Circular No. 202/2017/TT-BQP sets out the Technical Safety Inspection Procedure for YXHC drying and cooling stations with diameters of ϕ55-70 MЭ used within the Ministry of National Defense (Procedure QTKĐ 06:2017/BQP).

TECHNICAL SAFETY INSPECTION PROCEDURES

(Issued along with Circular No. 202/2017/TT-BQP dated August 22, 2017)

1.1. Scope of Regulation
4.1. Drying and Cooling Stations ЬХНС ϕ55-70 МЭ

9.2. Internal Technical Inspection
of the Minister of National Defense)

HANOI - 2017

 

Table of Contents

1. Scope and Objectives 

9.3. Technical Inspection and Testing           

1.2. Applicability  

2. Forms of Inspection 

3. Referenced Documents  

4. Terms and Definitions 

9.4. Operational Inspection

4.2. Initial Technical Safety Inspection   

4.3. Periodic Technical Safety Inspection   

4.4. Unusual Technical Safety Inspection

5. Inspection Steps 

6. Inspection Tools   

7. Inspection Conditions

8. Preparation for Inspection 

8.1. Unifying the Inspection Plan

8.2. Checking Documentation and History 

8.3. Preparing Inspection Tools  

8.4. Preparing Safety Measures During Inspection     

9. Conducting the Inspection

9.1. External Technical Inspection  

Technical Inspection Procedures for Safety and Technical Operation of drying and cooling stations ЬХНС ϕ55-70 МЭ used in the Ministry of National Defense (TIKĐ 06:2017/MND) were compiled by the Technical Department and submitted for issuance by the Minister of National Defense through Circular No. 202/2017/TT-BQP dated August 22, 2017.  

TIKĐ 08:2017/MND

Drying and Cooling Stations ЬХНС ϕ55-70 МЭ.       

10. Handling Inspection Results 

11. Inspection Period 

12. Appendix I

13. Appendix II         

Foreword

1. SCOPE AND APPLICABLE SUBJECTS These Technical Inspection Procedures for Safety and Technical Operation apply to initial technical safety inspections, periodic technical safety inspections, and extraordinary technical safety inspections of drying and cooling stations ЬХНС ϕ55-70 МЭ (referred to as drying and cooling stations) listed in the Catalogue of Machinery, Equipment, and Materials with Strict Requirements for Military Occupational Safety issued by the Ministry of National Defense.

4.1. Drying and Cooling Stations ЬХНС ϕ55-70 МЭ                                                                                             Based on these procedures, technical safety inspection organizations and inspectors within the Ministry of National Defense shall directly apply them or develop detailed procedures for each type of drying and cooling station but must not contravene the provisions of these procedures. Management units, enterprises, and individuals using drying and cooling stations have the responsibility to cooperate with inspection organizations and inspectors in accordance with the law.

- Management units, enterprises, organizations, and individuals managing and using drying and cooling stations within the Ministry of National Defense (collectively referred to as facilities);

QTKĐ:0

2. FORMS OF INSPECTION

1.1. Scope of Application

Technical Inspection Procedures for Safety and Technical Operation of drying and cooling stations must be fully implemented in the following cases: GUIDE

- QCVN 01:2008/BLĐTBXH - National Technical Regulations on Labor Safety for Boilers and Pressure Vessels;

1.2. Applicability

- TCVN 8366:2010 - Pressure Vessels - Technical Safety Requirements for Design and Construction;

- Relevant state management agencies.

+ TCVN 6174: 1997: Industrial explosives - Safety requirements for production, blasting tests, and acceptance;

- TCVN 6155:1996 - Pressure Vessels - Technical Safety Requirements for Installation, Use, and Repair;

- TCVN 6156:1966 - Pressure Vessels - Technical Safety Requirements for Installation, Use, Repair, and Testing Methods;

+ TCVN 4756 - 1989: Grounding and ungrounding regulations for electrical equipment;

+ TCVN 6734:2000: Electrical equipment used in mines and tunnels - Safety requirements for structure and use;

+ Electrical Equipment Regulations Part I. General Provisions - 11TCN-18-2006;

Including national technical standards and regulations on safety as follows:- TCVN 2622:1995 - Fire Prevention and Control for Buildings and Structures - Design Requirements;

