Approved by the order of the Minister of Emergency Situations of the Republic of Kazakhstan of October 29, 2008 No. 189

Requirements of the device and safe operation of the vessels working under pressure

List of amending documents

Chapter 1. General provisions

1. Requirements of the device and safe operation of the vessels working under pressure (further - Requirements), establish requirements to designing, the device, production, reconstruction, adjustment, installation, repair, technical diagnosing and operation of vessels, tanks, barrels, cylinders, pressures chamber working under excessive pressure (further - vessels).

2. In these Requirements the following terms and determinations are used:

1) the reinforced plastic - the material of heterogeneous structure consisting of plastic (binding) and filler;

2) pressure chamber - the vessel equipped with devices and the equipment and intended for accommodation of people in it;

3) cylinder - the vessel having one or two mouths for installation of gates, flanges or unions, intended for transportation, storage and uses compressed liquefied or dissolved under pressure of gases;

Barrel - vessel of cylindrical or other form which is rolled from one place on another and to put 4) on end faces without additional support, intended for transportation and storage of liquid and other substances;

5) capacity - the amount of internal cavity of vessel determined by the nominal sizes set on drawings;

6) the owner of vessel - the organization, the individual entrepreneur in whose property there is vessel;

7) pressure internal (outside) - pressure operating on internal (outside) surface of wall of vessel;

8) pressure trial - pressure with which testing of vessel is made;

9) pressure working - the maximum internal, excessive or outside pressure arising in case of normal course of working process;

10) pressure settlement - pressure on which calculation on durability is made;

11) pressure conditional - settlement pressure at temperature 20shs, used when calculating on durability of standard vessels (nodes, details, armature);

12) the admissible temperature of wall the maximum (minimum) maximum (minimum) temperature of wall at which operation of vessel is allowed;

13) the bottom - the integral part of the case of vessel limiting internal cavity from end face;

14) cap - the volume detail hermetically closing openings of the union or lug;

15) coil - the heat-exchanging device executed in the form of curved pipe;

16) excessive pressure - difference of the absolute pressure and pressure of the environment shown by barometer;

17) the case - the main assembly unit consisting of feedwells and the bottoms;

18) composition material (composite) - the material of heterogeneous structure consisting of several homogeneous materials (components);

19) cover - the otjemny part closing internal cavity of vessel or opening of the hatch;

20) the hatch - the device providing access to internal cavity of vessel;

21) leyner - the inside pressurizing layer of vessel from the reinforced plastic bearing part of loading;

22) metalplastic vessels - multilayer vessels in which the inside layer (cover) is made of metal; other layers are made of the reinforced plastic. The inside layer bears part of loading;

23) multichamber vessel - the vessel having two or more working cavities used under different or identical conditions (pressure, temperature, environment);

24) nonmetallic vessels - the vessels made of homogeneous or composition nonmetallic materials;

25) filler - the material reinforcing plastic; as the reinforcing material use fibers, woven and nonwoven fabrics;

26) the regulating documentation (further - ND) - requirements, requirements of industrial safety, industry and state standards, regulating documents, regulating documents on designing, production, repair, reconstruction, installation, adjustment, technical diagnosing (survey), operation;

27) the feedwell - the cylindrical cover of the closed profile opened from end faces;

28) observation port - the device allowing to observe working environment;

29) homogeneous material - the material consisting of one substance of alloy or solid solution, for example: glass, steel, ceramics and so forth;

30) sample witness - the sample made of the same material and on the same technology as the vessel used for determination of condition of material in use;

31) residual resource - total operating time of object from the moment of control of its technical condition before transition to limiting condition;

32) support - the device for installation of vessel in working provision and transfer of loads from vessel of the base or the bearing design;

33) support saddle - the support of horizontal vessel covering the lower part of ring section of the feedwell;

34) the permitted pressure of vessel (element) - the most admissible excessive pressure of vessel (element) established by results of engineering certification or diagnosing;

35) reconstruction - the change of design of vessel causing adjustment of the passport of vessel, for example the device of additional elements, and other defiant changes of parameters of work of vessel;

