RU2582029C2 - Method of ranking technical devices of processing installations of chemical, petrochemical and oil-refining systems based on expert point-based evaluation thereof - Google Patents

Abstract

FIELD: physics, computer engineering.

SUBSTANCE: method is intended to ensure industrial safety of processing equipment. The method includes analysing specifications of technical devices and entering the information into a database; evaluating the technical state of the technical devices at different periods of operation taking into account their technical state before operation; forming a general database on the actual technical state of devices at different periods of time and the dynamics of evolution of the technical state in the future based on the information obtained when evaluating the technical state at previous steps; wherein evaluation includes technical genetics of the state of technical devices to obtain data on the technical state at the previous period of time; technical diagnosis of their state at the current period of time; technical prognosis of their state at the next period of operation; selecting from the total number technical devices, which are part of the production system equipment, classified as weak links and most susceptible to degradation processes which lower their operational reliability; establishing reasons reducing the operational capacity. Based on expert point-based evaluation using a matrix form of analysis of the obtained information on the degree of reliability and safety of operation, any investigated object is assigned a numerical value of the hazard rank from 1 to 4 depending on the technical state thereof based on the results of technical genetics, technical diagnosis and technical prognosis. Further, depending on the hazard rank assigned to the technical device, the level, volume and frequency of non-destructive inspection of the technical state of the technical device is determined.

EFFECT: providing industrial safety of technical equipment.

10 cl, 27 tbl

Description

The invention relates to the field of ensuring industrial safety of technological equipment of plants (units) of chemical, petrochemical and oil refining industries under their operation with an increased interval between overhauls, and specifically relates to the distribution (ranking) of a set of technical devices of technological plants.

Recent emergency failures of various equipment in transport, in the energy, mining, chemical, petrochemical, oil refining, aerospace and other industries make it relevant to improve ways to ensure the industrial safety of this equipment for the entire period of its operation, allowing timely implementation of measures as predictive these emergencies, and identifying the causes of accidents, as well as take measures to prevent and the consequences of emergencies.

The reasons that determined this situation were the incompetence of staff, the deterioration of fixed assets and the insufficient level of investments aimed at their modernization, non-compliance with the requirements of labor protection rules, industrial safety, as well as violation of technological, labor discipline and a number of other aspects. Obviously, in combination, these factors determine the situational level that leads to catastrophic failures of potentially dangerous technological systems.

Minimizing the process of equipment failures and reversing this negative trend is possible only when organizing and conducting directly during the operation of technological systems, quality control of the technical condition of the components included in the system with strict observance of technological parameters.

Numerous methods are known in the art for extending the life of various technical devices of industrial facilities and for ensuring the reliability and safety of high-risk technical devices.

In particular, methods for predicting the average and assigned resource are known (see, for example, RD 26.260.005-91: “Methodological instructions. Chemical equipment. Nomenclature of indicators and methods for assessing reliability”), in which the resource is predicted by the mean time between failures and overhaul using probabilistic models of reliability theory. The methods do not find wide practical application due to the insufficient reliability of resource estimates for technical devices, since the resource is taken on the basis of nomenclature reliability indicators established for individual typical units and does not take into account the results of resource-strength studies and technical diagnostics, when data on the wear of the walls to be replaced are known. elements, mechanical stresses, defects that have arisen during operation, and the scope of technical diagnosis are identified.

According to the known method (see, for example, Makhutov NA and Pimshtein PG Determination of the service life and residual life of the equipment, "Safety problems in emergency situations", Issue 5, M., 1995.] the residual life is determined on based on the estimated service life and the probabilistic life of the excess wall thickness and the rate of its corrosion and erosion wear of the technical device Under cyclic load conditions with an allowable number of cycles and a loading period, creep depending on deformation, creep rate, brittle fracture According to the solution, the standard service life is assumed to be 20 years for most technical devices.The maximum value of the permissible operating time is determined from the set of the same values of the service life depending on the amount of control during diagnosis.The residual life is determined by the difference between the estimated service life and the operating time, however, it is not taken into account the effect of the safety margins of the replaced elements on the resource, the degree of responsibility (group or hazard class of the technical device) characterizing the likely degree of risk in the event of failure or destruction. The operational speed of reducing the safety factor of the replaced elements, corrosion indicators and corrosion resistance of materials are not taken into account, which does not provide sufficient accuracy for estimating the resource of a technical device.

