Rules for the safe operation of technological pipelines. Rules for the construction and safe operation of technological pipelines. Requirements for pneumatic testing

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

Read in our article:

Status for 2019 of the Decree of the Federal Mining and Industrial Supervision of Russia dated May 10, 2003 No. 80 "On Approval of the Rules for the Construction and Safe Operation of Process Pipelines"

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

Another important regulation, which need to be guided by the use and maintenance of TT, was adopted on December 27, 2012 "On the approval of the Safety Guide" Recommendations for the design and safe operation of technological pipelines "".

To date, the last two documents define the basic rules for the operation of TT for industrial purposes.

Pipeline operating rules

The operating PB "Technological pipelines" have strict requirements for the use, maintenance, revision of technological pipeline systems, as well as for the qualifications of the specialists working with them. Below we will describe these requirements in detail.

Operation procedure

First of all, you need to check the performance of the systems at regular intervals. It is on external inspection to check the technical condition of pipes or connections, inspection of areas subject to vibration with special devices, as well as on the elimination of all detected malfunctions.

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

• flange connections;
• insulation, coatings;
• drainage systems,
• support mounts.

If leaks are found, it is necessary to lower the working pressure to atmospheric, and the temperature (on the heating lines) to be reduced to 60 ° C. Only after that .

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

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

When using TT at hazardous production facilities, special attention should be paid personnel matters... Responsible specialists, as well as a sufficient number of qualified workers, should be involved in working with technological transportation systems. They should all production instructions and labor protection requirements.

Long before starting the system, the instructions for industrial safety at the enterprise, as well as separately - instructions for all responsible specialists and workers.

Requirements for qualifications, duties of employees

The safety of technological pipelines can only be ensured by employees with sufficient qualifications. They must be at least 18 years old with vocational education(in the case of specialists) or appropriate professional training (for workers). Before being admitted to work, which will be issued by a separate order, they must go through the following procedures:

• verification of knowledge of the requirements for safe work.

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

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

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

If damage was found, violation of safe operation conditions, deviations from technology or unacceptable changes in the parameters of the system, it is necessary to stop all work, or not start at all.

List job responsibilities for responsible specialists it will be much wider. You will need at least two of these employees with a technical professional background, certified in industrial safety.

The specialist who is responsible for must:

• inspect TT, check the mode of its operation;
• monitor the preparation of TT for examination, conduct all the necessary document flow;
• issue instructions when detecting violations in work;
• monitor compliance with industrial safety rules, own regulations or orders of state bodies, as well as repair, reconstruction of the system;
• take part in examinations, surveys;
• control the conduct of emergency training;
• upon identifying violating workers, demand their removal from work and sending them to an extraordinary examination of knowledge.

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

• ensuring the operability, repair, preparation of TT for technical examination, diagnostics;
• monitoring compliance by workers;
• holding and participating in periodic inspections, technical inspections of the system;
• storage of all technical documentation of TT (technical passport, instructions for installation, use, manuals), checking entries in the shift log;
• counter-emergency training of employees;
• fulfillment of all instructions to eliminate detected violations;
• keeping records of CT load cycles, if they are operated in a cyclic mode.

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

2.2.5. Seamless pipes made from ingots, as well as shaped parts from these pipes, may be used for pipelines of groups A and B of the first and second categories, provided that they are monitored by ultrasonic flaw detection (UZD) in the amount of 100% over the entire surface.

2.2.18. For pipelines transporting substances of groups A and B of technological objects of I category of explosion hazard, it is not allowed to use flange connections with a smooth sealing surface, except for the cases of using spiral-wound gaskets.

Fasteners

2.2.19. Fasteners for flange connections and materials for them should be selected depending on the operating conditions and steel grade of the flange according to.

Studs should be used to connect flanges at temperatures above 300 ° C and below minus 40 ° C, regardless of pressure.

2.2.20. When making studs, bolts and nuts, the hardness of the studs or bolts must be at least 10-15 HB higher than the hardness of the nuts.

2.2.21. The materials used for the manufacture of fasteners, as well as fasteners entering the warehouse, must have a manufacturer's certificate.

In the absence of a material certificate, the manufacturer of fasteners must carry out certification of materials based on the results of determining their physical and mechanical characteristics (including chemical composition) according to existing standards or specifications and draw up a certificate.

