Technical Supervision Regulations for Safety of Pressure Piping-Industrial Piping (TSG D000 1)
Rules for Periodic Inspection of Pressure Piping-Industrial Piping (TSG D7005)
2 Scope of application
(1) This procedure is applicable to the annual inspection of industrial pipelines in use specified in the Catalogue of Special Equipment.
(2) Classify the industrial pipelines in use within the applicable scope of this process according to the Regulation for Safety and Technical Supervision of Pressure Pipelines-Industrial Pipelines (TSG D000 1).
(3) Power pipelines (except those within the scope of boilers in TSG G000 1 Boiler Safety Technical Supervision Regulations) are classified according to the classification conditions of industrial pipelines, and their annual inspection is carried out with reference to this technology and the standards on which its construction is based.
3 methods, procedures, contents and requirements
3. 1 Check the business development
The annual inspection business is carried out by each department respectively.
3.2 Preparation before inspection
3.2. 1 This process can be used as a general scheme for annual inspection of pressure pipelines. In the actual inspection, inspectors can appropriately increase the inspection items and contents according to the actual situation.
3.2.2 Inspectors should have effective qualifications suitable for the inspection items they are engaged in, be familiar with the operation of inspection equipment and instruments, and be familiar with the basic situation of the inspected pipeline. When multiple inspectors participate in the inspection at the same time, the division of labor should be clear.
3.2.3 Before inspection, the inspector shall verify the basic information of the user and the pipeline to be inspected, and check the user's preparation. The user's preparation work mainly includes:
(1) Cleaning of external surface and environment of pressure pipeline;
(two) according to the needs of on-site inspection, do a good job of on-site lighting, climbing protection, partial removal of insulation layer, etc.
Cooperate with the work, and equip qualified protective articles such as noise prevention, dust prevention and toxic and harmful gas prevention when necessary;
(3) Prepare the installation data, use registration certificate, technical files, operation records and records of harmful impurities in the medium used;
(4) Prepare safety management rules and regulations and safety operation specifications for pressure pipelines;
(5) During the inspection, the pressure pipeline management personnel and relevant personnel of the employing unit shall be present to cooperate, assist in the inspection work, and provide other materials required by the inspectors in time;
(six) safety preparations should also comply with the relevant provisions.
3.2.4 Before inspection, the equipment and instruments used for verification and inspection must be within the effective verification or calibration period, and their quantity, accuracy and performance should meet the inspection requirements. When conducting inspection in inflammable and explosive places, explosion-proof and fire-proof equipment and appliances should be adopted.
3.2.5 In the process of inspection, inspectors should conscientiously implement the user's regulations on hot work, electricity consumption, high altitude, in the tank, safety protection and safety monitoring. , to ensure the safety of inspection work.
3.2.6 Before and during the inspection, the configuration and use of personal and on-site safety protection articles should be checked, and the specific requirements should be implemented in accordance with the inspection safety management system of our hospital.
3.2.7 In general, it is not required to remove the external insulation layer, but in any of the following circumstances, part or all of the insulation layer should be removed, and the location and proportion of the removal should be determined by the inspectors according to the actual situation before or during the inspection:
(a) The insulation layer is immersed in water or the pipeline becomes cold after it is put into use;
(two) the problems found in the spot check need to be removed for inspection and verification.
3.2.8 In case of any of the following situations during the inspection, the inspection shall be suspended, and the Department and EHS shall be informed in time:
(1) Encountering unexpected bad weather (such as rain, snow, lightning, high temperature, low temperature, etc.) may adversely affect the inspection quality or safety;
(2) When conditions such as safety protection change, which may adversely affect inspection safety;
(three) the inspection equipment has the requirements of explosion-proof and fire prevention, and does not have the corresponding conditions;
(four) other phenomena that may adversely affect the inspection quality or safety.
