Protective devices for production equipment. Regulator Safety Devices and Filters Safety device types are designed for

1. classification of safety devices

2 Certification of labor protection works:

3. Joint operation of fans: Two or more fans are often used for ventilation. The effectiveness of their joint work depends on the pressure characteristics and location in the ventilation network, as well as on the aerodynamic resistance of the network. There are three possible schemes for the joint operation of fans in the network: serial, parallel and combined. The energy of air movement in a passive ventilation network using two or more fans is supported by their useful power.

4. Air-mechanical foam as a fire extinguishing agent: foams are colloidal systems consisting of gas bubbles, the shell of which contains a 3-5% aqueous solution of a foaming agent. Foams are used to extinguish solid and liquid combustible substances that do not interact with water, and primarily to extinguish oil products. The fire extinguishing effect of foam is based on cooling the fire with water, as well as partial isolation of the combustion zone from fresh air. The advantages of foam as a fire extinguishing agent include:

Duration of foam preservation of its structure and volume, which allows both area and volume fire extinguishing

Possibility of remote influence on the fire source

The ability of foam to travel long distances and penetrate into hard-to-reach places

The fire-extinguishing properties of foam are largely determined by its multiplicity and durability. Multiplicity - the ratio of the volume of foam to the volume of the liquid phase. Stability - resistance of the foam to the process of destruction and is estimated by the duration of the release of 50% of the liquid phase from the foam. With an increase in the expansion ratio of the foam, the resistance decreases. The durability of medium expansion foam is about 2 hours. The durability can be improved by introducing stabilizing additives. The foam is electrically conductive, so it is forbidden to extinguish live installations with it.

5. Vibration, vibration disease and its prevention: vibration occurs as a result of mechanical vibrations and is a periodic movement with different amplitude and frequency. Harmful vibration occurs involuntarily during the operation of vehicles, engines, turbines, hammers, etc. It can lead to destruction of structures, parts, buildings. According to the impact on a person, vibration is divided into local (vibrations of a tool, equipment applied to individual parts of the body) and general (of the entire workplace). Under the influence of vibration, neurovascular disorders of the hands appear, which are expressed in changes in the blood filling of tissues, as well as changes in the elastic-viscous state and reactivity of blood vessels. Vibration affects the endocrine system, metabolism, blood composition, vegetative-vascular regulation. The first degree of manifestation of the impact of vibration is tingling of the fingertips, the second is episodic oscillation of the phalanges of the fingers when exposed to cold, the third is acrocyanosis with impaired blood circulation, the fourth is necrosis of the phalanges of the fingers. Vibration disease is divided into 3 degrees. Vibration protection - technical, organizational and application of PPE.

1. Classification of workplaces and premises according to the danger of electric shock: category 1 - premises without an increased risk of injury to people - dry, dust-free with an insulated floor.

a. Presence of humidity>75%

b. The presence of conductive dust

c. The presence of conductive bases

d. Presence of elevated temperature

e. Possibility of simultaneous contact of a person with metal structures connected to the ground and electrical equipment cases

Moisture (rain, snow, etc.)

The presence of a chemically active environment (aggressive vapors, gases, liquids that form deposits and mold, acting destructively on the insulation and current-carrying parts of electrical installations)

The presence of two or more conditions of increased danger.

2. General hygienic assessment of working conditions: the assessment of the actual state of working conditions in terms of the degree of harmfulness and danger of factors in the working environment is carried out in accordance with the Hygienic Criteria

Classes of working conditions are established according to the integral assessment of the combined action, taking into account the predominance of the action of certain parameters for 14 dangerous and harmful factors:

Chemical

Biological

Aerosols of fibrinogenic action

Infrasound

· Ultrasound

general vibration

local vibration

non-ionizing radiation, ionizing radiation

Microclimate

Lighting

The severity of labor

・Intensity of work

The results of the assessment are included in the final table for assessing the working conditions of workers in terms of the degree of harmfulness and danger. The general hygienic assessment of working conditions is established on the basis of data on the classes of working conditions for 14 harmful and dangerous factors

According to the highest class and degree of harmfulness

In the case of a combined effect of three or more factors related to 3.1, the overall assessment corresponds to class 3.2

· When combining 2 or more factors 3.2, 3.3, 3.4, the conditions are evaluated one step higher.

If there are no dangerous and harmful production factors at the workplace or if their actual values correspond to optimal or permissible values, as well as when the requirements for safety and security of workers are met, it is considered that working conditions at the workplace meet hygienic and safety requirements, the workplace is considered certified . Otherwise, the working conditions are considered harmful or dangerous. If the working conditions are assigned to the 3rd class, the workplace is considered to be conditionally certified with an indication of the class and degree of harmfulness; if it is attributed to the 4th class, the workplace is not certified and is subject to liquidation.

3. Mine self-rescuers - principle of operation, storage, checks: mine self-rescuers are designed to protect the respiratory organs of miners in mines and mines, which, as a result of an accident, find themselves in an atmosphere unsuitable for breathing (suffocating), and are used to withdraw from emergency areas to mine workings with fresh a stream of air. Mine rescue units use self-rescuers as one of the means of assistance delivered to the gassed workings by the department for the victims. According to the principle of operation, self-rescuers are divided into insulating and filtering. Isolating self-rescuers completely isolate the human respiratory organs from the atmosphere, which can contain no more than 10% CO, 2% sulfur dioxide, 1% hydrogen sulfide or nitrogen oxide, and 15% CO2. Oxygen may be completely absent. Filtering self-rescuers are used in case of confidence in a sufficient amount of oxygen in the surrounding air. Isolating self-rescuers contain chemically bound oxygen, which, when turned on, is released for breathing for 30 seconds, after which the exhaled air is purified. The principle of operation of filtering self-rescuers is based on the chemical absorption of harmful gases by the absorber. Self-rescuers are checked for tightness by the PGS device quarterly. The self-rescuer does not lose its properties within 2 years from the date of its issue to the worker or 3 years of storage. Self-rescuers are stored in a vertical position on racks or in boxes in a dry room. Self-rescuers must be protected from direct sunlight and be at least a meter away from heat emitting devices.

4. Sprinkler and deluge automatic fire extinguishing installations: sprinkler installations are water sprinklers protected by an individual fusible lock that melts when the temperature rises. They are performed in various thermal versions at 72, 93, 141, 182 degrees. They work directly above the fire.

Drenchers are sprinklers that are switched on centrally. The whole room is extinguished at once. They are activated manually or automatically by a signal from an automatic detector. They are used in rooms with the possibility of a very rapid spread of fire or to create water curtains.

5. The influence of high and low atmospheric pressure on a person

1. General safety requirements for lifting devices: 2.1.1. All lifts must be manufactured in full compliance with these Rules and regulatory documents approved in the prescribed manner. The development of regulatory documents is carried out by leading specialized organizations, and the development of projects is carried out by specialized organizations that have a license (permit) from the territorial bodies of the Gosgortekhnadzor of Russia*.

2.1.2. Hoists and their assembly units purchased abroad must comply with the requirements of these Rules and have a certificate of conformity (certified copy) indicating the serial number of the hoist. Possible deviations from these Rules must be agreed with the Gosgortekhnadzor of Russia before concluding a supply contract. Copies of the approval and the certificate of conformity must be attached to the passport, made in the form in accordance with Appendix 4.

Upon delivery of the lift, technical documentation must be attached, made in Russian and complying with the requirements of these Rules.

2.1.3. The electrical equipment of lifts, its installation, current supply and grounding must comply with the Rules, electrical installations.

2.1.4. The operation of the electrical equipment of the lifts must be carried out in accordance with the requirements of the Rules for the operation of electrical installations of consumers in terms of cranes and the Safety Rules for the operation of electrical installations of consumers.

2.1.5. Lifts intended for operation in premises and outdoor installations in which an explosive and flammable environment may form must be designed and manufactured in accordance with the requirements of the Electrical Installation Rules and other regulatory documents.

The ability to operate the lift in an explosive environment (with an indication of the category of environment) must be reflected in the passport, as well as in the operating manual for the lift.

2.1.6. Lifts, except for those intended for operation in heated rooms, must be manufactured to operate at temperatures from minus 40 ° C to plus 40 ° C and wind speeds of not more than 10 m / s at a height of up to 10 m.

2.1.7. Lifts intended for operation at temperatures below minus 40 °C must be manufactured in climatic version UHL (HL) in accordance with GOST 15150.

2.1.8. All changes in the drawings or calculations, the need for which may arise during the manufacture or repair of the lift, must be agreed between the design organization, the manufacturer or the customer.

2.1.9. .Before being put into operation, lifts must undergo registration and technical examination in the manner prescribed by these Rules.

2.1.10. The main technical characteristics, including the carrying capacity, must comply with state standards, specifications or other regulatory documents.

2.1.12. Lifts must be designed to:

1) ease of management, maintenance and repair;

2) the possibility of towing: smooth start and stop mechanisms;

3) replacement of elements of the hydraulic system of lifts without draining the working fluid from the entire hydraulic system.

2.1.13. Lifts must be equipped with a device for recording operating hours in engine hours.

2.1.14. Elevator mechanisms equipped with mechanical devices for switching them on must be designed in such a way as to exclude the possibility of their spontaneous switching on.

2.1.15. In the nodes of the lift mechanisms that transmit torque, in order to avoid turning the mating parts, it is necessary to use slotted, keyed, bolted and other connections, which must be protected from arbitrary unscrewing or separation. The use of spring washers for fastening the turntable is prohibited.

2.1.16. The fixed axles that support the individual components of the lift must be securely fastened to prevent their movement.

2.1.17. For lifts with telescopic retractable sections of the knees, reliable fixation of the extended sections in the working position should be provided.

2.1.18. Guides for ropes, chains and rods of the cradle floor orientation tracking system in a horizontal position must be designed so that they do not spontaneously fall off the rollers, sprockets, drums and jamming of the rods.

Successfully operate abroad. The issue of delimiting the rights of labor collectives and trade unions in production is topical. This problem is not new for Ukrainian labor law. 1. SUBJECT OF LABOR LAW. The branch is allocated in the system of law according to the criteria of the subject and method of legal regulation. The state is interested in specific legal management. Item Consists of: labor...

... : labor and collective; - internal labor regulations of the organization, responsibility for violation of these rules; -organization of work on the management of labor protection; - control and supervision over compliance with labor protection requirements in the organization; - the main dangerous and harmful production factors characteristic of this production; -PPE, the procedure and norms for issuing them and the timing of wearing them; - ...

Undertakes to provide the employee with work according to the stipulated labor function, to ensure the working conditions provided for by the legislation, agreements, local regulations containing labor law norms, to pay the salary to the employee in a timely manner and in full, and the employee undertakes to personally perform the labor function determined by this agreement, to comply operating in the organization...

Devices that ensure the safe operation of machinery and equipment by limiting speed, pressure, temperature, electrical voltage, mechanical load and other factors that contribute to the occurrence of dangerous situations are called safety devices. They should operate automatically with a minimum inertial delay when the controlled parameter goes beyond the allowable limits.

Safety devices against mechanical overloads are shear pins and pins, spring-cam, friction and gear-friction clutches, centrifugal, pneumatic and electronic regulators.

A pulley, sprocket or gear located on the drive shaft is connected to the drive (driven) shaft with shear pins or pins designed for a certain load. If the latter exceeds the allowable value, then the pin is destroyed and the drive shaft starts to rotate idle. After eliminating the cause of the appearance of such loads, the sheared stud is replaced with a new one.

Pin diameter, mm, safety clutch, which is usually made of steel 45 or 65 G,

where Mp is the design moment, N*m; R is the distance between the center lines of the transmission shafts and the pin, m; τav is the ultimate shear strength, MPa (for steel 45 and 65 G depending on the type of heat treatment under static load τav = 145...185 MPa; under pulsating load τav = 105...125 MPa; under symmetric alternating load τav = 80...95 MPa); for calculations, it is recommended to take smaller values.

Usually, the calculated moment Mp is taken 10 ... 20% higher than the maximum allowable moment Mp, i.e.

Mp = (1.1...1.2) Mpr.

