Questions regarding the renewal process for pressure pipelines

Generally, large enterprises have their own pressure piping management manuals or quality manuals.

The relevant design regulations have been posted in the upload area; please refer to http://bbs.hcbbs.com/thread-425206-1-1.html for the Technical Regulations on the Safety Management of Pressure Pipes. 1 Scope: These standards specify the guiding principles for the management of pressure pipes, the scope of such management, and the organizations responsible for it； Requirements that must be complied with in all aspects of pressure pipeline design, manufacturing, installation, operation and management, inspection, repair, and modification. This standard applies to the safety technical management of pressure pipelines in companies. 2 Management Responsibilities 　　2.1 The Company’s Mechanical Department is responsible for overseeing the design, manufacturing, installation, repair, modification, operation management, and inspection of pressure pipelines within the company. 　　2.2 The equipment management departments of each unit are the competent authorities for the management of pressure pipelines within their respective units. 3 Management Contents and Requirements 3.1 Management Contents 3.1.1 Scope of supervision and management is based on the \"Regulations on the Management of Pressure Pipelines in Chemical Enterprises\" issued by the former Ministry of Chemical Industry, as well as the \"Regulations on the Safety Management and Supervision of Pressure Pipelines\" issued by the former Ministry of Labor. Applicable to pipelines that meet all of the following conditions: a) inlet pressure Pw is greater than or equal to 0.1 MPa; b) nominal diameter Dg is greater than or equal to 50 mm; c) process pipelines for transporting chemical substances, steam pipelines used in chemical production, as well as utility gas pipelines and thermal pipelines. 　　3.1.2 For pressure pipelines that do not meet the above conditions, the using unit shall establish management procedures. 　　3.2 Pressure Pipeline Design 　　3.2.1 Only entities that possess qualifications for chemical engineering design or pressure pipeline design may engage in the design of pressure pipelines within the scope of their qualifications. 　　3.2.2 The design unit is technically responsible for the safety of the pressure pipelines it designs. The design documents must clearly specify the design standards, installation and construction specifications, material standards to be used, calculated wall thickness, corrosion allowance, and corrosion rate. 　　3.2.3 The Company’s Mechanical Department is responsible for the supervision and management of the quality assurance system of the pressure pipeline design units. 　　3.2.4 Factory pressure pipeline managers should participate in the design review of factory infrastructure, technical renovation, and technical improvement projects. 3.3 Manufacturing of pipe fittings and pipeline accessories 3.3.1 The manufacturers of pipe fittings and pipeline accessories used in pressure pipelines must possess the appropriate manufacturing qualifications and be registered with the **technical supervision department. 　　3.3.2 Products such as pipe fittings and pipeline accessories must come with certificates of conformity and performance reports; the using unit must conduct acceptance inspections, and re-inspections may be carried out if necessary. 3.4 Manufacturing and Installation of Pressure Pipelines 3.4.1 Pressure pipeline installation units shall possess a \"Pressure Pipeline Installation License\" issued by ** or the provincial quality and technical supervision bureau, and shall carry out pressure pipeline installation within the scope permitted by such license. 3.4.2 The manufacturing unit is responsible for the safety and quality of the pipes, fittings, and pipeline accessories it produces ； The installation unit is responsible for the quality of the pressure pipeline installation. 3.4.3 The pipes, welding materials, etc. used by the manufacturing and installation units must meet the design specifications, come with certificates of conformity, and be retested if necessary. When a material change occurs during manufacturing and installation, it must be approved by the technical supervisor of the design unit, who will then issue a material change order. 3.4.5 Factory pressure pipeline management personnel shall carry out product supervision over the manufacturing units based on the quality of the products. 　　3.4.6 The installation unit shall conduct self-inspections of the installation quality at all times, and submit itself to supervision and inspection by the relevant authorities, to ensure the quality of the installation, repair, and modification of pressure pipelines. 　　3.4.7 A qualification review system shall be implemented for outsourced projects. Units without the necessary qualifications shall not engage in the installation and maintenance of pressure pipelines. 　　3.4.8 In technical renovation and improvement projects, before the installation of pressure pipelines, the project owner shall submit a start-up report to the company’s Maintenance Department; the Maintenance Department, together with relevant departments, will conduct inspections of the construction conditions and on-site safety situation. 　　3.4.9 When the installation unit carries out the handover procedures to the user unit, it must transfer all technical documents and as-built drawings of the pressure pipeline to the user unit. 　　3.4.10 Welders who are involved in the manufacturing, installation, repair, and modification of pressure pipelines must hold a welder’s operation certificate issued by the technical supervision department, and they must carry out the corresponding welding work. The company’s Maintenance Department is responsible for organizing welder training. 　　3.5 Management of Pressure Pipeline Use 　　3.5.1 Before putting a new pressure pipeline into use, the user entity must have ready such documents as certificates of conformity for the main components, quality certificates, as-built drawings, and installation completion documents. It is also necessary to fill out three copies of the “Pressure Pipeline Use Registration Form”. After the company’s Machinery Department, in conjunction with relevant departments, conducts an inspection, the registration and filing procedures shall be carried out in accordance with relevant regulations before the pipeline can be put into use. 　　3.5.2 The procedures for obtaining a permit for the use of pressure pipelines in operation are in accordance with 3.5.1; in addition to the requirements mentioned above, the necessary documents also include a pressure pipeline inspection report or inspection records. 　　3.5.3 All units shall further establish and improve the archives and records related to pressure pipelines. The content of these archives should follow the \"Format for Technical Archives of Pressure Pipelines\" issued by the former Ministry of Chemical Industry. It is necessary to properly store the information related to pressure pipelines, ensure scientific management and easy access to such information, so as to guarantee the safe operation of pressure pipelines. 　　