Safe operation of vessels operating under excess pressure
The installation, placement, and connection of vessels shall ensure the possibility and safety of their maintenance, inspection, repair, flushing, and cleaning.
Vessels shall be installed in accordance with the vessel installation design.
The installation of vessels shall preclude the possibility of their overturning.
Platforms and ladders intended for the maintenance, inspection, and repair of vessels shall not compromise the strength and stability of the vessels. The welding of platforms, ladders, and external devices is permitted only to special pads (backing plates, plates) welded to the vessel body, in cases provided for by the design (engineering) documentation.
For pressure equipment, in cases provided for by the operating manual (instructions) and in accordance with the requirements of these Rules, commissioning and adjustment work, start-up and adjustment work, and work carried out as part of commissioning and adjustment tests (hereinafter referred to as adjustment work) shall be performed;
Start-up and adjustment work shall be carried out on pressure equipment after the completion of installation work and the issuance of a certificate of installation quality.
The adjustment of pressure equipment shall be performed by an adjustment organization with the participation of employees of the operating organization according to a program developed before the commencement of work by a specialized organization performing the relevant work and agreed with the operating organization. The program shall reflect the content and procedure for performing all technological and control operations, ensuring adjustment in all operating modes.
During adjustment, a quality control system shall be used to ensure that the work is carried out in accordance with these Rules and the adjustment work program.
The duration of adjustment work shall be determined by the adjustment work program, depending on the complexity of the equipment.
During the period of adjustment work on pressure equipment, responsibility for the safety of its maintenance shall be determined by the adjustment work program.
When commissioning work on pressure equipment is carried out simultaneously by several commissioning organizations and (or) for different types of commissioning work, the owner of the hazardous production facility, the operating organization must organize the coordination of the execution of this work.
Simultaneous commissioning, construction and installation, and other work on pressure equipment is not allowed.
During regime-commissioning work, the following is carried out:
flushing and blowing of equipment and pipelines (in cases established by the equipment design or operating manual (instructions);
testing of pressure equipment, including backup equipment, commissioning of working medium circulation, checking the operation of shut-off valves and control devices in manual mode;
checking of measuring instruments, adjustment and verification of the operability of automation systems, signaling, protection, interlocks, control, as well as adjustment of safety valves;
development and stabilization of the technological regime, analysis of the qualitative indicators of the technological regime;
bringing the technological process to a stable operating mode with a capacity corresponding to the design requirements.
Pressure equipment, in cases provided for by the operating manual (instructions), after commissioning work and during operation, must undergo regime-commissioning tests.
It is not allowed, after pressure equipment has been put into operation, to carry out arbitrary replacement or modification of its elements, complete or partial removal of safety devices and protective devices.
Upon completion of commissioning work by the commissioning organization with the participation of employees of the operating organization, a comprehensive test of the pressure equipment, as well as auxiliary equipment, is carried out at nominal load. For boilers, comprehensive testing is carried out for 72 hours.
The completion of comprehensive testing is documented by an acceptance certificate for equipment after comprehensive testing. The acceptance certificate for equipment after comprehensive testing must be accompanied by a technical report on commissioning works with tables and instructions, operating charts, schedules, and other materials reflecting the established and actually obtained data on the setup and adjustment of devices, as well as descriptions and drawings of all changes (schematic, structural) that were made during the commissioning stage.
The following works are sequentially performed for the commissioning (admission) into operation of pressure equipment:
conducting a technical inspection of the pressure equipment;
carrying out, in accordance with subparagraph 19.9.1 of clause 19 of the unified list of administrative procedures, the registration of the pressure equipment with the State Industrial Supervision Authority (authorized body);
carrying out commissioning works in cases provided for by the operating manual (instructions);
commissioning (admission) into operation of pressure equipment.
Pressure equipment (boilers) must comply with industrial safety requirements before being commissioned (admitted) into operation. For these purposes, an official of the State Industrial Supervision Authority inspects (examines) the pressure equipment being commissioned for:
the operability of all devices, including backup ones;
the operability of measuring devices;
the completeness and correctness of the setup of safety automation, signaling, and control systems;
the correct setup of safety valves;
the compliance of equipment operating modes with operating charts compiled
based on the results of operating and adjustment tests;
the serviceability of boiler feed devices and their compliance with the boiler house design and the requirements of these Rules;
the compliance of the boiler water treatment regime with the requirements of these Rules;
the correct connection of pressure equipment to pipelines in accordance with the design (engineering) documentation;
availability of personnel servicing pressure equipment and specialists meeting the qualification requirements, who have passed knowledge tests on industrial safety;
availability of operating instructions for personnel servicing pressure equipment, shift and repair logs, and other documentation provided for by these Rules;
availability of job descriptions for persons responsible for the proper condition and safe operation of pressure equipment.
Pressure equipment (vessels and apparatus) must comply with industrial safety requirements before its commissioning (admission) into operation.
