3.4.6. Hydraulic testing of vessels

The vessel is subjected to a hydraulic test together with the fittings installed on it (liquid level indicators, shut-off valves); if it is necessary to install plugs, they are installed behind the shut-off valves. For hydraulic testing, water with a temperature not lower than 5 and not higher than 40 ° C is used. When filling the vessel with water to remove air, the safety valve must be opened until water appears from it. If, as a result of filling the vessel with water, dew appears on its walls, then the test is carried out only after the walls have dried.

The pressure in the vessel during the test is measured using two class 2.5 pressure gauges tested with a scale of 1.2 times the test pressure. One control manometer. Pressure gauges use the same type, the same measurement limits, accuracy class and scale divisions.

Hydraulic test carried out under test pressure, the value of which is determined by the formula:

where
- allowable stress for the material of the vessel or its elements at a wall temperature of 20°C, N/m (kgf/cm ); - allowable stress for the material of the vessel or its elements at the design temperature of the wall, N/m (kgf/cm ); P is the design pressure that may occur at a temperature of +50 °C; it is equal to 2.0 MPa (20 kgf/cm ).

The rise in pressure to the test pressure is carried out slowly and smoothly without shocks, using a plunger pumping unit type П3/20. If it is not possible to achieve the specified pressure with a machine-driven pump, the pressure is raised hand pump. Upon reaching test pressure the water supply to the vessel is stopped; at the same time, there should be no decrease in pressure for 5 minutes. After 5 minutes, the pressure is gradually reduced to working pressure and close examination all welds of the vessel and adjacent areas. If noise, knocks or a sharp drop in pressure appear during the test period, the hydraulic test is immediately stopped, their causes are found out and eliminated.

The vessel and its elements are considered to have passed the hydraulic test if:

signs of rupture (surface cracks, tears, etc.);

leaks, tears and sweating in welded joints and base metal;

leaks in detachable connections;

visible residual deformations.

In case of detection of defects, depending on their nature, the inspector proceeds in the same way as indicated on p. 28.

The results of the technical examination of the vessel are recorded in the passport by the person who carried out the examination, indicating the permitted operating parameters of the vessel and the timing of the next surveys. The Supervisory Specialist enters the results of the technical examination in the book of accounting and examination of vessels.

3.4.7. Carrying out pneumatic tests for density (tightness) of poppy vessels

In accordance with the requirements of the regulations, pressure vessels harmful substances(liquids and gases) 1-, 2-, 3-, 4th hazard classes according to GOST 12.1.007-76, must be tested for tightness with air or inert gas at a pressure equal to the working one. Tests are carried out by the technical staff of the enterprise in accordance with production instruction approved by the chief engineer of the enterprise. Methodological guidelines establish the procedure for conducting such tests, which, if necessary, is specified taking into account local conditions.

The pneumatic density test is applied to all vessels used for the storage, transport and use of liquid ammonia. The test is allowed to be carried out only with positive results of the technical examination (external and internal examinations, hydraulic testing) and the availability of a permit for its operation.

All persons involved in checking the density (tightness) of liquid ammonia vessels must be trained in safe working methods in accordance with the "Rules for the safe use of liquid ammonia in agriculture" .

Pneumatic tests are carried out:

after installation before commissioning;

after conducting external and internal inspections by the administration of the enterprise;

after carrying out external and internal inspections, as well as a hydraulic test by a test pressure by an inspector of the State Mining and Technical Supervision;

after an extraordinary technical examination of vessels in operation;

after repairs (or other work) associated with the opening of the vessel.

A record of the readiness of the vessel for a pneumatic test is made in the journal of inspection of the vessels in working condition by a specialist responsible for the good condition and safe operation vessels at the enterprise-owner.

Newly assembled or repaired vessels must be strength tested prior to the pneumatic tightness test. Preliminary strength tests are also mandatory when installing new fasteners and other pressure-loaded parts in the vessel, the design of which does not allow their preliminary control for the absence of defects that reduce strength.

When testing for density at the installation site of storage vessels SZHA-100 (500), they are previously disconnected from other devices and pipelines (trestle bridges, ramps, compressor units, liquid separators) that do not require verification; plugs are placed on the fittings of the vessel; stuffing boxes are tightened in the shut-off and control valves installed on the vessels. The test vessels are also disconnected from other vessels requiring a tightness test, but at a different test pressure.