3.3 Check the implementation
The annual inspection of pressure pipeline shall at least include the inspection of pipeline safety management, pipeline operation and safety accessories and instruments, and the wall thickness and resistance value shall be measured when necessary.
3.3. 1 Inspection contents of pipeline safety management
(a) the safety management system and operating procedures are complete and effective;
(2) Whether the design documents, installation completion drawings, quality certificates, supervision and inspection certificates, installation, renovation and maintenance materials specified in relevant safety technical specifications are complete;
(three) whether the safety management personnel hold relevant certificates;
(four) whether the daily maintenance, operation records and regular safety inspection records meet the requirements;
(five) whether the annual inspection and periodic inspection reports are complete, and whether the problems raised in the inspection and inspection reports have been solved;
(six) whether the calibration (verification), repair and replacement records of safety accessories and instruments are complete;
(seven) whether the special emergency plan is formulated in accordance with the relevant requirements, and there are drill records;
(eight) whether there are records of accidents, failures and treatments.
3.3.2 Inspection of pipeline operation state
(a) check the key parts
During the inspection, the following parts should be considered:
(1) Import and export parts of compressors and pumps;
(2) Dead angle of compensator, tee joint, elbow (elbow), reducer, branch pipe connection, valve connection and medium flow;
(3) Pipe components and welded joints near the easily damaged parts of supports and hangers;
(4) the parts that affect the safe operation of the pipeline;
(5) key parts in the production process and pipe sections connected with important devices or equipment;
(6) Pipe sections with bad working conditions and alternating loads;
(7) The high-risk part given in the risk-based inspection and analysis report;
(8) The key monitoring sections proposed in the last regular inspection.
(2) Check the contents.
(1) Check whether the paint color and mark of the pipeline comply with relevant regulations;
(2) Check the pipeline components and their welded joints for cracks, overheating, deformation, leakage, damage and other defects; (Check at least one item in each category. If problems are found, scale up appropriately and check the parts with drawings. )
(3) whether the external surface is corroded, whether there is abnormal frosting and dew, etc. ;
(4) Whether there is abnormal vibration of the pipeline and whether there is collision and friction between the pipeline and adjacent components;
(5) Whether the insulation layer of the pipeline is damaged, falls off, is frozen, and whether the anticorrosion layer is damaged. ; When necessary, infrared thermal imaging detection, heat flow detection and other technical means can be used for monitoring and energy-saving evaluation;
(6) Check whether the hanger falls off, deforms, corrodes or is damaged, whether the welded joint under the principal stress is cracked, whether there is water at the contact between the hanger and the pipeline, whether the rotation displacement indication of the hanger with constant force spring meets the requirements, whether the hanger with variable force spring has abnormal deformation, deflection and load loss, whether the rigid hanger is in a state, whether the gap between steering brackets, the displacement of shock absorber and shock absorber and the liquid level of hydraulic shock absorber meet the requirements, and so on; (Check at least one item in each category. If problems are found, scale up appropriately and check the parts with drawings. )
(7) Check whether there is corrosion on the valve surface, cracks on the valve body surface, serious shrinkage cavity, loose connecting bolts, and so on and so forth; (Check at least one place. If problems are found, expand the proportion appropriately and make the attached drawings. )
(8) Check whether the setting positions of the vent (gas) valve and the sewage (water) valve are reasonable, and whether there is abnormal gas gathering and liquid accumulation; (Check at least one place. If problems are found, expand the proportion appropriately and make the attached drawings. )
(9) Check whether the flange is misaligned, abnormally warped, deformed and leaked, and whether the fasteners are complete, loose and corroded; (Check at least one place. If problems are found, expand the proportion appropriately and make the attached drawings. )
(10) Check whether there are scratches, dents, corrosion perforations and cracks on the surface of bellows expansion joint, whether the wave distance of bellows meets the requirements, whether there is instability, whether the hinge and pin shaft of hinge expansion joint are deformed, detached or damaged, and whether the pull rod, bolt and connecting bracket of pull rod expansion joint meet the requirements. (Check at least one item in each category. If problems are found, scale up appropriately and check the parts with drawings. )
(1 1) For pipelines with cathodic protection devices, check whether the protection devices are in good condition; (Check at least one place. If problems are found, expand the proportion appropriately and make the attached drawings. )
(12) For the pipeline with creep measurement requirements, check whether the creep measurement point or creep measurement area of the pipeline is intact; (Check at least one place. If problems are found, expand the proportion appropriately and make the attached drawings. )
(13) Other inspections deemed necessary by the inspector.
