ORDER OF THE MINISTER OF EMERGENCY SITUATIONS OF THE REPUBLIC OF KAZAKHSTAN

of November 10, 2011 No. 455

About approval of regulations in the field of industrial safety

According to subitem 17-1) of article 7 of the Law of the Republic of Kazakhstan "About industrial safety on hazardous production facilities", PRIKAZYVAYU:

1. Approve enclosed:

1) Requirements of industrial safety to the device and safe operation of electrode coppers and electroboiler rooms;

2) Requirements of industrial safety in case of operation of the heatconsuming installations and thermal networks of consumers;

3) Requirements of industrial safety in case of the address with sources of ionizing radiation.

2. To impose control of execution of this order on the Chairman of Committee on the state control of emergency situations and industrial safety of the Ministry of Emergency Situations of the Republic of Kazakhstan Akhmetov S. B.

3. This order becomes effective from the date of signing.

Brings Deputy Chairman of Committee on the state control of emergency situations and industrial safety

D. Bapy

It is approved Vice-minister Vice-minister Director of the department of legal support

V. Petrov Zh. Smailov A. Sansyzbayeva

Approved by the Order of the Minister of Emergency Situations of the Republic of Kazakhstan of November 10, 2011 No. 455

Requirements of industrial safety to the device and safe operation of electrode coppers and electroboiler rooms

Chapter 1. General provisions

1. These Requirements extend to boilers with the working pressure of more 0,07 of MPa (0,7 of kgf/cm 2) and boilers with water temperature above 115 °C (388 K).

The main terms and determinations used in these Requirements:

the electric copper - the device in which for receipt of hot water (boiler) or saturated steam (boiler) with pressure is higher than atmospheric is used warmth;

electric copper of direct heating - the device in which for receipt of hot water or saturated water vapor the warmth which is marked out in case of course of electric current directly through the heated water is used;

electric copper of indirect heating (with resistance electric heating elements) - the device in which for receipt of hot water or saturated water vapor the warmth which is marked out in case of course of electric current via resistance electric heating element shipped in the heated water is used;

stationary copper - the copper established on the motionless base;

copper borders on steam-and-water path - locking devices: the nutritious, safety, drainage and other valves and latches limiting internal cavities of elements of copper and the pipelines attached to them. In the absence of locking devices flange, muftovy or welded connections, the first from copper, are considered as limits of copper; in case of besshtutserny welding border of copper is the welded seam of welding of pipe;

overall dimensions of copper - the copper sizes on height, width and depth with isolation and covering, with the strengthening or basic elements, without speakers of devices, pipes of sampling, pulse tubes;

settlement service life of copper - service life in calendar years after which it is necessary to conduct expert examination of technical condition of the main details of copper working under pressure for the purpose of determination of admissibility of parameters and conditions of further operation of copper or its dismantle. Service life is estimated from the date of input of copper in operation;

settlement resource of copper (element) - duration of operation of copper (element) during which the manufacturer guarantees reliability of its work on condition of observance of the mode of operation specified in management of the manufacturer;

expert inspection of copper - the technical inspection of copper which is carried out after settlement service life of copper (irrespective of exhaustion of settlement resource of safe work), after accident or the found damages of the elements working under pressure for the purpose of determination of opportunity and conditions of further operation;

constructive gap in angular welded connection - the gap which is formed between the union (pipe) and the main detail and fully or partially remaining after welding accomplishment;

office properties of metal - complex of the mechanical and physical characteristics used in case of strength and thermal calculations;

settlement pressure - the maximum excessive pressure in detail on which calculation on durability in case of reasons for the main sizes ensuring reliable functioning of copper during settlement resource is made;

the permitted pressure of copper (element) - the most admissible excessive pressure of copper (element) established by results of engineering certification or control calculation on durability;

working pressure of copper - the maximum excessive pressure behind copper under normal conditions operation;