Vessels installed on vehicles and units for applying liquid ammonia to the soil are tested for density at a special site determined by the administration of the owner enterprise, taking into account the rules. The density test is carried out with air or nitrogen at the maximum permitted working pressure of 1.6 MPa (16 kgf / cm ).

Testing vessels of machines of the ammonia complex for density with air is allowed only when they were not in operation or when they were completely cleaned before testing and the safety of the medium in them was determined using a UG-2 gas analyzer or indicator paper. The vessel is filled with air using a special compressor, the high-pressure hose of which is connected to the gas valve fitting.

If the network pressure can exceed the test pressures in the vessel, then a pressure reducing valve adjusted to the test pressure must be installed on the supply pipeline. Before the shut-off valve, and when installing a pressure reducing valve, a safety valve is installed between it and the shut-off valve, adjusted to open at a pressure exceeding the test pressure by 2-3%. A checked and sealed pressure gauge of class 1.5 with a scale for pressure exceeding the test pressure by 1.2-1.5 times, as well as a valve for venting air from the vessel (a liquid valve with a hose) are installed on the vessel. The cross section of the passage opening of the safety valve and the valve for air release must be not less than the cross section of the shut-off valve in front of the vessel.

The pressure in the vessel is increased smoothly and with a stop to check for gaps at intermediate pressures equal to 0.1 MPa (1 kgf / cm ) and half of the working 0.8 MPa (8 kgf / cm ). The time for increasing excess pressure to 0.1 MPa (1 kgf / cm ) take 15-20 min, from 0.1 to 1 MPa (1-10 kgf / cm ) 60-90 min and from 1 to 1.6 MPa (10-16 kgf/cm ) 30-40 min.

Identification of leaks at intermediate and operating pressure is carried out during coating of seams, fittings and detachable joints with soapy water. If gaps are found, the pressure is completely reduced, after which their causes are eliminated. The pressure release is also carried out smoothly. If omissions require a repair work, identified defects and measures taken to eliminate them are recorded in the repair log (map). Elimination of defects and tightening of fasteners in vessels under pressure are not allowed. After elimination of defects, the test is repeated. During the pneumatic test, tapping or any impact on the body of the pressure vessel is prohibited.

Upon reaching the test pressure in the test vessel, the compressed air supply is stopped. A metal plug is installed between the supply pipeline and the shut-off valve and the pressure drop in the vessel is monitored for at least 4 hours for periodically checked vessels and at least 24 hours for newly installed vessels. The initial pressure is measured and the specified time is calculated after the temperatures inside and outside the vessel have equalized. The temperature of the gas in the vessel is determined by mercury thermometers mounted on the surface of the vessel with reliable thermal insulation from the environment of the part of the thermometer filled with mercury and the place of its installation.

The pressure drop in the vessel during the density test is determined by the formula

,

where
is the pressure drop per hour, in % of the test pressure; - sum of gauge and barometric pressures at the beginning of testing, kgf/cm or mm Hg. st; - the same at the end of the test; - absolute temperature at the beginning of the test, K; - the same at the end of the test; t - test time, h.

The vessel is recognized as having passed the density test and is suitable for operation if the pressure drop in 1 hour does not exceed 0.1%. The results of the test of the vessel, indicating the initial and final pressures, temperatures and duration of the test, are recorded in a special report signed by the persons who carried out the test.

Technical certification pressure vessels

6-3-1. Vessels covered by of these Rules, must be subject to technical examination (internal inspection and hydraulic test) before commissioning, periodically during operation and ahead of schedule.

The technical examination of vessels registered with the supervisory authorities must be carried out by the boiler supervision inspector.

6-3-2. If not possible (according to design features vessels) for internal inspections, the latter are replaced by a hydraulic test pressure test and inspection in accessible places.

6-3-3. It is allowed not to perform a hydraulic test of newly installed vessels during technical examination if less than 12 months have passed since such a test at the manufacturer's plant, the vessels were not damaged during transportation to the installation site and their installation was carried out without the use of welding or soldering of pressure elements .

6-3-4. Vessels in operation and registered with the state technical supervision bodies must be subject to technical examination by an inspector:

Internal examination in order to identify the condition of internal and external surfaces and the influence of the environment on the walls of blood vessels - at least once every four years,

Hydraulic test with a preliminary internal inspection - at least once every eight years.

