Testing and adjustment of automation equipment. Organization of adjustment works

1	General requirements
2	The main stages of installation of automation devices
3
4
5	The need for machines, technological equipment and materials
6	Operational control of the technological map by stages work on the installation of equipment and instruments of automation.
7
8	Annex A

General requirements

1.1 This flow chart (hereinafter referred to as TC) was developed for the installation of devices and automation equipment for the stop valve assembly, installation of engineering networks Yekaterinburg.

Before starting work, familiarize (under signature) with this TC to persons responsible for safe production works (senior foreman, foreman, foreman) and workers involved in the installation.

Installation of devices and means of automation, communication and fire alarm must ensure the accuracy of measurements provided for by the project, free access to instruments, their locking and adjustment devices,

Devices and means of automation, communication and fire alarms are installed according to the level and plumb line, if the design of the device provides for its installation in a horizontal (vertical) plane.

The devices are attached to the support structures using the parts included in their kit; if there is vibration at the installation site of the device, the threaded fasteners must have devices that prevent their spontaneous unscrewing (spring washers, lock nuts, cotter pins, etc.).

Corps electrical appliances must be grounded in accordance with the requirements of manufacturers' instructions and SNiP 3.05.06-85.

In the general case, the installation of devices and automation equipment is carried out in accordance with the requirements of SNiP 3.01.07-85 "Automation systems", VSN-015-89 "Communication and power lines", "Systems and complexes of security, fire and security and fire alarm systems"

The measuring device usually consists of a primary measuring transducer or selective device installed on process equipment or pipelines, an intermediate measuring transducer and a secondary measuring device.

The primary measuring device converts the measured value into an equivalent output signal in a form suitable for transmission over a relatively short distance and further conversion.

The selective device, in contrast to the primary measuring transducer, transmits the measured value to a measuring device or an intermediate measuring transducer over a certain distance without changing its physical nature.

The intermediary transducer, which often also functions as a local measuring device, amplifies and converts the signal from the primary measuring transducer into an equivalent output signal in a form suitable for transmission over long distances and further conversion.

The measuring device generates a measurement information signal that is unambiguously associated with the input signal in a form that can be directly perceived by the observer.

According to the indications of measuring instruments, the operator controls the technological process. With automatic process control, information about the value of the technological parameter is sent to special control devices, which, depending on the nature of the deviation of the parameter from the prescribed optimal value develop a regulatory impact on the object of regulation. The regulatory action is applied to the object of regulation through communication channels through the actuator and the regulatory body.

Thus, automatic control of the technological process is carried out according to closed control loops implemented using technical means.

Any work (including the movement of equipment) near and in the security zone of existing overhead lines, at least 15 working days before the start of work, should be agreed with the organization that owns the line in accordance with the "Rules for establishing security zones for objects power grid economy and special conditions for the use of land plots located within the boundaries of such zones.

Perform work in the security zone of existing overhead lines in accordance with the requirements of POTRM-016-2001 (as amended in 2003), the "Rules for establishing security zones for electric grid facilities and special conditions for the use of land plots located within the boundaries of such zones" and the technical specifications of line owners .

The main stages of installation of devices and automation equipment

2.1.1 The arrangement of instruments and automation equipment should be carried out in accordance with the requirements of the following documents:

- SNiP 3.05.07-85 "Automation systems";

- SNiP 12-01-2004 "Organization of construction";

– SNiP 12-03-2001 “Labor safety in construction. Part 1. General requirements"

– SNiP 12-04-2002 “Labor safety in construction. Part 2. Construction production»

- SNiP 3.05.06-85 "Electrical devices"

- NPB 88-2001. Fire extinguishing and signaling installations. Design norms and rules.

– RD-35.240.00-KTN-207-08 “Automation and telemechanization of main oil pipelines. Basic Provisions”;

2.1.2. Acceptance of the object for installation

As part of the general organizational and technical preparation, the following should be determined by the customer and agreed with the general contractor and the installation organization:

conditions for completing the facility with devices, automation equipment, products and materials supplied by the customer;
a list of devices, automation equipment, aggregate and computer complexes of automated process control systems, mounted with the involvement of installation supervision personnel of manufacturers;

3) conditions for transportation of blocks of panels, consoles, group installations of devices, pipe blocks to the place of installation.

Acceptance of construction and technological readiness for installation of automation systems should be carried out in stages for individual completed parts of the facility (control rooms, operator room, technological blocks, units, etc.).

In specialized premises intended for automation systems, as well as in production premises in places intended for the installation of devices and automation equipment, construction work must be completed.

After the specified premises are handed over for the installation of automation systems, construction works and installation of sanitary systems are not allowed in them.

By the beginning of the installation of the automation system on pipelines, the following should be installed:

1) Embedded and protective structures for the installation of primary devices. Embedded structures for the installation of selective pressure devices must end with shutoff valves.

Equipment was installed and main and distributing networks were laid to provide devices and automation equipment with electricity and energy carriers.
Grounding network completed.

2.1.3 Production of installation works

Installation of automation systems should be carried out in accordance with the working documentation, taking into account the requirements of manufacturers of devices, automation equipment, aggregate and computer systems.

All changes that occur during the construction and installation period are made only after agreement with the Design Organization.

Installation work should be carried out by the industrial method using small-scale mechanization, mechanized and electrified tools and fixtures.

Work on the installation of automation systems should be carried out in two stages:

At stage 1, you should do:

- preparation of mounting structures, units and blocks, electrical wiring elements and their pre-assembly outside the installation area;

- checking the presence of embedded structures, openings, holes in building structures and building elements, embedded structures and selective devices on process equipment and pipelines, the presence of a grounding network;

- marking of routes and installation of supporting and supporting structures for electrical and pipe wiring, actuators, devices.

At stage 2, you need to do:

– laying of pipe and electrical wiring according to the installed structures,

- installation of panels, stands, consoles, instruments and automation equipment, connection of pipe and electrical wiring to them, individual tests.

Mounted devices and automation equipment for the electrical branch of the State Instrumentation System (SSE), panels and consoles, structures, electrical and pipe wiring to be grounded in accordance with working documentation must be connected to the ground loop. If there are requirements of manufacturers, the means of aggregate and computer complexes must be connected to a special ground loop.

The customer and the contractor, together with the general design organization, must:

– agree on the volumes, technological sequence, deadlines for the implementation of construction and installation works, as well as the conditions for their combination with the work of production shops and sections of the reconstructed enterprise;

- determine the order of operational management, including the actions of builders and operators in the event of emergency situations;

– determine the sequence of disassembly of structures, as well as disassembly or transfer engineering networks, places and conditions for connecting temporary networks of water supply, electricity, etc.;

- draw up a list of customer services and his technical means that can be used by builders during the period of work;

– determine the conditions for organizing complete and priority delivery
equipment and materials, organization of transportation and warehousing of goods and
movement of construction equipment on the territory of the reconstructed enterprise, as well as
the same placement of mobile (inventory) buildings and structures.

During the installation of equipment and pipelines, operational quality control of the work performed should be carried out. Identified defects must be eliminated before the start of subsequent operations.

The end of work on the installation of automation systems is the completion of individual testing of equipment with the design of a kit executive documentation.

During individual testing, you should check:

a) compliance of the installed automation systems with working documentation
and the requirements of these rules;

b) pipe wiring for strength and density;

c) insulation resistance of electrical wiring.

Measuring the insulation resistance of electrical wiring of automation systems (measurement, control, power, signaling circuits) is carried out with a megohmmeter for a voltage of 500-1000 V and should not be less than 0.5 MΩ.

In the case of reconstruction at an existing facility, as the construction and installation work of individual AS units is completed, these units may be transferred to commissioning works (CW) with the execution of relevant acts.

During the installation and commissioning of automation systems in accordance with SNiP 3.05.07-85, the following production documentation is drawn up:

- The act of transferring working documentation for the production of work.

- The act of readiness of the facility for the production of work on the installation of automation systems.

– Certificate of interruption of installation work.

- Certificate of examination of hidden works.

- The act of testing pipe wiring for strength and density.

– Act on the degreasing of fittings, joints and pipes.

– Welding log (compiled for pipe wiring of categories I and II).

– Insulation resistance measurement protocol.

– Protocol for heating cables on drums (compiled when laying cables at low temperatures).

– Documents on electrical wiring in hazardous areas.

– Documents on electrical wiring in fire hazardous areas.

- The act of checking instruments and automation equipment.

– Permission to install devices and automation equipment.

- List of mounted devices and automation equipment.

– Act of acceptance of mounted automation systems.

– Permission to make changes to the working documentation.

– Act of acceptance into operation of automation systems.

– Act on acceptance of automation systems into operation.

– Measurement protocol optical parameters installed optical cable.

The system vendor must:

- chief - installation;

– development of a program of factory tests and comprehensive testing before commissioning;

- commissioning works;

– training of the Customer's personnel;

– delivery of the system to the Customer on a turnkey basis.

The delivery of the system must be carried out according to the programs corresponding to RD-19.020.00-KTN-158-07 "Requirements for the programs of individual testing of the equipment of the main oil pipeline facilities" and RD-19.020.00-KTN-156-07 "Requirements for the programs for the integrated testing of systems and objects of the main oil pipeline.

Delivery of mounted devices and automation equipment

Mounted devices and automation equipment are accepted by the customer from the installation company for commissioning.

To accept the completed installation, the customer appoints a working commission. To hand over the working commission, automation systems are presented, mounted in the volume provided for by the project, and passed individual testing.

Individual testing of installation work establishes:

- compliance of the installed automation systems with the working drawings of the project and the requirements of the chapter SNiP 3.05.07-85., as well as the quality of the installation work performed;

- the correct response of the tested instruments and automation equipment to artificially applied signals.

Upon completion of work on individual testing, an act of acceptance of equipment after individual testing is drawn up, to which production documentation is attached.

Testing and delivery of impulse pipe wiring

Testing and delivery of pipe wiring is carried out in accordance with SNiP 3.05.05-84 "Technological equipment and technological pipelines".

After the installation is completed, the pipe wiring is subjected to external inspection and tests for strength and density. When conducting these tests, the participation of representatives of the Gosgortekhnadzor of the Russian Federation is not required.

During an external examination, they check the absence of visible damage, the correctness and reliability of fastening and connection.

The strength and density of the mounted pipe wiring is determined by a hydraulic test by creating a test pressure PpR in them. Hydraulic testing checks the strength and tightness of impulse piping filled with liquids, as well as non-flammable and non-toxic gases. The entire line from the point of sampling to the device or sensor is subjected to the test.

Before testing, the pipe wiring is disconnected from the instruments and selective devices, purged compressed air(or inert gas), and, if necessary, washed and tightly plugged: the design of the plugs should ensure that they cannot be torn off from the ends of the pipes at test pressures.

Pipelines supplying test liquid, air or inert gases from pumps, compressors, cylinders, etc. to pipe lines, must be preliminarily tested with hydraulic pressure in assembled with shut-off valves and manometers.

The test pressure Ppr created in the piping is:

- at operating pressures up to 0.5 MPa-1.5R R (R R -working pressure), but not
less than 0.2 MPa;

- at operating pressures over 0.5 MPa-1.25 R R, but not less than 0.8 MPa.
Hydraulic tests:

as a test medium, water is used, pumped by a pipe pump to the desired pressure, determined by a pressure gauge. When testing in winter (at an ambient temperature below minus 5 ° C), industrial oil (grades 12, 20, 20c) or solutions of calcium chloride in water are used as a test medium;

pressure gauges and vacuum gauges used for testing must have measurement limits equal to 4/3 of the measured test pressure, and an accuracy class of at least 1.5. It is not recommended to carry out hydraulic tests at an ambient temperature below plus 5°С;

the device for supplying the test liquid should be located at the lowest point of the tested piping, and the device for removing air - at the highest point and at the intermediate stages of pressure rise, an exposure should be made for 1-3 minutes, during which the pressure gauge establishes the absence of a pressure drop in pipe lines;

at test pressure, the pipe wiring must be held for 5 minutes, then the pressure must be reduced to working pressure and a thorough inspection of the wiring must be carried out. In this case, metal pipe wiring is tapped with a hammer weighing no more than 0.5 kg;

- pipe wiring designed to operate at a pressure of PP = 200
kgf/cm2, must be kept under test hydraulic pressure for 10
min, after which the pressure is reduced to the working one and the pipe pipes are inspected
vodka when tapping them with a hammer. At the end of the inspection, the pressure should again
be raised to trial and held for 5 minutes, and then lowered to working,
at which it remains for the time necessary for inspection and detection
defects.

Pipe wiring is considered serviceable if no pressure drop is detected during hydraulic tests, and no bulges, cracks, leaks and fogging are detected during inspection.

All piping, after testing for strength and density, must be flushed with liquid or purged with air or nitrogen. An act is drawn up on the flushing and purging of pipe wiring.

Flushing of pipe wiring with water should be intensive at a water speed of 1-1.5 m / s until clean water appears at the outlet of the pipe being washed. After that, the pipe wiring is blown with compressed air;

Purge of pipe wiring should be carried out with an air pressure of not more than 40 kgf / cm2. The purge time, unless there are special instructions in the project, must be at least 10 minutes. During flushing or purging of pipe wiring, fittings installed on drain lines and dead ends must be fully open, and after flushing or purging, carefully inspected and cleaned.

Upon completion of hydraulic tests, a test report must be drawn up in the approved form.

5 Need for machines, technological equipment and materials

5.1 To perform work, use machines, technological equipment and materials according to Table 5.1.

Table 5.1

No. p / p	Process name or operations	Name of technical means	brand, technical characteristic	Required amount
1	Preparatory work	Construction laboratory	–	1
		Wooden supports for signal tape	GOST 12.4.011-89	60
		Signal tape, meters	GOST 12.4.011-89	300
		Set of warning signs	GOST 12.4.011-89	4
		Portable lamp with spotlight	ZHO-02-04-250	2
		Level	NT, NV-1	1
		Theodolite	4T 30P	1
		Mobile radio		2
		Roulette		1
		plumb line		1
2	Installation and electrical work	Truck	KAMAZ	1
		Hand grinder electric angle grinder	Metabo WX	3
		Standard kit for installation work	TsNIIOMTP	1
		Standard kit for electrical work	TsNIIOMTP
		Megaohmmeter	–	2
		multimeter	M41312	2
		Ohmmeter	M-372	1
		Circuit Resistance Meter	M-417	1
		Earth resistance meter	M-416	1

Operational control of the technological map for the stages of work on the installation of equipment and automation devices.