- QCVN 01:2011/BCT. National Standard on Safety in Underground Mining Operations;

- TCVN 6290:1997 - Gas Cylinders. Permanent Gas Cylinders - Inspection at Refill Time;

- TCVN 6713:2000 - Gas Cylinders. Safety in Handling;

- TCVN 6008:2010 - Pressure Equipment - Welding: Technical Requirements and Testing Methods;

- TCVN 9385:2012 - Lightning Protection for Building Structures - Guidance on Design, Inspection, and Maintenance of Drying and Cooling Stations;

- TCVN 9358:2012 - Installation of Drying and Cooling Stations Grounding Equipment for Industrial Structures - General Requirements.

In case the national technical regulations and national technical standards cited in these inspection procedures are amended, supplemented, or replaced, they shall be applied according to the provisions of the amended, supplemented, or replacement documents.

Inspections of technical safety elements of drying and cooling stations may be conducted according to other standards when requested by the user or manufacturer, provided that such standards have technical safety requirements equal to or higher than those specified in the national standards cited in these procedures.

4. TERMINOLOGY AND DEFINITIONS

This procedure uses the terms and definitions in the referenced documents above, and some terms and definitions in this procedure are understood as follows:

A drying and cooling station is an equipment used to carry out thermal or chemical processes for the preparation, storage of gases, and filling into pressure vessels with pressures greater than atmospheric pressure for military purposes.

4.2. Initial technical safety inspection is an activity to assess the technical safety condition of a drying and cooling station according to technical safety standards and regulations during installation, before its first use.

4.3. Periodic technical safety inspection is an activity to assess the technical safety condition of a drying and cooling station according to technical safety standards and regulations after the expiration of the previous inspection period.

4.4. Extraordinary technical safety inspection is an activity to assess the technical safety condition of a drying and cooling station according to technical safety standards and regulations when:

- After repair, upgrade, or improvement affecting the technical safety condition of the drying and cooling station;

9.4. Operational Inspection 5. INSPECTION STEPS

When conducting technical safety inspections of drying and cooling stations, the technical safety inspection organization must follow the steps below in sequence:

Step 1. Preparation for Inspection

Step 2. Review of Technical Documentation

Step 3. External and Internal Inspection

- When requested by the facility or competent authority.

Step 4. Technical Inspection and Testing

Step 5. Operational Inspection

Step 6. Processing of Inspection Results.

All inspection results of each step must be recorded in detail in the field record sheet according to the model prescribed in Appendix I and kept fully at the inspection organization.

6. INSPECTION EQUIPMENT

Step 4. Technical testing inspection

Step 5. Operational inspection

Step 6. Processing inspection results.

Note:

The subsequent inspection steps can only be conducted if the results of the previous step meet the requirements. All inspection results from each step must be fully recorded in the on-site record book according to the model specified in Appendix I and kept complete at the inspection organization. If it meets the requirements. All inspection results of each step must be fully recorded in the on-site record sheet according to the model prescribed in Appendix I and kept fully at the inspection organization.

6. INSPECTION TOOLS

The equipment and tools for inspection must be suitable for the object being inspected, must be calibrated and verified according to regulations, and must still be within their verification period, including:

6.1. Equipment and tools for search and seizure

- Lighting equipment with a power supply voltage not exceeding 12 V;

- A magnifying glass with appropriate magnification;

- Magnifying glasses with appropriate magnification;

- Measuring and mechanical tools: Micrometers, calipers, tapes, and other related tools;

- Internal inspection equipment: Endoscopes.

6.2. Equipment and tools for durability testing and leak testing

- Pressure generation equipment with technical characteristics (flow rate, pressure) suitable for the test object;

- Means and equipment for checking tightness;

- Cable and steel quality testing equipment;

- Pressure gauges with appropriate accuracy and scale for the test pressure;

- Ultrasonic thickness measuring equipment;

- Weld quality inspection equipment;

- Metal surface quality inspection equipment.