The hydraulic test may be carried out with water or other non-corrosive, non-toxic, non-explosive, non-viscous liquids.

6-3-5. In cases where hydraulic testing is not possible (large stresses from the weight of water in the foundation, floors or the vessel itself; difficulty removing water; the presence of a lining inside the vessel that prevents the filling of the vessel with water), it is allowed to replace it with a pneumatic test (air or inert gas) at the same test pressure. This type of test is allowed only if the results of a thorough internal examination and verification of the strength of the vessel by calculation are positive.

6-3-6. During a pneumatic test, precautions must be taken: the valve on the filling pipeline from the pressure source and pressure gauges must be removed outside the room in which the test vessel is located, and people should be removed to the safe places. The vessel must be under test pressure for 5 minutes, after which the pressure is gradually reduced to working pressure and the vessel is inspected to check the tightness of its seams and detachable joints with a soapy solution or in another way. Tapping of the pressure vessel during the pneumatic test is prohibited.

6-3-7. Vessels for transportation and storage of liquefied oxygen, nitrogen and other non-corrosive cryogenic liquids, protected by surface insulation or vacuum-based insulation, shall be subject to periodic technical examination at least once every 10 years.

6-3-8. Technical examination of vessels buried in the ground with a non-corrosive medium, as well as with petroleum gas with a hydrogen sulfide content of not more than 5 g per 100 m3, can be carried out without releasing them from the ground and removing outer insulation subject to measuring the thickness of the walls of blood vessels non-destructive method control.

Tanks installed (buried) in the ground for storing liquid petroleum gas with a hydrogen sulfide content of not more than 5 g per 100 m3 are subject to technical examination (internal inspection and hydraulic testing) at least once every 10 years.

6-3-9. Hydraulic testing of sulfite digesters and hydrolysis apparatuses with an internal acid-resistant lining may not be carried out, provided that the metal walls of these boilers and apparatuses are controlled by ultrasonic flaw detection. Ultrasonic testing should be done specialized organization during their overhaul, but at least once every 5 years according to the instructions in the amount of at least 50% of the body metal surface and at least 50% of the length of the seams so that 100% ultrasonic control is carried out at least every 10 years .

6-3-10. Vessels must be subject to early technical examinations:

A) after reconstruction and repair using welding or soldering of individual parts of the pressure vessel;

B) if the vessel before putting into operation was inactive for more than one year, with the exception of cases of storage conservation, in which the survey of vessels is mandatory before putting into operation when stored for more than three years;

C) if the vessel was dismantled and installed in a new place;

D) before applying a protective coating to the walls of the vessel, if it is produced by the enterprise - the owner of the vessel;

E) if such a survey is necessary at the discretion of the inspector, the person exercising supervision, or the person responsible for the good condition and safe operation of the vessel.

6-3-11. The technical examination of the vessels is carried out by the boiler supervision inspector in the presence of a person responsible for the good condition and safe operation of the vessels or an engineering and technical staff selected by the enterprise administration.

6-3-12. Enterprises - owners of vessels must produce:

A) internal inspection and hydraulic testing of newly installed vessels that are not subject to registration with the supervisory authorities - before putting them into operation;

B) internal inspection of all vessels (registered and not registered with the supervisory authorities) - at least every 2 years, with the exception of vessels operating with a medium that causes metal corrosion, which must be subjected to an internal inspection at least every 12 months. This requirement does not apply to vessels referred to in Articles 6-3-7 and 6-3-8.

An internal inspection of ammonia synthesis columns, as well as vessels included in systems with a continuously operating technological process, with a non-corrosive working medium, the shutdown of which is impossible due to production conditions, may be combined with overhaul, the inspection of the ammonia synthesis towers is also allowed to be combined with the catalyst replacement period, but it must be carried out at least once every 4 years.

During internal examinations of vessels, all defects that reduce their strength should be identified and eliminated;

C) periodic inspection of vessels in working condition;

D) hydraulic test with a preliminary internal inspection of vessels that are not registered with the supervisory authorities - at least once every 8 years;

E) early technical examination of unregistered vessels.

The technical examination of the vessels must be carried out by the person supervising the vessels at the enterprise, in the presence of the person responsible for the good condition and safe operation of the vessels.

The results and terms of the next technical examinations must be recorded in the vessel passport by the person who carried out this technical examination.