See Table 6.1 for operational quality control scheme.

Table 6.1

No. p / p	Name of processes and operations	Parameters to be controlled	Way control	control tool	Frequency of control	Responsible for control	Technical Criteria quality assessments
1	Incoming control of products and materials	Correctness of registration and availability of documentation	Visually	Visually	Before the start of the main work	Master	Before starting work, check the availability of certificates, passports corresponding to the project, standards and specifications for products and materials, completeness and quantity of materials.
1	Incoming control of products and materials	When accepting equipment, materials and products for installation	Visually	Visually	Before the start of the main work	Master	absence of damages and defects, safety of coloring and special coatings, safety of seals, presence special tool and accessories supplied by manufacturers.
2	Preparatory work	Marking installation sites for structures for instruments and automation equipment	Measurement, instrumental	Sample,	Before the installation of devices	Master, electrician	must not be violated hidden wiring, strength and fire resistance of building structures (bases); the possibility of mechanical damage to the mounted devices and automation equipment must be excluded.
2	Preparatory work	The distance between supporting structures on horizontal and vertical sections of the route	Measurement, instrumental	Sample, tape measure,	In the course of work	Master, electrician	According to the project The supporting structures must be parallel to each other, as well as parallel to the building structures (bases). Structures for wall-mounted appliances must be perpendicular to the walls. Racks installed on the floor must be plumb or level. When installing two or more racks side by side, they must be fastened together with detachable connections.
3	Installation work	Installation of boxes and trays	Measurement, instrumental	tape measure, steel ruler	In the course of work	Master, electrician	The location of the boxes after their installation should exclude the possibility of accumulation of moisture in them. All structures must be painted according to the instructions given in the working documentation.
3	Installation work	Installation of pipe and electrical wiring	Measurement, instrumental	tape measure, steel ruler	In the course of work	Master, electrician	The distance of horizontally laid wires from floor slabs should not exceed 150 mm. The passages of pipe and electrical wiring through walls and ceilings must be carried out in accordance with the working documentation.
4	Individual testing of instruments and equipment	compliance of the installed automation systems with working documentation and the requirements of SNiP 3.05.07-85					compliance of the installation sites of devices and automation equipment compliance with the requirements of SNiP 3.05.07-85 and operational instructions for how to install devices
		pipe wiring for strength and density					During hydraulic and pneumatic testing, the following stages of pressure rise: 1st - 0.3 R etc; 2nd - 0.6 R etc; 3rd - before R etc; 4th - decreases to R p [for pipe wiring with R p up to 0.2 MPa (2 kgf / cm 2) only the 2nd stage is recommended]. The pressure at the 1st and 2nd stages is maintained for 1-3 minutes; during this time, according to the readings of the manometer, the absence of a pressure drop in the piping is established. Test pressure (3rd stage) is maintained for 5 minutes. On pressure pipelines R p ³ 10 MPa test pressure is maintained for 10-12 minutes. Pressurizing the 3rd stage is a test of endurance. The working pressure (4th stage) is maintained for the time necessary for the final inspection and detection of defects. The 4th stage pressure is a density test.
		insulation resistance of electrical wiring					During insulation resistance measurements, wires and cables must be connected to the terminal assemblies of panels, cabinets, consoles, and junction boxes. Insulation resistance should not be less than 0.5 MΩ
5	Commissioning works						Commissioning work on automation systems is carried out in three stages 1. compliance of the main technical characteristics of the equipment with the requirements established in the passports and instructions of manufacturers. The results of verification and adjustment are recorded in the act or passport of the equipment. Faulty devices and automation equipment are transferred to the customer for repair or replacement. 2. checking the installation of devices and automation equipment for compliance with the requirements of the instructions of manufacturers of devices and automation equipment and working documentation; detected defects in the installation of devices and automation equipment are eliminated by the installation organization; 3. complex adjustment of automation systems, bringing the settings of instruments and automation equipment, communication channels to values at which automation systems can be used in operation.

6.1 In accordance with the requirements of SNiP 3.01.01. and GOST 23616, the following types of control are carried out in the enterprise:

- input;

- operational;

- acceptance;

- inspection;

6.2. Input control and testing are carried out by the enterprise upon acceptance from the supplier of purchased building materials, components, equipment and other necessary resources to the facility, on-site warehouse or storage facility.

The enterprise checks whether the product complies with the requirements of the standard referred to in the contract, in the project documentation, or specifications included in the purchase documentation. The enterprise takes into account the fact that, in accordance with the current legislation, claims for defects of purchased products not detected during the warranty period are not accepted and the responsibility for the low quality of purchased materials, products, equipment lies with the enterprise.

Input control is included in the functions of engineering and technical workers of sections, departments and services that carry out direct acceptance.

Responsibility for input control and testing rests with the heads of these departments.

Duties, rights and powers of employees of these units are indicated in job descriptions.

6.3 Operational control is carried out in the process of performing construction and installation and geodetic marking works, as well as measurements during quality control by the performers of these works.

Operational control of the execution of a technological operation is included in the functions of the performer of the technological operation. In the implementation of construction and installation works, he is included in the duties of the worker-performer.

The line worker carrying out the construction of the facility is responsible for the implementation of the operational control of construction and installation works. Therefore, he must also periodically conduct operational control of the construction and installation work performed by the contractor.

The acceptance of operational control during the performance of technological operations should be included in the procedure for performing a technological operation and brought to the attention of each performer as his duty.

5.4 Acceptance quality control of the work performed is carried out by those responsible for certain types of work after construction is completed, as well as after the work has been completed by subcontractors (interim acceptance control) and the facility as a whole, together with the responsible representative of the customer's technical supervision.

Tests are carried out in accordance with the requirements of the project or the customer.

Intermediate acceptance control is subject to the results of all types of work that have quality requirements and quality criteria in the design and technological documentation, namely:

- planned and high-rise position of structures;

- the actual values of the dimensions of the gaps and support areas;

- the results of the work, which are subsequently classified as hidden;

The customer also has the right to check the compliance of the technical characteristics of the materials, products and equipment used in the construction with the required ones.

The results of acceptance quality control are documented as-built documentation containing actual data on quality, as well as acceptance certificates in the form adopted in regulatory documents. Representatives of the technical supervision of the customer and the State Supervision Authority can, before signing the acceptance certificate, check the accuracy of the executive documentation.

Inspection control and testing are carried out within the enterprise, by the supervision of the customer and by third parties - government inspectors or experts belonging to government oversight bodies or accredited certification bodies.

Inspection quality control checks:

– implementation of all technological processes and regulations;

– performance by performers and line engineers of operational control;

- the availability and reliability of the results of executive documentation;

– the reliability of the results and the timeliness of the incoming control of the supplied materials, products, equipment;

– compliance with the terms of verification, adjustment, repair of control and measuring equipment, tools and fixtures metrological service organizations;

The results of incoming, acceptance and inspection control are entered into the relevant statements and drawn up in protocols and acts in accordance with the requirements of regulatory documents for incoming, acceptance and inspection control, testing and certification of the quality of products, works and services.

The control protocol must indicate the unit or official carrying out control and testing, as well as the person responsible for the release of products.

If the tested products did not pass the control and tests, then apply

procedures for managing products that do not comply established requirements.

If it is necessary to establish during the control process not only the compliance of the value of the controlled parameter with the established requirements, but also to determine the stability technological process, it is recommended to use a quantitative assessment, which is carried out in accordance with the requirements of GOST 20736. In this case, the actual deviations of the controlled parameters from the nominal values should be calculated and compared with the required values \u200b\u200bset in the project.

Basic provisions on labor protection

7.1 Managers and specialists of the organization according to the list of positions, approved by the head of the organization, before admission to work, and subsequently periodically within the established time limits, they are tested for their knowledge of the rules of labor protection and safety, taking into account their official duties and the nature of the work performed.

The procedure for conducting training and testing knowledge is established in accordance with SP 12-131-95* Occupational safety in construction.

The following workers may be allowed to work on the installation and installation of devices and means of automation, communications and fire alarms:

- those who have reached the age of 18, trained in safe methods and techniques for the production of work, passed the exams of the qualification commission and received documents (certificates) for the right to perform work;

- listened to the introductory briefing on labor protection and passed the briefing on safety at the workplace in accordance with GOST 12.04.2004;

- who have undergone a medical examination in accordance with the procedure established by the Ministry of Health of Russia.

Repeated safety briefing should be carried out for workers of all qualifications and specialties at least once every three months or immediately when the technology, conditions or nature of the work changes. The briefing is recorded in a special journal and attire - admission.

Employees who have not previously been trained in safe labor practices by profession, within a month from the date of admission to work, must be trained in accordance with GOST 12.0.004 in the scope of labor protection instructions for the relevant professions, drawn up on the basis of the Standard Industry Instructions for Labor Protection (TOI R 66 -01-95 to 66-20-93).

All workers must be provided with overalls, safety shoes and certified personal protective equipment not lower than the standards provided for in the Rules for providing employees with overalls, safety shoes and other personal protective equipment.

Personal protective equipment issued to workers must be in good working order and checked, and the workers themselves must be trained in how to use them.

All persons on the construction site are required to wear safety helmets.

At all stages of work on the construction of instruments and means of automation, communications and fire alarms, fire safety rules must be observed in accordance with GOST 12.1.004.

Construction sites are equipped with fire extinguishing equipment in accordance with the Fire Safety Rules in Russian Federation(PPB-01-93).

Construction machines, mechanisms and equipment must be in good order and adapted for their safe use, provided for by the technical documentation for operation.

During the operation of machines, measures are provided to prevent them from tipping over or spontaneous movement under the influence of wind or in the presence of a slope of the terrain (for example, installing stops under the wheels).

When performing work with earthmoving equipment, the size of the construction site is determined so as to provide space for viewing the working area and maneuvering.

During the operation of earth-moving equipment, a dangerous zone arises, the boundary of which is located at a distance of at least 5 m from the limiting position of the working body. The danger zone is surrounded by a temporary fence (for example, signal tape).

The mechanized method of loading and unloading is mandatory for goods weighing more than 50 kg, as well as when lifting goods to a height of more than 2 m.

When performing work using a lifting mechanism, it is not allowed to lift the load when people are in the body or cab of the vehicle. The device and operation of electrical installations are carried out in accordance with the requirements of the Rules for the Installation of Electrical Installations (PUE), the Safety Rules for the Operation of Consumer Electrical Installations (PTB), the Rules technical operation consumer electrical installations.

It is forbidden to operate construction machines without enclosing devices, interlocks, alarm systems provided for by their design.

Persons who have been trained, instructed and tested on safety precautions and work production technology are allowed to perform work. Performers (electricians on cable networks, concrete workers, excavators and other workers) performing these works must know all the requirements.

7.2 Requirements for labor protection during the installation of instruments and automation equipment.

Rooms for the installation of panels and consoles must be freed from formwork, scaffolding, scaffolds, cleared of construction debris; channels and openings in ceilings on the way of movement of boards and consoles should be closed with temporary solid boards at the same level with the floor.

When installing and moving panels and consoles or their individual components during the assembly process, measures must be taken to prevent them from tipping over; check the coincidence of the holes in the parts with a crowbar or a beard (it is forbidden to carry out this operation with your fingers)

Loading and unloading of panels and consoles and structures for them weighing more than 50 kg, as well as lifting them to a height of more than 3 m, should be carried out by lifting equipment.

Before installing the devices, you should check the reliability of the structures on which they will be mounted.

Mounting of devices on process equipment and pipelines should not violate the integrity and operability of pipelines and apparatus on which they are installed.

It is forbidden to carry out: installation of devices weighing more than 5 kg by one worker; installation work on the panels before their design fixing; installation of devices from stairs.

In places where devices and automation equipment are installed, which are difficult to access for installation and maintenance, the construction of stairs, wells and platforms must be completed before the start of installation in accordance with the working drawings of the construction part of the project.

Fastening devices and automation equipment on load-bearing structures(walls, shields, etc.) are produced with standard fasteners without stripped threads, slots and edges with the necessary tightening of threaded connections. In case of vibrations at the installation sites of devices, threaded connections must have devices that exclude their spontaneous unscrewing (spring washers, lock nuts, cotter pins, etc.)

The materials of packings and gaskets required for the installation of devices and automation equipment must be provided for by the project in accordance with the operating conditions of the devices and automation equipment. Changes in the material of embedded devices, pockets, etc. and their sizes without the permission of the design organization are prohibited.

When carrying, all opening parts of the devices must be securely closed, and for liquid devices, the liquid in leaky vessels. should be poured into a special container.

When testing devices and automation equipment individually, the following precautions should be observed:

a) trial switching on of electrical appliances and regulators (putting the circuit under voltage) should be carried out only after a thorough check of the correct assembly of the circuit according to the project, the reliability of the contacts on all devices, devices and other elements of the circuit, as well as after the installation of warning posters;

b) it is necessary to make sure that there are no people near live parts;

c) trial filling of pneumatic and hydraulic devices and regulators, as well as impulse lines with a working medium (setting the circuit under pressure) should be carried out only after a thorough check of the correct assembly of the circuit according to the project, as well as in accordance with the factory installation and operating instructions.

Individual testing of devices is carried out only after the impulse lines are disconnected from technological apparatus and pipelines.

7.3 Requirements for labor protection during the installation of pipe wiring.

Before starting the installation of pipe wiring, the reliability of the previously made installation of fasteners should be checked.

Installation of pipe wiring must be carried out from inventory scaffolding and scaffolding.

When installing high-pressure pipe wiring, technical control over the quality of work and paperwork should be carried out. Control is assigned by order of the contractor to the engineering and technical worker.

It is forbidden to install devices and fittings with gaskets and gland seals impregnated with any fat or oil on pipe wiring from technological oxygen pipelines.

It is not allowed to proceed with the installation of pipe oxygen pipelines with hands, clothes and tools contaminated with fats and oils.

It is allowed to proceed with the installation of pipe wiring and fittings that were in operation only if there is an act confirming the absence of residues of technological products in them, and permission to install them.

During pneumatic and hydraulic tests, it is not allowed to tap the pipes under pressure with a hammer. The locations of plugs and plugs for the duration of the test should be marked with warning signs, and people should be excluded from staying near them. Elimination of leaks, fistulas, gaps and similar defects noticed during the inspection of pipe wiring is allowed only after the pressure in the pipeline is relieved.

In hydraulic tests, water is used as a test medium for pipes and parts: when testing with temperatures below 5 ° C, solutions of calcium chloride in water or industrial grade oil should be used.