36) the reservoir - the stationary vessel intended for storage of gaseous, liquid and other substances;

37) vessel shirt - the heat-exchanging device consisting of the cover covering the case of vessel or its part, and forming jointly with vessel case wall the cavity filled with the heat carrier;

38) settlement service life of vessel - the service life in calendar years estimated from the date of input of vessel in operation;

39) settlement resource of vessel (element) - duration of operation of vessel (element) during which the manufacturer guarantees reliability of its work on condition of observance of the mode of operation specified in the instruction of the manufacturer, and settlement number of start-up from cold or hot condition;

40) vessel service life - duration of operation of vessel in calendar years before transition to limiting condition;

41) connection flange - motionless demountable connection of parts of vessel which hermeticity is provided by compression of sealing surfaces directly with each other or through the laying located between them from softer material compressed fasteners;

42) vessel - the hermetically sealed reservoir intended for conducting chemical, thermal and other engineering procedures, and also for storage and transportation of gaseous, liquid and other substances. Border of vessel are entrance and output the union;

43) vessel portable - the vessel intended for temporary use in different places or during its movement;

44) vessel stationary - constantly established vessel intended for operation in one certain place;

45) binding - the material providing solidity of composite;

46) joint welded connections - connections in which the welded elements adjoin to each other face surfaces and include seam and zone of thermal influence;

47) the specialized organization - the organization certified by Authorized body in the field of industrial safety on carrying out design works on creation, repair and reconstruction of vessels, on production, installation, repair, reconstruction of vessels and (or) their adjustment, diagnostics;

48) repair - recovery of the vessel elements damaged, worn out or become useless for any reason with finishing them to operating state;

49) temperature of working environment - minimum (min) (maximum) (max) temperature of the circle in vessel in case of normal course of engineering procedure.

50) wall temperature settlement - temperature at which physicomechanical characteristics are determined, the allowed tension of material and is carried out calculation on durability of elements of vessel;

51) technical diagnosing - determination of technical condition of object. Tasks of technical diagnosing - control of technical condition, search of the place and determination of causes of failure (defect), forecasting of technical condition;

52) technical diagnostics - the theory, methods and means of determination of technical condition of object;

53) the tank - the portable vessel which is constantly established on frame of the rail car, on the chassis of the car (trail car) or on other vehicles, intended for transportation and storage of gaseous, liquid and other substances;

54) the union - the element intended for accession to vessel of pipelines, pipeline armature, instrumentations and so forth;

55) vessel element - the combined unit of vessel intended for accomplishment of one of the main functions of vessel;

56) expert technical diagnosing - the technical diagnosing of vessel which is carried out after settlement service life of vessel or settlement resource of safe work after accident or the found damages of the elements working under pressure for the purpose of determination of possible parameters and conditions of further operation;

57) the self-extending high-temperature sintezfiziko-chemical process of synthesis of materials (powders, products, coverings and others) based on exothermic interaction of two or several components proceeding in the burning mode. Process proceeds in thin layer of mix of initial reagents after local initiation of reaction and spontaneously extends on all system thanks to warmly - and mass transfer from hot products to not heated initial substances.

Requirements to installation and repair are similar to requirements to production of vessels.

3. Requirements extend on:

1) the vessels working under pressure of water with temperature is higher 115shs or other non-toxical, not explosion-fire-hazardous liquids at temperature exceeding boiling temperature with MPa 0,07 pressure (0,7 of kgf/cm 2);

2) the vessels working under vapor pressure, gas or toxic explosion-fire-hazardous liquids over MPa 0,07 (0,7 of kgf/cm 2);

3) the cylinders intended for the transportation and storage, uses compressed liquefied and dissolved gases under pressure over MPa 0,07 (0,7 of kgf/cm 2);

4) tanks and barrels for transportation and storage of the compressed and liquefied gases which pressure of vapors at temperature to 50shs exceeds MPa 0,07 pressure (0,7 of kgf/cm 2);

5) tanks and vessels for the transportation or storage compressed, the liquefied gases, liquids and loose bodies in which pressure is higher than MPa 0,07 (0,7 of kgf/cm 2) is created periodically for their emptying;

6) pressures chamber.