6-3-13. Vessels operating under the pressure of toxic gases or liquids must be subjected by the administration of the enterprise - the owner of the vessel to a leak test in accordance with the production instruction approved by the chief engineer of the enterprise; the test should be carried out with air or an inert gas at a pressure equal to the working pressure of the vessel, or other equivalent safe method control.

6-3-14. The day of the internal inspection and hydraulic testing of the vessels is set by the administration of the enterprise, and the vessel must be presented for examination not late indicated in his passport. The administration of the enterprise is obliged to notify the inspector of the boiler supervision about the readiness of the vessel for examination no later than 10 days in advance.

6-3-15. In case of non-arrival of the boiler supervision inspector to survey the registered vessel, the administration of the enterprise is given the right, under its own responsibility, to conduct an examination by the commission of the enterprise appointed by order.

The results of the conducted and the date of the next survey are recorded in the vessel passport signed by all members of the commission, a copy of this entry is sent to the local state technical supervision body no later than 5 days after the survey.

A vessel approved for operation is subject to examination by a boiler supervision inspector no later than 12 months later.

6-3-16. The extension of the term of the technical examination of the vessel may be allowed by the local authority of the State Gortekhnadzor in exceptional cases for no more than three months upon a technically justified written request from the administration of the enterprise with the provision of data confirming the satisfactory condition of the vessel, and with positive results of the inspection of the vessel in working condition by the inspector of the boiler supervision.

6-3-17. The extension of the period of technical examination of vessels not registered with the supervisory authorities for no more than three months may be allowed by the chief engineer of the enterprise.

6-3-18. Before internal inspection and hydraulic testing, the vessel must be stopped, cooled (warmed), freed from the working medium filling it, disconnected with plugs from all pipelines connecting the vessel with a pressure source or with other vessels, cleaned of metal.

Lining, insulation and other types of corrosion protection should be partially or completely removed, if there are signs,

indicating the possibility of occurrence of defects in the metal of the vessel under the protective coating (leakage of the lining, gumming bulges, traces of wetting of the insulation, etc.). Electrical heating and vessel drive must be turned off.

6-3-19. Before a hydraulic test, all fittings must be thoroughly cleaned, taps and valves lapped, covers, hatches, etc. tightly closed.

6-3.20. Vessels with potent toxic substances and other similar media before any work inside them, as well as before internal inspection, must be thoroughly processed (neutralization, degassing) in accordance with the instructions for safe work, approved by the chief engineer of the enterprise.

6-3-21. When working inside the vessel (internal inspection, repair, cleaning, etc.), safe lamps with a voltage of not more than 12 V must be used, and in explosive environments - in an explosion-proof design. The use of kerosene and other flammable lamps is not permitted.

6-3-22. Vessels with a height of more than 2 m before internal inspection must be equipped with devices that provide secure access when examining all parts of the vessel.

6-3-23. During internal examinations Special attention should be addressed to identify the following defects:

A) on the inner and outer surfaces of the vessel - cracks, tears, corrosion of the walls (especially in the places of flanging and cutouts), bulges, bulges (mainly for vessels with shirts, as well as for vessels with fire or electric heating), shells (in cast vessels);

B) in welds - welding defects, cracks, tears, pickling; in rivet joints - cracks between rivets, head breaks, traces of gaps, tears in lumps of riveted sheets, corrosion damage to riveted joints (gaps under the edges of riveted sheets and under rivet heads), especially in vessels with oxygen and alkalis;

C) in vessels with protected surfaces - destruction of the lining, including leaks in the layers of lining tiles, cracks in the gummed, lead or other coating, chipping of enamel, cracks and bulges in metal liners, defects in the metal of the vessel walls in places of damaged protective coating.

*6-3-24. Hydraulic testing of vessels during periodic technical inspection should be carried out with test pressure in accordance with Table. 4-7-2. At the same time, for vessels operating at a wall temperature from +200 to 400 ° C, the value of the test pressure should not exceed the working pressure by more than 1.5 times, and at a wall temperature above +400 ° C - more than 2 times.

The vessel must be under test pressure for 5 minutes.

For vessels manufactured before the entry into force of these Rules, it is allowed to carry out a hydraulic test with the same test pressure as at the manufacturer's plant.

Hydraulic testing of enamelled vessels, regardless of pressure, must be carried out at the pressure indicated in the passport, but not less than the working one.