Pipes and pipe fittings filled with oxygen. should only be tested with water, and purge only with an inert gas free of oil and dust.

All pipe wiring filled with a medium with a temperature above 60 ° C, laid at a distance of less than 2.5 m from the floor, must be protected to prevent possible contact.

When purging impulse lines with harmful products, it is necessary to ensure that the products are safely discharged into the industrial sewer drain or into suitable vessels. Purge lines under pressure must be done carefully. Open the shut-off valve gradually. When purging impulse pipelines, it is necessary to beware of damage by small mechanical particles from the purged pipeline, and in the case of steam purging, hot steam.

Pneumatic testing of pipe wiring for strength is not allowed in existing workshops, on overpasses and in channels with existing gas pipelines.

For the duration of pneumatic testing of pipe wiring for strength, both indoors and outdoors, a protected area should be established. The minimum length of the zone should be at least 25 m for above-ground laying and at least 10 m for underground. The boundaries of the protected area should be marked with flags. During the rise in pressure in the pipeline and when it reaches the test pressure for strength, it is prohibited for anyone to stay in the security zone.

Inspection of the wiring is allowed only after the test pressure is reduced to the working one.

APPENDIX A

(mandatory)

Method for testing electrical apparatus, secondary circuits and electrical wiring with voltage up to 1 kV

1. General Provisions

This methodology provides descriptions of methods for monitoring the state of elements of electrical apparatus, secondary circuits and electrical wiring with voltage up to 1 kV, diagrams of recommended measurements, a list of recommended devices and their accuracy classes are given.

The scope of tests includes the following types of electrical tests and measurements:

– measurement of insulation resistance;

– test of isolation by increased voltage of industrial frequency;

- checking the operation of the maximum, minimum or independent releases of automatic switches;

– check of relay equipment;

– verification of the correct functioning of fully assembled circuits when different values operational current;

– checking of automatic switches and contactors at reduced and nominal operating current voltages;

- measurement of floor and wall resistance for insulating rooms, zones, sites.

The values of the measured parameters should be used to compile with maximum permissible values and to perform a comprehensive analysis of the state of the elements of electrical apparatus, secondary circuits and electrical wiring with voltage up to 1 kV in order to identify their malfunction.

2 Test methods

2.1 Measurement of insulation resistance

2.1.1 Insulation resistance is the main quality characteristic of elements of electrical apparatus, secondary circuits and electrical wiring with voltage up to 1 kV. It is measured during operational and acceptance tests, before testing with applied (increased) voltage and at the end of all tests and measurements.

2.1.2 Insulation resistance in almost all cases is measured with a megohmmeter - a device consisting of a voltage source - a DC generator, most often with a manual drive, a magnetoelectric ratiometer and additional resistances. The most common are megohmmeters of types F 4102M / 2, ESO 202 / 2-G, M4100, etc. voltage of 60 V and below and telemechanics circuits - with a megohmmeter for 500 V.

2.1.3 Before use, the megohmmeter should be subjected to control check, which consists in checking the readings on the scale with open and short-circuited wires. In the first case, the arrow should be at the “infinity” scale mark, in the second - at zero.

The insulation resistance value is highly dependent on temperature. Insulation resistance should be measured at an insulation temperature of at least + 10°C, except in cases specified in special instructions.

Before starting measurements, make sure that there is no voltage on the test object, carefully clean the insulation from dust. Measurements should be made with a steady position of the instrument pointer, for this you need to quickly, but evenly, rotate the generator knob (120 rpm) for 60 s. The insulation resistance is determined by the indication of the arrow of the megohmmeter device. To connect the megaohmmeter to the device or line under test, separate wires with a high insulation resistance (usually not less than 100 MΩ) should be used.

The absolute values of the insulation resistance do not always determine the degree of wetting of DC machines, therefore, an additional characteristic is the absorption coefficient K abs, which is the ratio of the insulation resistance measured in 60 s to the resistance measured in 15 s: K abs \u003d R60 / R15. For non-moistened oil power transformers, K abs at plus 10 - 30 0 C should not be lower than 1.3.

The insulation resistance and absorption coefficient K abs are strongly temperature dependent. Therefore, for comparison, their values measured at the same temperature should be used. The influence of temperature obeys the law:

- insulation resistance at temperatures T1 and T2, - coefficient depending on the type of insulation. For insulation class "A" = 40.0; for class "B" = 60.0.

The insulation resistance of class "A" with a decrease in temperature for every 10 ° C increases by 1.5 times and vice versa. Based on this, the following reduction factors to one temperature are determined:

Table 1

Temperature difference Т2-Т1°С	1	2	3	4	5	10	15	20	25	30
R60 change factor	1,04	1,08	1,13	1,17	1,22	1,5	1,84	2,25	2,75	3,4

The insulation resistance of class B with an increase in temperature for every 18 ° C decreases by about 2 times. This law is taken into account when reducing the measurement results Riz to one temperature for class B insulation. reliable results can only be obtained at temperatures exceeding +10°C.

2.1.4 Insulation resistance of electrically connected secondary circuits of RZAiT devices relative to the ground, as well as between circuits for various purposes, electrically not connected (measuring circuits, control current circuits, signaling), must be maintained within each connection not less than 1 MΩ, and for telecontrol output circuits and 220 V power supply circuits of telemechanics devices - not less than 10 MΩ.

The insulation resistance of the secondary circuits of the RZAiT devices, designed for an operating voltage of 60 V and below, powered from a separate source or through a separating transformer, must be maintained at least 0.5 MΩ.

When checking the insulation of secondary circuits of RZAiT devices containing semiconductor and microelectronic elements, measures must be taken to prevent damage to these elements.

The lowest permissible insulation resistance of devices, secondary circuits and electrical wiring up to 1 kV is given in table 2.

table 2

Test object	Megaohmmeter voltage, (V)		Note
Secondary circuits for control, protection, measurement, signaling, etc. in electrical installations with voltages above 1 kV. Busbars of operating current and busbars of voltage circuits on the control panel each connection of secondary circuits and power circuits of drives of switches and disconnectors	500-1000	10	The tests are made with the circuits disconnected. Tests are carried out with all connected devices (windings of wires, contactors, relays, devices, secondary windings of current and voltage transformers, etc.)
Secondary circuits of control, protection, signaling in relay-contactor circuits of installations with voltage up to 1 kV	500-1000	0,5	Tests are carried out with all connected devices (magnetic starters, contactors, relays, devices, etc.)
chains contactless circuits regulation and control systems, as well as elements connected to them	According to the manufacturer
Control, protection and excitation circuits of DC machines with voltage up to 1.1 kV connected to the main current circuits	500-1000	1	Tests are made with all connected devices
Power and lighting wiring. Distribution devices, boards and conductors with voltage up to 1 kV	1000	0,5	Tests in lighting wiring are carried out before screwing in the lamps with the connection of the neutral wire to the luminaire body. Insulation is measured between wires and against ground. Tests are made for each section of the switchgear

In control, protection, measurement, automation and telemechanics circuits, it is allowed not to measure the insulation resistance if the verification requires a significant amount of work to dismantle the circuit and these circuits are protected by fuses or releases that have characteristics inversely dependent on current. Checking the condition of such circuits, instruments and apparatus should be carried out by a thorough external examination at least once a year. With a grounded neutral, the inspection is carried out together with a check to ensure the operation of the protection, i.e. in case of a short to the case or neutral wire, a single-phase short-circuit current should occur, exceeding the rated current of the fuse-link of the nearest fuse or circuit breaker release no less than specified in the PUE (measurement of the resistance of the F-0 circuit or direct measurement of the short-circuit current) .

The minimum allowable insulation resistance during the operation of electrical installations and devices up to 1000 V is given in table 3.

Table 3

Name of the tested insulation	Megger voltage, (V)	Insulation resistance, (MΩ)	Test Guidelines
Electrical installations for voltages above 12V AC and 36V DC	100-1000V, and for electrical products with semiconductor blocks according to the manufacturer's instructions		In the absence of instructions, blocks with semiconductor elements are measured with a 100 V megger, while the semiconductor devices are shunted
Electrical devices for voltage, (V): above 42 to 100; above 100 to 380; Over 380;		It must correspond to that specified in the standard or specifications for a specific type of product, as a rule, not lower than 0.5	This subparagraph applies to K and T automatic and non-automatic switches of contactors, magnetic starters, relays, controllers, fuses, resistors, rheostats and other devices up to 1000 V, if they were dismantled for these purposes. Tests of non-dismantled devices, as well as their overhaul tests, are carried out in accordance with the requirements and frequency of measurements switchgears, shields, power, lighting or secondary circuits
Hand-held power tools and portable lamps with auxiliary equipment (transformers, frequency converters, circuit breakers, cables, extension cords, etc.) welding transformers	500	After overhaul: between live parts for working insulation - 2, for additional - 5, for reinforced - 7. In operation -0.5 for class II insulation - 2	For the tool, the resistance of the windings and the current-carrying cable is measured relative to the body and external metal parts: for transformers - between the primary and secondary windings and between each of the windings and the body at least 1 time in 6 months.
Power and lighting wiring	1000	0,5	The insulation resistance with fuses removed is measured between adjacent fuses or behind the last fuses between any wire and earth, and between any two wires. When measuring resistance in power circuits, electrical receivers, as well as devices, devices, etc., must be turned off. When measuring the insulation resistance in lighting circuits, the lamps must be unscrewed, and the sockets, switches and group shields connected. In lighting circuits from group shields to luminaires, it is allowed not to measure the insulation resistance if a significant amount of work is required to dismantle the circuit to check the insulation and these circuits are protected by fuses. Checking the condition of such circuits, instruments and apparatus should be carried out by a thorough external examination at least once a year. The insulation resistance of electrical wiring in particularly damp and hot rooms, in outdoor installations, as well as in rooms with a chemically active environment, is measured in in full at least once a year
Distribution devices, shields and conductors	1000	0,5	For each section of the switchgear. It is carried out simultaneously with the testing of electrical installations of power and lighting circuits connected to devices, panels or conductors
Secondary circuits for control, protection, measurement, automation, remote control, etc.	500	0,5	In control, protection, measurement, automation, telemechanics circuits, it is allowed not to measure the insulation resistance if the verification requires a significant amount of work to dismantle the circuit and these circuits are protected by fuses or releases that have characteristics inversely dependent on current. Checking the condition of such circuits, instruments and apparatus should be carried out by a thorough external examination at least once a year. With a grounded neutral, the inspection is carried out in conjunction with a check to ensure the operation of the protection
DC busbars and voltage busbars on the control panel (with disconnected circuits)	500	10	Same
Each connection of secondary circuits and supply circuits of drives of switches and disconnectors	500-1000	1	Produced with all connected devices (coils of drives, contactors, relays, devices, secondary windings of current and voltage transformers, etc.)
Circuits for control, protection, automation, telemechanics, excitation of DC machines for a voltage of 500-1000 V connected to the main current circuits	500-1000	1	The insulation resistance of voltage circuits up to 60 V, normally powered from a separate source, is measured with a 500 V megohmmeter and must not be lower than 0.5 MΩ
Circuits containing devices with microelectronic elements designed for operating voltage, V			The insulation resistance of voltage circuits up to 60 V, normally supplied from a separate source, is measured with a 500 V megohmmeter and should not be lower than 0.5 MΩ.

2.2 Power frequency overvoltage test.

2.2.1. During the tests, local defects are revealed: cracks, kinks, punctures, significant delaminations, etc. Each phase of electrical apparatus, secondary circuits and electrical wiring is subjected to tests in relation to the housing and other grounded (connected to the housing) phases.

2.2.2. Testing with increased voltage of industrial frequency is carried out from an external source of alternating current through a special test transformer or test installation, for example, UPN - 100. For testing, you can use measuring voltage transformers of types NOM - 3 and NOM - 6.

2.2.3. Testing of electrical equipment with increased voltage of industrial frequency should be carried out by teams of at least two people, of which the foreman must have an electrical safety group of at least IV, and the rest - at least III.

It is allowed to connect the connecting wire to the phase, pole of the equipment under test and disconnect it at the direction of the person in charge of the test, and only after they are grounded.

Before applying the test voltage to the test facility, the manufacturer must:

a) check whether all members of the team are at the indicated places, whether unauthorized persons are removed, whether it is possible to apply test voltage to the equipment;

c) warn the team about the voltage supply, making sure that the warning is heard by all members of the team, remove the ground from the output of the test facility, and then apply the 380/220 V voltage earlier.

From the moment the grounding is removed, the entire test installation, including the equipment under test and connecting wires, is considered to be energized and it is prohibited to make any reconnections in the test circuit and on the equipment under test.

It is allowed to connect the connecting wire to the phase, plus of the equipment under test and disconnect it at the direction of the person in charge of the test, and only after they are grounded.

Tests with increased voltage of industrial frequency are generally carried out according to the scheme (Fig. 1).

Figure 1 - Scheme for testing the insulation of electrical equipment with increased AC voltage:

A - automatic switch; RK - adjusting column; TI - test transformer; A - ammeter for measuring current on the side low voltage; V1, V2 - voltmeters; mA is a milliammeter for measuring the leakage current of the insulation under test; Kn - button that shunts mA to protect it from overloads; R1 - resistor for current limiting in the test transformer during breakdowns in the tested insulation (1-2 ohms per 1 V of test voltage); R2 - also to limit switching overvoltages on the insulation under test during the breakdown of the arrester (1 ohm per 1 V of the test voltage); R - arrester; O - tested winding; K - the body of the apparatus, the insulation of which is tested.

Test order.

The circuit is assembled and tested without applying voltage to the object under test. Before applying voltage, all the requirements of the Safety Regulations, paragraph 2.2.1, are met. . To accurately determine the voltage, electrostatic voltmeters are used, installed on the high voltage side of the test transformer. Electrostatic voltmeters can measure both AC and DC voltages.

The voltage rise and testing are carried out in compliance with all safety requirements at a speed: up to 25-30% Utest - unlimited, further rise to 50% at an arbitrary speed, but smooth; up to 100% Uisp - at a rate of 1-2% / s. After the test time (1 min.), the voltage gradually decreases and, at a value of 30% Utest, can be turned off. The test result is considered satisfactory if during the test there was no breakdown or overlap of insulation, there were no sharp throws of the arrows of the ammeter (increase in current) and voltmeters (decrease in voltage), no smoke, smell and burning were noticed, no discharges were heard. After testing the organic insulation, you should feel the surface and make sure that there are no local heatings. In order to avoid unacceptable overvoltages in the insulation caused by higher harmonics, the test motor is connected to a linear motor and not phase voltage(the most dangerous third harmonic is absent in the line voltage).

