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Approved by the order of the Minister of Emergency Situations of the Republic of Kazakhstan of July 27, 2009 No. 176

Requirements of industrial safety in case of operation of technology pipelines

(as amended of the Order of the Minister of Emergency Situations of RK of 21.10.2009 No. 244)

Chapter 1. General provisions

1. These Requirements extend to the projectible, again manufactured and upgraded steel technology pipelines intended for transportation of gaseous, vaporous and liquid circles in the range from the residual pressure (vacuum) of 0,001 of MPa (0,01 of kgf/cm) up to the conditional pressure of 320 MPas (3200 kgfs/cm) and working temperatures from - 196 ° C to 700 hail. With and operated on hazardous production facilities.

2. Thickness of wall of pipes and details of pipelines is determined by calculation on durability depending on calculated parameters, corrosion and erosive properties of the circle by normative and technical documents in relation to the operating range of pipes. In case of the choice of thickness of wall of pipes and details of pipelines features of technology of their production are considered (it is flexible, assembly, welding).

In the pipeline are accepted to settlement pressure:

1) settlement pressure for the device to which the pipeline is connected;

2) for pressure pipelines (after pumps, compressors, gas blowers) - the maximum pressure developed by the centrifugal machine in case of the closed latch from forcing; and for piston mashindavleny operations of the safety valve established on pressure source;

3) for pipelines with the safety valves established on them - pressure of setup of the safety valve.

Pipelines which are subjected to test for durability and density together with the device are expected durability taking into account pressure of testing of the device.

3. When calculating thickness of walls of pipelines to choose increase on compensation of corrosion depreciation to the settlement thickness of wall proceeding from condition of providing necessary settlement service life of the pipeline and speed of corrosion.

Depending on the speed of corrosion of the staly circle are subdivided on:

1) nonaggressive and low-aggressive - with corrosion speed to mm/year 0,1 (steel resistant);

2) sredneagressivny - with speed of corrosion of 0,1-0,5 of mm/year;

3) high-aggressive - with corrosion speed over mm/year 0,5.

At speed of corrosion of 0,1-0,5 of mm/year and over mm/year 0,5 steel is considered ponizhennostoyka.

4. In case of the choice of materials and products for pipelines to consider:

1) the settlement pressure and settlement temperature of the transported circle;

2) properties of the transported circle (aggression, vzryvo-and fire danger, harm and so forth);

3) properties of materials and products (durability, cold resistance, firmness against corrosion, svarivayemost and so forth);

4) the negative temperature of air for the pipelines located in the open air or in not heated rooms. For settlement, negative air temperature in case of the choice of materials and products for pipelines it is necessary to accept:

average temperature of the coldest five-day week of the area with security of 0,92, if the working temperature of wall of the pipeline which is under pressure or vacuum, positive;

absolute minimum temperature of this area if the working temperature of wall of the pipeline which is under pressure or vacuum can become negative from air impact.

5. For pipelines and fittings the project organization establishes useful life in the project documentation.

Chapter 2. Technology pipelines with the conditional pressure up to 10 MPas (100 kgfs/cm)

Paragraph 1. Classification of pipelines

6. Pipelines with pressure to 10 MPas (100 kgfs/cm) inclusive depending on class of danger of the transported substance (vzryvo-, fire danger and harm) are subdivided into groups A, B, B and depending on working parameters of the circle (pressure and temperature) - into five categories (I, II, III, IV, V).

Classification of pipelines is given in appendix of 1 these Requirements.

7. Categories of pipelines determine set of technical requirements to design, installation and amount of control of pipelines.

8. The class of danger of technology circles is determined by developer of the project based on classes of danger of the substances containing in the technology circle and their ratios.

9. Categories of pipelines are established by developer of the project for each pipeline and are specified in the project documentation.

10. It is allowed to accept depending on service conditions higher (what determined by working parameters of the circle) category of pipelines.

Designation of group of a certain transported circle includes designation of group of the circle (And, B, In) and the designation of subgroup (and, c) reflecting class of danger of substance.

