What data is applied by the manufacturer to the SynRM. Appointment of the PPC. Timing of calibration Calibration of the safety valve in Yanao
Dear experts, I ask you to clarify what specific regulatory and technical documents we need to be guided by when testing (calibrating) safety valves, since in the "Rules for the Design and safe operation technological pipelines (approved by the resolution of the Gosgortechnadzor of the Russian Federation of June 10, 2003 N 80) p. 9.3.31. It is indicated that "Safety valves are serviced in accordance with the technical documentation and normative and technical documentation on industrial safety", i.e. no detailed answer has been given on this issue. And the second question is whether we have the right to be guided by IPKM-2005 "Procedure for the operation, revision and repair of safety valves, membrane safety devices of oil refining and petrochemical enterprises of the Ministry of Industry and Energy of Russia", agreed with Rostekhnadzor of Russia, to determine the frequency of revision of the PIC.
Sincerely, Makarov E.
Answer:
Hello. Calibration is carried out on the basis of the factory
Manuals (instructions) for operation.
PB 03-583-03 also apply for membrane devices.
There are no similar BOPs in the oil and gas industry. It is possible to use the “Operation procedure ...” indicated by you, if it is extended to the oil and gas industry.
Rules for carrying out hot work in pumping and tanks.
Hot work in technological pumping stations, compressor stations and others industrial premises:
1. O.r. in industrial premises should be started only if there are no explosive substances in the air or if they are not higher than the MPC.
2. Before the start of the o.r. in technological pumping, compressor stations it is necessary:
Stop pumps and compressors;
Shut off the valves and install plugs at the intake and at the outlet;
Release pipelines from product residues and reduce pressure to atmospheric;
Technological communications undergoing repair, blow with live steam;
Carry out a gas analysis;
If necessary, thoroughly clean and rinse sewer trays and sewers with water, seal well hatches.
3. During the o.r. it is necessary to ensure constant ventilation of the room and establish control over the state of the air environment.
4. In the event of an increase in the content of explosive and hazardous substances in the air, o.r. must be stopped immediately.
5. Trenches, trays and other devices in which accumulation of liquids, gases or vapors is possible must be protected from sparks.
Hot work inside apparatuses, containers, in wells and pipelines pumping explosive and toxic products:
6. O.r. should only be started after complete completion preparatory work, provided for by the work permit for gas hazardous work, and also if the content of harmful vapors and gases does not exceed the MPC.
7. All devices must be stopped, de-energized, freed from toxic products.
8. Containers must be steamed and ventilated.
9. Take and analyze air samples at ten points.
10. When conducting o.r. inside tanks, apparatus, it is necessary to provide ventilation and lighting of the workplace.
11. As a rule, one person should work in the vessel, apparatus, when two people are appointed as observers.
The spring-loaded safety valve PPK is installed on vessels operating under pressure, relieves excess pressure, and protects vessels from rupture.
Device: 1-seat, 2-plate, 3-stem, 4-spring, 5-handle, 6-body.
Principle of operation: At the pressure of the PPC actuation, the gas lifts the plate and exits through the gas outlet into the flare or discharge line of the PPC, a hiss is heard. When testing the valve, we raise the stem by the handle, the plate rises under pressure, and a hiss or whistle is heard. This is a check of the valve, which is carried out 1 time per shift in winter, 1 time per week in summer, 1 time per year, the valve is calibrated (checked according to the schedule) with spring tension on the response pressure of the control panel and sealing.
What functional responsibilities will you add in case of an increase in the category?
Answer: According to ETKS (single tariff - qualification guide) by rank
What is AGZU and what is it intended for?
Answer: The automatic group metering unit (AGZU) is designed to measure the average daily volume flow of gas and to determine the average daily mass flow of oil produced from oil wells in automatic and manual modes.
What is a SPKK, decipher what it is for, what pressure it is calibrated for, the calibration time, what is written on the valve tag?
Answer: SPKK (special spring safety valve) is designed to release excess pressure.
The frequency of calibration should be at least every 24 months.