The operating procedure of the unit UPN - 100.

Preparation for work.

Set the controls of the unit to their original position. For this:

set the autotransformer regulator to the extreme right position;
set switch SA1 to position “0”;
set the “MAINS” switch to the “OFF” position.

Operating procedure.

Set the visible break switch on the control box to the “ON” position. At the same time, the “NETWORK” indicator should turn on.
Set switch SA1 “0-1” to position “1”. In this case, the contactor must move away from the voltage divider.

Note: At low temperature it is recommended to check the return of the contactor. To do this, switch SA1 several times from position “1” to position “0” and back.

Press the "START" button. This should turn on the high voltage indicator.

Note: The installation scheme provides for the impossibility of applying high voltage to the test object by push. Therefore, the voltage regulator knob must be in the extreme right position.

Turning the voltage regulator knob counterclockwise and observing the kilovoltmeter readings, set required value test voltage.
After the end of the test, gradually decrease the voltage and press the “STOP” button. The high voltage on indicator should turn off.
Set switch SA1 “0-1” to position “0”. In this case, a contactor must be superimposed on the voltage divider.
Set the visible break switch to the “OFF” position. At the same time, the “NETWORK” indicator should turn off.

2.2.4 When switching on again and for the first preventive test of the RZAiT devices, the isolation relative to the ground of the electrically connected circuits of the RZAiT and all other secondary circuits of each connection, as well as the isolation between electrically unconnected circuits located within the same panel (with the exception of circuits of elements designed for operating voltage of 60 V or less) shall be tested with 1000 V AC for 1 min.

In addition, a voltage of 1000 V for 1 min. the insulation between the cores of the control cable of those circuits where there is an increased probability of a short circuit with serious consequences (gas protection circuits, capacitor circuits used as a source of operational current, etc.) must be tested.

In subsequent operation, the insulation of RZAiT circuits, with the exception of circuits with a voltage of 60 V and below, is allowed to be tested during preventive tests with a rectified voltage of 2500 V for 1 min. using a megohmmeter.

Testing the insulation of relay protection and automation circuits with a voltage of 60 V and below and telemechanics circuits is carried out in the process of measuring its resistance with a 500 V megohmmeter.

When testing the windings of step-down transformers, the test voltage is applied in turn to each of the windings. In this case, the remaining windings must be electrically connected to the grounded case and the magnetic circuit.

At the rated voltage of the primary winding of the transformer (127220V), the test voltage is 1350 V, and at the rated voltage of the primary winding (380440V) - 1800 V of industrial frequency.

If the insulation resistance of power and lighting wiring turned out to be below 0.5 MΩ, tests are carried out with an increased voltage of industrial frequency. Test voltage value 1000 V, duration 1 min.

High-voltage test of the industrial frequency of the insulation of the windings and the current-carrying cable of a hand-held power tool relative to the body and external metal parts:

up to 42 V test voltage - 500 V;
above 42 V at power up to 1 kW - 900 V;
above 42 V with a power of more than 1 kW - 1350 V.

Power and secondary circuits with an operating voltage above 60 V that do not contain devices with microelectronic elements (insulation of switchgear elements of circuit breaker drives, short circuiters, separators, devices, as well as secondary control circuits, protection, automation, telemechanics, etc.) are tested with voltage 1000 V power frequency for 1 min.

2.3 Checking the operation of over, under or shunt trips of circuit breakers

Produced for circuit breakers with a rated current of 200 A or more. The operating limits of the releases must comply with the factory data and the requirements for ensuring protective characteristics.

2.4 Checking the relay equipment

Checking of protection, control, automation and signaling relays and other devices is carried out in accordance with the current instructions. Limits of operation of the relay on the working inserts must correspond to the calculated data. The U5053 installation, which consists of three separate blocks: an adjusting K 513 load K 514 and a K 515 prefix, has received wide application for setting up and testing relay protections and automation elements.

2.5 Checking the correct functioning of fully assembled circuits at various values of the auxiliary current

All elements of the circuits must function reliably in the sequence provided for by the project at the values of the operating current given in Table 4.

Table 4

Test object	Operating current voltage, % of nominal	Note
Protection and signaling circuits in installations with voltages above 1 kV	80, 100	–
Control circuits in installations above 1 kV: making test the same, but breaking	90, 100 80, 100	–
Relay-contactor circuits in installations with voltage up to 1 kV	90, 100	For simple button-magnetic starter circuits, low voltage operation is not checked
Non-contact circuits on logic elements	85, 100, 110	The voltage change is made at the input to the power supply

2.6 Checking the operation of automatic switches and contactors at reduced and rated operating voltages

The voltage value and the number of operations when testing circuit breakers and contactors by repeated switching on and off are given in Table 5.

Table 5

2.7 Measurement of floor and wall resistance for insulating rooms, zones, sites

2.7.1 If it is necessary to perform measurements for insulating (non-conductive) rooms, zones, sites, at least three measurements should be taken in each room. One of the measurements should be made approximately 1 m from the third-party conductive parts located in this room. The other two measurements must be taken at a greater distance. The above series of measurements must be made for each surface of the room.

2.7.2 A megohmmeter is used as a direct current source, providing an open circuit voltage of 500 V (or 1000 V if the rated voltage of the installation exceeds 500 V).

2.7.3 Resistance is measured between the measuring electrode and the protective conductor of the electrical installation. Tests are recommended to be performed before applying finishing coatings (lacquer, paints and other finishing materials) to the tested surfaces.

The measuring electrodes can be one of the following types. In case of disagreement, it is recommended to use electrode 1.

Measuring electrode 1

The electrode consists of a square metal plate with a side of 250 mm and a square of wet, water-absorbing paper or cloth, from which excess moisture is removed, with a side of approximately 270 mm, placed between the metal plate and the surface to be measured. During the measurement, the plate is pressed against the floor or wall surface with a force of approximately 750 or 250 N, respectively.

Measuring electrode 2

The measuring electrode is a tripod, the legs of which form the vertices of an equilateral triangle. Each leg has an elastic base that ensures close contact with the measured surface of approximately 900 mm 2 under load and a resistance of less than 5000 ohms.

Before measurement, the surface is moistened or covered with a damp cloth. During measurements, the tripods are pressed against the surface of the floor or wall with a force equal to 750 N or 250 N, respectively.

2.7.4 The highest allowable resistance values of grounding devices are given in Table. 2. “Method of testing grounding devices”

Assessment of the technical condition.

3.1. Assessment of the state of electrical apparatus, secondary circuits and electrical wiring should be carried out on the basis of an analysis of the totality of the results of the tests. In this case, the nature of the alleged defects and the tendency of their development (diagnosis) should be established.

3.2. When analyzing the data obtained during the tests, one should be guided by the established limit values of the controlled parameters, which are indicated above in subparagraphs No. 4 of the “Test Methods” section.

Security measures.

4.1. Work on measuring and characterizing electrical devices, secondary circuits and electrical wiring must be carried out in accordance with the requirements of: Safety regulations for the operation of consumer electrical installations, instructions for labor protection when working in ETL, instructions for labor protection when working with a megohmmeter.

4.2. Work at increased voltage must be carried out according to orders.

4.3. The team that tests electrical apparatus, secondary circuits and electrical wiring must consist of at least two people with IV and III safety qualification groups.

4.4. For testing electrical devices, secondary circuits and electrical wiring, both mobile high-voltage laboratories and installations assembled from individual elements (devices, devices) can be used.

4.5. Removal of grounding from electrical apparatus, secondary circuits and electrical wiring for testing can be carried out with the permission and at the command of the supervisor.

4.6. When assembling the test circuit, first of all, the protective and working grounding of the test set must be carried out. Before connecting the high voltage AC test set to the 380/220 V mains, the high voltage output of the set must be grounded. Connection to the mains 380/220 V. is carried out through a switching device with a visible break in the circuit or through a plug located near the test facility. After testing, grounding is applied to the high-voltage terminal of the test facility and, if necessary, to electrical apparatus, secondary circuits and wiring. For example, to remove residual charge

WITH THE TECHNOLOGICAL CARD ARE FAMILIARIZED WITH:

№	Position	FULL NAME.	Signature	the date
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

Characteristics of gas equipment

It is indicated for intra-house gas equipment - the number of apartments, the type and number of installed gas appliances, the total length of the gas pipeline and the number of locking devices on them; for in-shop equipment - the total length of the gas pipeline, the type and number of installed gas equipment, the working pressure of the gas

___________________________________________________________________________

2. List of attached certificates, technical data sheets

- (or their copies) and other documents,

Quality-certifying materials

and equipment

___________________________________________________________________________

Note. It is allowed to attach (or place in this section) extracts from these documents, certified by the person responsible for the construction of the facility, and containing the necessary information (certificate number, brand (type), GOST (TU),dimensions, batch number, manufacturer, date of issue, test results).

3. Data on gas pipeline joint welding

___________________________________________________________________________

(position, signature, initials, surname of the work supervisor)

4. Testing the gas pipeline for strength and tightness *

Item 1 should be deleted.

2.* "__" __________ 200_ the gas pipeline was tested for strength by air pressure ___ MPa (____ kgf / sq. cm) for 1 hour in the section from the disconnecting device at the inlet to the valves on the descents to the equipment (instruments). The gas pipeline passed the strength test.

3.* "__" _______ 200_, the gas pipeline was tested for tightness by a pressure of _____ MPa (___ kgf / sq. cm) for ___ hours with connected gas appliances. Actual pressure drop ______ MPa (___ kgf / sq. cm) with an allowable drop of ______ MPa (___ kgf / sq. cm). Leaks and defects were not found during external examination and testing of all connections. The gas pipeline passed the leak test.

Foreman of works ____________________________________________________________

(position, signature, initials, surname)

5. Conclusion

Intra-house (intrashop) gas equipment (including gas pipeline) was installed in accordance with the project developed by

___________________________________________________________________________

(name of design organization and project release date)

taking into account the agreed changes made to the working drawings No. _____

Construction started on "__" __________ 200_

Construction completed "__" __________ 200_

Chief Engineer of SSMU _________________________________________________________

(signature, initials, surname)

Representative of the gas industry _____________________________________________

(position, signature, initials, surname)

Note. If in the shop (boiler room) there is a GRU mounted in common room shop and serving only this shop, then it is allowed to draw up a common construction passport for the intrashop gas pipeline and the GRU. In this case, the following changes must be made to the above passport form:

a) in sec. the characteristics of the gas equipment of the workshop should be given in the following form:

The total length of the gas pipeline of the shop, m	Gas pressure, MPa (kgf / cm 2)		GRU equipment (type, size)				Gasified equipment (furnaces, boilers, appliances), pcs.
The total length of the gas pipeline of the shop, m	at the entrance, Р (max)	at the exit from hydraulic fracturing, (working) P(ser)	pressure regulator	shut-off valve	safety relief valve	filter	Gasified equipment (furnaces, boilers, appliances), pcs.

b) in sec. . . it is necessary to take into account the GRU;

c) supplement the passport with the section "Testing the GRU for strength and tightness";

d) in the "Conclusion" instead of the words "(including the gas pipeline)" should be written "(including the gas pipeline and GRU)".

Organization of adjustment works.

General requirements.

Work on the adjustment of electrical installations is a specialized, final part of the complex of electrical installation work and, as a rule, must be carried out by the organization (association, trust) that performs the main electrical work and is responsible for them.

The purpose of the adjustment work is to provide:

electrical parameters and modes of operation of electrical equipment for the possibility of complex testing of a technological installation or by nodes within the time limits determined by the approved schedule;

technical indicators set by the project (for example, speed, productivity) and reliability of work.

To achieve these goals, a set of acceptance tests must be performed, the scope of which is determined by Ch. 1-8 PUE current instructions of ministries and departments, as well as the requirements of production technology.

As a result of the performed adjustment operations and testing, a conclusion should be given on the possibility of transferring the electrical installation into operation.

Preparation for execution.

1. Prior to the commencement of commissioning work,
the following preparations must be made:

The electrical part of the project was studied, as well as its connection with the production technology and the technical documentation of the factories - suppliers of electrical equipment;

Verification calculation and coordination of control and protection relay settings were made;

A project for the production of adjustment work has been drawn up;

A work schedule has been agreed upon;

Picked up necessary instructions and technical literature, selected and multiplied in the required amount of protocol forms;

A park of instruments and devices has been prepared.

2. At the work site, the commissioning manager ensures that the following preparatory activities are carried out:

Defines industrial premises for storing instruments and equipment, for working with design and reporting documentation; premises for laboratories for testing and configuring relays and individual electrical units (control panels, UBSR blocks, blocks on logic elements, etc.). The premises should be located in close proximity to the facility being established. The area of the premises is determined by the project for the production of adjustment works and is specified on the spot depending on local conditions;

Together with the head of the installation works, it sets the start of the commissioning work and, in accordance with the general schedule for the implementation of the commissioning, draws up a schedule for the combined production of installation and commissioning works;

The organization of installation is built taking into account the constant and uniform workload of the adjusters' personnel.

3. In accordance with the volumes and terms
performing adjustment, a network of sections, teams and links at the facility is determined.

The site or team should be led by a qualified engineer with experience, a senior engineer or a commissioning superintendent; the link manager should be an engineer or a qualified technician, depending on the complexity of the equipment being adjusted.

4. Each section, team, link must receive a specific task and deadlines for the completion of work. This task should include the performance of all adjustment operations, up to the commissioning of the installation or unit. Work on assignments must be carried out by one team or one link, as a rule, of a permanent composition. If there are a relatively large number of similar objects on the site (substations, high-voltage power lines, converter units, roller table drives, etc.), it is advisable to create specialized teams (links) according to the types of installations. At the same time, at the first stage, work is carried out on the same type of installations; at the final stage, it is planned to complete the commissioning work in full for this object. This method of work production, due to its uniformity, significantly speeds up the adjustment of objects and creates conditions for improving the quality of the adjustment work.

5. The organization and equipment of the workplaces of brigades (links) are checked, each workplace is located in the immediate vicinity of the equipment being adjusted. At the workplace, a laboratory table of sufficient strength, of the required dimensions, must be installed, always made of wood to ensure electrical safety. In the immediate vicinity of the workplace, construction or mechanical installation work should not be carried out.