6-3-25. The vessel is recognized as having passed the test if:

A) there will be no signs of rupture in it;

b) leaks and sweating in the welds will not be noticed, and during the Pneumatic test - the passage of gas; the exit of water through the rivet seams in the form of dust or drops of “tears” is not considered a leak;

C) there will be no visible permanent deformation after testing.

1 6-3-26. If, during the technical examination of the vessel,

If it is in a dangerous condition or has serious defects that cast doubt on its strength, then the operation of such a vessel should be prohibited.

6-3-27. If during the technical examination there is doubt about the strength of the vessel at the permitted pressure, then the person who carried out the examination is allowed to reduce operating pressure. The reduction in pressure must be motivated by a detailed entry in the vessel's passport.

6-3-28. Vessels in which the action of the environment can cause deterioration chemical composition and mechanical properties of the metal, as well as vessels with a highly corrosive environment or a wall temperature above 475 ° C, must be subjected to additional examination by the technical personnel of the enterprise in accordance with the instructions approved by the chief engineer of the enterprise. The results of additional surveys, tests and studies must be recorded in a special log signed by the persons who carried out these surveys, tests and studies. The journal must be kept by the person who supervises the vessels at the enterprise.

Pressure vessels, steam and hot water boilers, steam pipelines hot water are in accordance with the Federal Law "On industrial safety hazardous production facilities” to hazardous production facilities. The manufacture of vessels and operation is regulated by: "rules for the design and safe operation of pressure vessels" Operation - heightened danger. (explosions are especially dangerous: boilers, vessels, steam and hot water pipelines - great destruction, injuries, accidents, material damage).

The rules for the design and safe operation of pressure vessels, boilers, steam and hot water pipelines are usually called the Boiler Supervision Rules, and the objects to which they apply are boiler supervision objects. (control - Rostekhnadzor of the Russian Federation; at the enterprise and in organizations, control over compliance with the Boiler Supervision Rules is carried out by boiler supervision inspectors who conduct technical examinations and inspections of boiler facilities. Failure to comply with the rules is punishable by fines. (responsibility for compliance with the rules, condition and operation of vessels is the responsibility of specialists supervising the technical condition and operation of the vessels.))

Vessel - a hermetically sealed container, designed for conducting chemical, thermal and other technological processes, as well as storage, transportation of gaseous, liquid and other substances. The boundary of the vessel is the inlet and outlet fittings.

Trial pressure is the pressure at which the vessels are tested.

Operating pressure - the maximum internal excess or external pressure that occurs during the normal course of the working process.

Design pressure - the pressure used in the strength calculation.

Conditional pressure - design pressure at a temperature of 20 C, used in the calculation of the strength of standard vessels.

The main causes of accidents of vessels, work under pressure.

The main causes of accidents:

• a) significant overpressure due to a malfunction safety valves, violation technological process or ignition of oil vapors in air collectors, absence (malfunction) of reducing devices;
• b) malfunction or absence safety devices vessels with quick-release lids;
• c) defects in the manufacture, installation and repair of vessels;
• d) overflow of vessels with liquefied gases;
• e) wear of vessel walls;
• f) maintenance of vessels by untrained personnel, violation of technological and labor discipline;
• g) violation of the requirements of the Rules due to their ignorance;
• h) the issuance by officials of instructions or orders forcing their subordinates to violate the Rules.

Danger: - the possibility of their destruction during a sudden adiabatic expansion of gases and vapors. i.e. loss mechanical strength shell walls (corrosion, local overheating, cracks. (explosions due to loss of mechanical strength of vessels, local overheating, impacts, excess operating pressure (potential energy - into the kinetic energy of fragments, destroyed equipment and shock wave (injuries to people.))) (k- 1)/k

Potential energy of the compressed medium: W= *(1-(p1/p2)) K - adiabatic index. P1 and P2 - initial and final pressure, respectively. V - initial volume of gas.