trial pressure - the excessive pressure with which hydraulic testing of copper or its element for durability and density is carried out;

normal service conditions - group of the operational modes provided by planned regulations of work: stationary mode, start-up, performance change, stop, hot reserve;

the certified project (design) organization - the organization, one of functions of which is designing of coppers or designing of their elements;

the organization - the owner of copper - the organization on balance of which is copper;

copper element - the assembly unit of copper intended for accomplishment of one of the main functions of copper;

pipeline element - the assembly unit of the pipeline of vapor or hot water intended for accomplishment of one of the main functions of the pipeline;

assembly unit of copper - product which components are subject to connection among themselves welded and other assembly transactions;

detail - the product made from homogeneous according to the name and brand of material without application of assembly transactions;

product - unit of industrial output which quantity can be estimated in pieces or copies;

temperature of working environment - the maximum temperature of vapor or hot water in the considered copper element;

extreme temperature of wall - the maximum temperature of wall of detail of copper or the pipeline from environment with the largest temperature determined by calculation or testing without temporary increase in heating;

settlement temperature of outside air - the average temperature of outside air for the coldest five-day week of year;

the specifications and technical documentation - technical documentation the having normative character;

technological documentation - the production schedules constituted by manufacturer of product;

the open carrying-out parts - not current carrying (metal) parts available to touch of the person between which (or between them and the earth) in case of violation of isolation of current carrying parts concerning the earth there can be tension exceeding value of tension of touch, maximum permissible for the person;

resistance electric heating element - the device in which warmth in case of course of electric current through the conductor made of alloy of high ohmic resistance is distinguished;

the electric heating element of resistance of the closed type - the electroheating device containing the current conductor from alloy of high resistance imprisoned in the outside cover preventing contact of the conductor with the heated water;

the tubular electric heater (Teng) - the electric heating element of the closed type consisting of the current conductor in the form of spiral from alloy of the high resistance located in the pressed electric insulation filler (periclase) and concluded in tubular metal cover.

2. These Requirements do not extend to coppers:

cars of railroad train;

established on ocean and river crafts, and on other watercrafts, on subjects to underwater application;

other substances using instead of water as the heat carrier, the m3 0,025 capacity (25 l) and less.

3. Requirements to installation and repair of coppers are similar to requirements to their production.

Due to the introduction of the International System of Units of measurement (SI) the table of ratios between these units and accepted in these Requirements is provided in appendix 1 to these Requirements.

4. The passport of each copper is constituted on state and Russian in form according to appendix 2 to these Requirements.

Chapter 2. Designing

5. Projects of electric boilers and their elements (including spare parts to them), and also projects of their installation or reconstruction, modification and upgrade of electroboiler rooms, including transportable are carried out by the project (design) organizations having the license for carrying out the corresponding works (further - the project).

6. Elektrkotla and his elements are calculated on durability and durability. Calculations are carried out according to the specifications and technical documentation (further - the specifications and technical documentation) on the vessels working under pressure.

7. Project changes of the electric boilers acquired abroad - are approved with the author of the project, and for coppers certified by the expert organization.

Chapter 3. Design

Paragraph 1. General provisions

8. The design of copper and its main parts provides its operation on calculated parameters during resource of safe work of copper (element) possibility of engineering certification, cleaning, washing, repair and operational control of metal.

9. The internal devices of coppers interfering survey and performing defectoscopy are carried out by removable. The manufacturer in the mounting and operating guide specifies procedure for removal and installation of these devices.

10. The design of copper provides uniform warming up of its elements in case of start-up and normal operating mode, free thermal expansion of separate elements of copper.

11. The design of copper provides possibility of removal of air from all elements which are under pressure in which air traffic jams when filling with water and start-up can be formed.

12. Devices of inputs of drinking, network water and giving in copper of chemicals exclude local chilling of walls of the body of copper for what protection devices are provided. The design of inputs of water without protection devices is allowed if it is proved by calculations on durability.