6. Temporary power supply networks must be made open with a wire of the appropriate section with the necessary insulation and sufficient mechanical strength. They must be securely fastened and suspended to a height that excludes the possibility of people touching them and damage in installation conditions. Power supply according to temporary schemes must be carried out through a switch, a knife switch or a closed circuit breaker with protection and a clear indication of the on and off positions. In series with the closed switching device, a switching device with a visible break is mounted (for example, a plug connector). It is not allowed to connect temporary networks or connect them with a surge (for example, lighting lamps).

The workplace must be well lit and reliable fencing in all places where tension may appear; in the course of work, warning posters are hung out. It is recommended to have the three most commonly used posters: “Stop - high voltage”, “Do not turn on - people are working”, “Work here”.

7. Responsibilities of the setup manager
work on the object is determined in specialized organizations by job description; the leader does:

General control over the course of adjustment works;

Technical and organizational management of departments;

Solving all emerging issues with representatives of the customer, design and electrical installation organizations;

Commissioning of individual units or electrical installations;

Control over the maintenance of operational technical documentation and execution of delivery documentation.

In order to timely prepare technical reporting documentation to be presented to the customer during commissioning, prompt records of test and measurement results are kept in the course of work in the appropriate protocol form.

Adjustment work organization project.

The project for the organization of adjustment work or the project for the production of adjustment work (PPNR) is a document that determines technical training and organization of commissioning work at the facility.

The project should include the following sections:

the volume in monetary and physical terms of the upcoming adjustment work (in relation to estimates);

the number and qualifications of the adjustment personnel necessary to complete the work on time, taking into account the average output;

distribution of performers at the facility in time and by sections, nodes, etc.;

the results of the analysis of project documentation, programs (tasks) for setting up the most complex electrical equipment;

work schedules, including schedules for the combined implementation of commissioning and installation work;

a list of technical and delivery documentation in relation to the items of the estimate (flow charts, PUE, instructions and forms of protocols);

a list of instruments, fixtures, materials and safety equipment necessary for the production of adjustment work;

for special cases, special safety instructions with a list of protective equipment;

a list of comments on the design, installation and defects of electrical equipment (filled in in the process of performing adjustment work);

proposals for the organization and technical training of commissioning personnel (selection of instructions, technological maps, reference and technical literature, technical training and briefing).

The commissioning project should include as a separate item the scope of commissioning work intended to be performed before the installation of electrical equipment at the facility, for example, preliminary adjustment of overhead crane cabins in the MEZ or checking UBSR units, static converter units, etc. in a specially designed maintained premises located near the object.

Stages of commissioning.
Commissioning of equipment is the most important stage of the installation process, which is a process of checking, adjusting and testing electrical equipment, which will ensure compliance with all modes and parameters specified in the electrical project. Adjustment of electrical equipment will help ensure the efficient operation of equipment, eliminate violations and shortcomings in the operation of equipment and networks, and also guarantee the safety of electrical installations.
As a rule, the installation and commissioning of equipment takes place in 4 stages or stages.

First stage is preparatory and it is at this stage that a serious commissioning organization, having requested from the customer the design and operational documentation, prepares a project for the production of works and a detailed work program, according to which the commissioning of electrical equipment will be carried out. At the same stage, it is necessary to take into account safety precautions during commissioning.
In addition, the performers must inform the customer about all the comments on the project, as well as prepare all the necessary equipment and fixtures, with the help of which the direct adjustment and testing of electrical equipment will be carried out.
The customer, in turn, is obliged to provide the specialists with all the necessary documents (project and documentation for the equipment), the equipment under test and apply voltage to the place of commissioning and installation works, agree with them on the deadlines and in every possible way promote their work.

On the second, no less important stage is the actual commissioning work in compliance with all electrical safety requirements: the commissioning of the installation and networks is carried out with the supply of electrical voltage. At this stage, the customer must coordinate with the organization in whose competence the repair and adjustment of electrical equipment, all questions and comments on installation and troubleshoot.
Upon completion of the second stage, commissioning and installation should be completed with the preparation of test reports for equipment and networks and the adjustment of the circuits of electrical voltage objects that were checked during the work.

At the third stage all individual tests of electrical equipment are carried out, and then tests of the entire technological equipment and only after that the equipment is considered fully accepted for operation. The act of technical readiness of the equipment indicates the commissioning of electrical equipment and its readiness for high-quality comprehensive testing.

Fourth stage is final and determines the final cost of commissioning. Here, a comprehensive testing of all electrical equipment takes place and, in case of successful completion of the tests, an important document is signed - an act of acceptance of commissioning and installation work.
Prices for commissioning of electrical equipment vary depending on the competence of the specialists conducting the tests.

Relations with the customer and related construction and installation organizations.

1. For the prompt resolution of organizational issues with the customer arising from the commissioning organization, no later than 1 month. before the start of adjustment work, the customer selects a group of representatives or one responsible representative (depending on the scope of adjustment work) who oversees all adjustment work (hereinafter the group is referred to as the customer).

2. Based on the practice of organizing commissioning work and drawing up contractual relations, the customer is obliged to:

within the terms agreed depending on the scope of the planned work, but no later than 3 months. before the start of commissioning work, submit to the commissioning organization all the necessary project documentation in two copies;

allocate a room for the adjustment organization to accommodate its staff and store measuring instruments. The premises are provided at the expense of the customer and must be separate, heated, secured, equipped with inventory and a local telephone;

provide the seconded personnel of the commissioning organization with living quarters with heating, lighting and bedding (in a hotel, guest house), with payment directly by the seconded workers or the commissioning organization at existing utility rates, but not more than the amounts paid to the seconded person as reimbursement of expenses for renting a living space in accordance with the current legislation; ensure the safety of equipment and installations to be adjusted, and a regime that excludes access to them by unauthorized persons; "coordinate the work schedule submitted by the commissioning organization;

to ensure the production of adjustment work, the customer, together with the electrical installation organization, must provide temporary power supply to the adjustment zone. The supply and removal of voltage must be carried out by the operating personnel at the request of the head of the adjustment work or a person allocated by him, with an entry in the log of the duty officer.

3. In order to timely master new electrical equipment, control circuits, protection and automation, the customer selects the necessary workers from the operational personnel to introduce the latter, in agreement with the commissioning organization, into the teams of adjusters.

The installation personnel eliminates all defects and shortcomings identified in the course of adjustment work and recorded in the "Journal of registration of defects in the design, installation and equipment" (form 2). The elimination of minor installation defects is carried out by the installation personnel under the supervision of the adjusters without registration in the "Journal of Adjustment and Installation Works". In other cases, in order to eliminate the unfinished work or correct installation defects, the installation is transferred to the installation organization in a disconnected state with registration in the "Magazine for the production of commissioning and installation work";

before applying voltage to the electrical installation, representatives of the installation and commissioning organizations inspect and determine the possibility of supplying voltage, and then participate in test runs.

The relationship between the commissioning organization and the general contractor is carried out through the electrical installation organization. The representative of the commissioning organization takes part in operational meetings and commissions considering the elimination of defects, the procedure and timing of tests, etc.

Preparation for commissioning of the simplest electrical installations, which do not require complex measurements, setting modes or adjusting settings, should be carried out by installation personnel.

These works include:

in power supply networks with voltage up to 1000 V - checking the phasing, measuring the insulation resistance of electrical wiring and current conductors in residential, communal and cultural buildings and change houses of industrial facilities;

measurement of insulation, determination of the direction of rotation and start-up testing of asynchronous squirrel-cage motors (with local control without a blocking device and automation) located in residential, communal and cultural facilities, as well as industrial facilities, if these engines are not included in the complex of equipment launched by the commissioning personnel;

4. During the production of adjustment work, the customer:

coordinates with the design organization or its architectural supervision, as well as with the factories - manufacturers of electrical equipment, issues related to changes in the project, the need for which was revealed in the process of commissioning;

ensures, if necessary, the design organization's supervision;

provides replacement of rejected and complete set of missing electrical equipment;

coordinates with the power system the installation of relay protection and the procedure for supplying voltage to objects;

accepts and evaluates the quality of work performed by the commissioning organization, both local and fully completed for this installation;

monitors the timely completion of installation work carried out in connection with a change in the project, the elimination of equipment defects and the comments of the acceptance committee;

organizes the preparation and conduct of trial mode operation, acceptance and acceptance tests and state tests;

draws up a program and approves the methodology for testing technological equipment for the period of trial mode operation.

5. After the completion of the commissioning work and receipt of test and commissioning reports, the customer organizes the acceptance of the equipment into operation, for which, together with the electrical installation, mechanical installation and commissioning organizations, it organizes comprehensive tests of the equipment to be handed over and its trial operation within the stipulated time (within 24 -72 hours, if there are no special instructions in the project or regulatory documents).

Delivery - acceptance of electrical installations is issued by the commissioning organization and the customer in a joint act.

6. By the time voltage is applied to the adjustment object, the operating mode is entered according to a constant scheme, while the customer must ensure that his staff is on duty to service switchgears, substations and electrical equipment associated with technological installations under voltage.

With an introduction operating mode security general conditions safety measures, execution of orders and permits for the production of commissioning or installation work in operating installations, as well as supervision during their implementation, are carried out by the customer's operational personnel.

7. Relations with the electrical installation organization (chief engineer, site manager, work foreman) are determined by the following provisions:

before the start of the commissioning, the head of the commissioning work, together with the head of the installation work, determines the degree of readiness of the object, sets the date for the start of the commissioning in accordance with the agreed schedule for the combined production of installation and commissioning works, outlines measures to ensure the safety of the production management of combined works;

permission to carry out adjustment work is issued by the head of the electrical installation work and the head of the adjustment work (at the node, section, facility) by recording in the "Journal of the production of adjustment and installation work" (form 1). At the same time, the working area for the production of adjustment work must be precisely defined (the place where the electrical equipment is located and where the test circuit will be assembled); when voltage is applied to the test circuit, the requirements of the safety regulations must be observed (posters are posted, fences are installed, etc.). The “Magazine for the production of adjustment and installation work” is kept by the head of the adjustment work. The schedule of combined work should be brought to the attention of all installation and commissioning personnel involved in the performance of work;

the installation personnel eliminates all defects and shortcomings identified in the process of commissioning and recorded in the "Journal of registration of defects in the project, installation and equipment" (form 2). The elimination of minor installation defects is carried out by the installation personnel under the supervision of the adjusters without registration in the "Journal of Adjustment and Installation Works". In other cases, in order to eliminate the unfinished work or correct installation defects, the installation is transferred to the installation organization in a disconnected state with registration in the "Magazine for the production of commissioning and installation work";

General requirements

92. Technical re-equipment of HIFs, installation (dismantling), repair, reconstruction (modernization), adjustment of pressure equipment must be carried out by specialized organizations that have the status of a legal entity and an organizational form that meets the requirements of the legislation of the Russian Federation, as well as individual entrepreneurs (hereinafter referred to as specialized organizations ).

93. When installing, repairing, adjusting pressure equipment, the requirements of the equipment manufacturer specified in the operating manual (instruction) must be met.

94. Reconstruction (modernization) of pressure equipment must be carried out according to the project developed by the organization - the manufacturer of the equipment or the design organization. If the reconstruction (modernization) is carried out with deviations from the requirements of the operating manual (instruction), then these deviations must be agreed with the developer of the operating manual (instruction). If the volume and nature of reconstruction (modernization) work involves changing the design of the main elements and technical characteristics of the equipment, creating the need for a new passport and operating manual (instruction), then after completion of the work, confirmation of compliance of the equipment with the requirements of TR CU 032 / 2013 with subsequent commissioning in accordance with the requirements of these FNR.

95. Used in the installation, repair and reconstruction (modernization) of pressure equipment, materials and semi-finished products must provide safe operating parameters determined by their mechanical properties, chemical composition, manufacturing technology, methods and volumes of testing and quality control, guaranteed level of design and technological characteristics , and must comply with the requirements of the manufacturer's technical documentation and project documentation. The use of other materials in the repair of equipment is allowed subject to agreement on the possibility of their use with the project developer and (or) manufacturer, and in case of their absence, on the basis of the conclusion of a research organization specializing in the field of materials science.

The use of semi-finished products made from new materials during installation, repair and reconstruction (modernization) of pressure equipment is allowed on the basis of the results of studies (research certification) carried out by a research organization confirming the provision of safe operating parameters, as well as positive experience in their use in the manufacture pressure equipment.

96. Employees of a specialized organization who directly carry out work on the installation (dismantling), repair, reconstruction (modernization) and adjustment of pressure equipment, in the manner established by the organization's administrative documents in accordance with the Regulations on the organization of work on the training and certification of specialists from organizations supervised by the Federal Service for Environmental, Technological and Nuclear Supervision (hereinafter referred to as the regulation on certification), and the Regulation on the organization of training and knowledge testing of workers organizations supervised by the Federal Service for Environmental, Technological and Nuclear Supervision (hereinafter referred to as the regulation on knowledge testing), approved by order of Rostekhnadzor dated January 29, 2007 N 37 (registered by the Ministry of Justice of the Russian Federation on March 22, 2007, registration N 9133; Bulletin of normative acts of federal executive bodies, 2007, N 16) as amended by orders of Rostekhnadzor dated July 5, 2007 N 450 (registered by the Ministry of Justice of the Russian Federation on July 23, 2007, registration N 9881; Bulletin of regulatory acts of federal executive authorities, 2007, N 31), dated August 27, 2010 N 823 (registered by the Ministry of Justice of the Russian Federation on September 7, 2010, registration N 18370; Bulletin of regulatory acts of federal executive authorities, 2010, N 39), dated December 15, 2011 N 714 (registered by the Ministry of Justice of the Russian Federation on February 8, 2012, registration N 23166; Bulletin of normative acts of federal executive bodies, 2012, N 13), by order of Rostekhnadzor dated December 19, 2012 N 739 (registered by the Ministry of Justice of the Russian Federation April 5, 2013, registration N 28002; Rossiyskaya Gazeta, 2013, N 80), must pass:

a) managers and specialists - training and certification in the field of industrial safety and these FNR in the scope of official duties established by the administrative documents of a specialized organization;

b) workers - testing knowledge in the scope of qualification requirements (as part of vocational training), as well as in the scope of requirements production instructions and (or) instructions for this profession.

Periodic certification of managers and specialists is carried out once every five years.

Testing the knowledge of the requirements of production instructions and (or) instructions for a given profession among workers is carried out once every 12 months.

Extraordinary certification of managers and specialists and testing of workers' knowledge is carried out in cases established by the regulation on certification and the regulation on knowledge testing.

