal of air from it during hydraulic testing and water after it.

60. If the pipeline design does not allow external and internal inspections, controls or tests, the project shall indicate the methodology, frequency and scope of inspection and repair, the implementation of which will ensure timely identification and elimination of defects.

61. Connections of pipeline elements operating under pressure up to 35 MPa (350 kgf/cm2) should be made by welding with butt welded joints without a backing ring. Flange connections may be provided in places where pipelines are connected to devices, fittings and other equipment that have mating flanges, in sections of pipelines that require periodic disassembly or replacement during operation. Pipeline connections under pressure above 35 MPa (350 kgf/cm2) must be made in accordance with the regulatory and technical documents for these conditions.

62. In pipelines intended to operate under pressure up to 35 MPa (350 kgf/cm2), welding of fittings in straight sections, the use of tees welded from pipes, and stamp-welded elbows with two longitudinal seams are allowed, provided that 100% control of welded joints is carried out using non-destructive methods .

63. Welding fittings into welds and bent elements (in places of bends) of pipelines is not allowed.

On pipeline bends operating under pressure up to 35 MPa (350 kgf/cm2), welding of one fitting (pipe) for a measuring device with an internal diameter of no more than 25 mm is allowed.

64. To connect pipeline elements made of high-strength steels with a tensile strength of 650 MPa (6500 kgf/cm2) or more, use threaded coupling or flange connections.

65. At the locations of the most stressed welded joints and points of measurement of residual deformation accumulated during metal creep, provide removable insulation sections.

Paragraph 2. Pipeline design requirements
66. High-pressure pipeline parts should be made from forgings, die forgings and pipes. The use of other types of workpieces is allowed if they ensure safe operation during the design service life, taking into account the specified operating conditions.

67. The ratio of the internal diameter of the branch to the internal diameter of the main pipe in forged tees-inserts is taken to be at least 0.25. If the ratio of the fitting diameter to the diameter of the main pipe is less than 0.25, tees or fittings are used.

68. The design and geometric dimensions of tees welded from pipes, stamp-welded rings, bent elbows and fittings comply with the requirements of the project.

69. Tees welded from pipes, stamp-welded bends, tees and bends from billets cast using electroslag technology can be used for pressures up to 35 MPa (350 kgf/cm2). In this case, all welds and metal of cast workpieces are subject to 100% non-destructive testing.

70. The ratio of the internal diameter of the fitting (branch) to the internal diameter of the main pipe in welded tees is taken to be no higher than 0.7.

71. The use of bends welded from sectors is not recommended.

72. Bent elbows are subjected to heat treatment after bending.

73. Bends bent from steel grades 20, 15GS, 14KhGS are subjected to tempering after cold bending, provided that before cold bending the pipes were subjected to hardening and tempering or normalization.

74. For detachable connections, use threaded flanges and butt-welded flanges, taking into account the requirements of paragraph 62 of these Requirements.

75. Use metal lens gaskets of flat, octagonal, oval and other sections as sealing elements of flange connections.

76. Standard threads are used on pipeline parts, threaded flanges, couplings and fasteners. The shape of the external threads is rounded. Thread tolerances - 6H, 6 g. The quality of the thread is checked by free passage of the thread gauge.

77. In the case of manufacturing fasteners by cold deformation, they are subjected to heat treatment - tempering. Thread rolling on austenitic steel studs for operation at temperatures above 500°C is not permitted.

78. The design and arrangement of welded joints ensure their high-quality execution and control by all provided methods during the manufacturing, installation, operation and repair process.

79. The distance between adjacent annular butt welded joints is not less than three times the nominal thickness of the elements being welded, but not less than 50 mm for a wall thickness of up to 8 mm and not less than 100 mm for a wall thickness of over 8 mm.

In any case, the specified distance makes it possible to carry out local heat treatment and control the seam using non-destructive methods.

Welded connections of pipelines should be located from the edge of the support at a distance of at least 50 mm for pipes with a diameter of less than 50 mm and at least at a distance of 200 mm for pipes with a diameter over 50 mm.

80. The distance from the beginning of the pipe bend to the axis of the circumferential weld for pipes with an outer diameter of up to 100 mm is not less than the outer diameter of the pipe, but not less than 50 mm.

For pipes with an outer diameter of 100 mm or more, this distance is at least 100 mm.