2.2.22. It is not allowed to make fasteners from boiling, semi-calm, Bessemer and free-cutting steels.

2.2.23. Material of workpieces or finished fasteners made of high-quality carbon, as well as heat-resistant and heat-resistant alloy steels must be heat-treated.

For fasteners used at pressures up to 1.6 MPa (16 kgf / cm 2) and operating temperatures up to 200 ° C, as well as fasteners made of carbon steel with threads up to 48 mm in diameter, heat treatment is not required.

2.2.24. In the case of using fasteners made of steels of the austenitic class at an operating temperature of the medium above 500 ° C, it is not allowed to manufacture a thread by the knurling method.

It is allowed to use materials of fasteners and flanges with coefficients of linear expansion, the values ​​of which differ by more than 10%, in cases justified by strength calculations or experimental studies, as well as for flange connections at an operating temperature of the medium not exceeding 100 ° C.

Gasket materials

Fittings of pipelines

2.2.27. Shaped parts of pipelines, depending on the parameters of the transported medium and operating conditions, should be selected according to the current NTD standards, norms, specifications, as well as according to the technical documentation of the project developer.

For pipelines of technological objects of the I category of explosion hazard, transporting substances of groups A and B, it is prohibited to use fittings made with deviations from the current normative and technical documents.

2.2.28. Shaped parts of pipelines must be made of steel seamless and longitudinal welded pipes or sheet metal, the metal of which meets the requirements of the project, regulatory and technical documents, as well as the conditions of weldability with the material of the pipes to be connected.

2.2.29. Parts of pipelines for environments causing corrosion cracking of metal, regardless of design, steel grade and manufacturing technology, are subject to heat treatment.

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

Welded parts

2.2.30. When choosing welded parts of pipelines, depending on the aggressiveness of the environment, temperature and pressure, one should be guided by these Rules and other applicable regulatory documents.

2.2.31. Welding of fittings and quality control of welded joints should be carried out in accordance with the requirements of the current NTD.

2.2.32. Branch from the pipeline can be performed in one of the ways shown in fig. , or in accordance with OST 36-45-81, OST 36-41-81 and the project developer's drawings. When installing tee connections, special attention should be paid to the quality of fitting and welding work. Reinforcement of tee connections with stiffeners is not allowed.

3.1.4. In pipelines designed for operation under pressure up to 35 MPa (350 kgf / cm 2), welding of fittings in straight sections is allowed, as well as the use of tees welded from pipes, stamped-welded elbows with two longitudinal seams, subject to 100% control of welded joints by ultrasonic flaw detection or transmission.

3.1.5. Welding of fittings into welded seams, as well as into bent elements (in places of bends) of pipelines is not allowed.

As an exception, on bends of pipelines operating under pressure up to 35 MPa (350 kgf / cm 2), welding of one fitting (pipe) for a measuring device with an inner diameter of not more than 25 mm may be allowed.

3.1.6. To connect pipeline elements made of high-strength steels with a ultimate tensile strength of 650 MPa (6500 kgf / cm 2) and more, only threaded coupling or flange connections should be used. Welded joints of such steels may be permitted in exceptional cases. The welding technology and quality control of such joints must be agreed with a specialized research organization.

3.1.7. At the locations of the most stressed welded joints and the points of measurement of the residual deformation accumulated during metal creep, removable sections of insulation must be provided.

3.2. Requirements for pipeline design

Forged and stamped parts

3.2.1. High pressure pipeline parts should be made from forgings, die forgings and pipes. It is allowed to use other types of blanks if, according to the conclusion of a specialized research organization, they ensure reliable operation during the estimated service life, taking into account the specified operating conditions.

3.2.2. The ratio of the inner diameter of the branch to the inner diameter of the main pipe in forged tees-inserts should not be less than 0.25. If the ratio of the diameter of the choke to the diameter of the main pipe is less than 0.25, tees or chokes must be used.

Bent and welded elements

3.2.3. The design and geometrical dimensions of tees welded from pipes, stamped welded rings, bent bends and unions must meet the requirements of standards, specifications and drawings.

3.2.4. Tees welded from pipes, stamped-welded bends, tees and bends from workpieces cast using electroslag technology are allowed to be used at pressures up to 35 MPa (350 kgf / cm 2). In this case, all welded seams and metal of cast billets are subject to ultrasonic inspection in the amount of 100%.

3.2.5. The ratio of the inner diameter of the nozzle (branch) to the inner diameter of the main pipe in welded tees should not exceed 0.7.