Friction-type clutches automatically operate in case of exceeding the torque to which they are pre-adjusted. Switching off condition, for example, for a gear-friction safety clutch:

where Mp is the design torque, N m; Mpred - maximum permissible torque, N * m; a is the angle of inclination of the side surface of the cam (α = 25...35°); β is the friction angle of the side surface of the cam (β = 3...5°); D is the diameter of the circumference of the points of application of the circumferential force to the cams, m; d is the shaft diameter, m; f1 is the coefficient of friction in the keyed connection of the movable bushing (f1 = 0.1...0.15).

Safety clutches for chain and belt drives of agricultural machines with toothed friction washers are standardized.

Diesels, steam and gas turbines, expanders are supplied with speed controllers, mainly of the centrifugal type. To prevent an increase in the crankshaft speed, which is dangerous for the machine and maintenance personnel, by limiting the supply of fuel or steam, a regulator is used.

Limit switches are necessary to prevent equipment breakdowns that occur when moving parts go beyond the established limits, limit the movement of the caliper on metal-cutting machines, for the movement of cargo in the vertical and horizontal planes during the operation of hoisting mechanisms, etc.

Catchers are used on hoisting and transporting machines, in elevators to hold the lifted load in a stationary state, even in the presence of self-braking brake systems, which, if worn or improperly maintained, may lose their performance. There are ratchet, friction, roller, wedge and eccentric catchers.

Safety valves and diaphragms are used to avoid excess steam or gas pressure. Safety valves are by type cargo (lever), spring and special; hull structures - open and closed; placement method - single and double; lifting height - low-lift and full-lift.

Lever valves (Fig. 7.3, a) have a relatively small capacity and, when the pressure exceeds the permissible value, they release working gas or steam into the environment.

Rice. 7.3. Schemes of safety lever (o), spring (b) valves and membranes (c and d):

1 - tension screw; 2 - spring; 3 - valve disc

Therefore, in vessels operating under pressure of toxic or explosive substances, closed-type spring valves are usually installed (Fig. 7.3, b), which discharge the substance into a special pipeline connected to the emergency tank. The lever valve is adjusted to the maximum allowable value on the pressure gauge by changing the mass of the load m or the distance b from the valve axis to the load. The spring valve is adjusted with the help of a tension screw 1, which changes the pressing force of the valve plate 3 with a spring 2. The main disadvantage of safety valves is their inertia, i.e. providing a protective effect only with a gradual increase in pressure in the vessel on which they are installed.

To determine the flow area of safety valves, the theory of gas outflow from the hole is used. Consider the following dependency:

where Q is the throughput of the valve, kg/h; μ is the outflow coefficient (for round holes μ = 0.85); SK is the cross-sectional area of the valve, cm2; p is the pressure under the valve, Pa; g = 9.81 cm/s2 is the free fall acceleration; M is the molecular weight of gases or vapors passing through the valve; k = cpcv is the ratio of heat capacities at constant pressure and constant volume (for water vapor k= 1.3; for air k = 1.4); L is the gas constant, kJ/(kg*K), for steam R = 461.5 kJ/(kg*K); for air R = 287 kJ/(kg*K); T is the absolute temperature of the medium in the protected vessel, K.

Substituting the values of μ, g, R and the average value of k with a known value of Q into the last formula, we can determine the cross-sectional area of the safety valve, cm2,

SK=Q/(216p√M/T).

The number and total cross section of safety valves are found from the expression

ndkhk = kkQk / pk,

where n is the number of valves (on boilers with a steam capacity of ≤ 100 kg/h, it is allowed to install one safety valve, with a boiler steam capacity of more than 100 kg/h, it is equipped with at least two safety valves); dk is the inner diameter of the valve disc, cm (dk = 2.5...12.5 cm); hк - valve lift height, cm; kk - coefficient (for valves with a small lift height at hk≤ 0.05dk kk = 0.0075; for full-lift valves at 0.05dk< hк≤ 0,25dк kк = = 0,015); Qк — производительность котла по пару при максимальной нагрузке, кг/ч; рк — абсолютное давление пара в котле, Па.

To protect vessels and apparatuses from a very rapid and even instantaneous increase in pressure, safety membranes are used (Fig. 7.3, c and d), which, depending on the nature of their destruction during operation, are divided into bursting, shear, breaking, popping, tear-off and special. The most common bursting discs, which collapse under the action of pressure, the value of which exceeds the tensile strength of the membrane material.

Membrane safety devices are made from various materials: cast iron, glass, graphite, aluminum, steel, bronze, etc. The type and material of the membrane is selected taking into account the operating conditions of the vessels and apparatus on which they are installed: pressure, temperature, phase state and aggressiveness of the medium, rate of pressure rise, overpressure release time, etc.

To ensure the operation of the membrane, it is necessary to determine the thickness of the membrane plates depending on the value of the breaking pressure. Throughput, kg/s, of membrane safety devices with increasing pressure in the protected vessel:

Qm=0.06Sworksppr√ M/Tg,

where Swork is the working (flow) section, cm2; ppr - absolute pressure in front of the safety device, Pa; Tg is the absolute temperature of gases or vapors, K.

Required thickness of the working part of the breaking membrane, mm,

Rice. 7.4. Scheme of operation of the low pressure water lock:
a - during normal operation; b - during reverse impact; 1—shut-off valve; 2— gas outlet tube; 3 - funnel; 4— safety tube; 5— body; 6 - control valve

b = ppdplkop(4[σcp]),

where pp is the pressure at which the plate must collapse, Pa; dm is the working diameter of the plate, cm; kon is a scale factor determined empirically (at d/b - 0.32 k - = 10...15); [σav] is the shear strength, MPa.

The thickness of membranes made from brittle materials

b = 1.1rpl√pp/[σout]

where rpl is the radius of the plate, cm; [σiz] is the bending strength of the plate material, Pa.

The safety devices that prevent the explosion of an acetylene generator include water locks (Fig. 7.4), which do not allow the flame to pass into the generator. In the event of a reverse flame strike, which occurs, for example, when a gas burner is ignited, the explosive mixture enters the seal and displaces some of the water through the gas outlet tube 2. Then the end of the tube 4 will receive communication with the atmosphere, the excess gas will come out, the pressure will return to normal and the device will start working again according to the scheme shown in Figure 7.4, a. To protect electrical installations from an excessive increase in current strength, which can cause a short circuit, fire and human injury, circuit breakers and fuses are used.

5.1.1. To control the work and ensure safe operating conditions, the vessels, depending on the purpose, must be equipped with:

shut-off or shut-off and control valves;
instruments for measuring pressure;
instruments for measuring temperature;
safety devices;
liquid level indicators.

5.1.2. Vessels equipped with quick-release lids must have safety devices that exclude the possibility of turning on the pressure vessel if the lid is not completely closed and opening it if there is pressure in the vessel. Such vessels must also be equipped with key-mark locks.

5.2. Shut-off and shut-off and control valves

5.2.1. Shut-off and shut-off and control valves should be installed on fittings directly connected to the vessel, or on pipelines leading to the vessel and removing the working medium from it. In the case of a series connection of several vessels, the need to install such fittings between them is determined by the project developer.

5.2.2. The fittings must have the following marking:

name or trademark of the manufacturer;
conditional pass, mm;
conditional pressure, MPa (it is allowed to indicate the working pressure and allowable temperature);
medium flow direction;
case material grade.

5.2.3. The number, type of fittings and installation locations must be selected by the developer of the vessel project based on the specific operating conditions and the requirements of the Rules.

5.2.4. The direction of rotation of the shut-off valve must be indicated on the handwheel when opening or closing the valve.

5.2.5. Vessels for explosive, flammable substances, substances of the 1st and 2nd hazard classes according to GOST 12.1.007-76, as well as evaporators with fire or gas heating, must have a check valve on the supply line from the pump or compressor, which is automatically closed by pressure from the vessel . The non-return valve must be installed between the pump (compressor) and the stop valves of the vessel.

5.2.6. Reinforcement with a nominal bore of more than 20 mm, made of alloyed steel or non-ferrous metals, must have a passport of the established form, which must contain data on chemical composition, mechanical properties, heat treatment modes and the results of quality control of manufacturing by non-destructive methods.

Reinforcement that is marked, but does not have a passport, is allowed to be used after the revision of the reinforcement, testing and checking the grade of the material. In this case, the owner of the fittings must draw up a passport.

5.3. Pressure gauges

5.3.1. Each vessel and separate cavities with different pressures must be equipped with direct-acting pressure gauges. The pressure gauge is installed on the vessel fitting or pipeline between the vessel and the stop valves.

5.3.2. Pressure gauges must have an accuracy class of at least: 2.5 - with a working pressure of the vessel up to 2.5 MPa (25 kgf / cm 2), 1.5 - with a working pressure of the vessel above 2.5 MPa (25 kgf / cm 2).

5.3.3. The pressure gauge must be selected with such a scale that the working pressure measurement limit is in the second third of the scale.

5.3.4. On the pressure gauge scale, the owner of the vessel must put a red line indicating the working pressure in the vessel. Instead of a red line, it is allowed to attach a metal plate to the pressure gauge case, painted red and tightly adjacent to the pressure gauge glass.

5.3.5. The pressure gauge must be installed so that its readings are clearly visible to the operating personnel.

5.3.6. The nominal diameter of the case of pressure gauges installed at a height of up to 2 m from the level of the observation site for them must be at least 100 mm, at a height of 2 to 3 m - at least 160 mm.

Installation of pressure gauges at a height of more than 3 m from the level of the site is not allowed.

5.3.7. Between the pressure gauge and the vessel, a three-way valve or a device replacing it should be installed, which allows periodic checking of the pressure gauge using a control one.

If necessary, the pressure gauge, depending on the operating conditions and the properties of the medium in the vessel, must be equipped with either a siphon tube, or an oil buffer, or other devices that protect it from direct exposure to the medium and temperature and ensure its reliable operation.

5.3.8. On vessels operating under pressure above 2.5 MPa (25 kgf / cm 2) or at an ambient temperature above 250 ° C, as well as with an explosive atmosphere or harmful substances of the 1st and 2nd hazard classes according to GOST 12.1.007- 76 instead of a three-way valve, it is allowed to install a separate fitting with a shut-off device for connecting a second pressure gauge.

On stationary vessels, if it is possible to check the pressure gauge within the time limits established by the Rules by removing it from the vessel, the installation of a three-way valve or a device replacing it is optional.

On mobile vessels, the need to install a three-way valve is determined by the developer of the vessel project.

5.3.9. Pressure gauges and pipelines connecting them to the vessel must be protected from freezing.

5.3.10. The pressure gauge is not allowed for use in cases where:

there is no seal or brand with a mark on the verification;
verification period is overdue;
the arrow, when it is turned off, does not return to the zero reading of the scale by an amount exceeding half the permissible error for this device;
the glass is broken or there is damage that may affect the correctness of its readings.

5.3.11. Verification of pressure gauges with their sealing or branding should be carried out at least once every 12 months. In addition, at least once every 6 months, the owner of the vessel must carry out an additional check of the working pressure gauges with a control pressure gauge, recording the results in the log of control checks. In the absence of a control pressure gauge, it is allowed to carry out an additional check with a tested working pressure gauge that has the same scale and accuracy class with the tested pressure gauge.

The procedure and terms for checking the serviceability of pressure gauges by service personnel during the operation of vessels should be determined by the instructions for the mode of operation and safe maintenance of vessels, approved by the management of the organization - the owner of the vessel.

5.4. Temperature measuring instruments

5.4.1. Vessels operating at varying wall temperatures must be equipped with devices to control the rate and uniformity of heating along the length and height of the vessel and benchmarks to control thermal movements.

The need to equip the vessels with the indicated devices and benchmarks, as well as the permissible rate of heating and cooling of the vessels, are determined by the project developer and indicated by the manufacturer in the vessel's passport or in the operation manual.

5.5. Overpressure safety devices

5.5.1. Each vessel (combination vessel cavity) must be equipped with safety devices to prevent pressure increase above the allowable value.

5.5.2. The following are used as safety devices:

spring safety valves;
lever-load safety valves;
impulse safety devices (IPD), consisting of a main safety valve (MPV) and a control impulse valve (IPK) of direct action;
safety devices with collapsing membranes (membrane safety devices - MPU);
other devices, the use of which is agreed with the Gosgortekhnadzor of Russia.

Installation of lever-load valves on mobile vessels is not allowed.