Each valve must have...
a plate made of stainless steel or aluminum is securely attached and sealed, on which the following are knocked out:
a) valve serial number;
b) valve setting pressure - Rust (setting pressure);
c) date (actual) of the last revision and calibration.
SPPK is calibrated for 1,15 Rrab.
Additionally, a red arrow is applied to the valve body, indicating the direction of movement of the lever when the valve is undermined.
What is written on the information plate of the SynRM? Terms of hydraulic testing of vessels, what pressure is hydrotesting carried out?
Answer: After installation, each vessel must be painted in a visible place or on a special plate with a format of at least 150x200 mm:
- registration number;
- permitted pressure;
— day, month and year of the next external inspection and hydraulic test
External examination and hydraulic tests (NO and GI) are carried out after 2 years
Hydrotesting of vessels is carried out 1,25 Rrab
What are pressure gauges for, what types are there? Requirements for pressure gauges, for what reasons pressure gauges are rejected, what is written on the stamp (seal), the accuracy class of the pressure gauge, what is the check and verification of the pressure gauge, the timing of their implementation, the selection of the pressure gauge from the pressure, what diameter the pressure gauge will be installed at a height of 2 -x up to 3 meters? I-08 is stamped on the seal (stamp), until what day is it to be used?
Answer: A manometer is a device that measures pressure.
Each vessel and separate cavities with different pressures must be equipped with direct-acting pressure gauges. The pressure gauge can be installed on the fitting of the vessel or pipelines up to the stop valves.
Pressure gauges must have an accuracy class of at least:
2.5 - at a working pressure of the vessel up to 2.5 MPa (25 kgf / cm 2);
1.5 - at a working pressure of the vessel over 2.5 MPa (25 kgf / cm 2).
The pressure gauge must be selected with such a scale that the working pressure measurement limit is in the second third of the scale.
The scale of the manometer shall be marked with a red line indicating the maximum working pressure in the vessel. Instead of a red line, it is allowed to attach a metal plate to the pressure gauge case, painted red and tightly adjacent to the pressure gauge glass.
The pressure gauge must be installed so that its readings are clearly visible to the operating personnel.
The nominal diameter of the case of pressure gauges installed at a height of up to 2 m from the level of the platform for monitoring them must be at least 100 mm, at a height of 2 to 3 m - at least 160 mm. Installation of pressure gauges at a height of more than 3 m from the level of the site is not allowed.
The pressure gauge is not allowed for use in cases where:
- there is no seal or stamp with a mark on the state verification;
- the period of state verification is overdue;
- the arrow, when it is turned off, does not return to the zero reading of the scale by an amount exceeding half the permissible error for this device;
- the glass is broken or there are damages that may affect the correctness of its readings.
Verification pressure gauges with their sealing or branding is carried out at least once every 12 months.
In addition, at least once every 6 months, the owner of the vessel must make additional verification working pressure gauges with a control pressure gauge with a record of the results in the log of control checks of pressure gauges. In the absence of a control pressure gauge, it is allowed to carry out an additional check with a working pressure gauge that has the same scale and class with the tested pressure gauge.
I-08 is stamped on the seal (stamp), until what day is it to be used? Until 01.01.2009
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ASKED QUESTIONS
1. What functional responsibilities will be added with an increase in the category?
According to ETKS to the increased category.
2. What is AGZU and what is it intended for?
AGZU - automated group metering unit.
Designed to measure the flow rate of the liquid (measurement of the flow rate of each well) and to measure the pressure in the reservoir.
AGZU is designed to automatically account for the amount of liquid and gas produced from oil wells with subsequent determination of the well flow rate. The unit allows you to control the operation of wells by the presence of liquid and gas supply and provides the transfer of this information, as well as information about the accident to the control room.
3. What inscriptions are put on the doors of the AGZU premises?
Warning signs, the inscriptions "Explosion class B-1a and fire hazard category" and "Flammable", grounding signs, ventilate for at least 20 minutes before entering, energy safety, responsible for fire safety
4. What is SPKK, decipher what it is for, what pressure is calibrated for? (for some reason, no one asked the timing of calibration!)