3.2.6. The use of bends welded from sectors is not allowed.

3.2.7. Bent bends after bending must be heat treated. The heat treatment mode is established by the standards, technical conditions, drawings.

3.2.8. Bent bends made of steel grades 20, 15GS, 14HGS after cold bending are allowed to be subjected only to tempering, provided that before cold bending the pipes were hardened with tempering or normalization.

Detachable connections and fasteners

3.2.9. For detachable connections, threaded flanges and butt-welded flanges should be used, taking into account the requirements of clause of these Rules.

3.2.10. As sealing elements of flange joints, metal gaskets should be used - lenses of flat, octagonal, oval and other sections.

3.2.11. Threads on pipeline parts, threaded flanges, couplings and fasteners should be performed according to,. The shape of the valleys of the external threads must be rounded. Thread tolerances - 6H, 6g on . The quality of the thread must ensure the free passage of the thread gauge.

3.2.12. In the case of the manufacture of fasteners by cold deformation, they must be subjected to heat treatment - tempering. Thread rolling on austenitic steel studs for operation at temperatures exceeding 500 ° C is not allowed.

Weld seams and their location

3.2.13. The design and location of welded joints must ensure their high-quality performance and control by all envisaged methods during manufacture, installation, operation and repair.

In any case, the specified distance should ensure the possibility of local heat treatment and non-destructive weld control.

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

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

3.2.16. If it is impossible to provide the distance specified in paragraphs. and, the question in each case is decided by a specialized research organization or the author of the project.

3.3. Requirements for materials used for high pressure pipelines

3.3.1. For the manufacture, installation and repair of steel pipelines for pressures above 10 MPa (100 kgf / cm 2) up to 320 MPa (3200 kgf / cm 2) and temperatures from minus 50 to plus 540 ° C, materials and semi-finished products should be used state standards and the technical conditions specified in table. 3.6.

GOSGORTEKHNADZOR OF RUSSIA

APPROVED BY
Resolution No. 11
Gosgortekhnadzor of Russia
from 02.03.95

DEVICE RULES
AND SAFE OPERATION
TECHNOLOGICAL PIPELINES

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

PB 03-108-96

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

"Rules for the design and safe operation of technological pipelines" were developed by the Gosgortekhnadzor of Russia, the Nizhne-Volzhsky District of the Gosgortekhnadzor of Russia, research and design institutes: VNIKTIneftehimoborudovaniya, NIICHIMMASH, Giprohimmontazh, IrkutskNIIhimmash, GIAP, VNIIneftemash, VNIPIneft, YuzhNIIgiprogaz, JSC "Sintezproekt" VNIImontazhspetsstroy taking into account comments of the Bashkir County Gosgortechnadzor Russia, JSC "Angarsk Oil Company", JSC "Salavatnefteorgsintez", JSC "Kuibyshevazot" NIIPThimnefteapparatury, OJSC "Nizhnekamskneftekhim" and other interested organizations and enterprises.

These Rules establish general provisions and the main technical requirements for process pipelines: conditions for the selection and use of pipes, pipeline parts, fittings and basic materials for their manufacture, as well as requirements for welding and heat treatment, placement of pipelines, conditions of normal operation and repair, the observance of which is mandatory for all industries, having production under the control of Gosgortekhnadzor of Russia.

With the entry into force of these Rules, the Rules for the Construction and Safe Operation of Pipelines for Flammable, Toxic and Liquefied Gases (PUG-69), approved by the USSR Gosgortekhnadzor in 1969, become invalid.

All current industry normative and technical documents and instructions regarding the design, installation, operation and repair of steel in-house and workshop process pipelines must be brought in accordance with these Rules.

The necessity and timing of bringing the existing pipelines in accordance with these Rules are determined by the administration of the enterprise and agreed with the regional bodies of the Gosgortechnadzor of Russia.

1. GENERAL PROVISIONS

1.1. Application area

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

* Rules for the construction and safe operation of technological pipelines hereinafter referred to as the Rules.

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

2. The terms "pressure", "conditional pressure", unless otherwise specified, should be understood as overpressure.

1.1.2. Along with these Rules, in the design, construction and operation of process pipelines, one should also be guided by the relevant sections of the Building Norms and Rules (SNiP), the corresponding rules of the Gosgortekhnadzor of Russia and other mandatory rules and regulations.