Paragraph 3. Requirements for materials used for high-pressure pipelines
81. For the manufacture, installation and repair of pipelines for pressures above 10 MPa (100 kgf/cm2) to 320 MPa (3200 kgf/cm2) and temperatures from –50 to 540°C, use standard materials and semi-finished products.

82. Conditions for the use of materials for corrosive environments containing hydrogen, carbon monoxide, ammonia are determined in accordance with Appendix 4 of these Requirements.

83. The parameters for the use of steels specified in Table 1 of Appendix 4 of these Requirements also apply to welded joints, provided that the content of alloying elements in the weld metal is not lower than in the base metal. Steel grades 15Х5М and 15Х5М-III according to Table 1 of Appendix 4 of these Requirements can be used up to 540°C at a partial hydrogen pressure of no more than 6.7 MPa (67 kgf/cm2).

The conditions of use in Table 2 of Appendix 4 of these Requirements are established for a carbonyl corrosion rate of no more than 0.5 mm/year.

The conditions of use in Table 3 of Appendix 4 of these Requirements are established for a nitriding rate of no more than 0.5 mm/year.

84. The quality and properties of semi-finished products are confirmed by certificates and appropriate markings. In the absence or incompleteness of a certificate or marking, carry out all the necessary tests and document their results in a protocol that supplements or replaces the certificate.

85. The manufacturer of semi-finished products controls the chemical composition of the material. The certificate includes the results of chemical analysis obtained directly for the semi-finished product, or data on the certificate for the workpiece used for its manufacture.

86. Control of the mechanical properties of semi-finished metal is carried out by tensile tests at 20°C, with determination of temporary tensile strength, conditional or physical yield strength, relative elongation, relative contraction for impact bending.

87. Semi-finished products are subjected to impact bending testing on samples with type U (KCU) and type V (KV) concentrators at a temperature of 20 ° C, at negative temperatures when the product is operated under these conditions.

Impact strength values ​​at all test temperatures for KSU are no less than 30 J/cm 2 (3.0 kgf m/cm), for KV - no less than 25 J/cm 2 (2.5 kgf m/cm 2).

88. Standardized values ​​of mechanical properties at elevated temperatures and test temperatures are indicated in the technical documentation for semi-finished products intended for operation at elevated temperatures.

89. For the material of semi-finished products intended for operation at temperatures above 400°C, the value of metal creep resistance is determined, which is indicated in the technical documentation.

90. The limits of use of pipe material, types of testing and control are established by regulatory and technical documentation and are indicated in the technical documentation.

91. Seamless pipes are made from rolled or forged billets.

92. Hydraulic tests are provided for each pipe. The test pressure value is indicated in the regulatory and technical documentation for the pipes.

93. Pipes are supplied in a heat-treated state, ensuring a given level of mechanical properties and residual stresses.

At the end of each pipe a stamp is placed containing the following data: heat number, steel grade, manufacturer and batch number.

94. Pipes with an internal diameter of 14 mm or more are controlled using non-destructive methods. Pipes with a diameter of less than 14 mm are inspected using magnetic particle or capillary (color) methods.

95. Pipes made of corrosion-resistant steels, if provided for by the design, are tested for susceptibility to intergranular corrosion (hereinafter referred to as ICC).

96. For the manufacture of forgings, use high-quality carbon, low-alloy, alloy and corrosion-resistant steels.

97. Forgings for pipeline parts are assigned to groups IV and IVK.

98. The dimensions of forgings are taken taking into account machining allowances, dimensional tolerances, technological allowances and allowances for samples.

99. Forgings made of carbon, low-alloy and alloy steels, having one of the overall dimensions of more than 200 mm and a thickness of more than 50 mm, are subject to piece-by-piece inspection by ultrasonic or other equivalent method.

At least 50% of the volume of the inspected forging is subjected to flaw detection. The control area is distributed evenly over the entire controlled surface.

100. Studs, nuts, flanges and lenses may be made from rolled steel.

101. The material of studs, nuts, flanges and lenses, made of rolled steel, meets the technical requirements specified in the regulatory and technical documentation for these products.

102. The limits of use of steels of various grades for flanges and fasteners, types of rigorous testing and control comply with the regulatory and technical documentation.

103. Materials of fasteners are selected in accordance with paragraph 34 of these Requirements.

104. Nuts and studs are made from steel of different grades, and when made from steel of the same grade - with different hardness. In this case, the hardness of the nut is lower than the hardness of the stud by at least 10-15 HB.