5.5.3. The design of the spring valve must exclude the possibility of tightening the spring in excess of the set value, and the spring must be protected from unacceptable heating (cooling) and direct exposure to the working environment, if it has a harmful effect on the spring material.

5.5.4. The design of the spring valve must include a device for checking the correct operation of the valve in working condition by forcibly opening it during operation.

It is allowed to install safety valves without a device for forced opening, if the latter is undesirable due to the properties of the medium (explosive, combustible, 1st and 2nd hazard classes according to GOST 12.1.007-76) or according to the conditions of the technological process. In this case, the check of the operation of the valves should be carried out on the stands.

5.5.5. If the working pressure of the vessel is equal to or greater than the pressure of the supply source and the possibility of pressure increase from a chemical reaction or heating is excluded in the vessel, then the installation of a safety valve and a pressure gauge on it is optional.

5.5.6. A vessel designed for a pressure less than the pressure of the source supplying it must have an automatic reducing device on the inlet pipeline with a pressure gauge and a safety device installed on the side of lower pressure after the reducing device.

If a bypass line (bypass) is installed, it must also be equipped with a reducing device.

5.5.7. For a group of vessels operating at the same pressure, it is allowed to install one reducing device with a pressure gauge and a safety valve on a common supply pipeline up to the first branch to one of the vessels.

In this case, the installation of safety devices on the vessels themselves is optional if the possibility of pressure increase is excluded in them.

5.5.8. In the case when the automatic reducing device cannot work reliably due to the physical properties of the working medium, it is allowed to install a flow regulator. In this case, protection against pressure increase must be provided.

5.5.9. The number of safety valves, their dimensions and throughput must be selected by calculation so that the pressure in the vessel does not exceed the calculated one by more than 0.05 MPa (0.5 kgf / cm 2) for vessels with pressure up to 0.3 MPa (3 kgf / cm 2), by 15% - for vessels with pressure from 0.3 to 6.0 MPa (from 3 to 60 kgf / cm 2) and by 10% - for vessels with pressure over 6.0 MPa ( 60 kgf / cm 2).

When the safety valves are in operation, it is allowed to exceed the pressure in the vessel by no more than 25% of the working pressure, provided that this excess is provided for by the project and is reflected in the vessel passport.

5.5.10. The capacity of the safety valve is determined in accordance with ND.

5.5.11. The safety device must be supplied by the manufacturer with a passport and operating instructions.

In the passport, along with other information, the flow coefficient of the valve for compressible and incompressible media, as well as the area to which it is assigned, must be indicated.

5.5.12. Safety devices must be installed on branch pipes or pipelines directly connected to the vessel.

The connecting pipelines of safety devices (inlet, outlet and drainage) must be protected from freezing of the working medium in them.

When installing several safety devices on one branch pipe (pipeline), the cross-sectional area of the branch pipe (pipeline) must be at least 1.25 of the total cross-sectional area of the valves installed on it.

When determining the cross section of connecting pipelines with a length of more than 1000 mm, it is also necessary to take into account the value of their resistance.

The selection of the working medium from the branch pipes (and in the sections of the connecting pipelines from the vessel to the valves), on which safety devices are installed, is not allowed.

5.5.13. Safety devices must be located in places accessible for their maintenance.

5.5.14. The installation of shut-off valves between the vessel and the safety device, as well as behind it, is not allowed.

5.5.15. The armature in front of (behind) the safety device can be installed provided that two safety devices are installed and blocked, which excludes the possibility of their simultaneous shutdown. In this case, each of them must have the capacity provided for in clause 5.5.9 of the Rules.

When installing a group of safety devices and fittings in front of (behind) them, the blocking must be done in such a way that, in any case of shutting off the valves provided for by the design, the safety devices remaining on have the total throughput provided for in clause 5.5.9 of the Rules.

5.5.16. The discharge pipelines of safety devices and the impulse lines of the IPU in places of possible accumulation of condensate must be equipped with drainage devices to remove condensate.

Installation of locking devices or other fittings on drainage pipelines is not allowed. The medium leaving the safety devices and drains must be discharged to a safe place.

Discharged toxic, explosive and flammable process fluids must be sent to closed systems for further disposal or to organized incineration systems.

Discharges containing substances that are capable of forming explosive mixtures or unstable compounds when mixed are prohibited.

5.5.17. Membrane safety devices are installed:

instead of lever-load and spring safety valves, when these valves cannot be used under the working conditions of a particular medium due to their inertia or other reasons;
in front of safety valves in cases where safety valves cannot work reliably due to the harmful effects of the working medium (corrosion, erosion, polymerization, crystallization, sticking, freezing) or possible leaks through a closed valve explosive and flammable, toxic, environmentally harmful, etc. . substances. In this case, a device should be provided to monitor the health of the membrane;
in parallel with safety valves to increase the capacity of pressure relief systems;
on the outlet side of the safety valves to prevent the harmful effects of working media from the side of the discharge system and to exclude the influence of back pressure fluctuations from this system on the accuracy of the safety valves.

The need and place of installation of membrane safety devices and their design is determined by the design organization.

5.5.18. Safety diaphragms must be marked, and the marking must not affect the accuracy of the diaphragms.

name (designation) or trademark of the manufacturer;
membrane batch number;
membrane type;
conditional diameter;
working diameter;
material;
minimum and maximum diaphragm response pressure in a batch at a given temperature and at a temperature of 20 °C.

The marking should be applied along the edge annular section of the membranes or the membranes should be provided with marking shanks (labels) attached to them.

5.5.19. For each batch of membranes, there must be a passport issued by the manufacturer.

name and address of the manufacturer;
membrane batch number;
membrane type;
conditional diameter;
working diameter;
material;
the minimum and maximum actuation pressure of membranes in a batch at a given temperature and at a temperature of 20 °C;
the number of membranes in the batch;
name of the normative document in accordance with which the membranes are manufactured;
name of the organization, according to the terms of reference (order) of which the membranes were manufactured;
manufacturer's warranty obligations;
procedure for admitting membranes to operation;
sample log of operation of membranes.

The passport must be signed by the head of the manufacturer, whose signature is sealed.

The passport must be accompanied by technical documentation for anti-vacuum supports, clamping and other elements, together with which the membranes of this batch are allowed to operate. Technical documentation is not attached in cases where the membranes are made in relation to the attachment points already available to the consumer.

5.5.20. Safety discs must only be installed in the attachment points intended for them.

The assembly, installation and operation of the membranes must be carried out by specially trained personnel.

5.5.21. Protective membranes of foreign production, manufactured by organizations that are not controlled by the Gosgortekhnadzor of Russia, can be allowed for operation only if there are special permits for the use of such membranes issued by the Gosgortekhnadzor of Russia in the manner prescribed by it.

5.5.22. Membrane safety devices must be placed in places open and accessible for inspection and installation and dismantling, the connecting pipelines must be protected from freezing of the working medium in them, and the devices must be installed on branch pipes or pipelines directly connected to the vessel.

5.5.23. When installing a diaphragm safety device in series with a safety valve (before or behind the valve), the cavity between the diaphragm and the valve must be connected by a drain pipe with a signal pressure gauge (to monitor the health of the diaphragms).

5.5.24. It is allowed to install a switching device in front of the membrane safety devices in the presence of a double number of membrane devices, while ensuring the protection of the vessel from overpressure in any position of the switching device.

5.5.25. The procedure and terms for checking the serviceability of the safety devices, depending on the conditions of the technological process, must be specified in the operating instructions for the safety devices, approved by the owner of the vessel in the prescribed manner.

The results of checking the serviceability of safety devices, information about their settings are recorded in the shift log of the operation of the vessels by the persons performing the specified operations.

5.6. Liquid level gauges

5.6.1. If it is necessary to control the liquid level in vessels with an interface between media, level indicators should be used.

In addition to level indicators, sound, light and other signaling devices and level locks can be installed on vessels.

5.6.2. Liquid level indicators should be installed in accordance with the manufacturer's instructions, and good visibility of this level should be ensured.

5.6.3. On vessels heated by flames or hot gases, in which the liquid level may drop below the permissible level, at least two direct-acting level indicators must be installed.

5.6.4. The design, number and installation locations of level indicators are determined by the developer of the vessel project.

5.6.5. Permissible upper and lower levels must be marked on each liquid level indicator.

5.6.6. The upper and lower allowable liquid levels in the vessel are set by the project developer. The height of the transparent liquid level indicator must be at least 25 mm below the lower and above the upper permissible liquid levels, respectively.

If it is necessary to install several pointers in height, they should be placed so that they provide continuity in readings of the liquid level.

5.6.7. Level gauges must be equipped with fittings (cocks and valves) to disconnect them from the vessel and purge with the removal of the working medium to a safe place.

5.6.8. When used in level gauges as a transparent element of glass or mica, a protective device must be provided to protect personnel from injury when they break.

218. An organization, an individual entrepreneur operating pressure equipment (operating organization) must ensure that pressure equipment is maintained in good condition and safe conditions for its operation.

For these purposes it is necessary:

a) comply with the requirements of the legislation of the Russian Federation in the field of industrial safety of HIFs, other federal laws, as well as these FNP and other regulatory legal acts of the Russian Federation in the field of industrial safety;

b) appoint by order from among the specialists who have passed certification in the field of industrial safety in accordance with paragraph 224 of these FNR, responsible (responsible) for the implementation of production control over the safe operation of pressure equipment, as well as responsible for the good condition and safe operation of pressure equipment. The person responsible for the implementation of production control over the safe operation of pressure equipment cannot combine the duties of the person responsible for the good condition and safe operation of pressure equipment;

c) appoint the required number of personnel (workers) servicing the equipment not younger than eighteen years of age, satisfying the qualification requirements, having no medical contraindications for the specified work and admitted to independent work in the prescribed manner;

d) establish such a procedure that the workers who are entrusted with the maintenance of pressure equipment maintain it in good condition and monitor the pressure equipment assigned to them by inspecting it, checking the operation of valves, instrumentation, safety and blocking devices , signaling and protection means, recording the results of inspection and verification in a removable journal;

e) approve the list of regulatory documents used in the operating organization to ensure industrial safety requirements established by the legislation of the Russian Federation and these FNR;

f) develop and approve instructions for the person responsible for the production control over the safe operation of pressure equipment and responsible for its good condition and safe operation, as well as the production instruction for workers servicing the equipment, developed on the basis of the manual (instruction) for the operation of a particular type of equipment , taking into account the features of the technological process established by the design and technological documentation;

g) provide workers operating pressure equipment with production instructions that define their duties, the procedure for the safe performance of work and responsibility. Production instructions for personnel should be issued against receipt before they are allowed to work;

h) ensure the procedure and frequency of certification in the field of industrial safety of specialists associated with the operation of equipment under pressure, as well as testing the knowledge of workers in the scope of production instructions and their admission to work. For these purposes, appoint an attestation commission from among the managers and chief specialists certified by the Rostechnadzor commission in the manner prescribed by the attestation regulation. The commission for testing the knowledge of workers includes specialists responsible for the good condition and safe operation, who have been certified by the certification commission of the operating organization;

i) ensure that works on technical examination, diagnostics, maintenance and scheduled preventive maintenance of pressure equipment are carried out in accordance with the requirements of these FNR and the work system adopted by the operating organization;

j) comply with the manufacturer's requirements established by the operating manual (instruction), do not allow the operation of faulty (inoperable) equipment under pressure that does not meet industrial safety requirements, in which defects (damage) have been identified that affect the safety of its operation, valves are faulty, control and measuring instruments, safety and blocking devices, signaling and protection means, and also if the period of operation exceeded the service life declared by the manufacturer (period of safe operation) specified in the equipment certificate, without technical diagnostics;

k) monitor the condition of the metal during the operation of pressure equipment in accordance with the requirements of the operating manual (instruction) and these FNR;

l) upon detection of violations of industrial safety requirements, take measures to eliminate them and further prevent them;

m) ensure that an industrial safety review of equipment is carried out at the end of its service life and in other cases provided for by the legislation of the Russian Federation in the field of industrial safety;

n) provide inspection, maintenance, inspection, repair and expert review of industrial safety of buildings and structures intended for the implementation of technological processes using equipment under pressure, in accordance with the requirements of technical regulations, other federal norms and rules in the field of industrial safety.

The number and date of the order on the appointment of a person responsible for the good condition and safe operation of the equipment must be recorded in the equipment passport.