13. Coppers and their elements are equipped with the devices providing possibility of their purge.

14. The design of copper excludes (within admissible changes of operating mode) possibility of electric discharges and electric arches.

15. Management systems, protection and control of work of copper provide possibility of automatic maintenance of the set thermal mode, regulation of capacity in the set limits, automatic shutdown of copper in emergencies.

16. Heat insulation of copper and its elements is made of materials with small specific weight and low heat conductivity. Temperature of outside surface of isolation does not exceed 55 °C in case of ambient temperature no more than 25 °C.

17. The electric equipment and grounding (zeroing) of the body of electric copper is carried out in compliance Construction Norms and Regulations 2.09.02-85 "Factory buildings".

18. Electric isolation of node of input of electrode in copper (electric insulation node) corresponds to the level of rated voltage, taking into account possibility of sedimentation of scum on its surface, has the mechanical durability and thermal firmness.

19. The method of connection of tires and cables to electrode coppers excludes transfer of mechanical loads of insulators of electric input.

20. In electric coppers of indirect heating the electric heating elements of resistance of the closed type intended for work in the water circle are used.

21. The design of the block of electric heating elements provides complete immersion of active part of elements on the heated environment and excludes contact them with each other.

22. The block of electric heating elements is available to survey, prevention and repair.

23. Fixing devices of electric heating elements provide hermeticity of their connection with the copper body, or removable flange in case of workers pressure and temperature.

24. Tokovvoda of electric coppers are closed by the casing providing in rooms with the normal circle degree of protection is not lower than IP00 or IP20.

25. In electric coppers of indirect heating tubular electric heaters (ten) of industrial production are used. Change of form of ten or bending of direct ten at the consumer is not allowed.

26. The design of the electroheating block consisting of ten provides temperature in sealing node zone no more than 150 °C, except the ten equipped with the thermoinputs allowing temperature to 400 °C.

27. On the boiler indexes of water level of direct action are established. Their amount and provision of the lower and upper limits of water in boilers are determined by the project.

Paragraph 2. Manholes, hatches, covers

28. The copper body with internal diameter more than 800 mm has quantity of manholes, sufficient for the survey and repair, located in the places available to servicing. The sizes of manholes of oval form, on the smallest and greatest axes respectively, at least 325 and 400 mm, diameter of round manholes in light - at least 400 mm.

Application instead of manholes of removable covers on flanges is allowed.

29. The copper body with internal diameter of 800 mm and less has in available places of walls of the body round or oval hatches the size on the smallest axis at least 80 mm. It is allowed to use instead of hatches openings for insulators through passage and branch pipes of input and withdrawal of the circle with a diameter at least 80 mm.

30. Covers of manholes removable. For covers weighing more than 20 kg the lifting and rotary, or other devices providing their opening and closing are provided.

31. In the presence of the removable bottoms or covers providing possibility of carrying out internal survey of the body, the device of manholes and hatches in it is not required.

32. Tightening devices of hatches and covers are protected from shift.

Paragraph 3. Bottoms

33. In coppers it is allowed to apply the bottoms: elliptic, hemispherical, torosferichesky (korobovy), spherical neotbortovanny, flat otbortovanny, flat neotbortovanny.

34. Application of the welded neotbortovanny flat bottoms is allowed for copper with internal diameter of body no more than 600 mm. This restriction is not required if the resource of copper is proved by testing calculation on durability.

35. The elliptic bottoms have height of convex part measured on internal surface, 0,2 of internal diameter of the bottom suffices. Reduction of this size in coordination with the project organization is allowed.

36. The Torosferichesky (korobovy) bottoms have:

height of convex part measured on internal surface 0,2 of internal diameter of the bottom suffices;

internal radius of collaring is at least 0,1 of internal diameter of the bottom;

internal radius of curvature of the central part of no more internal diameter of the bottom.