A known method for determining the residual life of technical devices (see, for example, "Vessels and pipelines of high pressure: Reference / AM Kuznetsov, VI Livshits and others", 2nd edition, additional Irkutsk: Publication of GP Irkutsk Regional Printing House No. 1. 1999. 600 pp., Taking into account the reserve of safety margin in relation to the allowable loads (calculated, for example, according to regulatory documents) to the actual loads from the ratio of actual wall thicknesses minus the addition to the calculated wall thickness. According to the known method, when calculating the resource, the influence of the safety margins of the replaced elements on the resource is not taken into account, the probable degree of responsibility (group or hazard class) of the technical device characterizing the probable degree of risk in case of failure or destruction is not taken into account. The operational speed of decreasing the safety margin of the replaced elements, the rate of corrosion and corrosion resistance of materials are not taken into account, which does not provide sufficient accuracy for predicting the initial, extended and residual life of technical devices.

There is a method of evaluating the effectiveness of the diagnosis of vessels, reservoirs and pipelines (see, for example, Cherepanov AP, Poroshin Yu.V. "Evaluation of the effectiveness of the diagnosis of vessels, reservoirs and pipelines.", Labor safety in industry. No. 10, 2004 , pp. 43-46.), using a quantitative indicator of the effectiveness of diagnosis taking into account the degree of responsibility (group or hazard class), which characterizes the likely degree of risk in case of failure or destruction, an indicator of the reliability of methods, completeness and scope of control, full at diagnosis. Failure to take into account the influence of the safety margins of the replaced elements, the corrosion and corrosion resistance of materials, and the operational rate of reduction of the safety margins also does not allow us to estimate the resource of technical devices with sufficient accuracy.

From RU 2253096, May 27, 2005, a method for assessing the technical condition of equipment is known, according to which an input control is carried out before the start of operation, the compliance of the normative and technical documentation with the operating conditions and control of operational parameters is determined, and the technical condition of at least one most typical unit is measured, develop compensating measures to eliminate identified inconsistencies, determine the amount of residual life and / or the value of operational parameters at which safe operation of the technical device is possible, and an expert opinion is being developed.

However, without taking into account the safety margins of the replaced elements, the completeness and quality of the diagnostics, the degree of responsibility (group or hazard class) characterizing the likely degree of risk in the event of failure or destruction, the operational speed of decreasing the safety margins, corrosion indicators and corrosion resistance of materials does not allow prediction of the resource replaceable elements of technical devices using the proposed method.

From RU 2436103, 12/10/2011, a method for predicting the resource of high-risk facilities is known, according to which the full resource is assessed from the start of operation to the transition to the ultimate state, the estimated resource, during which the manufacturer or expert organization guarantees reliability and safe operation, and the residual life from the moment of diagnosis before the transition to the limit state with a decrease in the safety margins according to the prevailing wear factors from the ratio of ultimate loads, deformations, and the number of cycles in loading, permissible loads and mechanical stresses to operational loads, deformations, the number of loading cycles and mechanical stresses acting on an object of increased danger during operation, taking into account existing defects, a quantitative indicator of the completeness and volume of technical diagnostics, a probabilistic reliability parameter for assessing safety factors, degree of responsibility characterizing the probable degree of risk in case of failure or destruction, corrosion index and corrosion resistance materials, and operational speed reduction safety factor of high risk.

The known method ensures the reliability and safety of high-risk facilities during design, manufacture and operation, however, it concerns mainly thin-walled structures, in particular pressure vessels (tanks, reactors, heat exchangers, tanks and pipelines), by predicting the resource according to the results of the assessment of the technical condition diagnostic methods by means of non-destructive testing.