The potential energy of the compressed medium is proportional to the product of the initial pressure and the volume of the vessel: W~PV

• - blast wave (damage to equipment and loss of life.)
• - vessels containing toxic media (risk of poisoning) and flammable media (risk of fire and explosion) are dangerous

Scope of the "rules of design and safe operation":

The rules apply to:

• - vessels operating under water pressure with a temperature above 115 C or other liquid with a temperature exceeding the boiling point at a pressure of 0.07 MPa hydraulic pressure;
• - vessels operating under steam or gas pressure over 0.07 MPa
• - cylinders intended for transportation and storage of compressed, liquefied and dissolved gases under pressure over 0.07 MPa
• - tanks and barrels for transportation and storage liquefied gases, whose vapor pressure at temperatures up to 50C exceeds 0.07 MPa.
• - tanks and vessels for transportation, storage of liquefied gases, liquids and bulk solids, in which pressure over 0.07 MPa is periodically created for emptying;

The rules do not apply to:

• - vessels manufactured in accordance with the "rules for the design and safe operation of equipment and pipelines of nuclear power plants”, (Rostekhnadzor), as well as vessels working with a radioactive environment;
• - vessels with a capacity of not more than 25 liters, regardless of pressure, used for scientific and experimental purposes.
• - vessels and cylinders with a capacity of not more than 25 liters, in which the product of MPa pressure and capacity in liters does not exceed 200.
• - vessels working under pressure, creating during the explosion inside them in accordance with the technological process;
• - vessels operating under vacuum;
• - vessels installed on sea, river vessels and other floating facilities;
• - vessels installed on airplanes and other aircraft;
• - air reservoirs for brake equipment of rolling stock of railway transport, cars and other vehicles;
• - vessels special purpose military department;
• -devices of steam and water heating;
• - tube furnaces;

HYDRAULIC AND PNEUMATIC TEST.

Hydraulic test:

All vessels are subject to this test after manufacture (coated and insulated, vessels are tested before insulation and coating are applied);

Uncast vessels: Ppr=1.25r (y20/yf)

Ppr - test pressure; MPa

p - design pressure of the vessel, MPa

y20 - allowable stress of the material of the vessel at 20 C, MPa;

yf - allowable stress of the vessel material at design temperature, MPa

Hydraulic testing of cast vessels and parts is carried out by test pressure, determined by the formula: Ppr \u003d 1.5r (y20 / yf).

Hydraulic testing of vessels and parts not from Me, with a viscosity of more than 20 J/cm2;

Ppr \u003d 1.3r (y20 / yf). If less than 20, then according to Ppr \u003d 1.6r (y20 / yf).

Hydraulic testing of cryogenic vessels in the presence of vacuum in the isolated space of the body is carried out

The test procedure must be specified in technical project and is specified in the manufacturer's instructions for the installation and operation of pressure vessels.

For hydraulic testing of vessels, water with a temperature of at least +5C and not higher than +40C should be used. By agreement with the developer of the project, another liquid can be used instead of water. When filling the vessel with water, the air must be completely removed. Hydraulic testing is carried out only after an internal inspection of the vessel. The pressure in the test vessel should be increased gradually. The use of compressed air or gas to raise the pressure is not permitted. The pressure during hydraulic testing is controlled by two pressure gauges of the same type, having the same measurement limits, accuracy class and division value.

The holding time of the vessel under test pressure is set by the project developer. In the absence of special instructions in the project, the exposure time (min) should not be less than:

Wall thickness -50 - 10 min; over 50 - 100mm - 20; over 100mm - 30; for children, multi-layered - 60 min.

After exposure under test pressure, it is reduced to the calculated one and the outer surface is inspected; planing of the walls during the test is not allowed.

The vessel is considered to have passed the test (hydraulic) if there are no: cracks, tears, sweating in welded joints, residual deformations, leaks in detachable connections, pressure drops on the pressure gauge. The vessel and its elements - in which defects were identified, after elimination, are subjected to repeated hydration. Trial pressure test. In the case when a hydraulic test is not possible, a pneumatic test is performed (air or inert gas.) (subject to control by the method of acoustic emission).

PNEUMATIC TEST:

(pressure is the same as with hydraulic, careful inspection of the internal state of the vessel, before testing;)

In pneumatic testing, the following precautions apply:

• 1) the valve on the pipeline and pressure gauges are taken out of the room;
• 2) people for the duration of the test are removed to a safe distance; 3) check valve- regardless of pressure fluctuations in front of it maintains a constant pressure behind it.

Under test pressure during pneumatic testing, the vessel must be kept for 5 minutes, after which the pressure is gradually reduced to the working pressure, at which the vessel is inspected with a check of the tightness of its seams and detachable joints with a soap solution or in another way. Tapping of the pressure vessel during the pneumatic test is prohibited. Vessels subject to registration with the Gosgortekhnadzor bodies must be subject to periodic technical examinations by the supervisory engineer of the Kotlonadzor. For the correct design of the vessel, for the calculation of its strength and the choice of material, for the quality of manufacture and installation, as well as for the compliance of the vessel with these Rules, the organization that performed the relevant work is responsible.