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

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

1.1.4. When designing and operating air and inert gas pipelines, along with these Rules, one should be guided by the requirements of the Rules for the construction and safe operation of stationary compressor units, air and gas pipelines.

1.1.5. When designing and operating pipelines transporting gas containing hydrogen sulphide, along with these Rules, one should be guided by industry scientific and technical documentation agreed with the Gosgortechnadzor of Russia, and the recommendations of specialized research organizations.

1.1.6. These Rules do not apply to pipelines:

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

acetylene and oxygen;

power plants, boiler houses, mines;

heating networks, water supply and sewerage lines;

lined with non-metallic materials;

gases containing explosive dust and fiber;

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

special purpose ( nuclear plants, mobile units, lubrication systems, which are an integral part of the equipment, etc.);

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

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

1.1.7. Depending on the working pressure, the process pipelines to which these Rules apply are subdivided into process pipelines low pressure with a nominal pressure of up to 10 MPa (100 kgf / cm 2) inclusive and high-pressure technological pipelines with a nominal pressure of over 10 MPa (100 kgf / cm 2) up to 320 MPa (3200 kgf / cm 2).

1.1.8. Development of industry-specific normative documents, governing the conditions and requirements of a particular industry, within the main provisions and requirements of these Rules.

1.2. Basic Provisions

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

1.2.2. For pipes, fittings and pipe fittings conditional ( R y) and the corresponding test ( R pr), as well as workers ( R slave) pressures are determined in accordance with GOST 356. At a negative operating temperature of the medium, the conditional pressure is determined at a temperature of plus 20 ° C.

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

The maximum working (design) pressure in the pipeline is taken as:

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

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

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

Pipelines that are tested for strength and tightness together with the apparatus must be rated for strength taking into account the test pressure of the apparatus.

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

Depending on the rate of corrosion carbon steels environments are subdivided into:

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

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

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

1.2.5. When choosing materials and products for pipelines, one should be guided by the requirements of these Rules, as well as the instructions of industry and interbranch scientific and technical documentation that establish their assortment, nomenclature, types, main parameters, conditions of use, etc. It should be borne in mind:

working pressure and working temperature of the transported medium;

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

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

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

1.2.6. For the choice of the pipeline scheme, the correctness of its design, strength calculation and material selection, for accepted date services, quality of manufacture, installation and repair, as well as the compliance of the pipeline with the requirements of rules, standards and other scientific and technical documentation are the responsibility of the organization or enterprise that performed the relevant work.

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

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

1.2.9. For pipelines and fittings in contact with explosive and fire hazardous and hazardous environments, the design organization sets the design life, which should be reflected in project documentation and entered in the pipeline passport.

Operation of pipelines that have fulfilled their estimated service life is allowed upon receipt technical opinion on the possibility of its further work and permission in the manner prescribed by regulatory documents.

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

2. TECHNOLOGICAL PIPELINES WITH NOMINAL PRESSURE UP TO 10 MPa (100 kgf / cm 2)

2.1. Classification of pipelines

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

The classification of pipelines is given in table. ...

Table 2.1

Classification of pipelines R at £ 10 MPa (100 kgf / cm 2)

Transported substances

III

R slave, MPa (kgf / cm 2)

t slave, ° С

R slave, MPa (kgf / cm 2)

t slave, ° С

R slave, MPa (kgf / cm 2)

t slave, ° С

R slave, MPa (kgf / cm 2)

t slave, ° С

R slave, MPa (kgf / cm 2)

t slave, ° С

Substances with toxic effects

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

Whatever

Whatever

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

Over 2.5 (25)

Above +300 and below -40

-40 to +300

Vacuum below 0.08 (0.8) (abs)

Whatever

Explosive and flammable substancesGOST 12.1.044

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

Over 2.5 (25)

Above +300 and below -40

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

-40 to +300

Vacuum below 0.08 (0.8) (abs)

Whatever

b) flammable liquids (flammable liquids)

Over 2.5 (25)

Above +300 and below -40

Over 1.6 (16) to 2.5 (25)

+120 to +300

Up to 1.6 (16)

-40 to +120

Vacuum below 0.08 (0.8) (abs)

Whatever

Vacuum above 0.08 (0.8) (abs)

-40 to +300

c) flammable liquids (GZh)

Over 6.3 (63)

Above +350 and below -40

Over 2.5 (25) to 6.3 (63)