Paragraph 4. Requirements for the manufacture of pipelines
105. Welding of assembly units is carried out in accordance with the requirements of technical documentation containing instructions on pipeline welding technology, the use of filler materials, types and scope of control, preliminary and concomitant heating and heat treatment.

106. The production of assembly units may be carried out by organizations that have the technical capabilities and specialists to ensure the quality of production of assembly units in full compliance with these Requirements.

107. During manufacturing, installation, and repair, carry out incoming inspection of pipes, forgings, parts of welded joints and welding materials for compliance with these Requirements and regulatory and technical documentation.

108. Pipes, forgings, parts and welding materials are equipped with certificates and marked.

109. The scope and methods of incoming inspection of metal of assembly units and pipeline elements comply with Appendix 5 of these Requirements.

110. In the absence of certificates or the necessary data in them, if the labels (tags) on the packages do not correspond to the certificate data, tests and control checks are carried out.

111. Pipes, forgings, parts and welding materials are submitted for inspection in batches. Control methods comply with the requirements of the technical specifications for delivery.

112. Inspection of the outer surface of pipes, parts and forgings may be carried out without the use of magnifying devices. The inner surface of the pipes is inspected using instruments.

If scratches, caps, sunsets, or flaws are detected, the depth of which exceeds the tolerances established by the technical requirements, the pipes are rejected.

113. Chains, caps, sandboxes, cavities discovered by external inspection on the processed surfaces of forgings are allowed provided that their depth does not exceed 75% of the actual, one-sided allowance for processing.

114. For mechanical tests, pipes and forgings with the highest and lowest hardness are selected.

115. From one end of each selected pipe the following is cut:

1) 2 samples for tensile testing at 20°C;

3) 2 samples for tensile testing at operating temperature;

4) 2 samples for impact bending tests at negative temperatures;

5) 1 sample for microstructure research;

6) 1 sample for flattening test;

7) 1 sample for static bending test.

116. From each selected forging the following is cut:

1) 1 sample for tensile testing at 20°C;

2) 2 samples for impact bending tests at 20°C;

3) 1 sample for tensile testing at operating temperature;

4) 2 samples for impact bending tests at subzero temperatures.

117. Sampling for testing resistance to intergranular corrosion is carried out in accordance with regulatory and technical documentation.

118. The need to test for resistance to intergranular corrosion of pipes, forgings, deposited metal or welded joint metal, and determine the content of the ferrite phase is established by the project.

119. For macro-examination of pipe metal, it is allowed to use samples on which impact bending was determined.

120. If the results of tests carried out in accordance with the requirements of paragraphs 114-116 are unsatisfactory for at least one of the indicators, repeated tests are carried out on it on a double number of samples taken from other pipes (forgings) of the same batch.

If the results of repeated tests are unsatisfactory, repeated tests of each pipe (forging) are carried out. Pipes (forgings) that show unsatisfactory results are rejected.

121. The chemical composition of the metal of pipes, forgings, and parts is indicated in the certificates for the workpiece.

122. The metal of pipes and forgings made of steel grade 03Х17Н14М3 is subject to control for the content of the ferrite phase. The ferrite phase content does not exceed 0.5 points (1-2%).

123. Marks from clamping dies are allowed on the surfaces of finished bends and bends.

124. Deviations in the overall dimensions of assembly units correspond to quality 16. The total deviation of the overall dimensions of the assembly unit does not exceed ± 10 mm.

125. The overall dimensions and weight of assembly units, including those in packaging, do not exceed the established dimensions and loads for transportation by vehicles.

126. Displacement of edges along the internal diameter in butt seams of pipes and pipeline parts is allowed within 10% of the wall thickness, but not more than 1 mm. If the displacement is more than 1 mm, boring is carried out along the inner diameter at an angle of 12-15°. The boring depth does not exceed the limits of the calculated wall thickness.

127. The displacement of edges along the outer diameter in butt seams of pipes and pipeline parts does not exceed 30% of the thickness of a thinner pipe or part, but not more than 5 mm. If the specified values ​​are exceeded, a bevel is made on the outside of the pipe or pipeline part at an angle of 12-15°. When assembling pipes with pipeline parts on which bevel is not allowed, adapters should be used that provide permissible displacement.

Industrial systems for transporting various substances through pipes can be dangerous, and therefore require high-quality, qualified service. In this article we will explain the rules for the design and safe operation of process pipelines, which have undergone significant changes in recent years.