Designation of group of the pipeline in general view corresponds to designation of group of the transported circle. The designation "pipeline of group of A(b)" designates the pipeline on which the circle of group of A(b) is transported.

The group of the pipeline transporting the circles consisting of different components is established on the component requiring reference of the pipeline to more responsible group. In case of content in mix of dangerous substances 1, 2 and 3 classes of danger and if concentration of one of them is most dangerous, determine group of mix by this substance.

If the most dangerous component on physical and chemical properties is part of mix in insignificant quantity, the question of reference of the pipeline to less responsible group or category is solved the project organization.

To establish category of the pipeline in the parameter requiring its reference to more responsible category.

For vacuum pipelines to consider not the conditional pressure, but absolute working pressure.

The pipelines transporting substances with the working temperature equal or the exceeding temperature of their self-ignition or working temperature below - 40 hail. With, and also incompatible with water or oxygen of air under normal conditions to refer to the I category.

Paragraph 2. Requirements to the materials applied to pipelines

11. Pipes, shaped connecting details, flanges, laying and fasteners used to pipelines on quality, technical characteristics and materials shall answer the corresponding specifications and technical documentation.

Quality and technical characteristic of the materials and finished products applied to production of pipelines is confirmed by certificates of the manufacturer. The materials and products which do not have certificates are allowed to be applied only to pipelines II and below categories and after their check and testing in compliance the specifications and technical documentation.

Material of details of pipelines, corresponds to material of the connected pipes. In case of application of diverse pipes and their welding to be guided by instructions of the relevant normative and technical documents.

12. Pipes and shaped details of pipelines are made of the steel having technology svarivayemost with the flowability limit attitude towards strength of no more 0,75, by relative lengthening of metal in case of gap on fivefold samples at least 16% and with an impact strength not lower than 30 J/cm (3,0 of kgf · m/cm) at the minimum settlement temperature of wall of element of the pipeline.

13. To choose pipes depending on parameters of the transported circle according to the specifications and technical documentation.

14. The seamless pipes made of ingot, shaped details for these pipes are allowed to be applied to pipelines of groups A and B of the first and second categories on condition of carrying out their control by method of ultrasonic defectoscopy (further - UZD) of 100% on all surface.

15. For the pipelines transporting the liquefied hydrocarbonic gases (further - SUG) and also to apply the substances relating to group of A (a) seamless goryache-and holodnodeformirovanny pipes. According to instructions of the specifications and technical documentation application of electrowelded pipes with a nominal diameter more than 400 mm for pipelines of the transporting the substances relating to group A (a) and liquefied hydrocarbonic gases at speed of corrosion of metal to mm/year 0,1 is allowed, with working pressure to MPa 2,5 (25 kgfs/cm) and hail with the temperature up to 200. With, undergone heat treatment, absolute control of welded seams (the UZD method or raying) in case of positive results of mechanical testing of samples from welded connections in full, including on impact strength.

It is allowed to apply as feedwell pipes, the devices manufactured of sheet steel according to requirements and safe operation of the vessels working under pressure on conditional pressure to MPa 2,5 (25 kgfs/cm).

16. Pipes with the normalized the chemical composition and mechanical properties of metal are applied to pipelines (group B).

17. Pipes are tested by the manufacturer the trial hydraulic pressure specified in the specifications and technical documentation pipes or to have specifying in the certificate on the guaranteed size of trial pressure.

It is allowed not to carry out hydrotesting of seamless pipes if they were exposed on all surface to control by nondestructive methods.

18. Pipes electrowelded with spiral seam are allowed to be applied only to direct sites of pipelines.

19. The electrowelded pipes applied to transportation of substances of groups of A(b), B (a), B(b) (appendix 1), the gases except for liquefied by pressure over MPa 1,6 (16 kgfs/cm) and groups of B(v) and In pressure over MPa 2,5 (25 kgfs/cm), with working temperature over 300 hail. With in the thermoprocessed condition, and their welded seams are subjected to absolute nondestructive control (the UZD method or radiography) and to testing for bend or impact strength.