219. Carrying out scheduled preventive repairs, to ensure the maintenance of pressure equipment in good (operating) condition and to prevent the risk of accidents, the operating organization shall carry out by means of its own divisions and (or) with the involvement of specialized organizations. The scope and frequency of work on the repair and maintenance of pressure equipment and its elements is determined by the schedule approved by the technical manager of the operating organization, taking into account the requirements specified in the operating manuals (instructions), as well as information on the current state of the equipment obtained from the results of technical surveys ( diagnostics) and operational control during the operation of equipment under pressure.

220. The operating organization that carries out work on the repair, reconstruction (modernization) and adjustment of equipment in operation must include a specialized division (divisions) that meets the relevant requirements specified in Section III of these FNR.

221. Workers directly involved in the operation of pressure equipment should:

a) undergo certification (specialists) in industrial safety in accordance with the established procedure, including testing knowledge of the requirements of these FNR (depending on the type of specific equipment for which they are allowed to operate), and not violate industrial safety requirements in the course of work;

b) meet the qualification requirements (workers) and have a certificate issued in accordance with the established procedure for the right to work independently in the relevant types of activity and not violate the requirements of production instructions;

c) know the performance criteria of the pressure equipment in operation, monitor compliance with the technological process and suspend the operation of the equipment in the event of a threat of an emergency, informing his/her immediate supervisor about this;

d) upon detection of damage to the pressure equipment, which can lead to an emergency or indicate an inoperable state of the equipment, do not start work until the pressure equipment is brought into working condition;

e) do not start work or stop working in conditions that do not ensure the safe operation of pressure equipment, and in cases where deviations from the technological process and an unacceptable increase (decrease) in the parameters of pressure equipment operation are detected;

f) act in accordance with the requirements established by the instructions in cases of accidents and incidents during the operation of pressure equipment.

222. The number of responsible persons specified in subparagraph "b" of paragraph 218 of these FNR, and (or) the number of production control service and its structure must be determined by the operating organization, taking into account the type of equipment, its quantity, operating conditions and the requirements of operational documentation, based on calculation of the time required for the timely and high-quality performance of the duties assigned to responsible persons by job descriptions and administrative documents of the operating organization.

The operating organization must create conditions for the responsible specialists to fulfill their duties.

223. Responsibility for the good condition and safe operation of pressure equipment should be assigned to specialists with technical professional education, who are directly subordinate to specialists and workers who provide maintenance and repair of this equipment, for which, taking into account the structure of the operating organization, specialists responsible for the good condition of the pressure equipment and the specialists responsible for its safe operation.

For the period of vacation, business trip, illness or in other cases of absence of responsible specialists, the fulfillment of their duties is assigned by order to employees replacing them in their positions, having the appropriate qualifications, who have passed industrial safety certification in the prescribed manner.

224. Certification of specialists responsible for the good condition and safe operation of pressure equipment, as well as other specialists whose activities are related to the operation of pressure equipment, is carried out in the certification commission of the operating organization in accordance with the regulation on certification, while participation in the work of this commission a representative of the territorial body of Rostekhnadzor is not required. Periodic certification of responsible specialists is carried out once every five years.

The certification commission of the operating organization must include a specialist responsible for the production control over the safe operation of pressure equipment, certified in accordance with the regulation on certification.

225. The specialist responsible for the implementation of production control over the safe operation of pressure equipment must:

a) inspect equipment under pressure and check compliance with the established modes during its operation;

b) exercise control over the preparation and timely presentation of pressure equipment for examination and keep records of pressure equipment and records of its surveys in paper or electronic form;

c) exercise control over compliance with the requirements of these FNR and the legislation of the Russian Federation in the field of industrial safety during the operation of pressure equipment, if violations of industrial safety requirements are detected, issue mandatory instructions to eliminate violations and monitor their implementation, as well as the implementation of instructions issued by a representative of Rostekhnadzor and other authorized bodies;

d) control the timeliness and completeness of the repair (reconstruction), as well as compliance with the requirements of these FNP during repair work;

e) check compliance with the established procedure for the admission of workers, as well as the issuance of production instructions to them;

f) check the correctness of maintaining technical documentation during the operation and repair of pressure equipment;

g) participate in surveys and surveys of pressure equipment;

h) demand suspension from work and conduct an extraordinary knowledge test for employees who violate industrial safety requirements;

i) supervise the conduct of emergency drills;

j) comply with other requirements of the documents defining his job responsibilities.

226. The specialist responsible for the good condition and safe operation of pressure equipment must:

a) ensure the maintenance of pressure equipment in good (operable) condition, the maintenance of production instructions by maintenance personnel, timely repairs and preparation of equipment for technical examination and diagnostics;

b) inspect pressure equipment with the frequency established by the job description;

c) check entries in a shift journal with a signature in it;

d) store passports of pressure equipment and manuals (instructions) of manufacturers for installation and operation, unless a different procedure for storing documentation is established by the administrative documents of the operating organization;

e) participate in surveys and technical examinations of pressure equipment;

f) conduct emergency drills with service personnel;

g) timely comply with the instructions to eliminate the identified violations;

h) keep records of the operating time of loading cycles of equipment under pressure, operated in a cyclic mode;

i) comply with other requirements of the documents defining his official duties.

227. Vocational training and final certification of workers with the assignment of qualifications should be carried out in educational organizations, as well as at courses specially created by operating organizations in accordance with the requirements of the legislation of the Russian Federation in the field of education. The procedure for checking knowledge on safe methods of performing work and admitting to independent work is determined by the administrative documents of the operating organization.

228. Periodic testing of the knowledge of personnel (workers) servicing equipment under pressure should be carried out once every 12 months. An extraordinary knowledge test is carried out:

a) upon transfer to another organization;

b) when replacing, reconstructing (modernizing) equipment, as well as making changes to the technological process and instructions;

c) in the case of transferring workers to service boilers of another type, as well as when transferring the boiler they serve to burning another type of fuel.

The commission for checking the knowledge of workers is appointed by order of the operating organization, participation in its work of a representative of Rostekhnadzor is optional.

The results of testing the knowledge of the service personnel (workers) are drawn up in a protocol signed by the chairman and members of the commission with a mark in the certificate of admission to independent work.

229. Before the initial admission to independent work after vocational training, before admission to independent work after an extraordinary test of knowledge provided for in paragraph 228 of these FNR, as well as during a break in work in the specialty for more than 12 months, the service personnel (workers) after testing the knowledge must pass internship for the acquisition (recovery) of practical skills. The internship program is approved by the management of the operating organization. The duration of the internship is determined depending on the complexity of the process and pressure equipment.

The admission of personnel to independent maintenance of pressure equipment must be issued by an order (instruction) for the workshop or organization.

Requirements for the operation of boilers

230. The boiler room must have a clock and a telephone for communication with consumers of steam and hot water, as well as with the technical services and administration of the operating organization. During the operation of waste heat boilers, in addition, a telephone connection must be established between the control panels of waste heat boilers and heat sources.

231. Persons who are not related to the operation of boilers and pressure equipment should not be allowed into buildings and premises in which boilers are operated. In necessary cases, unauthorized persons may be admitted to these buildings and premises only with the permission of the operating organization and accompanied by its representative.

232. It is forbidden to entrust specialists and workers on duty to maintain boilers to perform any other work during the operation of the boiler that is not provided for in the production instruction for the operation of the boiler and technological auxiliary equipment.

233. It is forbidden to leave the boiler without constant supervision by the service personnel both during the operation of the boiler and after it has been stopped until the pressure in it drops to a value equal to atmospheric pressure.

It is allowed to operate boilers without constant monitoring of their work by the maintenance personnel in the presence of automation, alarms and protections that provide:

a) maintaining the project mode of operation;

b) liquidation of emergency situations;

c) stopping the boiler in case of violations of the operating mode, which can cause damage to the boiler.

234. Sections of elements of boilers and pipelines with an elevated surface temperature, with which direct contact of service personnel is possible, must be covered with thermal insulation providing an outer surface temperature of not more than 55 ° C at an ambient temperature of not more than 25 ° C.

235. When operating boilers with cast-iron economizers, it is necessary to ensure that the temperature of the water at the outlet of the cast-iron economizer is at least 20°C lower than the saturated steam temperature in the steam boiler or the vaporization temperature at the existing operating water pressure in the boiler.

236. When burning fuel in boilers, the following must be ensured:

a) uniform filling of the firebox with a torch without throwing it on the walls;

b) exclusion of the formation of stagnant and poorly ventilated zones in the volume of the furnace;

c) stable combustion of fuel without separation and flashover of the flame in a given range of operating modes;

d) exclusion of liquid fuel droplets falling on the floor and walls of the furnace, as well as the separation of coal dust (unless special measures are provided for its afterburning in the volume of the furnace). When burning liquid fuels, it is necessary to install pallets with sand under the nozzles to prevent fuel from falling on the floor of the boiler room.

Heating oil or natural gas must be used as starting fuel for kindling devices of pulverized coal burners.

It is allowed to use other types of liquid fuels with a flash point of at least 61°C.

The use of flammable fuels as kindling is not allowed.

237. During operation, it is necessary to monitor the uniform distribution of the load and control the condition of the elements of the suspension system, as well as to ensure the adjustment of the tension of the suspensions after installation and during the operation of the boiler in the manner prescribed by the operating manual (instruction).

238. The selection of the medium from the branch pipe or pipeline connecting the safety device with the protected element is not allowed.

239. The installation of shut-off devices on the steam supply to the valves and on the pipelines between the pulse and main valves of the pulse safety devices is prohibited.

240. Water level indicators of direct action, installed vertically or with an inclination forward at an angle of not more than 30 °, must be located and illuminated so that the water level is clearly visible from the workplace of the personnel servicing the boilers.

To protect personnel from destruction of transparent plates on boilers with a pressure of more than 4 MPa, it is necessary to control the presence and integrity of the protective cover on direct-acting water level indicators.

241. If the distance from the site from which the water level in the steam boiler is monitored to direct-acting water level indicators is more than 6 m, and also in cases of poor visibility of the instruments, two lowered remote level indicators should be installed. In this case, it is allowed to use one direct-acting water level indicator on the boiler drums.

Reduced remote level gauges must be connected to the boiler drum on separate fittings, regardless of other water level gauges and have damping devices.

For waste heat boilers and power-technological boilers, readings of remote level indicators must be displayed on the boiler control panel.

242. If the design of the boiler (in justified cases) instead of direct action level indicators (with water-indicating glass) provides for level indicators of a different design (magnetic level indicator) or their installation was carried out during the reconstruction (modernization) of the boiler, then instructions must be included in the production instruction, provided for by the manual (instruction) for the operation of the boiler or project documentation for reconstruction (modernization), according to the procedure for servicing the installed level indicator and taking its readings, taking into account corrections for the error of its readings.

243. The pressure gauge scale is chosen based on the condition that at operating pressure the pressure gauge needle should be in the second third of the scale.

The scale of the pressure gauge should be marked with a red line at the division level corresponding to the working pressure for this element, taking into account the additional pressure from the weight of the liquid column.

Instead of a red line, it is allowed to attach a plate made of metal (or other material of appropriate strength), painted red and tightly adjacent to the glass of the pressure gauge, to the pressure gauge body.

The pressure gauge must be installed so that its readings are clearly visible to the maintenance personnel, while its scale must be located vertically or tilted forward up to 30 ° to improve the visibility of the readings.

The nominal diameter of manometers installed at a height of up to 2 m from the level of the manometer observation platform must be at least 100 mm; installed at a height of 2 to 5 m - not less than 160 mm; installed at a height of more than 5 m - not less than 250 mm. When installing a pressure gauge at a height of more than 5 m, a reduced pressure gauge must be installed as a backup.

244. A three-way valve or other similar device must be installed in front of each pressure gauge for purging, checking and shutting off the pressure gauge; in front of the manometer intended for measuring steam pressure, in addition, there must be a siphon tube with a nominal diameter of at least 10 mm.

On boilers with a pressure of 4 MPa and above, valves must be installed that allow you to disconnect the pressure gauge from the boiler, ensure its communication with the atmosphere and purge the siphon tube.