From RU 2443001, 02.20.2012 a method for collecting information about the ecological state of the region and an automated system for emergency and ecological monitoring of the environment of the region are known. When implementing this method, various environmental parameters are recorded and analyzed. All the objects that make up the infrastructure and which are considered as sources of environmental hazard during their regular work in emergency situations are put on the map of the region. The degree of danger of the production activities of the facilities is estimated. They rank individual districts according to the degree of environmental hazard, which can subsequently be taken into account when planning emergency response operations. The received information is documented and modified using ranking - distribution of objects, and a model is made for each of them. However, this method applies only to environmental monitoring using ranking of individual regions according to their environmental hazard. The method allows for environmental monitoring of the environment, helps to ensure environmental safety, controls the impact, for example, of deposits during their development and exploitation on the marine environment and the impact of hazardous natural phenomena on the condition of objects and their functioning.

As the closest analogue to the claimed invention, there may be a method for predicting the resource of technical devices known from RU 2454648, June 27, 2012, according to which, at any stage from design to reaching the limit state, an initial examination of industrial safety is carried out in the process of manufacturing a technical device for design operational and technical data and parameters of the initial actual technical condition, including actual sizes, thicknesses and sections of elements, configuration and size measures of existing defects at the time of manufacture, determined by primary technical diagnostics, according to which the initial resource-strength study is carried out with the strength calculations of the elements according to the calculated, allowable and ultimate mechanical characteristics of materials and standard safety margins, according to the calculated, allowable and ultimate loads, determine the degree of wear on the specified period of operation according to the initial, calculated and maximum allowable safety factors, taking into account the error of their assessment, at lower wall thicknesses and cross-sectional areas of elements subject, for example, to corrosion, wear, fatigue, creep, changes in the mechanical properties and chemical composition of the material, taking into account the indicators of corrosion and corrosion resistance of materials, the amount of non-destructive testing carried out during initial technical diagnosis, the coefficient of responsibility in depending on the group or hazard class of the technical device, determine the initial resource of the elements and develop the initial conclusion of the industrial examination without hazards with the assignment of a safe operation resource for the smallest initial resource of elements, at the time of the end of the initial or assigned resource according to the actual operational and technical data and the parameters of the actual technical condition determined by the secondary technical diagnosis, conduct a secondary (subsequent) resource-strength study with the strength calculations of the elements the actual design, allowable and ultimate mechanical characteristics of the materials determine the actual The maximum and maximum permissible loads when changing wall thicknesses, cross-sectional areas of elements subject to one or more damage mechanisms, such as corrosion, wear, fatigue, creep, changes in mechanical properties and chemical composition, corrosion index, corrosion resistance of materials, determine the degree of wear of elements over a period operation on the actual and maximum allowable safety margins, taking into account the error of their assessment, taking into account existing defects, the amount of non-destructive testing carried out by and secondary technical diagnostics, the coefficient of responsibility depending on the group or hazard class of the technical device, the reliability of assessing the safety margins, determine the extendable life of the elements and develop a secondary (subsequent) conclusion of the industrial safety examination with the purpose of a safe operation resource for the smallest extendable resource of technical device elements.

The need to replace or reinforce worn-out and weakened elements at the end of the initial or assigned resource of a technical device according to actual operational and technical data and parameters of the technical condition according to the degree of wear of elements, parts and assemblies is determined by actual or normative mechanical characteristics, a material grade is specified, thicknesses are determined or sections of elements that reinforce or are installed instead of worn out, determine their degree of wear for a given period of operation and when changing wall thicknesses, cross-sectional areas of elements subject to one or more damage mechanisms, for example, corrosion, wear, fatigue, creep, changes in mechanical properties and chemical composition, corrosion index, corrosion resistance of materials, taking into account existing defects, the amount of non-destructive testing carried out during secondary technical diagnosis, the coefficient of responsibility depending on the group or hazard class of the technical device, the reliability of the assessment of safety factors, p predicting the resource of elements that reinforce or install instead of worn and weakened elements, predicting the resource of undetected and unreinforced elements, determine the extendable resource of a technical device and develop a secondary (subsequent) conclusion of an industrial safety examination with the purpose of a safe operation resource for the smallest extendable resource of unreplaceable, reinforced and replaced elements of a technical device.