37. The spherical neotbortovanny bottoms are allowed to be applied with welded flanges, at the same time:

internal radius of the sphere of the bottom of no more internal diameter of copper;

welded connection of flange with the bottom is carried out with continuous pro-pitch.

38. In the welded convex bottoms consisting of several parts with arrangement of welded seams on chord, distance from axis of welded seam to the center of the bottom no more than 1/5 internal diameters of the bottom.

Circular seams of the convex bottoms are located from the center, at distance no more than 1/3 internal diameters of the bottom.

39. The flat bottoms with ring flute and cylindrical part (board) executed by mechanical boring are made of forging or of the leaf which underwent ultrasonic control on lack of internal defects. Production of the otbortovanny flat bottom from leaf is allowed if collaring is carried out by stamping, or leaf edge running in with bend on 90 °.

40. For otbortovanny and transitional elements of coppers, except for the convex bottoms, compensators and the extended mouths under welding of unions, distance from the beginning of curve of otbortovanny element to axis of welded seam depending on thickness of wall of otbortovanny element is accepted according to table 1 of these Requirements.

Table 1

Thickness of wall of otbortovanny element, mm	The distance to axis of seam, mm, is at least
To 5	15
Over 5 to 10	2S + 5
Over 10 to 20	S + 15
Over 20	S/2 + 25

Paragraph 4. Welded connections and their arrangement

41. Welded connections of coppers joint. For welding of the flat bottoms, flat flanges, unions of hatches, shirts tavrovy and angular welded connections are allowed. Welded connections are applied with complete pro-melting.

For welding of the strengthening rings and basic elements application of lap welded seams is allowed.

42. The design and arrangement of welded connections provide availability of monitoring procedure.

Application of angular seams with constructive gap without carrying out radio graphical and ultrasonic control for welding is allowed to the body of coppers of pipes and unions with internal diameter no more than 100 mm, and for welding of flat flanges of pipelines irrespective of diameter, for welding of flat flanges to the body of coppers with working pressure to MPa 0,8 (8 kgfs/cm 2) for steam and 1,3 of MPa (13 kgfs/cm 2) for boilers.

43. Longitudinal seams of adjacent feedwells and seams of the bottoms of coppers are displaced relatively each other at size of triple thickness of wall of the thickest element, but on 150 mm at least between axes of seams.

The specified seams are allowed be not to displaced rather each other in coppers with pressure of no more 1,6 of MPa (16 kgfs/cm 2), with nominal thickness of wall no more than 30 mm provided that these seams are carried out by automatic or electroslag welding and radio graphical or ultrasonic control of places of crossing of seams of 100% is provided.

44. When welding crossing of seams of welding with joint seams of the body on condition of preliminary radio graphical or ultrasonic control of the blocked site of seam of the body is allowed to the body of copper of internal and external devices (basic details, partitions and others).

45. In case of welding of support, or other elements to the copper body distance between edge of welded seam of copper and edge of seam of welding of element at least thickness of wall of the body of copper, but at least 20 mm.

For coppers from carbonaceous and low-alloyed staly, subjected after welding to heat treatment, irrespective of body wall thickness distance between edge of welded seam of copper and edge of seam of welding of element at least 20 mm.

46. In joint welded connections of elements of coppers with the different thickness of walls smooth transition from one element to another by gradual refining of edge of thicker element is provided. The tilt angle of surfaces of transition does not exceed 20 °.

If the difference in thickness of the connected elements constitutes no more than 30% of thickness of thin element and does not exceed 5 mm, then application of welded seams without preliminary thinning of edge of thick element is allowed. The form of seams provides smooth transition from thick element to thin.

When joining cast detail with details from pipes, hire or forgings it is necessary to consider that the nominal settlement thickness of cast detail is 25-40% more than the similar settlement thickness of wall of element from pipes, hire or forgings therefore transition from thick element to thin is carried out so that thickness of the end of cast detail was at least nominal settlement size.