245. When operating boilers, the following must be ensured:

a) reliability and safety of operation of all main and auxiliary equipment;

b) the possibility of achieving the nominal steam output of boilers, parameters and quality of steam and water;

c) the mode of operation established on the basis of commissioning and operational tests and the manual (instruction) for operation;

d) load regulation range determined for each type of boiler and type of fuel burned;

e) change in the steam output of boilers within the control range under the influence of automation devices;

e) minimum allowable loads.

246. Newly commissioned steam boilers with a pressure of 10 MPa and above after installation must be subjected to cleaning together with the main pipelines and other elements of the water-steam path. The cleaning method is indicated in the operating manual (instructions). Boilers with a pressure below 10 MPa and hot water boilers must be alkalized or otherwise cleaned in accordance with the instructions in the operating manual (instruction) before commissioning.

247. Before starting the boiler after repair, the serviceability and readiness to turn on the main and auxiliary equipment, instrumentation, remote and automatic control devices, technological protection devices, interlocks, information and operational communications should be checked. The malfunctions revealed at the same time must be eliminated before start-up.

Before starting the boiler after being in reserve for more than three days, the following must be checked:

a) operability of equipment, instrumentation, remote and automatic control devices, technological protection devices, interlocks, information and communication tools;

b) passing of technological protection commands to all actuating devices;

c) serviceability and readiness to turn on those devices and equipment on which repairs were carried out during the downtime.

The malfunctions revealed at the same time must be eliminated before the boiler is started.

In the event of a malfunction of the safety interlocks and protection devices that act to stop the boiler, its start-up is not allowed.

248. Starting and stopping the boiler can only be carried out at the direction of a specialist responsible for the good condition and safe operation, with a corresponding entry about this in the operational log in the manner prescribed by production instructions and regime cards. All personnel associated with the operation of the boiler being started are notified of the start time.

249. Before kindling, the drum boiler must be filled with chemically purified and deaerated feed water, while the quality of the water must comply with the requirements of these FNP and the operating manual (instruction).

In the absence of a deaeration plant in the boiler room, it is allowed to fill cast iron boilers with chemically purified water.

The once-through boiler must be filled with feed water, the quality of which must comply with the operating instructions, depending on the feed water treatment scheme.

250. Filling an uncooled drum boiler is permitted at a metal temperature of the top of the empty drum not higher than 160°C.

251. Filling a once-through boiler with water, removing air from it, as well as operations during flushing of impurities must be carried out in the area up to the valves built into the boiler duct in the separator firing mode or along the entire tract in the direct-flow firing mode.

The starting water flow must be equal to 30% of the nominal flow. Another value of the ignition flow can only be determined by the manufacturer's operating manual (instruction) or by the operating instructions adjusted on the basis of test results.

252. The consumption of network water before kindling a hot water boiler must be established and maintained in further operation not lower than the minimum allowable, determined by the manufacturer for each type of boiler.

253. When kindling once-through boilers of block installations, the pressure in front of the valves built into the boiler duct must be maintained at the level of 12-13 MPa for boilers with an operating pressure of 14 MPa and 24-25 MPa for boilers for supercritical pressure.

Changes to these values or sliding pressure fire-up are permitted by agreement with the manufacturer on the basis of special tests.

254. Before kindling and after stopping the boiler, the furnace and gas ducts, including recirculation ones, must be ventilated with smoke exhausters, draft fans and recirculation smoke exhausters with open dampers of the gas-air path for at least 10 minutes with an air flow rate of at least 25% of the nominal, unless otherwise specified by the manufacturer or adjustment organization.

Ventilation of pressurized boilers, hot water boilers in the absence of smoke exhausters should be carried out by blow fans and recirculation smoke exhausters.

Before kindling the boilers from the uncooled state, with the remaining excess pressure in the steam-water path, ventilation should begin no earlier than 15 minutes before the burners are ignited.

255. Before firing up a gas-fired boiler, the tightness of the closure of the shut-off valves in front of the burners must be checked in accordance with the regulations in force.

If there are signs of gas pollution in the boiler room, switching on electrical equipment, kindling the boiler, as well as using open fire is not allowed.

256. When kindling boilers, a smoke exhauster and a blower fan must be turned on, and when kindling boilers, the operation of which is designed without smoke exhausters, a blower fan.

257. From the moment the boiler is kindled, control over the level of water in the drum must be organized.

Purge of the upper water-indicating devices should be carried out:

a) for boilers with a pressure of 4 MPa and below - at an excess pressure in the boiler of 0.1 MPa and before being included in the main steam pipeline;

b) for boilers with a pressure above 4 MPa - at an excess pressure in the boiler of 0.3 MPa and at a pressure of 1.5-3.0 MPa.

Reduced water level indicators must be checked with water-indicating devices during the kindling process (subject to amendments).

258. The kindling of the boiler from various thermal states must be carried out in accordance with the start-up schedules drawn up on the basis of the manufacturer's operating manual (instruction) and the results of tests of starting modes.

259. In the process of kindling the boiler from a cold state after repair, but at least once a year, the thermal movement of screens, drums, steam pipelines and collectors should be checked against benchmarks.

260. If, prior to the start-up of the boiler, work was carried out on it related to the dismantling of flange connections and hatches, then at an excess pressure of 0.3-0.5 MPa, bolted connections must be tightened.

Tightening of bolted connections with higher pressure is not allowed.

261. When kindling and stopping boilers, control over the temperature regime of the drum should be organized. The rate of heating and cooling of the lower generatrix of the drum and the temperature difference between the upper and lower generatrix of the drum must not exceed the values established by the manual (instruction) for operation.

For boilers with pressures above 10 MPa, the above parameters must not exceed the following allowable values:

a) heating rate during boiler kindling, °С/10 min - 30;

b) cooling rate when the boiler is stopped, °C/10 min - 20;

c) temperature difference during boiler kindling, °С - 60;

d) temperature difference during boiler shutdown, °С - 80.

On all types of boilers, accelerated cooldown is not allowed.

262. The inclusion of the boiler in the common steam pipeline must be made after draining and warming up the connecting steam pipeline. The steam pressure behind the boiler when switched on must be equal to the pressure in the common steam pipeline.

263. Switching to the combustion of solid fuel (starting to supply dust to the furnace) on boilers operating on fuel with a volatile yield of less than 15% is permitted if the heat load of the furnace on pilot fuel is not lower than 30% of the nominal value. When operating on fuels with a volatile yield of more than 15%, it is allowed to supply dust at a lower thermal load, which must be established by the production instructions, based on ensuring stable dust ignition.

When starting the boiler after a short-term downtime (up to 30 minutes), it is allowed to switch to burning solid fuel with a volatile yield of less than 15% at a furnace heat load of at least 15% of the nominal value.

264. The mode of operation of the boiler must strictly comply with the mode map drawn up on the basis of equipment testing and operating instructions. In the case of reconstruction (modernization) of the boiler and a change in the brand and quality of fuel, commissioning or regime adjustment should be carried out with the preparation of a report and a new regime map.

265. During the operation of the boiler, thermal conditions must be observed that ensure the maintenance of permissible steam temperatures in each stage and each flow of the primary and intermediate superheaters.

266. When the boiler is operating, the upper limit level of water in the drum must not be higher, and the lower limit level not lower than the levels established on the basis of the data of the manual (instruction) for the operation and testing of the equipment.

267. The heating surfaces of boiler installations on the gas side must be kept in an operationally clean condition by maintaining optimal modes and using mechanized integrated cleaning systems (steam, air or water apparatus, pulse cleaning devices, vibration cleaning, shot cleaning). The devices intended for this, as well as the means of remote and automatic control of them, must be in constant readiness for action.

The frequency of cleaning of heating surfaces should be regulated by a schedule or manual (instruction) for operation.

268. When operating boilers, all working draft machines must be switched on. Long-term operation when turning off part of the draft machines (if it is specified in the operation manual (instruction) and regime map) is allowed provided that a uniform gas-air and thermal regime is ensured on the sides of the boiler. At the same time, the uniform distribution of air between the burners must be ensured and the overflow of air (gas) through the stopped fan (exhaust fan) must be excluded.

269. On steam boilers burning fuel oil with a sulfur content of more than 0.5% as the main fuel, in the control range of loads, its combustion should be carried out at excess air coefficients at the outlet of the furnace less than 1.03, unless otherwise established by the production instruction. At the same time, it is necessary to fulfill the established set of measures to transfer boilers to this mode (fuel preparation, the use of appropriate designs of burners and nozzles, sealing the furnace, equipping the boiler with additional control devices and means of automating the combustion process).

270. Oil nozzles should be tested on a water bench before being installed in the workplace in order to check their performance, spray quality and flame opening angle. The difference in the nominal output of individual nozzles in a set installed on an oil-fired boiler should be no more than 1.5%. Each boiler must be provided with a spare set of nozzles.

The operation of fuel oil nozzles without an organized air supply to them, as well as the use of non-calibrated nozzles, is not allowed.

When operating the nozzles and steam oil pipelines of the boiler room, conditions must be met that exclude the ingress of fuel oil into the steam pipeline.

271. The lining of boilers must be in good condition, have no visible damage (cracks, deformations), ensure the density of the furnace and the temperature on the surface of the lining, not exceeding the value established by the designer of the boiler project and specified by the manufacturer in the operating manual (instruction).

272. The furnace and the entire gas path of the boilers must be tight. Air suction into the furnace and into the gas path before leaving the superheater for steam oil-fired boilers with a steam output of up to 420 t/h should be no more than 5%, for boilers with a steam output above 420 t/h - 3%, for pulverized coal boilers - 8 and 5%, respectively .

Furnaces and flues with all-welded screens must be suction-free.

Suction in the gas path in the area from the entrance to the economizer (for pulverized-coal boilers - from the entrance to the air heater) to the exit from the smoke exhauster should be (excluding ash collectors) with a tubular air heater no more than 10%, and with a regenerative one - no more than 25%.

Suctions into the furnace and gas path of hot water gas-oil boilers should be no more than 5%, pulverized coal (excluding ash collectors) - no more than 10%.

Air suction in electrostatic precipitators should be no more than 10%, and in ash collecting plants of other types - no more than 5%.

Suction rates are given as a percentage of the theoretically required amount of air for the nominal load of the boilers.

273. The density of the enclosing surfaces of the boiler and gas ducts, including the serviceability of explosive valves (if any), must be monitored by inspection and determination of air suction at the intervals established in the production instructions, but at least once a month. Suckers in the furnace must also be determined instrumentally at least once a year, as well as before and after repairs. Leaks in the furnace and flues of the boiler must be eliminated.

274. Checking the serviceability of the operation of pressure gauges, safety valves, water level indicators and feed pumps should be carried out within the following periods:

a) for boilers with operating pressure up to 1.4 MPa inclusive - at least once per shift;

b) for boilers with operating pressure over 1.4 to 4.0 MPa inclusive - at least once a day (except for boilers installed at thermal power plants);

c) for boilers installed at thermal power plants, according to the instructions in accordance with the schedule approved by the technical manager (chief engineer) of the power plant.

The results of the check are recorded in the shift log.

275. The serviceability of the pressure gauge is checked using a three-way valve or shut-off valves replacing it by setting the pressure gauge needle to zero.

At least once every 12 months (unless other periods are established by the documentation for a specific type of pressure gauge), pressure gauges must be verified in the prescribed manner.

Pressure gauges are not allowed to be used in the following cases:

a) if there is no seal or brand on the pressure gauge with a mark on the verification;

b) if the period for checking the pressure gauge has expired;

c) if the arrow of the pressure gauge, when it is turned off, does not return to the zero mark of the scale by an amount exceeding half of the permissible error for this pressure gauge;

d) if the glass is broken or there are other damages to the pressure gauge, which may affect the correctness of its readings.

276. Checking water level indicators is carried out by blowing them. The serviceability of the reduced level indicators is checked by reconciling their readings with the readings of direct-acting water level indicators.

277. The serviceability of safety valves is checked by their forced short-term opening (undermining).

278. Checking the serviceability of standby feed pumps is carried out by putting them into operation for a short time.

279. Checking the serviceability of the alarm and automatic protections should be carried out in accordance with the schedule and instructions approved by the technical manager (chief engineer) of the operating organization (separate subdivision).

280. On the valve flywheels, the designations of the direction of rotation must be preserved when opening and closing the valve.

281. Operational tests of the boiler to draw up a regime map and adjust the operating instructions should be carried out when putting it into operation, after making design changes, when switching to another type or brand of fuel, and also to find out the reasons for the deviation of parameters from the specified values.