97. Welders and welding production specialists involved in the repair, installation, reconstruction (modernization) of pressure equipment must undergo certification in accordance with the established procedure in accordance with the Rules for the certification of welders and welding production specialists approved by the Decree of the Federal Mining and Industrial Supervision of Russia dated October 30, 1998 N 63 (registered by the Ministry of Justice of the Russian Federation on March 4, 1999, registration N 1721; Bulletin of normative acts of federal executive bodies, 1999, N 11-12), as amended by order of the Federal Service for Ecological, Technological and Nuclear supervision of October 17, 2012 N 588 (registered by the Ministry of Justice of the Russian Federation on November 23, 2012, registration N 25903; Rossiyskaya Gazeta, 2012, N 283); Technological regulations for the certification of welders and specialists in welding production, approved by the Decree of the Federal Mining and Industrial Supervision of Russia of June 25, 2002 N 36 (registered by the Ministry of Justice of the Russian Federation on July 17, 2002, registration N 3578; Bulletin of regulatory acts of federal executive bodies, 2002, No. 32), as amended by Order No. 588 of the Federal Environmental, Industrial and Nuclear Supervision Service of October 17, 2012 (registered by the Ministry of Justice of the Russian Federation on November 23, 2012, registration No. 25903; Rossiyskaya Gazeta, 2012, No. 283).

98. Personnel performing non-destructive testing of the quality of welded joints must, in accordance with the established procedure, undergo certification in accordance with the Rules for Certification of Personnel in the Field of Non-Destructive Testing, approved by Decree of the Federal Mining and Industrial Supervision of Russia dated January 23, 2002 N 3 (registered by the Ministry of Justice of the Russian Federation 17 April 2002, registration N 3378; Bulletin of normative acts of federal executive bodies 2002, N 17).

99. Employees must know how to provide first aid to victims of accidents.

Requirements for organizations that carry out installation, repair, reconstruction (modernization), adjustment of equipment and for employees of these organizations

100. The management structure in a specialized organization should provide each employee with a specific area of activity and the limits of his powers. The distribution of responsibility of employees of a specialized organization should be established in the regulation on monitoring compliance with technological processes of a specialized organization.

101. The specialized organization must:

a) have managers and specialists who meet the requirements of paragraphs 96, 97 of these FNR, to ensure the performance of work within their official duties and powers, including the identification of cases of deviation from the requirements for the quality of work, from the procedures for performing work and taking measures to prevent or reducing such derogations;

b) to have personnel in the amount established by the administrative documents of a specialized organization and allowing to ensure the implementation of technological processes in the performance of the relevant work;

c) not allow persons under the age of eighteen or persons with medical contraindications to the performance of these works to carry out work on the installation (dismantling), adjustment or repair or reconstruction (modernization) of equipment under pressure;

d) determine the procedures for monitoring compliance with technological processes;

e) establish the responsibility, powers and procedure for the relationship of employees involved in the management, performance or verification of the performance of work.

102. Technological preparation of production and manufacturing process in a specialized organization should exclude the use of materials and products for which there are no documents confirming their compliance and quality (certificates, passports, forms).

When installing, repairing, reconstructing (modernizing) equipment, it is prohibited to use steel pipes that were previously in use.

103. A specialized organization should have the following necessary documentation ensuring the performance of the declared types of work:

a) a list of regulatory documents used in the performance of relevant work in a specialized organization to ensure industrial safety requirements established by the legislation in the field of industrial safety and these FNR, approved by the head of a specialized organization;

b) design and technical documentation (including a set of working drawings) of pressure equipment, installation (dismantling), adjustment, repair, reconstruction (modernization) of which is carried out;

c) technological documentation for the production of the declared types of work, developed before the start of these works;

d) programs-methods for testing mounted (repaired, reconstructed) equipment under pressure, carried out upon completion of work.

104. To ensure technological processes during installation (dismantling), adjustment or repair or reconstruction (modernization), a specialized organization, depending on the types of activities carried out, must have:

a) kits necessary equipment to perform work on monitoring the technical condition of pressure equipment before and after work;

b) assembly and welding, thermal equipment necessary for cutting, straightening, welding and heat treatment of metal, as well as the necessary welding materials. The welding technologies used must be certified in the prescribed manner;

c) control equipment, instruments and tools necessary to detect unacceptable defects in welded joints. To perform work on non-destructive and destructive quality control of welded joints, a specialized organization must have or engage on a contractual basis a laboratory certified in the prescribed manner;

d) measuring and control instruments that have passed metrological verification and allow performing adjustment work, assessing performance, performing repairs, reconstruction (modernization);

e) rigging and mounting devices, lifting mechanisms, jacks, slings necessary for mounting (dismantling), repair, reconstruction (modernization), as well as auxiliary devices (scaffolds, fences, scaffolding) that can be used during work .

105. Employees of specialized organizations directly performing installation (dismantling), adjustment or repair or reconstruction (modernization) of pressure equipment during its operation must meet the following requirements:

a) have documents confirming the passage of vocational training in the prescribed manner in the relevant types of working specialties, as well as a certificate of admission to independent work(for workers);

b) have documents confirming the passage of attestation in accordance with the established procedure (for managers and specialists);

c) know and comply with the requirements of technological documents and instructions for carrying out the declared work;

d) know the main sources of hazards during the specified work, know and put into practice methods of protection against them, as well as safe methods of performing work;

e) know and be able to apply the methods for identifying and eliminating defects in the process of installation, repair, reconstruction (modernization);

f) to know and be able to use for the installation (dismantling), repair and reconstruction (modernization) of equipment rigging and mounting devices, lifting mechanisms, slings, corresponding in terms of carrying capacity to the masses of the mounted (dismantled), repaired and reconstructed (modernized) elements;

g) know and be able to apply the procedure for exchanging conditional signals established in the instructions between the employee supervising the installation (dismantling) and other employees involved in the installation (dismantling) of equipment;

h) know and follow the rules of slinging, the basic schemes for slinging goods (when performing the duties of a slinger), as well as industrial safety requirements for lifting and moving goods;

i) know the procedure and methods for performing work on setting up and regulating equipment;

j) be able to use control tools, instruments, devices during verification, adjustment and testing.

Requirements for installation, repair and reconstruction (modernization) of equipment

106. Installation, repair and reconstruction (modernization) of pressure equipment using welding and heat treatment must be carried out according to the technology and working drawings developed before the commencement of work by a specialized organization performing the relevant work.

All provisions of the adopted technology should be reflected in the technological documentation regulating the content and procedure for performing all technological and control operations.

107. During installation, repair and reconstruction (modernization) with the use of welding and heat treatment, the quality control system (input, operational, acceptance) established by the administrative documents of a specialized organization must be applied, ensuring the performance of work in accordance with these FNP and technological documentation.

108. Routine preventive repairs and maintenance of equipment that do not require the use of welding and heat treatment are performed by employees (repair personnel) of the operating or specialized organization. The order of performance, volume and frequency of work performance are determined by the production and technological instructions, developed taking into account the requirements of the manuals (instructions) for operation and the actual condition of the equipment.

Cutting and deformation of semi-finished products

109. Cutting of sheets, pipes and other semi-finished products, as well as cutting holes can be done by any method (mechanical, flame, electric arc, plasma). The specific method and technology of cutting is established by technological documentation depending on the classes of steels (material characteristics).

110. The technology used for thermal cutting of materials sensitive to local heating and cooling should exclude the formation of cracks on the edges and the deterioration of metal properties in the heat-affected zone. In necessary cases, provided for by the technological documentation, preheating and subsequent machining of the edges should be provided to remove a layer of metal with properties degraded during the cutting process.

111. Bending of pipes is allowed to be carried out by any method mastered by a specialized organization that ensures the quality of the bend that meets the requirements of the technological documentation.

112. To ensure the mating of the transverse joints of pipes, boring, expansion or compression of the ends of the pipes is allowed. The values of boring, expansion deformation or reduction are accepted within the limits established by the technological documentation.

113. Cold tension of pipelines, if it is provided for by the project, can be made only after all welded joints have been completed, with the exception of the closing, final fixing of fixed supports at the ends of the section subject to cold tension, as well as after heat treatment (if necessary) and control the quality of welded joints located along the entire length of the section on which it is necessary to produce a cold fit.

Welding

114. During additional manufacturing at the place of operation, installation, repair, reconstruction (modernization) of pressure equipment, a welding technology certified in accordance with established requirements must be applied.

115. Technological documentation should contain instructions on metal welding technology (including tack welding), use of filler materials, types and scope of control, as well as on preliminary and concomitant heating and heat treatment. Welding requirements also apply to overlays.

116. To perform welding, serviceable installations, equipment and fixtures must be used to ensure compliance with the requirements of technological documentation.

117. Welders who have a certificate for the right to perform these welding operations are allowed to carry out work on welding and tacking of equipment elements designed to work under pressure. Welders must perform only those types of welding work for which, according to the certificate, they are admitted.

A welder who for the first time in this specialized organization starts welding pressure equipment and its elements, regardless of whether he has a certificate, must undergo a test by welding and testing a trial welded joint before being allowed to work. The design of the test welded joint must correspond to the types of work specified in the welder's certificate. Methods, volumes and norms of quality control of welding of a test welded joint must meet the requirements of technological documentation.

118. The management of assembly, welding and quality control of welded joints should be entrusted to a specialist who has passed certification in the prescribed manner.

119. Before starting welding, the assembly quality of the elements to be joined, as well as the condition of the joined edges and adjacent surfaces, should be checked. When assembling, it is not allowed to adjust the edges by impact or local heating.

120. Preparation of edges and surfaces for welding must be performed by mechanical processing or by thermal cutting or gouging (oxygen, air-arc, plasma-arc) followed by mechanical processing (cutter, cutter, abrasive tool). Depth machining after thermal cutting (gouging) should be indicated in the technological documentation, depending on the susceptibility of a particular steel grade to the thermal cycle of cutting (gouging).

121. When assembling butt joints of pipes with one-sided cutting of edges and welded without backing rings and root welding, the displacement (mismatch) of the inner edges should not exceed the values established in the technological documentation.

122. The edges of the parts to be welded and the areas adjacent to them must be cleaned of scale, paint, oil and other contaminants in accordance with the requirements of the technological documentation.

123. Welding and removal auxiliary elements(assembly devices, temporary fasteners) must be produced in accordance with the instructions of the drawings and technological documentation for a technology that excludes the formation of cracks and hardening zones in the metal of pressure equipment. Welding of these elements must be carried out by a welder authorized to carry out welding work on this pressure equipment.

124. Tacking of elements assembled for welding must be performed using the same welding consumables that will be used (or are allowed to be used) for welding this joint.

Tacks during further welding are removed or remelted with the main seam.

125. Welded joints of elements operating under excessive pressure with a wall thickness of more than 6 mm are subject to marking (branding), which makes it possible to establish the name of the welder who performed the welding. The marking system is indicated in the technological documentation. The method of marking should exclude hardening, hardening or unacceptable thinning of the metal thickness and ensure the safety of the marking throughout the entire period of operation of the equipment.

The necessity and method of marking welded joints with a wall thickness of 6 mm or less is established by the requirements of technological documentation.

126. If all welded joints of this equipment are made by one welder, then it is allowed not to mark each welded joint. In this case, the welder's stamp should be placed near the name plate or on another open area enclose the equipment and the place of branding in a frame applied with indelible paint. Marking places must be indicated in the equipment passport (or in the assembly drawings attached to the passport).

127. If a welded joint was performed by several welders, then it must be stamped by each welder who participated in its implementation, in the manner established in the technological documentation.

128. Welding consumables used for welding pressure equipment during its installation, repair, reconstruction (modernization) must comply with the requirements of design documentation and operating manual (instruction).

129. Brand, assortment, storage conditions and preparation for use of welding consumables must comply with the requirements of technological documentation.

130. Welding consumables must be controlled:

a) availability of relevant supporting documentation;

b) each batch of electrodes - for welding and technological properties, as well as for the compliance of the content of alloying elements with the normalized composition by steeloscopy (or other spectral method that provides confirmation of the presence of alloying elements in the metal) of the deposited metal made by alloyed electrodes;

c) each batch of flux-cored wire - for welding and technological properties;

d) each coil (coil, coil) alloyed welding wire- for the presence of the main alloying elements by steeloscopy or another spectral method that provides confirmation of the presence of alloying elements in the metal;

e) each batch of wire with each batch of flux, which will be used together for automatic submerged arc welding, on the mechanical properties of the weld metal.

131. Welding technology during installation, repair, reconstruction (modernization) of pressure equipment is allowed to be used after confirming its manufacturability on real products, checking the entire range of required properties of welded joints and mastering effective methods for controlling their quality. The applied welding technology must be certified in accordance with the established requirements.

132. Certification of welding technology is divided into research and production. Research certification is carried out by a research organization in preparation for the introduction of a new, previously uncertified welding technology. Production certification is carried out by each specialized organization on the basis of recommendations issued based on the results of research certification.

133. Research certification of welding technology is carried out in order to determine the characteristics of welded joints necessary for calculations in the design and issuance of technological recommendations (area of application of the technology, welding materials, heating, welding and heat treatment modes, guaranteed indicators of acceptance characteristics of a welded joint, control methods).

The characteristics of welded joints, determined during research certification, are selected depending on the type and purpose of the base metal and the following operating conditions for welded joints:

a) mechanical properties at normal (20 ± 10 ° C) and operating temperatures, including tensile strength, yield strength, relative elongation and relative narrowing of the weld metal, impact strength of the weld metal and welding heat-affected zones, tensile strength and angle bending of the welded joint;

b) long-term strength, ductility and creep;

c) cyclic strength;

d) critical temperature of brittleness of the weld metal and welding heat-affected zone;

e) stability of the properties of welded joints after thermal aging at operating temperature;

f) the intensity of oxidation in the working environment;

g) the absence of unacceptable defects;

h) resistance to intergranular corrosion (for welded joints of elements made of austenitic steels);

i) characteristics specific to the performed welded joints, established by the organization conducting their research certification.

Based on the results of the research certification, the organization that conducted it should issue recommendations necessary for its practical application.

134. The production certification of the welding technology is carried out before the start of its application in order to verify the compliance of the welded joints made according to it in specific production conditions with the requirements of these FNP and technological documentation. Production certification must be carried out for each group of the same type of welded joints performed in this specialized organization.

135. Production certification is carried out by an attestation commission established in a specialized organization in accordance with a program developed by this organization and approved by the chairman of the commission.