4. Requirements do not extend on:

1) the vessels of atomic power stations, vessels working with the radioactive circle;

2) vessels the capacity of no more 0,025 of m3 (25 l) irrespective of pressure used for the scientific and experimental purposes. In case of determination of capacity the amount occupied by lining, pipes and other internal devices is excluded from general reservoir of vessel. The group of vessels, vessels consisting of separate cases and connected among themselves by pipes to internal diameter more than 100 mm are considered as one vessel;

3) vessels and cylinders the capacity of no more 0,025 of m3 (25 l) which have work of pressure in MPa (kgf/cm 2) on capacity in m3 (liters) of no more 0,02 (200);

4) the vessels working under pressure which is created in case of explosion in them according to engineering procedure or burning in the mode of the self-extending high-temperature synthesis;

5) the vessels working under vacuum;

6) the vessels established on ocean, river crafts and other watercrafts (except drags);

7) the vessels established by airplanes and other aircraft;

8) air reservoirs of the brake equipment of railway vehicles of rail transport, cars and other vehicles;

9) vessels of special purpose of military department;

10) devices of steam and water heating;

11) tubular furnaces;

12) the vessels consisting of pipes with internal diameter no more than 150 mm without collectors with the collectors executed from pipes with internal diameter no more than 150 mm;

13) the parts of machines which are not representing independent vessels (cases of pumps or turbines, cylinders of engines of steam, hydraulic, air machines and compressors).

Chapter 2. Designing

5. Projects of vessels and their elements (including spare parts to them), projects of their installation or reconstruction are carried out by the specialized organizations.

6. The heads and specialists occupied with designing, production, reconstruction, installation, adjustment, repair, diagnostics, operation and testing of vessels undergo examination according to the legislation of the Republic of Kazakhstan on industrial safety.

7. Projects and regulating documents (further - ND) on production of vessels are approved and affirm in accordance with the established procedure.

8. Changes in the project and (or) ND, need for which arises in case of production, reconstruction, installation, adjustment, repair or operation, are approved with the organization developer of the project and (or) ND on vessel. In case of impossibility to satisfy this condition of change in the project and ND are approved with the specialized organization.

9. When designing the vessels used in chemical industries requirements of existing rules and rules of industrial safety for these organizations are considered.

10. Departure from these Requirements is allowed only as an exceptional case on permission of authorized body in the field of industrial safety (further - authorized body).

11. For receipt of permission to authorized body the corresponding reasons, and in case are represented to neobkhodimostitakzha the conclusion of the specialized or expert organization. The copy of the deviation permit from Requirements is attached to the passport of the vessel working under pressure, developed according to appendix 1 to these Requirements.

Chapter 3. Design of vessels

12. The design of vessels ensures reliability and safety of operation during settlement service life and provides possibility of carrying out engineering certification, cleaning, washing, complete emptying, purge, repair, operational control of metal and connections.

13. For each vessel settlement service life taking into account service conditions is established and is specified in the passport.

14. The devices interfering outside and internal surveys of vessels (mixers, coils, shirts, plates, partitions and other devices), are provided removable.

In case of use of welded devices the possibility of their removal for carrying out outside and internal surveys and the subsequent installation into place is provided. The procedure for renting and installation of these devices is specified in the operation manual on vessel.

15. If the design of vessel does not allow carrying out the outside and internal surveys or hydraulic testing provided by these Requirements, developer of the project of vessel in the operation manual the technique, frequency and amount of control which accomplishment provides timely detection and elimination of defects is specified. In case of absence in management of such instructions the technique, frequency and amount of control are determined by the specialized organization.

16. Designs of internal devices provide removal from air vessel in case of hydraulic testing and waters after hydraulic testing.

17. Vessels have the union for filling and discharge of water, for removal of air in case of hydraulic testing.

18. On each vessel the gate, the crane or other device allowing to exercise control of lack of pressure in vessel before its opening is provided; at the same time withdrawal of the circle goes to the safe place.

19. The vessels intended for work in the conditions of cyclic and sign-variable loadings are calculated on durability taking into account these loadings.