Paragraph 5. Arrangement of openings in walls of coppers

47. Openings for hatches, hatches and unions shall be located out of welded connections.

In welded connections the arrangement of openings is allowed:

on longitudinal connections of cylindrical feedwells of the body of coppers with diameter of openings no more than 150 mm;

on cross connections of cylindrical feedwells of coppers without restriction of diameters of openings;

on welded connections of elements of the convex bottoms without restriction of diameters of openings.

Welded seams of vvarka of unions and hatches are carried out with complete pro-melting.

48. On the torosferichesky (korobovy) bottoms the arrangement of openings only within the central spherical segment is allowed. At the same time the distance from opening edge to the center of the bottom measured on chord, no more 0,4 of outer diameter of the bottom.

49. The distance between centers of two next openings in cylindrical elements and the convex bottoms on outside surface is at least 1,4 of diameter of opening, or 1,4 of half-sum of diameters of openings if diameters are different.

Paragraph 6. Curvilinear elements

50. In coppers it is allowed to apply bent, steeply curved (having the radius of gib of less 3,5 of outer diameter, but outer diameter), shtamposvarny and sector branches suffices.

51. Sector branches are allowed to be applied with working pressure of no more 1,6 of MPa (16 kgfs/cm 2) provided that the corner of the sector does not exceed 30 °, and the distance between the next welded seams on inside of branch provides possibility of nondestructive control of these seams on both sides on outside surface.

52. Shtamposvarny and sector branches are allowed to be applied on condition of carrying out radio graphical or ultrasonic control of all welded connections of 100%.

53. Wall thickness on the external and internal parties, ovality of cross section of branch does not go beyond the admissible values established by the specifications and technical documentation on products.

54. Application of branches which curvature is formed at the expense of folds (corrugation) on inside of branches is not allowed.

The sinuosity on inside of branches does not go beyond the admissions established by the specifications and technical documentation on products.

Paragraph 7. Copper pipelines

55. Each copper has pipelines:

supply of drinking or network water;

purges of copper and descent of water in case of its stop;

removals of air from copper when filling with its water and start-up;

water sampling;

input of chemicals during operation or cleaning of copper;

removal of network water or vapor.

Combination of the specified pipelines, or their absence is specified to the project documentation.

56. The quantity and places of accession to elements of copper of blowing-off, spuskny, drainage and air pipelines are chosen when designing so that to provide removal of water, condensate and rainfall from the lowermost, and air from the upper parts of copper. When it is impossible to remove working environment with drift, its forced removal by purge vapor, compressed air, or by other methods is provided.

57. The blowing-off pipeline dewaters in the reservoir working without pressure. Use of the reservoir working under pressure on condition of providing is allowed 10-fold pressure difference between reservoir and the blown copper element suffices.

58. On all sites of steam line which are disconnected by locking bodies the drainages providing removal of condensate are established.

59. Constructive and layout solutions of systems of purges, the emptyings, drainage, input of chemicals and so forth accepted by the design and project organizations for the specific equipment provide operation of copper in all modes, including emergency.

Chapter 4. Materials and semifinished products

Paragraph 1. General provisions

60. The materials and semifinished products specified in tables 1-5 of appendix 3 to these Requirements are applied to production, installation and repair of the electric coppers and their elements working under pressure.

61. Use of the materials specified in tables 1-5 of appendix 3 to these Requirements for production of the coppers working with the parameters going beyond the set limits, use of other materials and semifinished products, reducing amount of testing and control in comparison with requirements of this Chapter and specified in tables of appendix 3 to these Requirements can be allowed based on the expert opinion of the certified organization.

62. Semifinished products (their delivery characteristics, amount and regulations of control) are delivered according to the specifications and technical documentation.

63. Quality data and properties of material of semifinished products are confirmed by the certificate of the manufacturer of semifinished product and the corresponding marking. In case of absence, or incompleteness of certificates (marking) the manufacturer (the specialized organization installing repair of copper) carries out testing with registration of results the protocol supplementing (replacing) the certificate of the supplier of semifinished product.