3.5.4 All units must, in conjunction with the equipment inspection system, equip themselves with the necessary facilities to conduct regular, scheduled inspections of the pipelines in the plant area as well as the utility ductwork, in order to promptly identify and repair leaks and eliminate any signs of potential accidents. The entity that uses or manages the pressure pipeline is responsible for its safety condition. 　　3.5.5 It is generally strictly prohibited to repair defects in pipelines while they are in operation under pressure. If cold tightening, hot tightening, or plugging leaks under pressure is necessary during production, strict safety measures must be established; these measures shall be approved by the technical supervisor of the construction unit and authorized by the safety department before they can be implemented. 　　3.5.6 In the event of any of the following situations during use and inspection, the operator is authorized to take immediate emergency measures and report to the higher-level authorities at the same time: a) The pipeline is overheated, overpressured, or undercooled, and these conditions do not improve despite attempts to address them ； 　　b) Pipeline leaks or ruptures pose a threat to safe production ； 　　c) Fires, explosions, or accidents involving adjacent equipment and pipelines that directly threaten the safe operation of the pipeline. 　　3.5.7 The user unit must provide safety and technical training for personnel who operate pressure pipelines, as well as those involved in the technical management, inspection, and maintenance of such pipelines, and must implement a system requiring certification before working. 　　3.5.8 For in-service pressure pipelines that have been out of use for more than two years, a pressure test, macroscopic inspection, and wall thickness measurement must be carried out before use; if necessary, they should be inspected by a testing agency. 　 　3.6 Inspection of pressure pipelines 　3.6.1 The contents and inspection intervals for the regular inspection of pressure pipelines shall be in accordance with the requirements set out in the former Ministry of Chemical Industry’s \"Regulations on the Inspection of Pressure Pipelines in Chemical Enterprises\". 　 　3.6.2 In principle, the inspection of pressure pipelines should be carried out by qualified inspection units within the company; in special cases where external assistance is required, the Company’s Logistics Department shall arrange for other qualified inspection units to carry out the work. 3.6.3 Inspectors of pressure pipelines must obtain the corresponding qualification certificates through assessment by labor administrative departments at or above the provincial level, and carry out inspection work within the scope permitted by such certificates. 3.6.4 The factory shall prepare a monthly inspection plan based on the annual inspection plan and actual production conditions, and submit the inspection plan for the following month to the company’s Logistics Department by the 20th of each month. 　　3.6.5 The factory is responsible for providing information on the pressure pipelines to be inspected, carrying out technical preparations for these pipelines, and preparing a safety inspection plan; it also assists the inspection agency with the necessary procedural steps. 　　3.6.6 Implement a process card transmission system for inspections; the inspection plans formulated by the inspection unit must be approved by the factory, and after the inspections are completed, the user unit shall conduct checks and acceptance according to the inspection plans item by item. 　　3.6.7 If defects exceeding the standards are detected during inspection, the factory shall be notified promptly to arrange repairs; it can only be put into use after passing re-inspection. 　　3.6.8 The inspection unit shall submit the inspection report or inspection notice card within two weeks after the inspection is completed, to ensure timely vehicle operation. 　　3.6.9 The charging standards for pressure pipeline inspections shall be established separately. 　　3.7 Repair and modification of pressure pipelines 　　3.7.1 Repair of pressure pipelines mainly refers to the repair of areas with defects that exceed the specified limits identified during inspections, as well as the repair of issues such as leaks that occur during operation. 　　3.7.2 Units that hold a pressure pipeline installation license are deemed to have the corresponding qualifications for pressure pipeline maintenance. When repairing and modifying pressure pipelines, the construction techniques and management requirements shall be consistent with those for newly built pressure pipelines. 3.7.3 A qualification approval system shall be implemented for outsourced projects involving repair and modification. Plant pressure pipeline managers are responsible for supervising the construction quality of outsourced projects. 3.8 Inspection of Pressure Pipeline Accessories 3.8.1 The inspection of pipeline accessories such as valves, safety valves, and pressure gauges on pipelines is carried out in two ways: during operation and when the pipeline is shut down. 3.8.2 When the factory conducts routine inspections on pressure pipelines, it also checks the pipeline accessories during operation. 3.8.3 Shutdown inspections are carried out by the factory. 3.8.3.1 The calibration of safety valves is carried out in accordance with Article 4.2.13 of the company’s “Regulations on Safety Technology Management for Boilers and Pressure Vessels”, which deals with the inspection of safety accessories. 3.8.3.2 Pressure gauges must be calibrated within the timeframe specified by the metrology department, with regular arrangements made by the factory. 3.8.4 The factory shall maintain records for the safety valves of pressure pipelines as well as records of the set pressures. 3.8.5 Important pipeline accessories must not be moved or removed arbitrarily; if it is necessary for production purposes, approval from the design department and the technical supervisor of the unit is required. 3.8.6 During regular inspections of pressure pipelines, random sampling of pipeline accessories shall be conducted. 3.9 Incident Management 3.9.1 In the event of accidents such as explosions, leaks, or fires, it is necessary to report them promptly to the company’s Logistics Department. 3.9.2 The competent leader shall promptly organize relevant personnel to analyze the causes of the accident and take measures to remedy it in a timely manner. Afterward, it is necessary to conduct a thorough summary and take appropriate action. 3.10 Periodic Reports 3.10.1 Summary Table of Basic Data Survey for Pressure Pipelines. 3.10.2 Annual pressure pipeline repair schedule. 3.10.3 Annual pressure pipeline installation (modification, renewal) plan table. 3.10.4 Annual pressure pipeline inspection plan table. The above tables shall be submitted to the company’s Logistics Department by October 20. This post was last edited by zhangyong6404 on 2009-3-25 at 10:26.]