Read our article:

Status for 2019 of the resolution of the Federal Mining and Industrial Supervision of Russia dated May 10, 2003 No. 80 “On approval of the Rules for the design and safe operation of process pipelines”

Before we talk about this document, let us recall what exactly is classified as process pipelines (TP). These are complex devices for moving various substances (water, fuel, reagents, steam, raw materials, semi-finished products, finished products), which are used at industrial facilities and are necessary to ensure technological processes during equipment operation.

Another important regulatory act that must be followed when using and servicing CTs was adopted on December 27, 2012 “On approval of the Safety Guide “Recommendations for the design and safe operation of process pipelines””.

Today, the last two documents define the basic rules for the operation of industrial transformers.

Rules for operating pipelines

The current industrial safety regulations “Technological pipelines” impose strict requirements for the use, maintenance, and inspection of technological pipeline systems, as well as for the qualifications of specialists working with them. Below we will talk about these requirements in detail.

Operating procedure

First of all, you need to check the performance of the systems at certain intervals. We are talking about an external inspection to check the technical condition of pipes or connections, examination of areas subject to vibration with special instruments, as well as the elimination of all detected problems.

Every month you need to examine the following areas of the TT with special passion:

  • flange connections;
  • insulation, coating;
  • drainage systems,
  • support fastenings.

If leaks are detected, it is necessary to lower the operating pressure to atmospheric pressure and reduce the temperature (on the heating lines) to 60ºС. Only after that .

The above-mentioned Order No. 116 prohibits the use of technological TT in the following situations:

  • malfunction or complete inoperability of the system;
  • inconsistency;
  • the presence of defects that may affect operational safety;
  • malfunction of fittings, instrumentation, safety, interlocking devices, protective equipment, alarm systems;
  • expiration of the service life specified in the equipment passport.

When using TT at hazardous production facilities, special attention must be paid to personnel issues. Responsible specialists, as well as a sufficient number of qualified workers, must be involved in working with technological transportation systems. All of them comply with production instructions and labor protection requirements.

Long before the system is launched, it is necessary to approve instructions on industrial safety at the enterprise, as well as separately - instructions for all responsible specialists and workers.

Qualification requirements, employee responsibilities

The safety of process pipelines can only be ensured by workers with sufficient qualifications. These must be people at least 18 years of age who have a vocational education (in the case of specialists) or appropriate vocational training (for workers). Before being allowed to work, which will be issued by a separate order, they must undergo the following procedures:

  • testing knowledge of safe work requirements.

At least once every 12 months, employees must undergo short-term training with a knowledge test and subsequent internship. On the requirements for welders, welding production specialists who are engaged in repair, installation, reconstruction, modernization of technological pipeline systems,

Now let's talk about the responsibilities of employees. Workers who are involved in the operation of TT are obliged to:

  • understand all criteria for CT performance;
  • control technical processes;
  • in case of accidents or incidents, be able to act strictly according to instructions;
  • in the event of any emergency or threat of its occurrence, suspend the operation of the system by informing your supervisor.

If damage, violations of safe operating conditions, deviations from technology or unacceptable changes in system operating parameters are detected, it is necessary to stop all work or not start it at all.

The list of job responsibilities for responsible specialists will be noticeably wider. You will need at least two such employees with technical vocational education and certified in industrial safety.

The specialist who is responsible for must:

  • carry out inspection of the TT, check its operating mode;
  • exercise control over the preparation of technical equipment for examination and maintain all necessary document flow;
  • issue instructions when violations are detected;
  • monitor compliance with industrial safety rules, own regulations or orders of government bodies, as well as repairs and reconstruction of the system;
  • take part in examinations and examinations;
  • control the implementation of emergency drills;
  • when identifying violating employees, demand their removal from work and send them for an extraordinary knowledge test.

The second employee is a specialist responsible for safe operation. His responsibilities include:

  • ensuring operability, repair, preparation of TT for technical examination and diagnostics;
  • monitoring worker compliance;
  • Conducting and participating in periodic inspections and technical examinations of the system;
  • storage of all technical documentation of the TT (technical passports, installation and use instructions, manuals), checking entries in the shift log;
  • conducting emergency training for employees;
  • compliance with all instructions to eliminate identified violations;
  • keeping records of CT load cycles if they are operated in cyclic mode.