All changes in the project in the process of manufacture or installation of the vessel must be agreed in writing between the design organization that requested the change in the project and Gosgortekhnadzor. If the device has passed the strength test, then it is carried out for tightness.

LEAK TEST:

Vessels operating under the pressure of harmful substances (liquids and gases) of the 1st and 2nd hazard class according to GOST 12.1.007-76 are tested by the owners of the vessels for tightness with air or inert gas (nitrogen) under pressure,

Equal to working pressure. if the tightness is broken, the equipment breaks - danger (fragments, blast wave, a calculation is made for the strength of the apparatus;)

Upon reaching the test pressure, the supply of compressed air or nitrogen is stopped, a metal plug is placed between the inlet and the pipeline and the shut-off valve and the pressure drop is monitored. (Tests are carried out - 24 hours - new; 4 hours repeated tests). The measurement of the initial pressure and the calculation of the specified time is made after the temperatures inside and outside the vessel have equalized. The temperature of the gas in the vessel must be measured either by setting mercury thermometers into the sleeves in the vessel, or thermometers to the surface. The degree of tightness is characterized by the number of gases leaving the apparatus per unit time: m = (Pn-Pk) / Pn f; m- coefficient of tightness (used in determining the amount of harmful substances that have entered the air of industrial premises from equipment, based on this, productivity is determined ventilation unit.); f-time;

pressure drop: Dr= 100/f (1- (Pk Tk/PnTn))

Dr - pressure drop;

Pk ;Pn - final and initial pressure in the apparatus.

Tk, Tn - final and initial temperature in the device.

The tightness is satisfactory if Dr is not more than 0.1% per hour for toxic environments and 0.2% per hour for flammable environments (for new devices). And 0.5% for retests. For devices with P work less than 0.7 atm, Rispyt = P work + 30 kPa. Apparatus for work - not under vacuum tested for strength and tightness:

Strength - 0.2MPa

For tightness - 0.1MPa

Hydraulic testing of vessels is carried out only with satisfactory results of external and internal examination.

The vessel and fittings installed on it are subjected to the test.

6.3.19. Hydraulic tests must be carried out in accordance with the requirements set forth in the section of the Operation Rules. vessels. In this case, the value of the test pressure can be determined based on the permitted pressure for the vessel. The vessel must be under test pressure for 5 minutes.

Hydraulic testing of enamelled vessels by the manufacturer, regardless of the operating pressure, must be carried out with a test pressure indicated in the vessel certificate.

The day of the technical examination of the vessel is set by the administration of the enterprise and is preliminarily agreed with the inspector of the Gosgortekhnadzor. The vessel must be stopped no later than the survey period specified in its passport, the Administration of the enterprise must notify the inspector about the forthcoming survey of the vessel no later than 5 days in advance.

In case of non-appearance of the inspector within the agreed period, the administration of the enterprise is given the right to conduct an independent examination by a commission appointed by order of the head of the enterprise.

The results of the next survey carried out on time are recorded in the vessel's passport and signed by all members of the commission.

A copy of this record is sent to the local Gosgortekhnadzor body no later than 5 days after the survey.

The term of the next survey established by the commission should not exceed that indicated in column 3 of the table; the survey must be carried out by an inspector of Gosgortekhnadzor.

6.3.22. The Administration is responsible for the timely and high-quality preparation of the vessel for survey.

SVD up to must be subject to Tech. Osvid. (external, internal inspection and hydraulic test) after installation before commissioning, as well as periodically during operation.

--- External and internal inspection within 2 years for SVD with metal corrosion up to 0.1 mm/year.

--- Nar. and internal inspection within 1 year for SVD with metal corrosion more than 0.1 mm/year.

--- Nar. and internal inspection within 4 years with the participation of the Gosgortekhnadzor inspector.

Hydrotesting is carried out for 8 years.

All vessels are subject to hydraulic testing after their manufacture.

Vessels that have protective covering(enamelled, lining) or insulation, are subjected to a hydraulic test before coating or insulation.

Vessels with an outer casing are subjected to a hydraulic test before the installation of the casing.