3.3.3 Inspection of safety accessories and instruments
(1) General requirements
Safety accessories and instruments shall meet the requirements of safety technical specifications and corresponding current national standards. Safety accessories and instruments under any of the following circumstances shall not be put into use:
(1) No product certificate and nameplate;
(2) the performance does not meet the requirements;
(3) Failing to conduct inspection, calibration or verification within the time limit;
(4) No product supervision and inspection certificate (required by relevant safety technical specifications).
(2) Safety valve inspection requirements
(1) Whether the selection of safety valve meets the design requirements;
(2) Whether the safety valve is within the validity period of calibration and whether the set pressure meets the requirements of pipeline operation;
(3) Whether the lead sealing device of the adjusting screw of the spring safety valve is in good condition;
(4) If a block valve is set between the safety valve and the discharge port, whether the block valve is in the fully open position and whether the lead seal is in good condition;
(5) Whether the safety valve leaks;
(6) Whether the snorkel is unobstructed and the rain cap is in good condition.
In case of wrong selection, exceeding the validity period of verification or leakage during inspection, the user shall take effective measures to ensure the safe operation of the pipeline, otherwise the pipeline operation shall be suspended.
(3) Inspection contents of bursting disc device
(1) Whether the bursting disc exceeds the service life specified in the product manual;
(2) Whether the installation direction of bursting disc is correct, and whether the bursting pressure and temperature on the product nameplate meet the use requirements;
(3) Whether the bursting disc device leaks;
(4) Whether there is overpressure blasting or no overpressure blasting during the use of bursting discs;
(5) Whether the vent pipe connected with the bursting disc support is unobstructed, whether there is water (or ice) in the vent pipe, and whether the waterproof cap and rainproof sheet are in good condition;
(6) When a block valve is installed between the bursting disc device and the pipeline, whether the block valve is fully opened and whether the lead seal is in good condition;
(7) When the bursting disc device is used in series with the safety valve, if the bursting disc device is arranged at the outlet side of the safety valve, check whether the pressure gauge and block valve installed between the bursting disc device and the safety valve, and whether the pressure, drainage and discharge between them meet the requirements; If the bursting disc device is installed at the inlet side of the safety valve, check whether the pressure gauge installed between the bursting disc device and the safety valve has pressure indication and whether there is gas leakage after the block valve is opened.
During inspection, if it is found that the bursting disc device has exceeded the specified service life, the installation direction is wrong, the bursting pressure and temperature do not match, or the bursting disc is used in series with the safety valve, the user should take effective measures to ensure the safe operation of the pipeline, otherwise the pipeline operation should be suspended.
(4) Inspection contents of flame arresters
(1) Whether the installation direction of the flame arrester device is correct (one-way flame arrester only);
(2) Whether the nominal pressure, applicable medium and temperature calibrated by the flame arrester meet the use requirements;
(3) Abnormal conditions such as leakage of flame arresters.
During the inspection, it is found that the installation direction of the flame arrester device is wrong, the calibration parameters do not meet the operation requirements, the body leaks, the specified verification or maintenance period is exceeded, and condensation, crystallization or icing occur. And no effective measures have been taken, the user unit shall take effective measures to ensure the safe operation of the pipeline, otherwise the pipeline operation shall be suspended.
(5) emergency cut-off valve's inspection contents.