The boilers must be equipped with the necessary devices for performance testing.

282. When the boiler is taken into reserve or repair, measures must be taken to preserve the heating surfaces of the boiler and heaters in accordance with the current guidelines for the conservation of heat and power equipment.

At the end of the heating season, boilers and heating networks are preserved if there is no need for repairs. Before and after repairs, measures must be taken to preserve the equipment.

At the end of the heating season or during a shutdown, hot water boilers and heating systems are mothballed. The preservation methods are chosen by the owner, based on local conditions, based on the recommendations of the current guidelines for the conservation of heat and power equipment, the manual (instruction) for the operation of the boiler and included in the conservation instructions approved by the technical manager of the operating organization. When hot water boilers are put into operation, as well as before the start of the heating season, heating networks and internal heat consumption systems are pre-washed.

283. Internal deposits from the heating surfaces of boilers must be removed by washing with water during crushing and shutdowns or during cleaning. Cleaning methods are indicated in the operating manual (instruction).

The frequency of chemical cleaning should be determined by the operating manual (instruction) taking into account the results of a quantitative analysis of internal deposits.

284. Feeding a stopped boiler with water drainage in order to accelerate the cooling of the drum is not allowed.

285. The discharge of water from a stopped steam boiler with natural circulation is permitted after the pressure in it is reduced:

a) up to 1 MPa - for power boilers operated at thermal power plants;

b) up to atmospheric pressure - for other boilers.

If there are rolling joints in the stopped boiler, it is allowed to drain water from it at a water temperature not higher than 80°C.

It is allowed to drain water from a stopped once-through boiler at a pressure above atmospheric, the upper limit of this pressure must be set by the operating manual (instruction), depending on the drainage system and expanders.

It is allowed to drain water from the boiler after cooling the water in it to a temperature equal to the temperature of the water in the return pipeline, but not higher than 70°C.

When the boilers of block power plants are stopped, the intermediate superheater must be deevaporated into the turbine condenser.

286. When the boiler is put into reserve, after ventilation of the furnace and gas ducts for a period of time of at least 15 minutes, the draft machines (devices) must be stopped. All shut-off gates on gas ducts, manholes and hatches, as well as guide vanes of draft machines (devices) must be tightly closed.

287. In winter, a boiler that is in reserve or under repair must be monitored for air temperature.

If the air temperature in the boiler room (or the outside temperature in an open layout) is below 0°C, measures must be taken to maintain positive air temperatures in the furnace and gas ducts, in shelters near the drum, in the areas of purge and drainage devices, heaters, impulse lines and sensors instrumentation, water heating in boilers or its circulation through the screen system should also be organized.

288. The mode of cooldown of boilers after shutdown when taking them out for repair must be determined by the operating manual (instruction). Cooling down boilers with natural circulation by draft machines is permitted provided that the allowable temperature difference between the metal between the upper and lower generatrices of the drum is ensured. Modes with and without maintaining the water level in the drum are allowed.

Cooling down once-through boilers can be carried out immediately after shutdown.

289. Supervision of the personnel on duty over the stopped boiler must be organized until the pressure in it is completely reduced and the voltage is removed from the electric motors; control over the temperature of gas and air in the area of the air heater and flue gases can be stopped no earlier than 24 hours after the shutdown.

290. When boilers operate on solid or gaseous fuels, when fuel oil is a reserve or starting fuel, the schemes of fuel oil management and fuel oil pipelines must be in a condition that ensures the immediate supply of fuel oil to the boilers.

291. In the event of a rupture of the fuel oil or gas pipeline within the boiler room or strong leakages of fuel oil (gas), all measures must be taken to prevent the outflow of fuel through damaged areas, up to turning off the fuel oil pump and closing the shut-off valves at the gas distribution point, as well as to prevent fire or explosion .

292. In order to ensure the operation of the boiler and the feed duct without damage to their elements due to deposits of scale and sludge, an increase in the relative alkalinity of boiler water to dangerous limits or as a result of metal corrosion, the operating organization must maintain a water-chemical mode of operation of boilers, including pre-boiler and in-boiler treatment water, regulate the quality of boiler water, as well as provide chemical control over compliance with the water chemistry regime.

Steam boilers with natural and multiple forced circulation with a steam capacity of 0.7 t/h or more, once-through steam boilers regardless of steam capacity, as well as hot water boilers must be equipped with pre-boiler water treatment plants.

It is also allowed to use other effective water treatment methods that guarantee the operation of the boiler and the feed path without the above damage.

To ensure the safety of boilers with a steam output of less than 0.7 t / h, such a period between cleanings should be set so that the thickness of deposits on the most heat-stressed areas of the heating surface of the boiler does not exceed 0.5 mm by the time it is stopped for cleaning.

The technology and methods of pre-boiler and intra-boiler water treatment are determined by the design documentation based on the recommendations of the project developer and the boiler manufacturer, established by the manual (instruction) for the operation of the boiler, and also taking into account the features of the technological process for which the boiler is used.

293. Feeding of boilers equipped with devices for pre-boiler water treatment with raw water is not allowed.

In cases where the project provides for the boiler to be fed with raw water in emergency situations, two shut-off valves and a control valve between them must be installed on the raw water lines connected to the lines of softened additional water or condensate, as well as to the feed tanks. During normal operation, the shut-off elements must be in the closed position and be sealed, and the control valve must be open.

Each case of feeding the boilers with raw water must be recorded in the water treatment log (water-chemical regime), indicating the duration of the feeding and the quality of the feed water during this period. At the same time, the boilers must operate at reduced temperature parameters with the temperature of the coolant at the outlet of the boiler not exceeding 60°C.

294. Pre-boiler and intra-boiler water treatment, water quality regulation is carried out according to instructions and regime maps for maintaining the water-chemical regime developed by commissioning organizations, and must ensure the quality of feed, boiler, make-up and network water in accordance with the standards established by the developer of project documentation, the manufacturer of the boiler and Appendix No. 3 to these FNP.

The operation of pre-boiler water treatment plants is carried out according to production instructions developed on the basis of the operating manuals (instructions) for the operation of organizations - manufacturers of plants, taking into account the requirements of design and technological documentation.

Instructions and regime cards must be approved by the head of the operating organization and be at the workplaces of the personnel.

295. Chemical control during the operation of boilers must ensure:

a) timely detection of violations of the operating modes of water treatment, heat power and heat supply equipment, leading to corrosion, scale formation and deposits;

b) determination of the quality (composition) of water, steam, condensate, sediments, reagents, preservative and washing solutions, fuel, slag, ash, gases, oils and wastewater.

296. The frequency of sampling of source, chemically treated, boiler, network, feed and make-up water, condensate and steam is established by the commissioning organization depending on the type of boiler equipment, its mode of operation and the quality of source and feed water and the water treatment scheme.

297. On the basis of internal inspections of boilers and auxiliary equipment, sampling of deposits, cutting out pipe samples (if necessary), reports are drawn up on the condition of the internal surface, on the need for operational cleaning and other measures to prevent corrosion and deposits.

298. The operating organization must ensure timely repair of boilers according to the approved schedule of preventive maintenance.

A repair log must be kept for each boiler, in which the person responsible for the good condition and safe operation of the boiler enters information about the repair work performed, the materials used, welding and welders, about stopping the boilers for cleaning and washing. Replacement of pipes, rivets and rolling of pipe connections with drums and headers should be noted on the pipe (rivet) layout attached to the repair log. The repair log also reflects the results of the inspection of the boiler before cleaning, indicating the thickness of scale and sludge deposits and all defects identified during the repair period.

299. Prior to the start of work inside the drum or collector of the boiler, connected to other operating boilers by pipelines (steam pipeline, feed, drainage, drain lines), as well as before internal inspection or repair of pressure elements, the boiler must be disconnected from all pipelines with plugs if flanged fittings are installed on them.

If the fittings of the steam and water pipelines are flangeless, the boiler must be switched off by two shut-off devices with a drainage device between them with a nominal diameter of at least 32 mm, which has a direct connection to the atmosphere. Valve drives, as well as open drain valves and emergency drain lines from the drum, must be locked so that there is no possibility of weakening their tightness when the lock is locked. The keys to the locks must be kept by the person responsible for the good condition and safe operation of the boiler, unless the company has established a different procedure for their storage.

300. The thickness of the plugs used to turn off the boiler is set based on the strength calculation. The plug must have a protruding part (shank), by which its presence is determined. When installing gaskets between the flanges and the plug, the gaskets must be without shanks.

301. The admission of people into the boiler, as well as the opening of the shut-off valves after the removal of people from the boiler, must be carried out only with a written permit (together with a permit) issued in the manner prescribed by the administrative documents of the operating organization.

Requirements for the operation of pressure vessels

302. The operation of pressure vessels must be carried out in accordance with the production instructions developed and approved by the management of the operating organization on the mode of operation and safe maintenance of vessels. In particular, the instructions should regulate:

a) vessels covered by the instruction, their purpose;

b) the duties of the personnel on duty to monitor and control the operation of the vessel;

c) the procedure for checking the serviceability of the serviced vessels and related equipment in working condition;

d) the procedure, terms and methods for checking fittings, safety devices, automatic protection and signaling devices;

e) the procedure for starting up and stopping (stopping work) of the vessel;

f) safety measures when equipment is taken out for repair, as well as additional safety measures for vessels with a working medium of group 1 (in accordance with TR CU 032/2013);

g) cases requiring an immediate stop of the vessel, provided for by these FNR, as well as others, due to the specifics of the operation of the vessel. The procedure for emergency shutdown and pressure reduction to atmospheric pressure is set depending on the specific scheme for switching on the vessel and the technological process;

h) actions of personnel in case of emergency response;

i) the procedure for maintaining a shift log (registration of the acceptance and delivery of duty, verification of the record by a person responsible for the good condition and safe operation of the vessel).

303. The production instructions for the mode of operation and safe maintenance of autoclaves with quick-release lids should additionally include instructions on:

a) the procedure for using the key-mark and the lock;

b) allowable rates of heating and cooling of the autoclave and methods of their control;

c) the procedure for monitoring the thermal movements of the autoclave and monitoring the absence of pinching of the movable supports;

d) control over the continuous removal of condensate.

304. The management of the operating organization must approve the scheme for switching on the vessel, indicating: pressure source; parameters; working environment; fittings, control and measuring devices, means of automatic control; safety and blocking devices. Schemes for switching on vessels should be at the workplace.

305. When operating vessels heated by hot gases, it is necessary to ensure reliable cooling of the walls under pressure, preventing the wall temperature from exceeding the permissible values.

306. In order to exclude the possibility of putting into operation vessels (autoclaves) with quick-release lids when the lid is not completely closed and opened when there is pressure in the vessel, it is necessary to equip such vessels with locks with a brand key. The order of storage and use of the key-mark should be reflected in the production instructions for the mode of operation and safe maintenance of vessels.

307. When operating a vessel with a working pressure of up to 2.5 MPa, it is necessary to use direct-acting pressure gauges with an accuracy class of at least 2.5, and at an operating pressure of more than 2.5 MPa, the accuracy class of the pressure gauges used must be at least 1.5.

308. On the pressure gauge scale, the owner of the vessel must put a red line indicating the working pressure in the vessel. Instead of a red line, it is allowed to attach a plate (made of metal or other material of sufficient strength) to the pressure gauge body, painted red and tightly adjacent to the pressure gauge glass.

The pressure gauge must be selected with such a scale that the working pressure measurement limit is in the second third of the scale.

309. The installation of a pressure gauge on a vessel must ensure that its readings are clearly visible to the maintenance personnel.

The nominal diameter of the case of pressure gauges installed at a height of up to 2 m from the level of the observation site for them must be at least 100 mm, at a height of 2 to 3 m - at least 160 mm.

Installation of pressure gauges at a height of more than 3 m from the level of the site is not allowed.

310. To periodically check the working pressure gauge, it is necessary to install a three-way valve or a device replacing it between the pressure gauge and the vessel.

Pressure gauges and pipelines connecting them to the vessel must be protected from freezing.

311. Instead of a three-way valve on vessels operating under pressure above 2.5 MPa or at a medium temperature above 250°C, as well as with a medium belonging to group 1 (in accordance with TR TS 032/2013), it is allowed to install a separate fitting with shut-off device for connecting a second pressure gauge.