SPPK - separation (special?) spring safety valve. The valve is calibrated (if the pressure in the vessel is from 30 - 60 atm., 10% - 15% more than the permitted pressure. If the pressure in the vessel is up to 30 atm., Then 10% more than the permitted pressure. number, set pressure and date of actual calibration Calibration period 1 time in 2 years The valve is installed to prevent overpressure.
Specially spring-loaded safety valve installed on vessels, apparatus and pipelines of workshops / sites /
The design of the spring valve should include a device for checking the correct operation of the valve in working condition by forcibly opening it during the operation of the vessel.
The necessity and timing of checking the operation of the valve in working condition by forced opening should be determined by: at least once every 10 days, for vessels (devices) technological installations(DNS, KNS, UPSV, OPN, etc.), and at least once every 3 (three) days for separation tanks AGZU. The time and date of checking the operation of the valve in working condition, by forced opening, must be recorded by the maintenance personnel with an entry in the watch log (well pad maintenance log).
Adjustment of safety valves for pressure start of opening - set pressure/cotton/ is produced on a special stand.
The setting pressure of the valve is determined based on the operating pressure in the vessel, apparatus or pipeline, based on the approved technological schedule.
A safety valve (hereinafter referred to as PC) is a predominantly direct-acting pipeline valve (there are also PCs controlled by pilot or pulse valves), designed for emergency bypass (discharge) of the medium when the pressure in the pipeline exceeds the set value. After release of excess pressure, the PC must be hermetically sealed, thus stopping further discharge of the medium.
This manual uses 2 terms:
1. Setting pressure (hereinafter Рn) – this is the greatest excess pressure at the inlet to the valve (under the spool) at which the valve is closed and tight. If Рн is exceeded, the valve must open to such an extent that it would provide the required flow rate of the medium to reduce the pressure in the pipeline, vessel.
2. The pressure of the beginning of the opening (hereinafter Pn. o.) is the pressure at which the so-called “pop” in the jargon of the manufacturers occurs, i.e. the pressure at which the valve spool opens a certain amount, relieves some of the pressure and then closes back. "Cotton" is clearly distinguishable in gaseous media, in liquid media this concept is defined with great difficulty.
Checking the settings and performance must be carried out at least once every 6 months in accordance with GOST 12.2.085 “Pressure vessels. Valves safety safety requirements.
The pH pressure can only be checked on so-called "full consumable» stands, i.e. on those that repeat the operating parameters of the pipe (vessel) in terms of pressure and flow. Taking into account the variety of objects on which PCs are installed even within the same enterprise, it is not possible to have such a number of stands.
Therefore, when checking and adjusting the PC, the determination of pressure Рн is used. about. Based on numerous experiments in the course of many years of practice, it has been established that Rn. about. should be higher than pH by no more than 5-7% (in Western standards 10%).
Checking valves for operability and pressure pH. about. held on "cost-free" benches, a typical representative of which is a bench for testing and adjusting safety valves SI-TPA-200-64 manufactured by the Design Bureau of Pipeline Valves and Special Works.
Stand for testing and setting safety valves SI-TPA-200-64 provides the following pneumatic tests (medium - air, nitrogen, carbon dioxide, other non-combustible gases):
- tightness tests of the saddle-body connection;
- tightness tests of the seat-spool pair (tightness in the valve);
- tests for performance (for operation);
- settings for actuation pressure.
It is possible to manufacture a stand in a complete set for testing with water.
The stand provides testing of pipeline fittings with a flange type of connection (threaded connection as an option)
with a maximum diameter of 200. The maximum test pressure depends on the type of pressure regulator supplied with the control panel, the basic equipment of the control panel is a regulator from 0 to 1.6 MPa. The test of valves with a union connection is carried out using an adapter (not included in the delivery set).
The test pressure source is not included in the scope of delivery.
Available with pressure source terms of reference customer.
Test stand SI-TPA-200-64 passed the certification of UkrSEPRO, comes complete with instruction manual, passport.
Adjustment (adjustment) of safety valves for actuation at a given pressure is carried out:
Before installation. After a major overhaul, if the safety valves or their overhaul(complete disassembly, turning of sealing surfaces, replacement of chassis parts, etc.), in case of replacement of the spring. During the periodic check. After emergencies caused by the inoperability of the PC.