The estimated resource of a technical device at any stage from design to reaching the limit state according to the results of technical diagnostics and resource-strength research is determined by the function:

где

Where

W is the volume of non-destructive testing carried out during technical diagnosis;

ξ is the coefficient of responsibility depending on the hazard group of the technical device;

β is the defectiveness coefficient, taking into account the presence of permissible or unacceptable defects in the technical device detected during technical diagnosis;

Z is the degree of wear of the technical device.

The known this method allows to increase the reliability and operation of technical devices, however, it does not address the issue of possible safe operation of production facilities of increased danger, their service life in different periods, including periods between overhauls, does not take into account the totality of factors affecting the determination of the possibility and terms of operation technical devices and therefore does not have the necessary accuracy in determining the possible safe operation of specific technical devices and the terms of their operation.

The technical objective of the claimed method is to expand the arsenal of tools that ensure industrial safety of industrial facilities of increased danger at different periods of their operation, including in the conditions of an extended time interval between overhauls, as well as increasing the effectiveness of these tools for industrial safety of specific technical devices of technological equipment of industrial objects.

The stated technical task and the required technical results are achieved by ranking the technical devices of equipment included in the production facilities of the industrial production of the chemical, petrochemical and oil refining industries, based on the distribution of technical devices according to the degree of their technical hazard due to possible failure during operation, including (a) analysis of the requirements of regulatory documents on technical devices and recording information about their characteristics characteristics in the information database, (b) an assessment of the technical condition of technical devices at different periods of their operation, taking into account their technical condition before operation, that is, they carry out the procedure of technical genetics of the state of technical devices to obtain data on their technical condition for the previous (past) period time, conduct technical diagnostics of their condition for the present (current) period of time, as well as technical forecast of their condition for the subsequent period of their operation, and p In technical genetics, they establish (determine, fix) the design features of technical devices taking into account the changes made in their design, their installation, used materials, operating conditions, data on their strength, failures in work, accidents and the causes that cause them, and also take into account the results of the survey for the previous period of time, during technical diagnostics, the corrosion state of technical devices is examined, the degree of corrosion effect on them during operation is determined societies taking into account the influence of temperature, pressure, exposure to hazardous aggressive environments, the presence of defects, the establishment of the causes of their occurrence, the influence of all these factors on the operation of technical devices, and when conducting technical diagnostics, the results of the technical genetics are taken into account, then the technical forecast of the technical condition of technical devices which determine the possibility of their further safe operation on the basis of data obtained during technical genetics and technical diagnostics of them and take into account their available margin of safety, fatigue, degree of corrosion failure, (c) further, based on the results obtained during technical genetics, technical diagnostics, and technical forecasting, conducting an expert ball assessment using the matrix form of analysis of the information received on the degree of reliability and operational safety, one or another device under investigation is assigned a numerical value of the hazard rank from 1 to 4, and the critically hazardous techniques are referred to the first hazard level devices that allow operation after reconditioning, performing periodic or comprehensive continuous monitoring and control of their technical condition, or decommissioning, hazardous technical devices that allow operation with restrictions or periodic monitoring (include control) of their technical condition, to the third rank of danger are potentially hazardous technical devices that allow operating and with the simultaneous monitoring of their technical condition during the overhaul period, the fourth hazard class includes technical devices that allow further operation without restrictions, and then, depending on the hazard rank assigned to the technical device, the level, volume and frequency of non-destructive testing of the technical condition of the technical device , (d) then the procedure for the formation of a common information database on the actual technical condition of devices in p znye periods of time and the dynamics of the technical condition in the future on the basis of information obtained from the evaluation of the technical state with the establishment of the rank and level of technical state control.