7. INSPECTION CONDITIONS

7. INSPECTION CONDITIONS

When conducting inspections of drying and cooling stations, the following conditions must be met:

7.1. The drying and cooling station must be in a state ready for inspection.

7.2. The documentation of the drying and cooling station must be complete.

7.3. Environmental and weather factors must not affect the inspection results.

7.5. Safety and labor hygiene conditions must be met to operate cables and cranes.

7.5. Safety and labor hygiene conditions must meet requirements for inspecting the drying and cooling station.

8. PREPARATION FOR INSPECTION

Prior to conducting inspections of the drying and cooling station, the following preparatory work must be carried out:

8.1. Unify the inspection plan, preparatory work, and coordination between the inspection organization and the facility, including the following contents:

8.1.1. Prepare the documentation of the drying and cooling station in accordance with the regulations;

8.1.2. Remove the medium, clean inside and outside the drying and cooling station;

8.1.3. Prepare facilities to ensure that all parts of the drying and cooling station can be examined;

8.1.4. Separate the heating elements or moving parts from the tanks in the drying and cooling station if they are powered by electricity;

8.1.5. Prepare personnel and materials for the inspection; appoint individuals to participate and witness the inspection.

8.2. Checking Documentation and History

Based on the type of inspection, check and review the technical documents of the drying and cooling station.

8.2.1. When conducting initial safety technical inspection:

- Check the history of the drying and cooling station and the tanks within it according to QCVN 01:2008/BLĐTBXH, paying attention to reviewing the following documents:

+ Specifications on metal manufacturing and welding;

+ Calculations of the strength of pressure-bearing components;

+ Drawings showing all critical dimensions;

+ Operation, maintenance, and repair instructions;

+ Certificates of conformity issued by designated organizations (if applicable), in cases where national technical standards have been established for the inspected objects (if applicable).

- Check the factory release documents of the tanks in the drying and cooling station:

+ Certificates on metal manufacturing and welding;

+ Results of weld quality inspections;

+ Factory acceptance reports;

+ Documents of other components in the drying and cooling station.

- Check calibration reports of measurement devices; grounding, lightning protection, and protective device inspection records (if applicable).

- Check installation documents of the drying and cooling station:

+ Name of the installation and using facility;

+ Diagrams of the working principle of the station;

+ Installation design;

+ Characteristics of additional materials used during installation;

+ Welding data such as welding technology, electrode code, welder name, and results of weld tests;

+ Inspection reports of individual station components (if applicable);

+ Overall acceptance report of the station.

- Check the procedures of the drying and cooling station:

+ Pre-inspection bottle checking procedure;

+ Charging procedure;

+ Fire prevention and control documents.

8.2.2. When conducting periodic safety technical inspection of the drying and cooling station:

- Check the history of the station, previous inspection reports, and results;

- Management, operation, maintenance documents of the drying and cooling station; inspection and supervision reports (if applicable).

8.2.3. When conducting extraordinary safety technical inspection of the drying and cooling station:

- In case of repairs, modifications, or upgrades: Design documents for repairs, modifications, or upgrades, and acceptance reports after repairs, modifications, or upgrades;

- In case the system has not operated for 12 months or more, review documents similar to those required for periodic safety technical inspection.

Evaluation:

The inspection of the station's history and documents meets the requirements when:

- The station's history and pressure vessel records are complete and comply with the requirements set forth in Clause 2.4 of QCVN 01:2008/BLĐTBXH;

- If not, the facility must take supplementary measures as stipulated in Clause 3.2.2 of QCVN 01:2008/BLĐTBXH.

8.4. Develop and unify the implementation of safety measures with the facility before inspection. Equip sufficient personal protective equipment to ensure safety during the inspection.

9. CONDUCTING INSPECTION

9. CONDUCTING THE INSPECTION

When conducting inspections of the drying and cooling station, the following sequence must be followed:

9.1. External Technical Inspection

9.1.1. Ground layout and installation location;

9.1.2. Operational lighting system;

9.1.3. Work platforms, stairs, hanging racks, walkways, and related items;

9.1.4. Electrical grounding and lightning protection systems;

9.1.5. Check technical parameters on the labels of the drying and cooling station and its tanks against the design and historical records;

9.1.6. Check the status of safety, measurement, and auxiliary equipment in terms of quantity, type, and technical parameters against the design and specified standards;

9.1.7. Check the types and quantities of pipes, valves, and pipe fittings installed on the station against the design and specified standards;

9.1.8. Check the status of other auxiliary equipment accompanying the station's operations;

9.1.9. Check the condition of welds and metal surfaces of pressure-bearing components. If there is doubt, require the facility to apply appropriate supplementary inspection methods to assess more accurately;

9.1.10. Technical condition of insulation layers (if present);

9.1.11. Check joint details;

9.1.12. Check cooling systems for charging tanks (if present). Inspect the charging rack and tank securing details during the charging process. Determine the amount of gas charged.