The organization carrying out the operation and maintenance of pressure equipment must ensure its proper condition and safe operating conditions. For this purpose, it is necessary to:
appoint by order a person responsible for the proper condition and safe operation of pressure equipment. The order number and date of appointment of the person
responsible for the proper condition and safe operation of pressure equipment must be recorded in the pressure equipment passport;
appoint the required number of personnel servicing pressure equipment;
develop operating instructions for pressure equipment;
provide personnel servicing pressure equipment
with operating instructions and process diagrams. Personnel
servicing pressure equipment, before being admitted to independent work, must be familiarized with the operating instructions and sign them. Instructions must be kept at the workplaces;
organize industrial control over compliance with industrial safety requirements during the operation of pressure equipment;
ensure the conduct of technical inspection, technical diagnostics, maintenance, and repairs of pressure equipment;
comply with the manufacturer's requirements established by the operating manual (instructions), and do not allow the operation of pressure equipment with faulty shut-off and control valves, measuring instruments, safety and interlock devices, signaling and protection means;
take measures to eliminate and prevent violations of industrial safety requirements when detected.
The organization carrying out the operation of pressure equipment, for the organization
and the implementation of industrial safety production control during the operation of pressure equipment, develops, based on the model regulation on the organization and implementation of industrial safety production control, approved by the Ministry of Emergency Situations, a regulation on the procedure for organizing and implementing industrial safety production control.
To ensure industrial safety production control, the head of the organization or its separate division shall introduce an industrial safety engineer into the staff or, by a local legal act, assign to one of the employees the relevant duties for carrying out industrial safety production control. The number of employees of the service carrying out production control and its structure shall be determined by the owner of the pressure equipment on which the pressure equipment is operated, taking into account the type of equipment, its quantity, and operating conditions.
The head of the organization operating pressure equipment shall create conditions for the persons responsible for carrying out production control and the persons responsible for the proper condition and safe operation of pressure equipment to fulfill the duties assigned to them.
Maintenance of pressure equipment shall be carried out by specialized organizations. Personnel aged 18 years or older, meeting the qualification requirements and having undergone a medical examination in cases and in the manner determined by the Instruction on the procedure for conducting mandatory and unscheduled medical examinations in accordance with the Instruction on the procedure for issuing a certificate of qualification for the maintenance of potentially hazardous facilities, approved by the Resolution of the Ministry of Emergency Situations of the Republic of Belarus of July 6, 2016 No. 31, shall be allowed to maintain pressure equipment.
An employee who has undergone training and knowledge testing on industrial safety in accordance with the Instruction on the procedure for training and knowledge testing on industrial safety, approved by the Resolution of the Ministry of Emergency Situations of the Republic of Belarus of July 6, 2016 No. 31, shall be appointed as the person responsible for the proper condition and safe operation of pressure equipment.
During the absence of the person responsible for the proper condition and safe operation of pressure equipment due to vacation, business trip, or illness, their duties shall be assigned by a local legal act to other employees who have undergone training and knowledge testing on industrial safety (without entering information into the pressure equipment passport) in accordance with the Instruction on the procedure for training and knowledge testing on industrial safety.
Training of persons responsible for the proper condition and safe operation of pressure equipment shall be carried out at least once every five years.
It is not permitted to simultaneously appoint the same person as responsible for the proper condition and safe operation of pressure equipment and responsible for carrying out industrial safety control.
When performing official duties, the person responsible for the proper condition and safe operation of pressure equipment must be guided by these Rules, the job description, in accordance with the requirements of which, he must, among other things:
ensure that pressure equipment is kept in good working order;
ensure that pressure equipment is serviced by trained and certified personnel, and that they comply with the operating instructions;
ensure timely repairs are carried out;
inspect pressure equipment that is in working condition at intervals established by the head of the organization operating and servicing the pressure equipment;
personally conduct external and internal inspections at intervals established by these Rules;
check entries in the shift log daily on working days and sign them;
keep pressure equipment passports, design and operating documentation from manufacturing organizations (including operating manuals/instructions);
organize the preparation and conduct of technical inspections of pressure equipment by an expert in industrial safety;
conduct emergency drills with personnel servicing pressure equipment in the manner established by the operating organization;
participate in inspections, monitoring, technical (technological, verification) measures carried out by regulatory (supervisory) bodies and inspections carried out by the person responsible for production control, and promptly comply with the requirements (orders) issued by them to eliminate identified violations;
timely eliminate identified malfunctions of pressure equipment and auxiliary equipment of hazardous production facilities, boiler facilities;
keep records of the number of loading cycles for pressure equipment operating in a cyclic mode.
When performing official duties, the person responsible for implementing industrial control must be guided by the regulation on the procedure for organizing and implementing industrial control in the field of industrial safety.
Operation of pressure equipment must be carried out in accordance with the operating instructions developed and approved by the operating organization, which, among other things, must reflect:
pressure equipment to which the operating instructions apply, its purpose;
duties of employees during duty shifts for monitoring and controlling the operation of pressure equipment;
procedure for checking the serviceability of the maintained pressure equipment in working condition;
procedure, deadlines, and methods for checking fittings, safety devices, automation devices for protection and signaling;
procedure for starting up and shutting down (stopping operation) of pressure equipment;
procedure for starting up pressure equipment in winter;
safety measures when taking equipment out for repair, as well as additional safety measures for vessels with a working medium classified as Group 1 in accordance with TR CU 032/2013;
cases requiring emergency shutdown of pressure equipment. The procedure for emergency shutdown and reduction of pressure to atmospheric is established depending on the specific connection diagram of the pressure equipment and the technological process;
actions of employees in case of an accident or incident;
procedure for maintaining the shift log (registration of shift handover and acceptance, checking entries by the person responsible for the proper condition and safe operation of pressure equipment).