Application of not thermoprocessed pipes with ratio of outer diameter of pipe is allowed to wall thickness, equal or more than 50 for transportation circles which are not causing corrosion cracking of metal.

20. The electrowelded pipes contacting with the environment causing corrosion cracking of metal irrespective of pressure and thickness of wall in the thermoprocessed condition, and their welded seams are full-strength to the main metal and are subjected to absolute control by nondestructive methods (UZD or radiography).

21. Pipes from carbonaceous semi-quiet steel are allowed to be applied to circles of group B at thickness of wall no more than 12 mm in areas with settlement temperature of outside air not below - 30 hail. With when ensuring temperature of wall of the pipeline in use is not lower - 20 hail. Page.

Pipes from the carbonaceous boiling steel are allowed to be applied to circles of group B at thickness of wall no more than 8 mm and pressure of no more 1,6 of MPa (16 kgfs/cm) in areas with settlement air temperature not nizhe10grad. Page.

22. For them to choose design of flanges and materials taking into account parameters of working environments according to the specifications and technical documentation.

23. Flat welded flanges are applied to the pipelines working with conditional pressure no more 2, to MPa (25 kgfs/cm) and temperature of the circle is not higher than 300 has some. C. The flanges provided on the conditional pressure of 1,6 of MPa (16 kgfs/cm) are applied to pipelines of groups A and B with the conditional pressure up to 1 MPa (10 kgfs/cm).

24. For the pipelines working with conditional pressure over MPa 2,5 (25 kgfs/cm) irrespective of temperature and also for pipelines with working temperature over 300 hail. With irrespective of pressure flanges, welded end-to-end are applied.

25. Flanges, welded end-to-end, are made of forgings or bandage procurements.

Production of flanges, welded end-to-end, by rolling of procurements on the leaf plane for the pipelines working with conditional pressure of no more 2,5 of MPa (25 kgfs/cm) or gib of shod strips for the pipelines working with conditional pressure of no more 6,3 of MPa (63 kgfs/cm) on condition of absolute control of welded seams is allowed by radio graphic or ultrasonic graphic approach.

26. In case of the choice like sealing surface of flanges to be guided by appendix of 2 these Requirements.

27. For the pipelines transporting substances of groups A and B of technology objects of 1 category of potential of explosion application of flange connections with smooth sealing surface, except as specified applications spiralno of the wound laying with restrictive ring is not allowed.

28. And materials for them to choose fasteners for flange connections depending on operating conditions and brands staly flanges.

For connection of flanges at temperature over 300 hail. With and nizhe40grad. With irrespective of pressure to apply hairpins.

29. In case of production of hairpins, bolts and nuts the hardness of hairpins or bolts is higher than the hardness of nuts on 10 - 15 NV at least.

30. It is not allowed to manufacture fasteners of the boiling, semi-quiet, Bessemer and automatic staly.

31. Material of procurements or ready fasteners from high-quality carbonaceous, heatproof and heat resisting alloyed staly termoobrabotana.

For the fasteners used with pressure to MPa 1,6 (16 kgfs/cm) and working temperature to 200 hail. With, heat treatment is allowed be not to carried out fasteners from carbonaceous steel with carving with a diameter up to 48 mm.

32. In case of use of fasteners from staly austenitic class at working temperature of the circle over 500 hail. With to produce carving the method of nakatka does not allow.

33. To choose materials of fasteners with the coefficient of linear expansion close to coefficient of linear expansion of material of flange in case of difference in values of coefficients of linear expansion of materials it is not higher than 10%.

It is allowed to apply materials of fasteners and flanges with coefficients of linear expansion which values differ more than for 10%, in the cases proved by calculation on durability or pilot studies for flange connections at working temperature of the circle no more than 100 hail. Page.

34. Laying and pro-masonry materials for consolidation of flange connections are chosen depending on the transported circle and its working parameters according to the project, the specifications and technical documentation.

35. To choose shaped details of pipelines depending on parameters of the transported circle and service conditions according to the specifications and technical documentation.

36. To make shaped details of pipelines of steel seamless and straight-line-seam welded pipes or sheet hire which metal meets the requirements of the project, the specifications and technical documentation, svarivayemost conditions with material of the attached pipes.