Evaluation:

External inspection of the drying and cooling station meets the requirements when:

- Meeting the requirements of the applicable standard;

- For pressure vessels in the system: Complying with the provisions of Article 3 of TCVN 6155:1996 and Article 8 of TCVN 8366:2010.

- There are no cracks, bulges, dents, or corrosion exceeding the specified limits on the pressure-bearing parts and at the welds and connections.

Technical Inspection Procedures for Safety and Technical Operation of drying and cooling stations ЬХНС ϕ55-70 МЭ used in the Ministry of National Defense (TIKĐ 06:2017/MND) were compiled by the Technical Department and submitted for issuance by the Minister of National Defense through Circular No. 202/2017/TT-BQP dated August 22, 2017.

9.2.1. Inspect the surface condition of the metal of the pressure-bearing parts;

9.2.2. Inspect the dirt, rust, and corrosion of the inner metal surfaces of the pressure-bearing parts;

9.2.3. Inspect the welds and the surface condition of the metal of the pressure-bearing parts. If there is any doubt, require the facility to apply appropriate additional inspection methods to assess more accurately;

9.2.4. For positions that cannot be inspected internally during testing, the technical condition inspection must be carried out according to the technical documentation of the manufacturer. The documentation must clearly state: items, methods, and sequence of inspection;

9.2.5. When internal inspection of the pressure-bearing parts is not possible due to the structural characteristics of the station, it is permissible to replace the internal inspection with a strength test at the specified test pressure and inspect the accessible parts;

Evaluation:

The results of the internal technical inspection of the drying and cooling station meet the requirements when:

- For pressure vessels in the system: Complying with the provisions of Article 3 of TCVN 6155:1996 and Article 8 of TCVN 8366:2010.

- There are no cracks, bulges, dents, or corrosion exceeding the specified limits on the pressure-bearing parts and at the welds and connections;

9.3. Technical inspection, testing

9.3.1. If the system has a multi-part structure operating at different pressure levels, each part may be separated and tested individually;

9.3.2. During inspection, isolation measures must be taken to ensure that automatic protection devices and measuring instruments are not destroyed at the test pressure. In cases where this cannot be guaranteed, these devices must be removed;

9.3.3. Strength Testing:

Cylinders in the system are exempt from strength testing during initial inspection if they have been factory-tested within 18 months, stored properly, and show no signs of impact or deformation during transportation and installation. The inspection report must clearly state the reasons and attach the factory test reports of the manufacturer, and the acceptance reports for installation (if available). The strength testing period shall not exceed once every six years, and in case of abnormal inspection, strength testing must be conducted with the following requirements:

- The test medium is liquid (water) or gas (compressed air or inert gas), with the test medium temperature below 50°C and not lower than the ambient temperature by more than 5°C;

- The test pressure and holding time are specified in Table 1;

Table 1

1. Test pressure and holding time for strength testing of the station after initial installation

Remarks- Working pressure._{but not less than 2 bar} 2. Test pressure and holding time for strength testing of the station after regular and abnormal inspections.

Gas storage tanks

Remarks- Sequence of strength testing:_{but not less than 2 bar} 2. Test pressure and holding time for strength testing of the station after regular and abnormal inspections.

+ Load the test medium: Fill the test medium into the system (note the venting of gas when using liquid);

+ Increase the pressure to the test pressure (note to increase gradually to avoid sudden expansion damaging equipment and strictly prohibit hammering at test pressure). Monitor and detect any abnormalities during the test;

+ Maintain the test pressure as prescribed;

+ Gradually reduce the pressure to the working pressure, maintain this pressure throughout the inspection process. Then reduce the pressure to (0), rectify any deficiencies (if any), and recheck the rectified results;

- Strength testing is only allowed when satisfactory results are obtained from external and internal technical inspections and strength calculations based on direct measurement data;

- When testing with gas, the following safety measures must be applied:

+ The valve and pressure gauge on the gas charging line must be moved away from the equipment location or placed outside the equipment room;

+ During the time the cylinder is subjected to gas pressure testing, unauthorized personnel must stay in a safe place;

- Check for tightness using soap solution or other methods. Strictly prohibit hammering on the tank wall during gas pressure testing;

The results of the strength testing of the drying and cooling station meet the requirements when:

Evaluation:

- There are no cracks;

- No bubbles, water droplets, or water seepage through the welds and connections are found;

- No deformation is detected;

- Allowable pressure drop during the holding time of the test pressure: <= 0.5% of the test pressure;

9.3.4. Tightness Testing:

Only applicable when required by technology or by the manufacturer's request;

- Test medium: Air or inert gas;

- Test pressure and holding time are specified in Table 2;

Pressure, medium, and holding time for tightness testing

Table 2

Gas pipeline

Remarks- Working pressure._{but not less than 2 bar} 2. Test pressure and holding time for strength testing of the station after regular and abnormal inspections.

Note:

- Sequence of tightness testing:

+ Load the test medium into the station and increase the pressure to the test pressure;

+ Detect leaks using soap solution or other methods;

The results of the tightness testing of the drying and cooling station meet the requirements when:

Evaluation:

- No gas leaks are detected;

- Allowable pressure drop during the holding time of the tightness test: <= 3%;

9.4.1. Inspect all conditions necessary to put the station into operation;

Drying and Cooling Stations ЬХНС ϕ55-70 МЭ.

9.4.2. Inspect the operational status of the station and its accessories; the operation of measuring and protective devices;

9.4.3. When the station operates stably, increase the pressure to test and calibrate the working pressure of the safety valve, seal the safety valve;

9.4.4. The safety valve can be calibrated and sealed separately from the operational testing process;

9.4.5. The safety valve is calibrated and sealed as follows:

- The set pressure of the safety valve does not exceed the value below:

+ 0.5 bar - When

+ P_{but not less than 2 bar} the working pressure is up to 3 bar; + 15% P

+ P_{but not less than 2 bar} - When_{but not less than 2 bar} the working pressure is above 3 bar to 60 bar; + 10% P

+ P_{but not less than 2 bar} working pressure is above 60 bar._{but not less than 2 bar} the working pressure is above 3 bar to - For the gas charging rack, calibration and sealing are performed

with the set pressure as specified by the manufacturer; - Safety valves of the compression stages on the compressor are adjusted and sealed according to the manufacturer's requirements;

The results of the operational inspection of the drying and cooling station meet the requirements when auxiliary equipment and measuring and protective devices operate normally, and the operating parameters are stable;

Evaluation:

10. HANDLING THE INSPECTION RESULTS

10. PROCESSING INSPECTION RESULTS

10.1. Prepare the inspection report with all contents according to the model prescribed in Appendix II accompanying this procedure. The report must clearly record all contents and standards applied during the inspection, including safety standards requested by the equipment owner that are higher than those specified in the relevant Technical Standards for Vietnam (TCVN) under Article 3 of this Procedure (when the equipment is manufactured in accordance with these standards, the corresponding safety criteria shall apply).

10.2. Approve the inspection report

The minimum participants required to approve the inspection report must include the following members:

- A representative of the facility or a person authorized by the facility;

- A person assigned to participate and witness the inspection;

- Inspector conducting the inspection.

When the report is approved, the inspector, witnesses to the inspection, representatives of the facility, or persons authorized by the facility shall sign and affix their seals (if applicable) on the report. The inspection report shall be prepared in two (02) copies, each party responsible for retaining one copy.

10.3. Summarize the inspection results in the maintenance history of the drying and cooling station (clearly recording the inspector's name, date of inspection, and applied standards).

10.4. Affix the inspection label: When the inspection results in the maintenance history of the station meet technical safety requirements, the inspection label shall be affixed in a visible location (the inspection label model follows the regulations of the Ministry of National Defense). The inspection label shall be affixed in a position easily observable.

10.5. Issue the Certificate of Inspection Results

10.5.1. When the drying and cooling station has inspection results meeting technical safety requirements, the inspection unit shall issue a certificate of inspection results to the station within five working days from the date of approval of the inspection report at the facility.