20. Vessels which in use change the position in space have the devices preventing their self-capsizing.

21. The design of the vessels warmed by hot gases provides reliable chilling of the walls which are under pressure up to the settlement temperature.

22. For quality check of welding of the rings strengthening openings for hatches, manholes and unions the carving control opening is provided in ring if it is welded outside, or in wall if the ring is welded from the inside of vessel.

This requirement extends also to the slips or other strengthening elements welded outside on the case.

The outside deaf elements (for example, slips) which are not working under pressure have drainage openings in the lowest places.

23. Grounding and the electric equipment of vessels are carried out with observance of regulations of technical operation of electroinstallations of consumers and safe engineering in case of operation of electroinstallations of consumers in accordance with the established procedure.

24. Vessels are supplied with the necessary number of the hatches and viewing hatches providing survey, cleaning and repair of vessels, installation and dismantle of folding internal devices.

The vessels consisting of the cylindrical case and lattices with fixed in them tubes (heat exchangers), and vessels intended for transportation and storage of cryogenic liquids, the vessels intended for work with substances of the 1st and 2nd class of danger according to GOST 12.1.007, but which are not causing corrosion and scum it is allowed to produce without hatches and hatches irrespective of diameter of vessels on condition of fulfillment of requirements of Item 15.

25. Vessels with internal diameter more than 800 mm have hatches, and with internal diameter of 800 mm and less - hatches.

26. Internal diameter of round hatches - at least 400 mm. The sizes of oval hatches on the smallest and greatest axes in light - at least 325-400 mm.

Internal diameter round or the size on the smallest axis of oval hatches - at least 80 mm.

27. Hatches and hatches are located in the places available to servicing. Requirements to the device, arrangement and servicing of observation ports in pressures chamber are determined by the project organization and are specified in the mounting and operating guide of manufacturing plant.

28. Covers of hatches are removable. On the vessels isolated on the basis of vacuum welded covers are allowed.

29. Covers weighing more than 20 kg are supplied with lifting and rotary or other devices for their opening and closing.

30. The design pivotally - folding or plug-in bolts, collars, tightening devices of hatches, covers and their flanges prevents their spontaneous shift.

31. In the presence on vessels of unions, flange sockets, the removable bottoms or covers which internal diameter is at least these Requirements specified for hatches in Item 26 providing possibility of carrying out internal survey it is allowed not to provide hatches.

32. In vessels the bottoms are applied: elliptic, hemispherical, torosferichesky, spherical neotbortovanny, conic otbortovanny, conic neotbortovanny, flat otbortovanny, flat neotbortovanny.

33. The elliptic bottoms have height of convex part measured on internal surface, 0,2 of internal diameter of the bottom suffices. Reduction of this size is approved with the specialized research organization.

34. The Torosferichesky (korobovy) bottoms are made by the sizes:

1) height of convex part measured on internal surface is at least 0,2 of internal diameter;

2) the internal radius of collaring is at least 0,1 of internal diameter of the bottom;

3) internal radius of curvature of the central part of no more internal diameter of the bottom.

35. The spherical neotbortovanny bottoms are applied with welded flanges, at the same time:

1) the internal radius of the sphere of the bottom - no more internal diameter of vessel;

2) welded connection of flange with the bottom is carried out with continuous pro-pitch.

36. In the welded convex bottoms, except for the hemispherical, consisting of several parts with arrangement welded seams on chord, the distance from axis of welded seam to the center of the bottom is chosen no more than 1/5 internal diameters of the bottom.

Circular seams of the convex bottoms are located from the center of the bottom at distance no more than 1/3 internal diameters of the bottom.

37. The conic neotbortovanny bottoms have the central corner no more than 45 highways. The central corner of the conic bottom increases according to the conclusion of the specialized research organization for apparatostroyeniye.

38. The flat bottoms with ring flute and cylindrical part (board) made by mechanical boring are made of forging. Production of the otbortovanny flat bottom from leaf is allowed if collaring is carried out by stamping or running in of edge of leaf with bend on 90 highways.