The matrix itself, with the help of which matrix analysis is carried out, is formed by entering into the corresponding cells the results determined during the expert evaluation, in the form of points and expert estimates. Each established hazard level is determined by the corresponding values of the results in the form of scores and ratings obtained taking into account the influence of all internal and external factors on the technical condition of technical devices.

Factors affecting the possibility and period of operation of technical devices and assigning them one or another hazard class include the corrosive effects of aggressive and technological environments, defectiveness (the presence of various detected defects), residual life by corrosion rate, the presence of general corrosion, the duration of operation, the presence of changes in technical devices in the process of their operation.

When identifying defects, the registration (fixing) time of this defect, the type of defect, the cause of the defect, their frequency and consequences caused by the appearance of the defect are taken into account.

When establishing the operational capability and assigning a hazard rating to a technical device, the calculated (set) life period for it, the mileage or the period of its operation in excess of the calculated time limit established for it shall be taken into account.

At the same time, the rank of a technical device with an operating life beyond the calculated one is determined by the number of non-destructive testing performed, including external and internal (visual) inspection, ultrasonic testing, including ultrasonic thickness measurement, magnetic particle testing, acoustic emission testing, penetrating (chemical) substances , X-ray control, thermal control, metallographic studies, measurement of mechanical properties, magnetic memory control, eddy current th control.

When identifying factors affecting the possibility and period of operation of technical devices, they determine (establish) the changes that have occurred in technical devices in the previous period of their operation, taking into account changes in their operating conditions, including temperature, pressure, working process environment, change in the strength characteristics of individual structural elements and their properties materials from which they are made, change in corrosion rate under changed operating conditions.

Further, depending on the established hazard rank of the technical device, after ranking, taking into account the results obtained according to the results of the matrix analysis system, the volume and level of non-destructive testing of the technical condition of technical devices (and equipment in general) are established (determined).

The following is a more detailed disclosure of the claimed as a invention method of ranking technical devices of industrial equipment of the chemical, petrochemical and oil refining industries, which generally contributes to ensuring the industrial safety of their existing process plants and process equipment, especially in conditions of an extended interval between their overhauls.

The following basic terms and definitions apply:

Ranking is a method of distributing the totality of technical devices of technological units according to the idea of their physical condition, state control, determining the possibility of their operation without occurrence of events leading to significant damage to production and the environment, death and injury to people.

Rank - an indicator of the position of a technical device certified on the principle of "weak link".

Technical devices - technological equipment of various types and purposes (vessels, apparatuses, containers, furnaces, chimneys, tanks, columns, reactors, heat exchangers, process pipelines, steam and hot water pipelines, dynamic equipment), aggregates, technical systems (complexes), apparatus , devices, their units and components used at hazardous production facilities.

Operation parameters - a set of physical, chemical, hydraulic and thermodynamic data characterizing the technological processes taking place in the technical device.

Defect - each individual discrepancy between the parameters (characteristics) of the structural elements of technical devices to the requirements of normative and technical documentation.

Corrosion is a physicochemical process of spontaneous destruction of metals and alloys due to their interaction with the environment, which is based on chemical and electrochemical reactions, and sometimes mechanical influences of the medium, leading to a change in the properties of the material and the deterioration of its functional characteristics. The patterns of corrosion are determined by the general laws of thermodynamics and kinetics of heterogeneous systems.

So, when implementing the claimed ranking method, technical devices of technological plants are divided according to the degree of their technical hazard, based on their actual technical condition, which determines the possibility of operating the plants as a whole, excluding events that lead to significant damage to production and the environment, death and injury to people .

Dividing the technical devices of technological plants according to the degree of their technical hazard allows rationally and efficiently organizing control of its actual technical condition in real time and taking timely measures to eliminate detected problems. In the case of successful results, it becomes possible to increase the boundaries of the interval between overhauls with a natural decrease in the volume of overhauls.