Over +250 to +350

Over 1.6 (16) to 2.5 (25)

Over +120 to +250

Up to 1.6 (16)

-40 to +120

Vacuum below 0.003 (0.03) (abs)

Also

Vacuum below 0.08 (0.8) (abs)

Also

Vacuum up to 0.08 (0.8) (abs)

Over +350 to +450

Over 2.5 (25) to 6.3 (63)

From +250 to +350

Over 1.6 (16) to 2.5 (25)

Over +120 to +250

Up to 1.6 (16)

-40 to +120

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

2. Designation of the pipeline group in general view corresponds to the designation of the group of the transported medium. The designation "pipeline of group A (b)" denotes the pipeline through which the medium of group A (b) is transported.

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

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

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

6. For vacuum lines, not the nominal pressure, but the absolute working pressure should be taken into account.

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

2.1.2. Piping categories define the totality technical requirements for the design, installation and scope of inspection of pipelines in accordance with these Rules.

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

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

2.2. Requirements for materials used for pipelines

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

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

The material of the piping parts, as a rule, must match the material of the pipes to be connected. When using and welding dissimilar steels, the instructions of the relevant regulatory and technical documents should be followed.

It is allowed, upon the conclusion of specialized research organizations, to use pipes and pipeline parts made of materials not specified in these Rules.

2.2.2. Pipes and fittings of pipelines must be made of steel with technological weldability, with a ratio of yield strength to tensile strength of no more than 0.75, relative elongation of the metal at break at fivefold samples of at least 16% and impact strength of at leastKCU = 30 J / cm 2 (3.0 kgf · m / cm 2) at the minimum allowable temperature of the pipeline element wall during operation.

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

Order Federal Service on environmental, technological and nuclear supervision of December 27, 2012 No. 784 "0b approval of the Safety Guide" Recommendations for the design and safe operation of technological pipelines "
I. General Provisions
II. Recommended piping classification
III. Construction and material execution of pipelines
IV Application of pipeline fittings
V. Recommendations for the arrangement of pipelines
Vi. Piping Installation Recommendations
Vii. Welding and heat treatment requirements
VIII. Testing and acceptance of installed pipelines
IX. Recommendations for the operation of the pipeline
X. Underground pipelines
XI. Repair and installation works
Appendix 1. Terms, definitions and abbreviations
Appendix 2. Passport of the pipeline
Appendix 3. Recommended classification of pipelines
Appendix 4. Recommended types of flange sealing surfaces for soft gaskets
Appendix 5. Recommended materials for steel pipelines and pipeline parts
Appendix 6. Recommended regulations for winter start-up (shutdown) or leak testing of pipelines located outdoors or in unheated rooms and operated under pressure at positive temperatures
Appendix 7. Recommended scope of incoming inspection assembly units and piping elements
Appendix 8. Passport of fittings
Appendix 9. Recommended distances between the axes of adjacent pipelines and from pipelines to the walls of channels and walls of buildings, mm, not less
Appendix 10. Recommended minimum vertical distance from the upper process pipelines of the overpass to power lines (lower wires, taking into account their sagging)
Appendix 11.
Appendix 12. Deviation from perpendicularity to the axis of the flange sealing surface
Appendix 13. Permissible displacement of inner edges when assembling pipe joints
Appendix 14. Recommended parameters for assessing the quality of welded joints of pipelines based on the results of visual and radiographic inspection, depending on volumetric defects (inclusions, pores)
Appendix 15. Recommended scope of ultrasonic or radiographic inspection of welded joints as a percentage of the total number of joints welded by each welder
Appendix 16. Recommended assessment of the quality of welded joints of pipelines based on the results of radiographic inspection, depending on the size and length of flat defects (lack of penetration along the weld axis, lack of fusion, etc.)
Appendix 17. Permissible defects in welded seams of pipelines PN no more than 10 MPa, revealed during ultrasonic testing
Appendix 18. Recommended assessment of the quality of welded joints by hardness
Appendix 19. Permissible sample sizes after removing defects in pipeline welds
Appendix 20. Recommended number of test welded joints for mechanical tests and metallographic studies
Appendix 21. Mechanical properties of welded joints
Appendix 22. Recommended frequency of pipeline inspections with pressure up to 10 MPa
Appendix 23. Recommended values ​​of pipe undershoot when assembling pipes and parts with flat welded flanges, depending on the nominal pipe diameter