The program should provide for non-destructive and destructive testing of welded joints, assessment of the quality of welding based on the results of control and execution of the final document based on the results of production certification.

The procedure for conducting production certification is determined by the technological documentation.

If, during the production certification of a welding technology, unsatisfactory results are obtained for any type of test, the certification commission must take measures to find out the reasons for the discrepancy between the results obtained and the established requirements and decide whether it is necessary to re-test or this technology cannot be used for welding production joints and needs in revision.

136. In the event of a deterioration in the properties or quality of welded joints in relation to the level established by research certification, a specialized organization must suspend the use of welding technology, establish and eliminate the causes that caused their deterioration, and conduct a re-production certification, and, if necessary, research certification.

137. When installing, repairing, reconstructing (modernizing) equipment under pressure, any certified welding technologies may be applied.

It is not allowed to use gas welding for parts made of austenitic steels and high-chromium steels of martensitic and martensitic-ferritic class.

138. Welding of elements operating under excess pressure, as a rule, should be carried out at a positive ambient temperature. It is allowed to perform welding in conditions of negative temperature, subject to the requirements of technological documentation and the creation of the necessary conditions to protect the welding site and the welder from the effects of wind and precipitation. At negative ambient temperatures, the metal in the area of the welded joint must be dried and heated before welding, bringing the temperature to a positive value.

139. The need for and mode of preliminary and concomitant heating of the parts to be welded are determined by the welding technology and must be indicated in the technological documentation. At a negative ambient temperature, heating is carried out in the same cases as with a positive one, while the heating temperature should be 50 ° C higher.

140. After welding, the seam and adjacent areas must be cleaned of slag, metal splashes and other contaminants.

The internal flash in the joints of pipes made by resistance welding must be removed to ensure a given flow section.

141. Heat treatment of equipment elements during installation, repair, reconstruction (modernization) is carried out in cases established by the technological documentation, taking into account the manufacturer's recommendations specified in the operating manual (instruction).

Quality control of welded joints

142. During additional production at the place of operation, installation, repair, reconstruction (modernization) of pressure equipment, a quality control system for welded joints must be applied, which guarantees the detection of unacceptable defects, high quality and reliability of operation of this equipment and its elements.

143. Control methods must be selected in accordance with the requirements of these FNR and specified in the technological documentation.

144. Quality control of welded joints should be carried out in the manner prescribed by the design and technological documentation.

145. Quality control of welded joints is carried out by the following methods:

a) visual inspection and measurements;

b) ultrasonic flaw detection;

c) radiography (X-ray, gammagraphy);

d) capillary and magnetic particle control;

e) steeloscopy or another spectral method that provides confirmation of the actual grade of the metal or the presence of alloying elements in it;

e) hardness measurement;

g) control mechanical properties, resistance test against intergranular corrosion, metallographic studies (destructive testing);

h) hydraulic tests;

i) acoustic emission;

j) radioscopy;

k) eddy current control;

l) determination of the content of the ferrite phase in the weld metal;

m) pneumatic tests, if hydraulic tests are not carried out according to the manufacturer's instructions;

n) running a metal ball (for elements of pipe heating surfaces of boilers in the case of welding for their assembly during installation or repair).

146. Acceptance quality control of welded joints should be carried out after all technological operations have been completed.

147. Visual and measurement control, as well as steeloscopy provided for by the technological documentation (or other spectral method that provides confirmation of the actual metal grade or the presence of alloying elements in it) must precede control by other methods.

148. The results for each type of control carried out and the place of control should be recorded in the reporting documentation (journals, forms, protocols, route passports).

149. Means of control must undergo metrological verification in the prescribed manner.

150. Each batch of materials for flaw detection (penetrants, powder, suspensions, radiographic film, chemical reagents) must be subjected to incoming control before they are used.

151. Methods and scope of control of welded joints of welded parts that do not work under internal pressure must be established by technological documentation.

152. The results of quality control of welded joints are recognized as positive, if no internal and surface defects that go beyond the allowable standards established by the design and technological documentation are detected during any provided type of control.

Visual inspection and measurements

153. Visual inspection and measurements are subject to all welded joints in order to identify the following defects:

a) cracks of all types and directions;

b) fistulas and porosity of the outer surface of the weld;

c) undercuts;

d) influxes, burns, unmelted craters;

e) deviations in geometric dimensions and relative position elements to be welded;

f) displacement and joint removal of the edges of the elements to be welded in excess of the prescribed standards;

g) non-compliance of the shape and dimensions of the seam with the requirements of technological documentation;

h) defects on the surface of the base metal and welded joints (dents, delaminations, shells, lack of penetration, pores, inclusions).

154. Before visual inspection of the surface of the weld and adjacent sections of the base metal with a width of at least 20 mm on both sides of the weld, they must be cleaned from slag and other contaminants.

Inspection and measurements of welded joints should be carried out from the outer and inner sides (if possible) along the entire length of the welds. If it is impossible to inspect and measure the welded joint from both sides, its control must be carried out in the manner prescribed by the project developer.

155. Surface defects revealed during visual inspection and measurements must be corrected before testing by other non-destructive methods.

Ultrasonic flaw detection and radiographic inspection

156. Ultrasonic flaw detection and radiographic control is carried out in order to identify internal defects in welded joints (cracks, lack of penetration, slag inclusions).

The control method (ultrasonic, radiographic, both methods in combination) is chosen based on the possibility of providing the most complete and accurate detection of defects in a particular type of welded joints, taking into account the characteristics of the physical properties of the metal and this control method.

The scope of control for each specific type of pressure equipment is indicated in the design and process documentation.

157. Butt welded joints that have been subjected to repair overcooking (elimination of a weld defect) must be checked by ultrasonic flaw detection or radiographic control along the entire length of the welded joints.

Repair welds of metal samples should be checked by ultrasonic flaw detection or radiographic inspection throughout the welding area, including the welding heat-affected zone in the base metal, in addition, the surface of the area should be checked by magnetic particle or capillary flaw detection. When welding through the entire thickness of the wall, surface inspection must be carried out on both sides, except in cases of inaccessibility inside for control.

158. If unacceptable defects are found during selective inspection of welded joints made by a welder, then all welded joints of the same type along the entire length made by this welder shall be subjected to control.

159. Ultrasonic flaw detection and radiographic control of butt welded joints, in agreement with the developer of project documentation, can be replaced by other non-destructive testing methods that allow detecting internal defects in welded joints.

Capillary and magnetic particle testing

160. Capillary and magnetic particle testing of welded joints are additional control methods established by technological documentation in order to determine surface or subsurface defects.

The class and level of sensitivity of capillary and magnetic particle testing must be established by the technological documentation.

Steeloscopy control

161. Control by steeloscopy or other spectral method, which provides confirmation of the actual grade of the metal or the presence of alloying elements in it, is carried out in order to confirm the compliance of the alloying of the metal of welds and elements of equipment under pressure with the requirements of drawings, technological documentation.

Hardness measurement

162. Measurement of the hardness of the metal of a welded joint is carried out in order to check the quality of the heat treatment of welded joints. Hardness measurement is subject to the weld metal of welded joints made of alloyed heat-resistant steels of pearlitic and martensitic-ferritic classes, by methods and to the extent established by the technological documentation.

Mechanical tests, metallographic studies, tests for resistance to intergranular corrosion

163. Control butt welded joints should be subjected to mechanical tests in order to verify the compliance of their mechanical properties with the requirements of design and technological documentation. Mandatory types of mechanical tests are tests for static tension, static bending or flattening. For pressure vessels obligatory view test is also an impact test. Impact bending tests are carried out for vessels made of steels prone to hardening during welding, as well as for other vessels intended for operation at a pressure of more than 5 MPa or a temperature above 450 ° C, for operation at a temperature below -20 ° C.

Mechanical tests are carried out at:

b) control of welded butt joints made by gas and resistance welding;

c) input control of welding consumables used in submerged arc welding and electroslag welding.

If unsatisfactory results are obtained for any type of mechanical testing, a second test is allowed on a double number of samples cut from the same control welded joints, according to the type of tests for which unsatisfactory results were obtained. If, during a repeated test, at least on one of the samples, property indicators that do not meet the established standards are obtained, the overall assessment of this type of test is considered unsatisfactory.

164. The necessity, scope and procedure for mechanical testing of welded joints of cast and forged elements, pipes with cast parts, elements made of steels of various classes, as well as other single welded joints are established by design and technological documentation.

165. Metallographic studies are carried out in order to identify possible internal defects (cracks, lack of penetration, pores, slag and non-metallic inclusions), as well as areas with a metal structure that adversely affects the properties of welded joints.

Metallographic studies are carried out at:

a) certification of welding technology;

b) control of welded butt joints made by gas and contact welding, as well as parts made of steels of different structural classes (regardless of the welding method);

c) control of welded corner and tee joints, including joints of pipes (fittings) with shells, drums, collectors, pipelines, as well as tee joints;

d) control of the degree of graphitization of welded joints of equipment elements made of carbon steels and working under pressure with a working medium temperature of more than 350°C.

Metallographic studies are allowed not to be carried out:

a) for welded joints of vessels and their elements made of austenitic steels, up to 20 mm thick;

b) for welded joints of boilers and pipelines made of pearlitic steel, subject to the control of these joints by ultrasonic flaw detection or radiographic control in the amount of 100%;

c) for welded joints of pipes of heating surfaces of boilers and pipelines, made by contact welding on special machines for contact butt welding with an automated work cycle during a shift-based check of the quality of the machine's adjustment by testing control samples.

166. Tests for resistance against intergranular corrosion for boilers, pipelines and their elements are carried out in cases provided for by technological documentation, in order to confirm corrosion resistance welded joints of parts made of austenitic steels.

Testing of welded joints for resistance against intergranular corrosion should be carried out for vessels and their elements made of steels of austenitic, ferritic, austenitic-ferritic classes and two-layer steels with a corrosion-resistant layer of austenitic and ferritic steels. The shape, dimensions, number of samples, test methods and criteria for assessing the susceptibility of samples to intergranular corrosion must comply with the requirements of design and process documentation.

167. Mechanical tests, metallographic studies, tests for resistance to intergranular corrosion must be performed on samples made from control welded joints. The control welded joints must be identical to the controlled production ones (in terms of steel grades, sheet thickness or pipe sizes, shape of the groove, welding method, welding materials, weld position in space, heating modes and temperature, heat treatment) and made by the same welder and on the same welding equipment simultaneously with a controlled production connection.

The control welded joint is subjected to 100% control by the same non-destructive control methods that are provided for production welded joints. In case of unsatisfactory results of the control, the control compounds should be made again in a double quantity. If unsatisfactory results are obtained during repeated non-destructive testing, then the overall result is considered unsatisfactory. In this case, the quality of materials, equipment and qualifications of the welder must be subjected to additional checks.

The dimensions of the control joints must be sufficient to cut out the required number of samples from them for all types of tests and studies provided, as well as for repeated tests and studies.

From each control butt weld, the following shall be cut:

a) two static tensile test specimens;

b) two test pieces for static bending or flattening;

c) three test pieces for impact bending;

d) one sample (section) for metallographic studies when inspecting welded joints made of carbon and low-alloy steel, and at least two - when inspecting welded joints made of high-alloy steel, if this is provided for by the technological documentation;

e) two test specimens for resistance to intergranular corrosion.

168. Tests for static bending of the control joints of tubular elements with a nominal pipe diameter of less than 100 mm and a wall thickness of less than 12 mm can be replaced by flattening tests.

Hydraulic (pneumatic) test

169. Hydraulic test in order to check the density and strength of equipment under pressure, as well as all welded and other joints, is carried out:

a) after installation (additional production) at the installation site of equipment transported to the installation (additional production) site in separate parts, elements or blocks;

b) after reconstruction (modernization), repair of equipment using welding of pressure elements;

c) when carrying out technical examinations and technical diagnostics in cases established by these FNR.

Hydraulic testing of individual parts, elements or blocks of equipment at the place of installation (additional production) is not mandatory if they have passed a hydraulic test at their places of manufacture or have been subjected to 100% control by ultrasound or other equivalent non-destructive method of flaw detection.

It is allowed to conduct a hydraulic test of individual and prefabricated elements together with the equipment, if under the conditions of installation (additional production) it is impossible to test them separately from the equipment.

Hydraulic testing of equipment and its elements is carried out after all types of control, as well as after the elimination of detected defects.

170. Vessels with a protective coating or insulation are subjected to a hydraulic test before coating or insulation is applied.

Vessels with an outer casing are subjected to a hydraulic test before the casing is installed.

It is allowed to subject enamelled vessels to a hydraulic test with working pressure after enamelling.

171. The minimum value of test pressure * during a hydraulic test for steam and hot water boilers, superheaters, economizers, as well as for pipelines within the boiler, is taken:

a) at a working pressure of not more than 0.5 MPa - 1.5 working pressure, but not less than 0.2 MPa;

b) at working pressure over 0.5 MPa - 1.25 working pressure, but not less than working pressure plus 0.3 MPa.

When conducting a hydraulic test of drum boilers, as well as their superheaters and economizers, the pressure in the boiler drum is taken as the working pressure when determining the value of the test pressure, and for drumless and once-through boilers with forced circulation, the pressure of the feed water at the inlet to the boiler, established by the project documentation.

The maximum value of the test pressure is set by calculations for the strength of steam and hot water boilers.

The value of the test pressure (between the maximum and minimum) should ensure the greatest detection of defects in the boiler or its elements subjected to hydraulic testing.

172. The value of test pressure P pr during hydraulic testing of metal vessels (with the exception of cast ones), as well as electric boilers, is determined by the formula:

where P - working pressure, MPa;

Permissible stresses for the material of the vessel (electric boiler) or its elements, respectively, at 20°C and design temperature, MPa.

The ratio of materials of assembly units (elements) of the vessel (electric boiler) operating under pressure is taken according to the used materials of the elements (shells, bottoms, flanges, nozzles, etc.) of the vessel, for which it is the smallest, with the exception of bolts (studs), as well as heat exchange tubes of shell-and-tube heat exchangers.

The test pressure when testing a vessel calculated by zones should be determined taking into account the zone, the design pressure or design temperature of which is less important.

The test pressure for testing a vessel designed to operate in several modes with different design parameters (pressures and temperatures) should be taken equal to the maximum of the determined test pressure values for each mode.