4.6.14. The vessel is considered to have passed the hydraulic test if it is not found:

1) leaks, cracks, tears, sweating in welded joints and on the base metal;

2) leaks in detachable connections;

3) visible residual deformations.

4.6.15. The vessel and its elements, in which defects were revealed during the test, after their elimination, are subjected to repeated hydraulic tests with a trial pressure established by the Rules.

4.6.16 Hydraulic testing carried out at the enterprise should be carried out on a special test bench that has an appropriate fence and meets the safety requirements and instructions for conducting hydraulic tests, approved in the manner established by the ministry (department).

4.6.17. It is allowed to replace the hydraulic test with a pneumatic one, provided that this test is controlled by the acoustic emission method.

Pneumatic tests should be carried out according to the instructions providing necessary measures safety and approved by the chief engineer of the enterprise.

Pneumatic test vessel is carried out with compressed air or inert gas.

The value of the test pressure is assumed to be equal to the value of the test hydraulic pressure. The holding time of the vessel under test pressure is set by the project developer, but should not be less than 5 minutes.

Then the pressure in the test vessel should be reduced to the calculated one and the vessel should be inspected with a check of the tightness of its seams and detachable joints with a soapy solution or in another way.

4.6.18. The test pressure value and test results are recorded in the vessel passport.

4. Basic provisions and industrial safety requirements in accordance with the Law of the Republic of Kazakhstan "On industrial safety at hazardous production facilities".

1. Industrial safety is ensured by:

1) establishment and implementation mandatory requirements industrial safety;

2) admission to the use of technologies at hazardous production facilities, technical devices, materials that have passed the procedure for confirming compliance with industrial safety standards;

4) state control, as well as production control in the field of industrial safety;

5) examination of industrial safety of hazardous production facilities;

6) certification of organizations for work in the field of industrial safety;

7) industrial safety monitoring.

2. Industrial safety requirements must comply with protection standards industrial personnel population and territories from emergencies, sanitary and epidemiological welfare of the population, environmental protection natural environment, environmental safety, fire safety, safety and labor protection, construction, as well as the requirements of technical regulations in the field of industrial safety.

5. Control and maintenance of GPM.

Owners of lifting machines, containers, removable lifting devices, crane tracks, ensure their maintenance in good condition and safe conditions work by organizing production control.

For these purposes:

1) engineering and technical workers for control are appointed to ensure the safe operation of hoisting machines, removable load-handling devices and containers;

2) periodic inspections are provided, Maintenance and repair, ensuring the maintenance of lifting machines, crane tracks, removable load-handling devices and containers in good condition;

3) a provision is being developed on production control, technological regulations.

320. If malfunctions, violations of these Requirements during the operation of hoisting machines and their maintenance are detected, the control person ensuring the safe operation of hoisting machines takes measures to eliminate them, and, if necessary, stops the machine.

It is not allowed to operate the lifting machine when:

1) detection of malfunctions of brakes, blocks, ropes and their fastening of chains, hooks, winches, running wheels, blocking devices and safety devices, non-compliance of the crane electrical circuit with the project;

2) the presence of cracks and deformations in the supporting metal structures;

3) identifying malfunctions of the crane track (Appendix 10);

4) expiration of the period of technical examination or normative term machine service;

6) absence of registration of the load-lifting machine;

7) the absence of removable load-handling devices and containers corresponding to the mass and nature of the transported goods or their malfunction;

8) non-compliance with the instructions of control persons or instructions of state inspectors;

9) malfunctions of grounding or electrical equipment;

321. For the management of hoisting machines and their maintenance, the owner appoints crane operators, mechanics, and electricians.

322. An assistant crane operator is appointed in cases provided for guidelines operating instructions for the crane, or if required by local operating conditions.

323. Driving a truck crane is allowed to the driver after training him in the program for crane operators and certification.

324. Slingers are appointed to hook and tie (sling) the load onto the hook of the load-lifting machine. As slingers, workers (riggers, assemblers and other professions) trained in the performance of cargo slinging work are allowed.

329. Signalers are allowed workers from among certified slingers.

Crane operators inspect lifting machines before starting work, for which the owner of the crane allocates appropriate time.

The results of the inspection and verification by the crane operators of the lifting machine are recorded in the logbook (Appendix 11).

Slingers inspect removable load-handling devices and containers before their use in work.