An important factor in the implementation of the ranking method is the formation of information about the actual technical condition of technical devices within each technological installation, information about the technical condition of a technical device at some past point in time (technical genetics), at the current time (technical diagnostics), at a future moment time (technical forecast).

Technical genetics includes the following information about the technical device:

- design features of the technical device and changes made to the design, installation information, materials used, etc .;

- operating conditions and their changes for the entire life of the technical device;

- Strength calculations of technical devices in general and individual structural units;

- failures, incidents, accidents, their causes, and measures taken to eliminate them;

- the results of a planned and unscheduled comprehensive survey, technical diagnosis and examination of industrial safety for the entire previous period of operation;

Technical diagnostics includes the following information about the technical device:

- corrosive properties circulating in technical media devices;

- corrosion processes actually occurring in technical devices, under the influence of temperatures, pressures and circulating media, aggregate states of flows and flow rates;

- the results of the diagnosis of a technical device at present taking into account its genetics;

- detected defects, establishing their nature and dynamics of development, assessing their impact on the technical device as a whole from the point of view of ensuring its safe operation;

Technical forecast includes the following information about the technical device:

- determination of the possibility of operating a technical device based on an analysis of data from technical genetics and diagnostics;

- establishing criteria for the limiting state of a technical device (static strength, low and high cycle fatigue, long-term strength, brittle fracture, corrosion failure);

- determination of the limiting state of a technical device using various programs, theories and methods;

- forecasting the period of safe operation of a technical device.

The information obtained makes it possible, in a huge variety and variety of equipment operating under conditions of varying severity and danger, to select the equipment that is most susceptible to degradation processes (the least reliable during operation), which, to one degree or another and for various reasons, is close to exhausting its operational reliability. The identification of such "weak links", as well as the identification of the reasons that led to a decrease in their performance, allows us to develop a system of measures aimed at timely elimination of the causes of their increased degradation, which in turn is one of the ways to minimize the number of accidents.

The detection of "weak links" in many technical devices of technological installations, like any multifactorial task, includes an assessment of a number of factors on which the operational reliability of the equipment depends. These are the processes of technology, the ongoing corrosion processes, material performance, design features, conditions and changes in operating conditions that have occurred over the entire period of operation, the actual technical condition according to the data of surveys, examinations and comprehensive diagnostics, duration of operation, failure rate; MTBF; incoming control, etc.

An expert assessment of these factors makes it possible to attribute technical devices to a particular hazard level, which determines their proximity to the exhaustion of bearing capacity, the knowledge of which will reduce the degree of damage to the environment and humans in the event of their depressurization in emergency situations, or completely eliminate it.

According to the degree of danger, technical devices can be divided into four groups with assignment to them of an appropriate rank depending on their technical condition, associated with the influence of degradation processes on the operability and reliability of equipment, indicating the conditions that determine the possibility of their further operation:

I rank - critically hazardous equipment that is allowed into operation after restoration repair when equipped with a monitoring system of periodic or continuous operation or is decommissioned;

II rank - hazardous equipment that is allowed to operate with restrictions or when equipped with a periodically operating monitoring system;

Rank III - potentially hazardous equipment that is allowed into operation with the establishment of measures to control the technical condition during the overhaul period;

IV rank - potentially safe equipment that is allowed to operate without restrictions.

The basis for determining the rank of a technical device is the matrix form of analysis of the final information of the aggregate factors determining changes in the reliability and safe operation of capacitive equipment: vessels, apparatuses, columns, heat exchange equipment, as well as process pipelines and steam and hot water pipelines.

Due to the fact that one of the basic measures aimed at eliminating the negative consequences of failures during equipment operation is the creation of an individual control system for a technical device, it is necessary to establish the structure and approaches for implementing the control system.