The installation of a three-way valve or a device replacing it is optional if it is possible to check the pressure gauge in a timely manner by removing it from a stationary vessel.

312. Manometers are not allowed to be used on vessels in the following cases, if:

313. Verification of pressure gauges with their sealing or branding must be carried out at least once every 12 months, unless other terms are established in the documentation for the pressure gauge. The service personnel must check the serviceability of the pressure gauge using a three-way valve or shut-off valves replacing it by setting the pressure gauge pointer to zero. The procedure and terms for checking the serviceability of pressure gauges by maintenance personnel during the operation of vessels must be determined by the production instruction on the mode of operation and safe maintenance of vessels, approved by the management of the operating organization.

314. When operating vessels operating at varying wall temperatures, it is necessary to monitor compliance with the requirements for the permissible rates of heating and cooling of vessels, which (if such control is necessary) are indicated in the operating manual (instruction).

315. Check of serviceability of action of the spring safety valve is carried out by:

a) inspection of its forced opening during operation of the equipment at intervals established in the production instructions for the operation of safety valves;

b) checking the operation of the valve on the stands, if the forced opening of the valve is undesirable either due to the properties of the working environment (explosive, combustible, toxic), or according to the conditions of the technological process.

When operating a spring-loaded safety valve, its spring must be protected from inadmissible heating (cooling) and direct exposure to the working medium, if it has a harmful effect on the spring material.

316. The installation of a pressure gauge and a safety valve is optional on a vessel whose working pressure, set by the manufacturer in the passport, is equal to or greater than the pressure of the supply source, and provided that the possibility of pressure increase from a chemical reaction or heating is excluded in this vessel, including in case of fire.

317. On the inlet pipeline of a vessel designed for a pressure less than the pressure of the supply source, it is necessary to install an automatic reducing device with a pressure gauge and a safety device installed on the side of lower pressure, after the reducing device. If a bypass line (bypass) is installed, it must also be equipped with a reducing device.

It is allowed to install one reducing device with a pressure gauge and a safety valve on a supply pipeline common to a group of vessels operating at the same pressure up to the first branch to one of the vessels. At the same time, the installation of safety devices on the vessels themselves is optional if the possibility of pressure increase is excluded in them.

If, due to the physical properties of the working medium, reliable operation of the automatic reducing device is not ensured, the installation of a flow regulator is allowed and protection against pressure increase is provided.

318. The throughput of safety valves is determined in accordance with the current regulatory documentation, taking into account the flow coefficient for each valve (for compressible and incompressible media, as well as the area to which it is assigned) specified in the safety valve passport.

When the safety valves are in operation, the pressure in the vessel is not allowed to exceed:

a) permitted pressure by more than 0.05 MPa - for vessels with pressure up to 0.3 MPa;

b) permitted pressure by more than 15% - for vessels with pressure from 0.3 to 6 MPa;

c) permitted pressure by more than 10% - for vessels with pressure over 6 MPa.

When safety valves are in operation, it is allowed to exceed the pressure in the vessel by no more than 25% of the working pressure, provided that this excess is provided for by the project and is reflected in the vessel's passport.

If during operation the working pressure of the vessel is reduced, then it is necessary to calculate the capacity of the safety devices for the new operating conditions.

319. In order to ensure the safe operation of vessels, the connecting pipelines of safety valves (inlet, outlet and drainage) should be protected from freezing of the working medium in them.

The selection of the working medium from the branch pipes (and in the sections of the connecting pipelines from the vessel to the valves), on which safety devices are installed, is not allowed.

320. When installing several safety devices on one branch pipe (pipeline), the cross-sectional area of the branch pipe (pipeline) must be at least 1.25 of the total cross-sectional area of the valves installed on it. When determining the cross section of connecting pipelines with a length of more than 1000 mm, it is also necessary to take into account the value of their resistance.

321. Installation of shut-off valves between the vessel and the safety device, as well as behind it, is not allowed.

For a group of safety devices (two or more), the fittings in front of (behind) the safety device (s) can be installed provided that the safety devices are equipped with a blocking made in such a way that in any case of shutting off the valves (valve) provided for by the project, the remaining switched on safety devices have a total throughput ensuring the fulfillment of the requirements of paragraph 318 of these FNR. When installing two safety devices, the interlock must exclude the possibility of their simultaneous disconnection.

322. The medium leaving the safety devices must be discharged to a safe place. Discharged toxic, explosive and flammable process fluids must be sent to closed systems for further disposal or to organized incineration systems.

In cases justified by the design documentation, it is allowed to discharge non-toxic explosive and flammable media into the atmosphere through discharge pipelines, provided that their design and location ensure explosion and fire safe dispersion of the discharged medium, taking into account the requirements of fire safety standards.

Discharges containing substances that are capable of forming explosive mixtures or unstable compounds when mixed are prohibited.

323. To ensure the removal of condensate, the discharge pipelines of safety devices and the impulse lines of impulse safety valves must be equipped with drainage devices in places where condensate may accumulate. Condensate must be drained from the drain pipes to a safe place.

Installation of locking devices or other fittings on drainage pipelines is not allowed.

324. Membrane safety devices must be installed on branch pipes or pipelines directly connected to the vessel in places open and accessible for inspection and installation and dismantling.

The membranes must be placed only in the attachment points intended for them.

Connecting pipelines must be protected from freezing of the working medium in them.

325. When installing a membrane safety device in series with a safety valve (before or behind the valve), the cavity between the membrane and the valve must be connected by a drain pipe with a signal pressure gauge (to monitor the health of the membranes).

It is allowed to install a switching device in front of the membrane safety devices in the presence of a double number of membrane devices, while ensuring the protection of the vessel from overpressure in any position of the switching device.

326. The procedure and terms for checking the serviceability of operation, repair and checking the setting of operation of safety devices at the stand, depending on the conditions of the technological process, must be indicated in the production instructions for the operation of safety devices approved by the management of the operating organization.

The results of checking the serviceability of safety devices, information about their setting are recorded in a shift log, information about their setting is drawn up by acts of the person performing the specified operations.

327. When operating vessels with an interface between media, which require liquid level control, the following requirements must be met:

a) ensuring good visibility of the readings of the liquid level indicator;

b) if it is possible to lower the liquid level below the permissible level on vessels heated by flames or hot gases, the implementation of level control using two direct action indicators;

c) a clear indication on the liquid level indicator of the permissible upper and lower levels, subject to the condition that the height of the transparent liquid level indicator must be at least 25 mm below the lower and above the upper permissible liquid levels, respectively;

d) when equipping a vessel with several level indicators in height, placing them in such a way that they ensure continuity of liquid level readings;

e) when purging fittings (taps, valves) installed on the level indicator, ensuring the removal of the working medium to a safe place;

f) the use of a protective device to protect personnel from injury in the event of a rupture of a transparent element used on the level indicator, made of glass or mica;

g) ensuring reliable operation of sound, light and other signaling devices and level locks provided for by the project and installed along with level indicators.

328. In order to maintain vessels in good condition, the operating organization is obliged to organize timely repair of vessels in accordance with the schedule. At the same time, it is not allowed to repair vessels and their elements under pressure. In order to ensure safety during repairs associated with the performance of work inside the vessel, prior to the commencement of these works, the vessel connected to other operating vessels by a common pipeline must be separated from them by plugs or disconnected. Disconnected pipes must be plugged. Only plugs of appropriate strength, installed between the flanges and having a protruding part (tail), by which the presence of a plug is determined, are allowed to be used to disconnect the vessel. When installing gaskets between flanges, they must be without shanks.

329. When working inside the vessel (internal inspection, repair, cleaning), safe lamps with a voltage of not more than 12 V must be used, and in explosive environments - in an explosion-proof design. If necessary, the air environment should be analyzed for the absence of harmful or other substances exceeding the maximum allowable concentrations. Work inside the vessel must be carried out according to the work permit.

330. At negative ambient temperatures, the start-up, shutdown or leak test of vessels operated outdoors or in unheated premises must be carried out in accordance with the winter start-up procedure established in the production instruction, developed on the basis of the requirements of the operating manual (instruction). and project documentation.

Taking into account the dependence of the strength characteristics of the material from which the vessel is made on temperature, as well as the minimum temperature at which steel (or other material) and welded joints of this vessel are allowed to work under pressure, the regulations for starting a vessel in winter (groups of the same type in design vessels operating under the same conditions) should determine:

a) the minimum values of pressure of the working medium and air temperature at which it is possible to put the vessel into operation;

b) the order (schedule) of pressure increase (from the minimum start-up pressure to the working one) in the vessel during start-up and decrease - at stop;

c) the allowable rate of increase in the temperature of the vessel wall during start-up and decrease - when stopped.

Requirements for the operation of pipelines

331. For the pipeline, the operating organization develops and approves the executive scheme of the pipeline, which indicates:

a) steel grades, diameters, thicknesses of pipes, length of the pipeline;

b) the location of supports, compensators, hangers, fittings, air vents and drainage devices;

c) welded joints indicating the distances between them;

d) the location of indicators for controlling thermal displacements, indicating the design values of displacements, devices for measuring creep (for pipelines that operate at temperatures that cause metal creep).

332. In order to prevent accidents in pipelines operating at a temperature that causes metal creep, the operating organization is obliged to establish systematic monitoring of the growth of residual deformations. This requirement applies to steam pipelines made of carbon, manganese, silicon-manganese and molybdenum steels operating at a steam temperature of 400°C and above, from alloyed chromium-molybdenum and chromium-molybdenum-vanadium steels at a steam temperature of 500°C and above, and from high-alloy chromium and chromium-nickel (austenitic) steels at steam temperature of 530°C and above. Also, these pipelines must be subjected to technical diagnostics, non-destructive, destructive testing, including before they reach the designated resource (service life), in accordance with the requirements established in the operating manual (instruction), production instructions and other administrative documents adopted in the operating organizations.

333. After a major overhaul, as well as repairs associated with cutting and re-welding sections of the pipeline, replacing fittings, adjusting supports and replacing thermal insulation, before putting the equipment into operation, the following must be checked:

a) the absence of temporary assembly and repair screeds, structures and fixtures, scaffolding;

b) the serviceability of fixed and sliding supports and spring fasteners, ladders and platforms for servicing pipelines and fittings;

c) the size of the tightening of the springs of the suspensions and supports in the cold state;

d) serviceability of thermal displacement indicators;

e) the possibility of free movement of pipelines during their heating and other operating conditions;

f) condition of drains and air vents, safety devices;

g) the magnitude of the slopes of the horizontal sections of pipelines and their compliance with the provisions of these FNP;

h) ease of movement of the moving parts of the reinforcement;

i) conformity of the indications of the extreme positions of the shutoff valves (open-closed) on the control panels to its actual position;

j) serviceability of thermal insulation.

334. During the operation of pipelines and fittings in accordance with the current instructions, the following must be controlled:

a) the magnitude of thermal displacements of pipelines and their compliance with the calculated values according to the indications of indicators (benchmarks);

b) absence of pinching and increased vibration of pipelines;

c) density of safety devices, fittings and flange connections;

d) temperature regime of metal operation during starts and stops;

e) the degree of tightening of the springs of suspensions and supports in working and cold condition at least once every two years;

f) tightness of stuffing box seals of fittings;

g) compliance of the indications of the position indicators of the control valves on the control panels with its actual position;

h) the presence of lubrication of bearings, units of drive mechanisms, screw pairs spindle - threaded bushing, in gearboxes of valve electric drives.

335. When filling uncooled steam pipelines with a medium, the temperature difference between the pipeline walls and the working medium must be monitored, which must be kept within the calculated values.

336. The drainage system must ensure the complete removal of moisture during heating, cooling and emptying of pipelines.

When replacing parts and elements of pipelines, it is necessary to maintain the design position of the axis of the pipeline.

When laying drainage lines, the direction of thermal movements must be taken into account in order to avoid pinching of pipelines.

When combining the drainage lines of several pipelines, shutoff valves must be installed on each of them.

337. On fittings or on a special metal tag, names and numbers should be applied according to technological schemes of pipelines, as well as indicators of the direction of rotation of the handwheel.

Control valves must be equipped with indicators of the degree of opening of the regulating body, and shut-off valves - with indicators "Open" and "Closed".