The actuation of the valves during adjustment is determined by a sharp pop accompanied by the noise of the ejected medium, observed when the spool is separated from the seat. For all types of PC, the operation is controlled by the beginning of the pressure drop on the pressure gauge.
Before starting work on setting up (checking) the PC, it is necessary to instruct the shift and adjustment personnel involved in the work on adjusting the valves.
Staff should be well aware design features subject to adjustment of the PC and the requirements of the instructions for their operation.
GENERAL PROCEDURE FOR CHECKING SAFETY VALVES.
Install on the stand a flange of the type that corresponds to the type of flange of the tested PC. Install the required gasket. Install the valve on the stand flange. Tighten the stand screw until the PC is fully fixed in the clamps. Create the maximum possible counterpressure force on the PC spool. Shut off the access of the medium under the valve spool using a shut-off device. Feed the medium into the control panel and set the required response pressure (beginning of opening) at the outlet of the control panel. Open the locking device and apply the test medium under the PC spool. Relieve the counterpressure force until the valve opens. Block the access of the medium under the PC spool. Re-supply the medium under the spool of the PC - the valve must operate at the required pressure. Repeat p. 10 and p. 11 at least 3 times. If it is not possible to properly adjust the PC, return the valve to the RMC for additional grinding of the seat and (or) spool. When the operability of the PC is confirmed, dismantle the PC from the stand, having previously blocked the flow of medium under the spool and into the control panel. Fill in the operational documentation of the PC and the log of the work of the stand. Seal the PC and backpressure adjustment mechanisms. Disable stand. Drain water (condensate) from the cavities of the stand, wipe dry, apply protective lubricant. Ensure the safety of the stand from dust and moisture until the next operation.
FEATURES OF ADJUSTING LEVER-CARGO VALVES.
Adjustment of lever-load valves of direct action is carried out in the following sequence:
1. The weights on the valve levers move to the end position.
3. The weight on one of the valves is slowly moved towards the body until the valve actuates.
4. After closing the valve, the position of the weight is fixed with the stop screw.
5. Pressurize again and check the pressure value at which the valve operates. If it differs from the required one, the position of the weight on the lever is corrected and the correct operation of the valve is rechecked.
6. After the end of the adjustment, the position of the load on the lever is finally fixed with the locking screw. To prevent uncontrolled movement of the load, the screw is sealed.
7. If the value of the counterpressure created by the load is insufficient, an additional load is placed on the lever of the adjustable PC and the setting is repeated in the same sequence.
FEATURES OF ADJUSTMENT OF SAFETY VALVES OF DIRECT ACTION.
1. The protective cap is removed and the adjusting screw is tightened as far as possible (“to the bottom”).
2. A pressure is set on the pressure gauge of the stand, which is 10% higher than the calculated (allowed).
3. Turning the adjusting sleeve counterclockwise reduces the compression of the spring to the position at which the valve will actuate.
4. Pressurize again and check the value at which the valve opens. If it differs from the required one, then the spring compression is corrected and the valve is rechecked for operation. At the same time, the pressure at which the valve closes is monitored. The difference between the actuation pressure and the closing pressure should be no more than 0.3 MPa (3.0 kgf/cm2). If this value is greater or less, then it is necessary to correct the position of the adjusting sleeve.
For this:
for TKZ valves, unscrew the locking screw located above the cover and turn the damper sleeve counterclockwise - to reduce the difference or clockwise - to increase the difference;
for valves PPK and SPKK, the pressure difference between the actuation and closing pressures can be adjusted by changing the position of the upper adjusting sleeve, which is accessed through a hole closed by a plug on the side surface of the body.
5. After the adjustment is completed, the position of the adjusting screw is locked with a lock nut. To prevent unauthorized changes in the tension of the springs, a protective cap is installed on the valve, covering the adjusting sleeve and the end of the lever. The bolts securing the protective cap are sealed.
FEATURES OF ADJUSTING IMPULSE-SAFETY DEVICES WITH IMPULSE VALVES USED AT POWER PLANTS.