If, in order to ensure strength and tightness conditions during testing, it becomes necessary to increase the diameter, number or replacement of the material of bolts (studs) of flange connections, it is allowed to reduce the test pressure to the maximum value at which, during testing, the strength conditions of bolts (studs) are provided without increasing them diameter, quantity or replacement of material.

If the vessel as a whole or individual parts of the vessel operate in the creep temperature range and the allowable stress for the materials of these parts at the design temperature is determined on the basis of the ultimate strength or creep limit, it is allowed in formulas (1), (7) to use the allowable stress value instead at the design temperature , obtained only on the basis of time-independent characteristics: yield strength and tensile strength without taking into account creep and long-term strength.

During hydraulic testing of technological pipelines, the value of test pressure * is determined by formula (1).

173. The value of test pressure P pr during hydraulic testing of cast and forged vessels is determined by the formula

It is allowed to test castings after assembly and welding in an assembled unit or a finished vessel test pressure accepted for vessels, subject to 100% control of castings by non-destructive methods.

174. Hydraulic testing of vessels and parts made of non-metallic materials with an impact strength of more than 20 J / cm 2 must be carried out with a test pressure determined by the formula:

Hydraulic testing of vessels and parts made of non-metallic materials with an impact strength of 20 J / cm 2 or less must be carried out with a test pressure determined by the formula:

175. The value of test pressure P pr during hydraulic testing of cryogenic vessels in the presence of vacuum in the insulating space is determined by the formula:

R pr \u003d 1.25 R-0.1 (5)

176. Hydraulic testing of metal-plastic vessels must be carried out with a test pressure determined by the formula:

Rpr= (6)

where K m is the ratio of the mass of the metal structure to the total mass of the vessel;

a\u003d 1.3 - for non-metallic materials with an impact strength of more than 20 J / cm 2;

a\u003d 1.6 - for non-metallic materials with an impact strength of 20 J / cm 2.

177. Hydraulic testing of vessels installed vertically is allowed to be carried out in horizontal position, in this case, the calculation of the strength of the vessel body should be performed, taking into account the accepted method of support for conducting a hydraulic test.

In combined vessels with two or more working cavities designed for different pressures, each cavity must be subjected to a hydraulic test with a test pressure determined depending on the design pressure of the cavity.

The procedure for testing such vessels must be established by the developer of the design technical documentation and specified in the vessel's operating manual.

178. The minimum value of test pressure during hydraulic testing of pipelines of steam and hot water, their blocks and individual elements should be 1.25 working pressure, but not less than 0.2 MPa. Fittings and fittings of pipelines must be subjected to a hydraulic test with test pressure in accordance with the technological documentation. The maximum value of the test pressure is set by calculations for the strength of pipelines.

The value of the test pressure (between the maximum and minimum) should ensure the greatest detection of defects in the pipeline or its elements subjected to hydraulic testing.

179. For hydraulic testing of equipment under pressure, water should be used. The water temperature should not be lower than 5°C and not higher than 40°C, unless the technical documentation of the equipment manufacturer indicates a specific temperature value that is acceptable under the conditions for preventing brittle fracture.

During hydraulic testing of steam pipelines operating at a pressure of 10 MPa and above, the temperature of their walls must be at least 10 ° C.

During hydraulic testing of steam and hot water boilers, the upper limit of water temperature can be increased in agreement with the design organization to 80°C. If the temperature of the drum top metal exceeds 140°C, filling it with water for hydraulic testing is not allowed.

The water used for hydraulic testing must not contaminate the equipment or cause severe corrosion.

The temperature difference between the metal and the ambient air during the hydraulic test should not lead to moisture condensation on the surface of the equipment walls.

In technically substantiated cases provided by the manufacturer, it is allowed to use another liquid when conducting a hydraulic test during the operation of vessels.

180. When filling equipment with water, air must be completely removed from it.

The pressure in the equipment under test should be raised smoothly and evenly. The total pressure rise time (up to the test value) must be indicated in the technological documentation. Water pressure during hydraulic testing should be controlled by at least two pressure gauges. Both pressure gauges choose the same type, measurement limit, the same accuracy classes (not lower than 1.5) and divisions.

The use of compressed air or other gas to pressurize equipment filled with water is not permitted.

The exposure time under test pressure for steam and hot water boilers, including electric boilers, steam and hot water pipelines, as well as vessels assembled at the installation site, is set by the manufacturer in the operating manual and must be at least 10 minutes.

The exposure time under test pressure of vessels of element-by-element block supply, additionally manufactured during installation at the place of operation, must be at least:

a) 30 minutes with a vessel wall thickness of up to 50 mm;

b) 60 minutes with vessel wall thickness over 50 to 100 mm;

c) 120 min with vessel wall thickness over 100 mm.

For cast, non-metallic and multilayer vessels, regardless of the wall thickness, the holding time must be at least 60 minutes.

The exposure time of process pipelines under test pressure during a hydraulic test must be at least 15 minutes.

If the process pipeline is tested together with the vessel (apparatus) to which it is connected, the exposure time is taken according to the time required for the vessel (apparatus).

181. After exposure under test pressure, the pressure is reduced to a value justified by the strength calculation, but not less than the working pressure, at which visual inspection of the outer surface of the equipment and all its detachable and one-piece connections is carried out.

182. During a hydraulic test, the boiler is considered to have passed the test if it is not found:

a) visible residual deformations;

b) cracks or signs of rupture;

c) leaks in welded, detachable connections and in the base metal;

In the detachable connections of the boilers, the appearance of individual drops is allowed, which do not increase in size during time delay.

183. During a hydraulic test, the pipeline is considered to have passed the test if it is not found:

a) leaks, sweating in welded joints and in the base metal;

b) visible residual deformations;

c) cracks or signs of rupture;

d) pressure drop on the pressure gauge.

184. During a hydraulic test, the vessel is considered to have passed the test if it is not found:

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

b) leaks in detachable connections;

c) visible residual deformations, pressure drop on the pressure gauge.

185. After a hydraulic test, it is necessary to ensure the removal of water from the equipment under test.

The equipment and its elements, in which defects are revealed during the hydraulic test, after they are eliminated, are subjected to repeated hydraulic tests with test pressure.

186. Hydraulic testing of technological pipelines with a pressure of not more than 10 MPa, as well as vessels, may be replaced by pneumatic testing (compressed air, inert gas or a mixture of air with an inert gas), subject to simultaneous control by the acoustic emission method.

Test pressure during pneumatic testing should be determined by the formula:

(7)

Where P is the working pressure.

If the probability of brittle fracture during a pneumatic test is greater than under operating conditions, and its consequences represent a significant danger, the test pressure must be reduced to a technically justified level, but not less than the operating pressure.

In technically justified cases provided by the manufacturer, when conducting pneumatic tests, during operation of the equipment, it is allowed to use the gaseous working medium of the test object as a loading medium, while the test pressure is determined by formula (7).

The exposure time of the vessel (process pipeline) under test pressure during pneumatic testing must be at least 15 minutes and is indicated in the process documentation.

After exposure under test pressure, the pressure is reduced to a value justified by the strength calculation, but not less than the operating pressure, at which visual inspection of the outer surface and the tightness of welded and detachable joints are carried out.

Correction of defects in welded joints

187. Inadmissible defects found during installation (additional manufacturing), repair, reconstruction (modernization), testing must be eliminated (corrected) with subsequent control of the corrected sections.

The technology for eliminating defects is established by the technological documentation. Deviations from the accepted defect correction technology must be agreed with its developer.

Methods and quality of elimination of defects must ensure the necessary reliability and safety of the equipment.

188. Removal of defects should be carried out mechanically, ensuring smooth transitions at sampling sites. The maximum dimensions and shape of the samples to be brewed are established by the technological documentation.

It is allowed to use thermal cutting (gouging) methods to remove internal defects, followed by mechanical processing of the surface of the sample.

The completeness of defect removal must be checked visually and by non-destructive testing (capillary or magnetic particle flaw detection or etching).

189. Sampling of detected places of defects without subsequent welding is allowed, provided that a minimum allowable thickness part walls in the place of maximum sampling depth and confirmation by strength calculation.

190. If defects are found during the inspection of the corrected section, then a second correction must be carried out in the same order as the first.

Correction of defects in the same section of the welded joint is allowed to be carried out no more than three times.

In the case of cutting out a defective welded joint of pipes and subsequent welding of an insert in the form of a pipe segment, two newly made welded joints are not considered to be the correction of defects.

Quality control of the work performed. Requirements for the final documentation

191. Quality control of installation (pre-production) must be confirmed by a certificate of installation quality. The installation quality certificate is drawn up by the organization that performed the installation, signed by the head of this organization, as well as the head of the operating organization, and sealed.

The certificate of quality of installation must contain the following data:

a) the name of the installation organization;

b) name of the operating organization;

c) the name of the organization - the manufacturer of the equipment and its serial number;

d) information about the materials used by the installation organization that were not included in the scope of supply of the manufacturer and additionally specified in the equipment passport;

e) information about welding, including the type of welding, type and brand of electrodes;

f) information about welders, including the names of welders and numbers of their certificates;

g) information on heat treatment of welded joints (type, mode);

h) methods, scope and results of quality control of welded joints;

i) information about the main fittings, flanges and fasteners, fittings;

j) a general conclusion on the compliance of the installation (additional fabrication) work with the requirements of these FNR, the operating manual (instruction), technological documentation and on the suitability of the equipment for operation with the parameters specified in the passport.

The certificate of equipment installation quality is one of the evidentiary materials when confirming its compliance with the requirements of TR CU 032/2013.

The certificate of the quality of installation upon transfer to the operating organization must be accompanied by certificates of manufacture of equipment elements; documents confirming the compliance of equipment elements with the requirements of TR CU 032/2013; copies of documents (certificates) for basic and welding materials used during installation; documents based on the results of quality control of work performed in accordance with these FNR, drawn up in accordance with the forms approved by a specialized organization (protocols, conclusions, reports and acts on the results of non-destructive, destructive testing and hydraulic or pneumatic tests).

192. Quality control of repairs using welding and heat treatment must be confirmed by the final documentation based on the results of the work performed, including: documents based on the results of quality control of work performed in accordance with these FNP, drawn up in accordance with the forms approved by the specialized organization (protocols, conclusions, reports and acts according to the results of non-destructive, destructive testing and hydraulic or pneumatic tests); repair working drawings and forms, if necessary, containing information about the sequence, dates of work and critical operations, about the workers who performed them.

Repair working drawings should indicate:

a) damaged areas to be repaired or replaced;

b) materials used for replacement;

c) deformed elements and sections of elements to be corrected by editing, with the appointment of the editing method;

d) types of welded joints and methods for their implementation;

e) types of processing of welds after welding;

f) methods and standards for the control of welded joints (places subject to control or verification);

g) permissible deviations from the nominal dimensions.

193. Control over compliance with the requirements of technological documentation for repairs, repair working drawings should be carried out by the technical control unit of the organization performing repairs, reconstruction (modernization) of equipment.

194. Upon completion of work on the repair, reconstruction (modernization) of pressure equipment, the organization that carried out these works must provide information on the nature of the work performed and information on the materials used, attaching a set of repair documentation in accordance with paragraph 192 of these FNP, on the basis of which the authorized person the operating organization makes a record of the work performed in the passport and the equipment repair log.

195. An organization that performed installation (additional manufacturing), repair, reconstruction (modernization) of pressure equipment of poor quality shall be liable in accordance with the legislation of the Russian Federation.

Setup Requirements

196. Start-up and adjustment works in cases stipulated by the operating manual (instruction) are carried out on pressure equipment after completion of installation work with the issuance of a certificate of installation quality and initial technical examination.

197. Adjustment of pressure equipment must be carried out according to the program developed before the commencement of work. The program is developed by the organization that performs the relevant work. This program must be agreed with the operating organization. The program must reflect the content and procedure for the implementation of all technological and control operations with the provision of adjustment in all modes of operation established by the project.

In the event that adjustment at electric power facilities is carried out on equipment under the control (maintenance) of the dispatcher, the adjustment work program must be agreed with the regional dispatch unit of the energy system.

198. When setting up, a quality control system must be applied to ensure the performance of work in accordance with these FNR and the program.

199. The duration of the adjustment work is determined by the program, depending on the complexity of the equipment. The start-up of equipment for commissioning is carried out in the order installed by the program joint operating organization and commissioning organization after verification:

a) the availability and serviceability of instrumentation, safety and signaling devices, provided for by the requirements of technical regulations, the project and these FNR;

b) the availability of trained service personnel who have passed the knowledge test and certified specialists;

c) the presence at the workplace of approved production instructions and the necessary operational documentation;

d) serviceability of feeding devices and ensuring the required quality of feed water (for boilers);

e) the correct connection of the boiler to the common steam pipeline, as well as the connection of the supply purge and drainage lines;

f) act of acceptance of fuel supply equipment (for boilers);

g) completion of all installation work that impedes the adjustment.

200. During the period of adjustment work on pressure equipment, responsibility for the safety of its maintenance should be determined by the adjustment program.

201. During adjustment work, the following is carried out:

a) flushing and purging of equipment and pipelines in cases established by the project and the operating manual;

b) testing of equipment, including reserve equipment, adjustment of circulation of working media, check of operation of stop valves and control devices in manual mode;

c) checking of measuring instruments, setting up and checking the operability of automation, alarm, protection, interlocking, control systems, as well as adjusting safety valves;

d) development and stabilization of the technological regime, analysis of the qualitative indicators of the technological regime;

e) the output of the technological process to a stable mode of operation with a capacity corresponding to the design requirements.

For boilers, additionally, the combustion mode is adjusted and the water-chemical mode is adjusted.

202. When carrying out adjustment of equipment using hazardous substances or in explosive zones, the program must specify safety measures, and it must also provide for preliminary testing of the stages of the technological process on inert media, followed by adjustment on working media.

203. Upon completion of the adjustment work, a comprehensive testing of equipment under pressure, as well as auxiliary equipment at a rated load, is carried out according to the integrated testing program developed by the organization conducting the relevant work and agreed with the operating organization. The beginning and end of the integrated testing is established by a joint order of the operating organization of the equipment and the organization conducting the adjustment work. For boilers, comprehensive testing is carried out within 72 hours, and for pipelines of heating networks - within 24 hours.

The end of complex testing is formalized by an act fixing the commissioning of equipment under pressure. The act must be accompanied by a technical report on the adjustment work with tables and instructions, regime maps, graphs and other materials reflecting the established and actually received data on setting up and adjusting devices, descriptions and drawings of all changes (circuit, structural) that have been made to setup stages.

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