The mechanism for the practical implementation of the system for monitoring the technical condition of equipment is the optimal choice of the volume, means, frequency and route of non-destructive testing of the technical condition of the device, which are in obvious functional dependence on the established rank. At the same time, the classification of technical devices accepted in the current normative and technical documentation into groups that take into account the danger of the environment (explosion and fire hazard, toxicity), as well as the operating parameters of the equipment by temperature and pressure, is taken into account. The result of the proposed ranking is to determine the level of non-destructive testing corresponding to the established rank of the technical device.

Working with the matrix provides for the inclusion in the appropriate cells of the fields of the matrix of the results (or points) obtained during the expert evaluation of each factor. The maximum value for the combination of factors and will correspond to the established rank. The result thus obtained is not a fixed quantity. It can be adjusted on the basis of more significant information obtained in the analysis of one or another factor. The ranking of technical devices according to their degree of danger with the help of a criteria-based, point-based assessment of all cumulative factors makes it possible to identify “weak links” for a balanced decision about their fate.

The value of the scores or criteria scores determines the position of technical devices in the ranking register. The maximum number of points or criteria-based assessments allows us to say that in the aggregate this technical device is a "weak link" and requires appropriate measures to ensure its industrial safety. The entire scale of scores or criteria for each factor is divided into four fields in accordance with the above division into ranks. The matrix is filled according to the results of the analysis of each factor included in it.

Table 1 No pp Factor Analysis Area Characteristic parameter Factor rank I II III IV one Corrosive effects of media Score > 80 from 25.0 to 80 from 5.0 to 25.0 from 0.5 to 2.0 2 Residual resource for the rate of general corrosion t years up to 3x from 3 to 5 from 5 to 10 > 10 3 Operating time Status Analysis Data According to the aggregate data that determine the factor of the duration of operation, according to the corresponding tables four Defectiveness According to the aggregate data determining the failure factor, according to the corresponding tables 5 Changes during operation According to the aggregate data determining the factor of changes that have occurred during the operation, according to the corresponding tables 6 Possible additional ranking factors According to the aggregate data determining the factor

I. Corrosion processes (corrosive effects of media) - occurring and developing in technical devices - table 1, p. 1 - are the main and permanent degradation factors that reduce their operational reliability. Therefore, the ranking of technical devices by the factor of the corrosive effects of circulating process media on equipment material that is characteristic of potentially hazardous industries is considered one of the most important factors in determining the "weak link" due to the variety of aggressive components that affect the equipment, the most active of which are: hydrogen sulfide , sulfur, mercaptans, hydrochloric acid, sulfuric acid, chlorides, hydrogen, sulfides, naphthenic acids, oxygen-containing substances, mechanical have others.

The above leads to various types and forms of corrosion degradation of the material of technical devices, such as: low-temperature and high-temperature hydrogen sulfide corrosion, hydrochloride-hydrogen sulfide corrosion, accompanied by low-temperature hydrogenation, hydrogen embrittlement and separation of carbon steels; intergranular corrosion and intergranular corrosion cracking of stainless steels; intergranular corrosion cracking in combination with general corrosion; high temperature hydrogen corrosion and cracking of steels; high temperature vanadium corrosion, sulfuric acid and carbonyl corrosion; carburization and embrittlement of low alloy steels; general, pitting and ulcerative corrosion, corrosion-erosion destruction and cavitation, coke formation and other specific types of corrosion.

Taking into account the types and forms of corrosion degradation is relevant due to the fact that the raw materials currently processed may not meet the requirements of GOST 9965-76 "Oil for oil refineries. Technical conditions" according to its composition. The appearance of new unaccounted components in the medium, as well as deviations of the actual operating conditions of the installation from the requirements of the regulation, increase the likelihood of sudden failures.

An important point that reduces the risk of events that quickly and with high probability can entail significant material damage is the control of the composition and nature of media used in technological installations, as well as the ranking of the process as a tool aimed at creating conditions that reduce the danger to technical devices.