39. For otbortovanny and transitional elements of vessels, except for the convex bottoms, compensators and the extended mouths under welding of unions, the distance (L) from the beginning of curve of otbortovanny element to otbortovanny edge depending on thickness of wall (s) of otbortovanny element is chosen at least, specified in table 1.

To table 1

+-----------------------------+---------------------------+
|Толщина стенки отбортованного|Расстояние до отбортованной|
|элемента s, мм               |кромки L, мм, не менее     |
+-----------------------------+---------------------------+
|До 5                         |           15              |
|Свыше 5 до 10                |         2s + 5            |
|Свыше 10 до 20               |          s + 15           |
|Свыше 20 до 150              |        s/2 + 25           |
|Свыше 150                    |           100             |
+-----------------------------+---------------------------+

40. When welding feedwells and pipes, welding of the bottoms joint seams with complete foundering are applied to feedwells.

Welded connections in the Tauri and angular with complete foundering are applied to welding of the flat bottoms, flat flanges, pipe lattices, unions, hatches, shirts.

Lap welded seams are applied to welding to the case of the strengthening rings, basic elements, podkladny sheets, plates under platforms, ladders, brackets and so forth.

41. The constructive gap in angular and tee welded connections is applied in the cases provided by ND approved in accordance with the established procedure.

42. Welded seams are carried out available to the control in case of production, installation and operation of vessels provided by these Requirements, the corresponding standards and ND.

43. Longitudinal seams of adjacent feedwells and seams of the bottoms of vessels are displaced relatively each other at size of triple thickness of the thickest element, but on 100 mm at least between axes of seams.

The specified seams are not displaced relatively each other in the vessels intended for work under pressure of no more 1,6 of MPa (16 kgfs/cm 2) and temperature of wall are not higher 400shs, with nominal thickness of wall no more than 30 mm provided that these seams are carried out by automatic or electroslag welding and places of crossing of seams are controlled by method of radiography or ultrasonic defectoscopy of 100%.

44. When welding crossing of these welded seams with joint seams of the case on condition of preliminary check of the blocked site of seam of the case radio graphical control or ultrasonic defectoscopy is allowed to the case of vessel of internal and external devices (basic elements, plates, shirts, partitions and others).

45. In case of welding of support or other elements to the vessel case the distance between edge of welded seam of vessel and edge of seam of welding of element is chosen at least thickness of wall of the case of vessel, but at least 20 mm.

For vessels from carbonaceous and low-alloyed the manganous and manganic and siliceous staly (appendix 2 "Division staly on types and classes" these Requirements), subjected after welding to heat treatment, irrespective of case wall thickness the distance between edge of welded seam of vessel and edge of seam of welding of element is chosen at least 20 mm.

46. In horizontal vessels local overlapping by saddle support of ring (cross) welded seams on total length no more 0, 35pid, and in the presence of podkladny leaf - no more 0, 5pid where D - the outer diameter of vessel is allowed.

At the same time the blocked sites of welded seams on all length are checked by method of radiography or ultrasonic defectoscopy. Overlapping of places of crossing of seams is not allowed.

47. In joint welded connections of elements of vessels with the different thickness of walls smooth transition from one element to another by gradual thinning of edge of thicker element is provided. Tilt angle of surfaces of transition no more than 20 highways.

If the difference in thickness of the connected elements constitutes no more than 30% of thickness of thin element and no more than 5 mm, then application of welded seams without preliminary thinning of thick element is allowed. The form of seams provides smooth transition from thick element to thin.

When joining cast detail with details from pipes, hire or forgings consider that the nominal settlement thickness of cast detail is 25-40% more than the similar settlement thickness of wall of element from pipes, hire or forgings therefore transition from thick element to thin is carried out so that thickness of the end of cast detail was at least settlement size.

48. Openings for hatches, hatches and unions are located out of welded seams.

The arrangement of openings is allowed:

1) on longitudinal seams of cylindrical and conic feedwells of vessels if the nominal diameter of openings is no more than 150 mm;

2) on ring seams of cylindrical and conic feedwells of vessels without restriction of diameter of openings;

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