10.5.2. When the drying and cooling station does not meet inspection requirements, only steps 10.1 and 10.2 shall be carried out; only the inspection report shall be issued to the facility, clearly stating the reasons why the equipment does not meet inspection requirements, recommending corrective actions and deadlines for implementing such recommendations; simultaneously sending the inspection report and notification to the labor safety management authority of the entity directly under the Ministry of National Defense managing the installation and use of the equipment.

11. INSPECTION PERIOD

11.1. The periodic technical safety inspection period is three years; for drying and cooling stations that have been in use for more than twelve years, the periodic technical safety inspection period is two years; and for drying and cooling stations that have been in use for more than twenty-four years, the periodic technical safety inspection period is one year.

11.2. In cases where the manufacturer specifies or the facility requests a shorter inspection period, it shall be implemented according to the manufacturer's regulations and the facility's requirements.

11.3. When shortening the technical safety inspection period, the inspector must clearly state the reasons in the inspection report.

11.4. When the technical safety inspection period is stipulated in national technical standards, it shall be implemented according to the provisions of those standards.

11.5. In cases requiring irregular inspections, follow the provisions in Clause 4.4 of this procedure./.

Appendix I

SAMPLE FIELD RECORD FORM

......,day...month...year 20...

FIELD RECORD

(Record all testing parameters accurately according to the inspection procedure)

I. General Information:

Equipment Name: ..................................................................................................................................... 

Name of Organization or Individual Requesting: ................................................................................................................................

Main Address (Headquarters of the Facility): ................................................................................................................................ 

Installation Address:    ................................................................................................................................ 

Content of Work Session with the Facility:

- Worked with whom (information):

- Witness:

II. File Review

1. Initial Inspection

a) Factory Documents:

- Maintenance history of the drying and cooling station;

- Principle operation drawings of the station;

- Construction drawings of pressure equipment in the station;

- Operation and maintenance instructions;

- Quality inspection certificates of manufacturing materials;

- Welding quality inspection certificates.

b) Installation Documents:

- Installation design;

- Overall acceptance report of the station;

- Charging procedures;

- Fire prevention and control documents.

c) Measurement Inspection Certificates:

- Calibration certificates of measuring instruments.

- Grounding and lightning protection inspection reports.

- Protection device inspection reports.

2. Periodic Inspection:

a) Maintenance history, previous inspection report, and inspection result certificate.

b) Operation logbook.

c) Repair and maintenance records; inspection and testing reports (if any).

3. Unusual Inspection:

a) Documents as in periodic inspection.

b) Repair documents; quality inspection and modification reports.

III. External Technical Inspection

1. Position (distance from walls, between equipment).

2. Operating lighting.

3. Technical parameters compared to maintenance history (model number, manufacturing number, country of manufacture, month and year of manufacture, design pressure, operating pressure, temperature, volume, medium...).

4. Condition of pressure-bearing parts: Deformation, swelling, corrosion, cracking.

5. Safety valves (number, type, DN, PN, adjusted pressure).

6. Pressure gauges (number, scale, units, accuracy grade, calibration label number).

7. Ventilation system for compressor room.

8. Discharge ports of safety valves.

9. Cooling system for charging cylinders (if any).

10. Charging rack and cylinder securing details during charging.

11. System for checking and determining the amount of gas charged.

IV. Internal Technical Inspection

1. Dirt condition.

2. Metal surface condition: Deformation, swelling, corrosion, cracking.

V. Durability and Tightness Testing of Drying and Cooling Stations

1. Test medium.

2. Test pressure.

3. Test duration.

4. Pressure gauge (scale, units, accuracy grade, calibration label number).

5. Medium supply equipment (type, model number).

6. Results:

+ Leakage condition.

+ Pressure drop.

+ Deformation condition.

VI. Operational Testing of Drying and Cooling Stations

1. Condition.

2. Maximum regulation pressure.

3. Charging pressure.

4. Safe equipment operational condition.

5. Measuring equipment operational condition.

6. Charging rack operational condition.

7. Cooling equipment operational condition.

8. Control system operational condition.

 

Location:................................................................................................................................................................................

The minutes were prepared in................copies, each party retains................dated

We, the inspectors who carried out this inspection, are fully responsible for the accuracy of the comments and evaluation results recorded in this report./.