64. Organizational and technical actions for prevention of influence of low temperatures on elements of copper and technique of accounting of such influence it is specified the manufacturer of copper in the mounting and operating guide.

65. The materials applied to production of coppers, their elements, including electrodes and anti-electrodes have corrosion resistance.

66. Insulators of electrode coppers through passage are manufactured of the materials having the physics and technology properties kept at working temperature and chemically resistant outside covering. Electric durability of insulators corresponds to working tension.

67. Covers of electric heating elements of resistance are made of carbonaceous or stainless chromonickel steel depending on value rn and corrosion aggression of the circle. In reasonable cases use of non-ferrous metals, or covers with corrosion-resistant coverings is allowed.

Paragraph 2. Steel semifinished products. General requirements

68. The manufacturer of semifinished products carries out control of the chemical composition of material. In the certificate it is brought the results of the chemical analysis received directly for semifinished product or similar data on the certificate on the procurement (except castings) used for its production.

69. Semifinished products are delivered in thermally processed condition. The mode of heat treatment is specified in the certificate of the manufacturer of semifinished product.

Delivery of semifinished products without heat treatment is allowed if:

the mechanical and technical characteristics on metal established in the specifications and technical documentation remain after production of semifinished product (for example, hire method);

at the manufacturer of the equipment the semifinished product is exposed to the hot shaping combined with heat treatment or the subsequent heat treatment.

In these cases the supplier of semifinished products controls properties on thermally processed samples. In other cases admissibility of use of semifinished products without heat treatment is confirmed by the certified organization for materials and technology.

70. The manufacturer of semifinished products carries out control of mechanical properties of metal by testing for stretching in case of 20 °C with determination of temporary resistance, conditional limit of flowability in case of residual deformation of 0,2 (1%), or the actual limit of flowability, relative lengthening and relative narrowing (if testing are carried out on cylindrical samples). Values of relative narrowing are allowed to be given as help data. When values of relative narrowing are normalized, control of relative lengthening is not required.

71. Semifinished products according to the requirements specified in tables 1-5 of appendix 3 to these Requirements are subjected to tests for impact strength at thickness of leaf, forging (casting), or wall of pipe of 12 mm and more, or with diameter of round hire (forging) of 16 mm and more.

Upon the demand of the author of the project of copper of testing for impact strength are carried out for pipes, leaf and forgings with thickness of wall of 6-11 mm. This requirement is specified in the specifications and technical documentation product, or in design documentation.

72. Testing for impact strength at temperature below 0 °C metal of details of flange connections of the pipelines laid in the open air in soil, channels, or in not warmed rooms where temperature of metal can be below 0th °C, other details upon the demand of the design organization that is specified in the specifications and technical documentation product, or in design documentation is exposed.

73. Testing for impact strength on samples with the concentrator of type U (KCU) are carried out in case of 20 °C, and in cases, stipulated in Item 72 these Requirements, at one of temperatures specified in table 2 of these Requirements.

Table 2

Temperature of metal, °C	Temperature of testing, °C
From 0 to - 20	- 20
From - 20 to - 40	- 40
From - 40 to - 60	- 60

 

Testing for impact strength on samples with the concentrator of type of V (KCV), according to the specifications and technical documentation on semifinished products are carried out in case of 20 °C, 0 °C.

Values of impact strength at temperatures of testing not lower than 30 J/cm2 (3 kgfs · m/cm 2) for KCU; 25 J/cm2 (2,5 of kgf · m/cm 2) - for KCV.

In case of assessment of impact strength average arithmetic size from three results of testing with variation of the minimum value for separate sample no more than on 10 J/cm2 is determined (1,0 of kgf · m/cm 2) from regulation, but not below the values stated above. The criterion of impact strength of KCU or KCV is chosen developer and to be specified in the specifications and technical documentation, or design documentation.

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