(1) Whether the nameplate of emergency cut-off valve meets the requirements;
(2) Whether there is any leakage or other abnormal situation in emergency cut-off valve;
(3) Whether the overcurrent protection device in emergency cut-off valve meets the requirements.
In the process of inspection, if it is found that the contents of emergency cut-off valve nameplate do not meet the requirements, or the valve body leaks and the emergency cut-off valve moves abnormally, the user should take effective measures to ensure the safe operation of the pipeline, otherwise the pipeline operation should be suspended.
(6) Pressure gauge inspection content
(1) Whether the pressure gauge selection meets the requirements;
(2) The regular maintenance system of pressure gauge, and whether the validity period of verification and its seal meet the requirements;
(3) Whether the appearance, precision grade, measuring range and dial diameter of the pressure gauge meet the requirements;
(4) Whether the position, opening mark and locking device of the three-way cock or needle valve between the pressure gauge and the pipeline meet the requirements;
(5) Whether the readings of various pressure gauges on the same system are reasonable.
In the process of inspection, if the pressure gauge is selected incorrectly, the dial glass cover is damaged, the dial scale is blurred, the seal is damaged, the verification validity period is exceeded, the spring tube leaks, the pointer is loose or twisted, the shell is seriously corroded, the opening mark of the three-way cock or needle valve is unclear, and the locking device is damaged, etc., the user should take effective measures to ensure the safe operation of the pipeline, otherwise the pipeline operation should be suspended.
(7) Inspection contents of temperature measuring instruments
(1) Whether the periodic calibration and maintenance of temperature measuring instruments meet the requirements;
(2) Whether the measuring range of the thermometer matches the temperature range it detects;
(3) Whether the appearance of the temperature measuring instrument and its secondary instrument meets the requirements.
In the process of inspection, if it is found that the temperature measuring instrument exceeds the specified calibration and maintenance cycle, the instrument and its protection device are damaged or the instrument range is wrong, the user should take effective measures to ensure the safe operation of the pipeline, otherwise the pipeline operation should be suspended.
Determination of wall thickness
The wall thickness of pipelines that need to be managed mainly or elbows, tees, reducing pipes and adjacent straight pipe sections with obvious corrosion shall be determined by fixed points or spot checks. The location and frequency of wall thickness measurement should be determined according to the prediction results of corrosion site.
The location of measuring points for fixed-point thickness measurement should be indicated on the single-line diagram, and the wall thickness measurement results should be given in the annual inspection report. When abnormal wall thickness is found, the wall thickness measuring points should be appropriately increased, and the wall thickness of all pipe sections and fittings should be measured when necessary.
resistance measurement
For pipelines conveying inflammable and explosive media, the anti-static grounding resistance and the contact resistance between flanges should be determined through spot checks. The anti-static grounding resistance shall be no greater than100Ω, and the contact resistance between flanges shall be less than 0.03Ω. (Each project should be checked at least once. If problems are found, the proportion will be appropriately expanded, and drawings will be attached to the spot check parts. )
3.4 Result processing
Defect and problem handling, inspection conclusion
The defects and problems found in the inspection (hereinafter collectively referred to as problems) shall be recorded and located in detail, and the treatment that meets the requirements, basically meets the requirements and does not meet the requirements shall be made according to the types of problems (pipeline safety management, pipeline operation, safety accessories and instrument problems) and the degree of impact on safety:
Meet the requirements, that is, there are no minor defects that do not affect the safe use, and they can continue to be used within the allowable parameters;
(2) It basically meets the requirements, that is, it is found that the pipeline has general defects, which can ensure the safe operation of the pipeline after the user takes measures, and can be used under the monitoring conditions, and the monitoring conditions, problems to be solved in the monitoring operation and the completion period are indicated in the inspection conclusion;
(3) Unqualified means that the pipeline is found to have serious defects, which can not guarantee the safe operation of the pipeline, and it is not allowed to continue to be used, so it must be stopped or further inspected by the inspection agency.