The valve must be accessible for maintenance. At the installation sites of fittings and indicators of thermal displacements of steam pipelines, service platforms should be installed.

Fittings must be used strictly in accordance with its functional purpose.

338. Checking the serviceability of the operation of pressure gauges and safety valves (except for safety valves of process pipelines intended for transportation of explosive and chemically hazardous substances) must be carried out within the following periods:

a) for pipelines with operating pressure up to 1.4 MPa inclusive - at least once per shift;

b) for pipelines with operating pressure over 1.4 to 4.0 MPa inclusive - at least once a day;

c) for pipelines with a working pressure of more than 4 MPa, as well as for all pipelines installed at thermal power plants - within the time limits established by the instruction approved in the prescribed manner by the technical manager (chief engineer) of the organization.

The results of the check are recorded in the shift log.

339. When operating pipelines with a working pressure of up to 2.5 MPa, it is necessary to use pressure gauges with an accuracy class of at least 2.5.

When operating pipelines with a working pressure of more than 2.5 to 14 MPa, it is necessary to use pressure gauges with an accuracy class of at least 1.5.

When operating pipelines with a working pressure of more than 14 MPa, it is necessary to use pressure gauges with an accuracy class of at least 1.

The pressure gauge scale is chosen from the condition that at operating pressure the pressure gauge needle is in the second third of the scale.

The pressure gauge must have a red line indicating the allowable pressure.

Instead of a red line, it is allowed to attach a metal plate or a plate made of composite materials, painted red and tightly adjacent to the pressure gauge glass, to the pressure gauge body.

340. The pressure gauge must be installed so that its readings are clearly visible to the maintenance personnel, while its scale must be located vertically or tilted forward up to 30 ° to improve the visibility of the readings.

The nominal diameter of pressure gauges installed at a height of up to 2 m from the level of the pressure gauge observation site must be at least 100 mm, at a height of 2 to 3 m - at least 150 mm and at a height of 3 to 5 m - at least 250 mm. When the pressure gauge is located at a height of more than 5 m, a reduced pressure gauge should be installed as a backup.

341. Before each pressure gauge there must be a three-way valve or other similar device for purging and turning off the pressure gauge. There must be a siphon tube with a diameter of at least 10 mm in front of the manometer intended for measuring steam pressure.

342. During the operation of the pipeline, the service personnel checks the serviceability of the pressure gauge at intervals established in the production instructions, using a three-way valve or shut-off valves replacing it by setting the pressure gauge needle to zero.

At least once every 12 months (unless other periods are established by the documentation for the pressure gauge), the pressure gauges must be verified, and a brand or seal must be installed on each of them.

Pressure gauges are not allowed for use in cases where:

a) there is no seal or brand on the pressure gauge with a mark on the verification;

b) the period for checking the pressure gauge has expired;

c) the pointer of the pressure gauge, when it is turned off, does not return to the zero mark of the scale by an amount exceeding half of the permissible error for this pressure gauge;

d) the glass is broken or there are other damages to the pressure gauge, which may affect the correctness of its readings.

343. The serviceability of safety valves is checked by their forced short-term undermining (opening) or by checking the operation of the valve on the stands, if the forced opening of the valve is undesirable due to the conditions of the technological process.

Safety devices must be designed and adjusted so that the pressure in the protected element does not exceed the permitted one by more than 10%, and at the permitted pressure up to 0.5 MPa - by no more than 0.05 MPa.

Exceeding the pressure with the full opening of the safety valve higher than 10% of the permitted one can be allowed only if this is provided for by the calculation of the strength of the pipeline.

If the operation of the pipeline is allowed at a reduced pressure, then the adjustment of the safety devices must be made according to this pressure, and the throughput of the devices must be verified by calculation.

Sampling of the medium from the branch pipe on which the safety device is installed is not allowed. Safety valves must have discharge pipelines that protect personnel from burns when the valves actuate. These pipelines must be protected from freezing and equipped with drains to drain the condensate accumulating in them. Installation of locking devices on drains is not allowed.

344. When operating a pipeline, the design pressure of which is lower than the pressure of the source supplying it, to ensure safety, a reducing device with a pressure gauge and a safety valve, which are installed on the side of lower pressure (reducing-cooling plant or other reducing devices), must be used. Reducing devices must have automatic pressure control, and reducing-cooling devices, in addition, automatic temperature control.

345. The organization operating the pipelines must keep a repair log, in which, signed by the person responsible for the good condition and safe operation of the pipelines, they must enter information about the repair work performed that does not necessitate an extraordinary technical examination.

Information about repair work that necessitates an extraordinary survey of the pipeline, about the materials used in the repair, as well as information about the quality of welding, must be entered in the pipeline passport.

346. Prior to the start of repair work on the pipeline, it must be separated from all other pipelines by plugs or disconnected.

If the valves of the steam and hot water pipelines are flangeless, then the pipeline must be disconnected by two shut-off devices with a drainage device between them with a nominal diameter of at least 32 mm, which has a direct connection to the atmosphere. The actuators of gate valves, as well as valves of open drains, must be locked so that there is no possibility of weakening their tightness when the lock is locked. The keys to the locks must be kept by the person responsible for the good condition and safe operation of the pipeline.

The thickness of the plugs and flanges used when disconnecting the pipeline must be determined by the strength calculation. The plug must have a protruding part (shank), by which its presence is determined.

Gaskets between flanges and plug must be without shanks.

347. Repair of pipelines, fittings and elements of remote control of fittings, installation and removal of plugs separating the repaired section of the pipeline must be carried out only on the basis of a work permit in the manner established by the operating organization.

348. The fittings after repair must be tested for tightness with a pressure equal to 1.25 working pressure - for the one being removed from the place and the working pressure - for the installation being repaired without removal from the place.

349. Thermal insulation of pipelines and fittings must be in good condition. The temperature on its surface at an ambient temperature of 25°C should not exceed 55°C.

350. Thermal insulation of flanged joints, fittings and sections of pipelines subjected to periodic control (welded joints, bosses for measuring creep) must be removable.

351. Thermal insulation of pipelines located in the open air and near oil tanks, oil pipelines, fuel oil pipelines must have a metal or other coating to protect it from moisture or combustible oil products. Pipelines located near cable lines must also have a metal coating.

352. Pipelines with a temperature of the working medium below the ambient temperature must be protected from corrosion, have hydro- and thermal insulation.

For thermal insulation, materials that do not cause corrosion of the pipeline metal should be used.

Procedure in the event of an accident or incident during the operation of pressure equipment

353. The boiler must be immediately stopped and switched off by the action of protections or personnel in cases provided for by the instructions, and in particular in cases of:

a) failure detection of the safety valve;

b) if the pressure in the boiler drum has risen by 10% above the allowed one and continues to grow;

c) lowering the water level below the lowest permissible level;

d) raising the water level above the highest permissible level;

e) shutdown of all feed pumps;

f) termination of all direct water level indicators;

g) if cracks, bulges, gaps in their welds, breakage of an anchor bolt or connection;

h) unacceptable increase or decrease in pressure in the once-through boiler path up to the built-in valves;

i) extinction of torches in the furnace during chamber combustion of fuel;

j) reducing the water flow through the boiler below the minimum allowable value;

k) lowering the water pressure in the boiler duct below the permissible level;

l) increasing the water temperature at the outlet of the hot water boiler to a value 20°C below the saturation temperature corresponding to the operating water pressure in the outlet header of the boiler;

m) malfunctions of safety automatics or alarms, including power failure on these devices;

o) the occurrence of a fire in the boiler room that threatens the operating personnel or the boiler.

354. The vessel must be immediately stopped in cases provided for by the instruction on the mode of operation and safe maintenance, in particular:

a) if the pressure in the vessel has risen above the permitted level and does not decrease, despite the measures taken by the personnel;

b) when a malfunction of the safety device against pressure increase is detected;

c) upon detection of leaks, bulges, rupture of gaskets in the vessel and its elements operating under pressure;

e) when the liquid level drops below the permissible level in vessels with fire heating;

f) in case of failure of all liquid level indicators;

g) in case of malfunction of safety blocking devices;

h) in the event of a fire that directly threatens the vessel under pressure.

355. The pipeline must be immediately stopped and turned off by the action of protections or personnel in the cases provided for by the instruction, in particular:

a) when a malfunction of the safety device against pressure increase is detected;

b) if the pressure in the pipeline has risen above the permitted level and does not decrease, despite the measures taken by the personnel;

c) if cracks, bulges, gaps in their welds, breakage of an anchor bolt or connection are found in the main elements of the pipeline;

d) if the pressure gauge malfunctions and it is impossible to determine the pressure using other instruments;

e) in case of malfunction of safety blocking devices;

f) in case of pinching and increased vibration of the pipeline;

g) in case of malfunction of drainage devices for continuous removal of liquid;

h) in the event of a fire that directly threatens the pipeline.

356. Causes of emergency shutdown of equipment under pressure should be recorded in shift logs.

357. HIFs that use pressure equipment must develop and approve instructions that establish the actions of workers in emergency situations. Instructions must be issued to the workplace against the signature of each employee associated with the operation of pressure equipment. Knowledge of the instructions is checked during the certification of specialists and the admission of workers to independent work.

The scope of the instructions depends on the specifics of the process and the type of pressure equipment being operated.

358. In the instructions establishing the actions of workers in emergency situations, along with the requirements determined by the specifics of HIFs, the following information should be indicated for workers involved in the operation of pressure equipment:

a) operational actions to prevent and localize accidents;

b) ways and methods of liquidation of accidents;

c) evacuation schemes in the event of an explosion, fire, release of toxic substances in the room or on the site where the equipment is operated, if the emergency cannot be localized or eliminated;

d) the procedure for using the fire extinguishing system in case of local fires of HIF equipment;

e) procedure for bringing pressure equipment to a safe position when not in service;

f) places for disconnecting power supply inputs and a list of persons entitled to disconnect;

g) location of first aid kits;

h) methods of providing first aid to workers who have fallen under electrical voltage, received burns, poisoned by combustion products;

i) the procedure for notifying HIF employees and specialized services involved in the implementation of actions to localize accidents.

The responsibility for the availability of these instructions lies with the management of the HIF, which uses pressure equipment, and their implementation in emergency situations - with each employee of the HIF.

359. The procedure for actions in the event of an incident during the operation of pressure equipment is determined by the operating organization and established in the production instructions.

Safety devices include impulse safety devices (IPU) and direct acting safety valves. Safety devices are designed to ensure the safe operation of equipment and systems of power plants by protecting against excess pressure of the working medium (saturated or superheated water vapor) above the permissible value.

Safety devices operate automatically and, when opened, discharge the excess of the working medium from the protected vessel or system into the atmosphere. IPU are designed for installation on drums and outlet manifolds of boiler units with a nominal steam pressure of 10.0, 14.0 and 25.5 MPa, on "cold" and "hot" lines of pipelines for reheating steam, as well as on pipelines of reduced and cooled steam ( behind reduction-cooling units) with a nominal pressure of 6.3 MPa.

The main difference between the pulse valves (IC), which are part of the IPU, supplied for the protection of cogeneration units, and those supplied for reheat pipelines, as well as reduced and cooled steam, is their equipping with an electromagnetic drive, which ensures high accuracy of operation (opening and closing ) of these valves and IPU as a whole. Such an electromagnetic drive is based on two electromagnets or one double-acting electromagnet, which ensure the timely opening and closing of the device.

Setting the IPU to a given opening and closing pressure is done only by a pulse valve. This is achieved by placing a weight on the IK lever in a position that allows the valve to open at set pressure. The IC and IPU as a whole are closed at a pressure lower than the nominal one. In the event of a loss of electrical power in the control circuit, the safety device is activated by the action of a weight on the lever of the impulse valve.

GPK are equipped with a hydraulic damper in order to mitigate the impact of the undercarriage parts when the valve is actuated to open and close. The brake fluid is technical water, the constant supply of which to the damper is provided by the device shown in the wiring diagram.

The choice of one or another direct-acting valve or IPU from the nomenclature given in this catalog is carried out depending on the parameters of the working medium in the protected vessel or system, as well as on the required throughput, i.e. steam flow through the valve per unit time.

The number of safety valves and their throughput for general-purpose power plants must be selected according to the calculation in accordance with the NTD agreed with the technical supervision of the Republic of Belarus.