37. Details of pipelines for the environments causing corrosion cracking of metal irrespective of design, brand became and manufacturing techniques are subject to heat treatment.

Local heat treatment of welded connections of section branches and welded tees from pipes is allowed if the thermoprocessed pipes are applied to their production.

38. In case of the choice of welded details of pipelines depending on aggression of the circle, temperature and pressure to be guided by the specifications and technical documentation.

39. To make welding of fitting and quality control of welded joints according to requirements of the normative and technical and project documentation.

40. The branch from the pipeline is carried out by one of the methods stated in annex of 3 these Requirements. Strengthening of troynikovy connections with the help of stiffening ribs is not allowed.

41. Accession of branches on the method "and" (appendix 3) is applied when weakening of the main pipeline is compensated by the available margins of safety of connection.

42. In case of the choice of method of accession of branches to the main pipeline to give preference to the methods, "v", "e" (appendix 3).

43. Overlay for the branched-off pipeline (accession on the method "e" in appendix 3) establish in case of the relation of diameters of the branched-off and main pipelines 0,5 suffices.

44. Welded tees apply with pressure of Ru - up to 10 MPas (100 kgfs/cm).

45. Branches Du =150, welded with conditional pass? 400 mm should be applied to technology pipelines with pressure of Ru of no more 6,3 of MPa (63 kgfs/cm).

Branches Du =500, welded with conditional pass? 1400 mm are allowed to be applied to technology pipelines with pressure of Ru of no more 2,5 of MPa (25 kgfs/cm 2).

46. Welded concentric and eccentric transitions with conditional pass of Du =250? 400 mm are allowed to apply to technology pipelines with pressure of Ru to 4 MPas (40 kgfs/cm), and with Du 500? 1400 mm - in case of Ru to MPa 2,5 (25 kgfs/cm).

Limits of application of steel transitions depending on temperature and aggression of the circle correspond to limits of application of the attached pipes for similar brands of staly.

Welded seams of transitions are subject to absolute control by ultrasonic or radio graphic approach.

47. Application of petal transitions for technology pipelines with the conditional pressure of Ru of no more 1,6 of MPa (16 kgfs/cm) and with a nominal diameter of Du =100 is allowed? 500 mm.

It is not allowed to establish petal transitions on the pipelines intended for transportation of the liquefied gases and substances of group A (a) (appendix 1).

48. Weld petal transitions with the subsequent absolute control of welded seams ultrasonic or radio graphic approach.

After production to subject petal transitions to high-temperature leave.

49. Welded crosspieces are allowed to be applied on pipelines from carbonaceous staly at working temperature not higher than 250 hail. Page.

Crosspieces from electrowelded pipes are allowed to be applied with pressure of Ru of no more 1,6 of MPa (16 kgfs/cm 2), at the same time they are made of the pipes recommended for application with pressure of Ru MPa 2,5 (25 kgfs/cm 2) suffices.

Crosspieces from seamless pipes are allowed to be applied with pressure of Ru of no more 2,5 of MPa (25 kgfs/cm 2), on condition of their production from the pipes recommended for application with pressure of Ru at least 4 MPas (40 kgfs/cm 2).

50. To apply the steeply curved branches made of seamless and welded straight-line-seam pipes by method of hot stamping or broach, bent and shtamposvarny branches to technology pipelines.

51. The bent branches produced from seamless pipes are applied instead of steeply curved and welded branches when it is required to reduce as much as possible the hydraulic resistance of the pipeline, on pipelines with the pulsing circle flow (for the purpose of decrease in vibration), on pipelines in case of conditional pass of Du less than 25 mm.

Limits of application of gladkognuty branches with radius of gib of R? 2dn from pipes of the operating range correspond to limits of application of pipes of which they are made.

52. In case of the choice of radius of gib of gladkognuty branches to be guided project and the specifications and technical documentation.

To accept the minimum length of the direct site from the end of pipe prior to the beginning of curve pipe Dn equal to diameter, but at least 100 mm.

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