The ranking of technical devices by the corrosion factor with the determination of the corrosion activity score n _{a is} calculated using a special equation (formula):

where the values of the coefficients (given in tables 2.-8.):

K _T - coefficient taking into account the influence of temperature;

K _dav - coefficient taking into account the effect of pressure;

K _am - coefficient taking into account anti-corrosion measures;

ψ is the correction factor;

Ki _i - coefficient of corrosion intensity.

Corrosion intensity coefficient is a factor characterizing the impact on the material of the technical device of the technological environment and determining the degree of corrosion hazard during the occurrence of a particular type of corrosion in the metal of the equipment, which is calculated by the formula:

Ki = [1+ (1-1 / Sq)]

where Kv is the coefficient of the type of ongoing corrosion process;

Ks _j - coefficient taking into account the increase in the corrosivity of the medium.

There may be cases when aggressive components appear in the circulating media, the presence of which is not provided for by the regulation, which is associated with the non-compliance of the supplied raw materials with the requirements of GOST, as well as with anticorrosive measures that appear during the process. Such aggressive components can be: magnesium chloride and calcium chloride, oxygen-containing substances (resins, naphthenic, carboxylic acids), mechanical impurities, nitrogen compounds, organochlorines, mercaptans, polysulfides, residual sulfur, alkali, and others. The presence of these components can lead to an increase in the corrosive effect of the medium on the material from which the processing equipment is made. The impact factor of unaccounted components is adjusted using the coefficient of enhancement of the corrosion activity of the process medium, which is calculated by the formula:

Ks = 1-1 / γ

where γ is the correction factor that takes into account the presence of certain aggressive environmental components that are not taken into account in the regulation.

The following tables 2.-8. illustrate the various obtained values of the coefficients given in formula (1).

Table 2. Coefficient taking into account the influence of operating temperature Temperature ° C * less than 30 from 30 to 50 51 to 70 from 71 to 100 from 101 to 150 from 151 to 250 from 251 to 320 from 321 to 400 from 401 to 500 from 501 to 600 Over 600 K _T one 1.05 1,1 1,2 1.4 1.8 2.0 2.2 2,5 2.7 3.0 Note: * For technical devices having several technological spaces (heat exchangers and others) or sections (pipelines), a higher permitted temperature is accepted for expert evaluation

Table 3. Coefficient taking into account the influence of working pressure Pressure, MPa * less than 0.2 from 0.2 to 0.6 from 0.6 to 1.0 1.0 to 3.0 3.0 to 6.0 more than 6.0 K _dave one 1.25 1.8 2.0 2,3 2,5 Note: * For technical devices having several technological circuits (heat exchangers and others), or sections (pipelines) for the expert assessment, the allowed pressure of the most loaded space (section) is accepted.

Table 4. Coefficient taking into account the use of anti-corrosion coating ANTI-CORROSION EVENTS * To _am No events one Partial heat treatment 0.9 Complete heat treatment 0.8 The use of inhibitors, passivation 0.7 anticorrosion coating 0.6 Cladding 0.5 The use of bimetals 0.4 Note: * If the technical device has several types of anticorrosive protection, then choose the type having the minimum coefficient. If there is no information on anti-corrosion measures, K _{am is} taken equal to 1.

The impact and the degree of corrosiveness of the media is taken into account using the coefficient of corrosion intensity K _and shown in table 5.

Table 5. The coefficient of corrosion intensity Ki. Type of corrosion * Description of the corrosion process Corrosion determining media components K _and * Atmospheric Corrosion of metals and alloys caused by condensed atmospheres. Ambient humid atmosphere. 1,0 Enhance corrosion: contamination by corrosion-active components, temperature changes, defects t / and. Overall uniform Corrosion flowing at the same speed over the entire metal surface. Any environment. 1.34 Enhances corrosion: low pH, high T and aggressive component concentrations. General uneven Corrosion occurring at different speeds on different parts of the surface of the material. Any environment. 1,50 Increase corrosion: low pH, high T and concentration of aggressive components, surface heterogeneity.

Type of corrosion * Description of the corrosion process Corrosion determining media components K _and ^* Ulcerative Local type of corrosion, when certain parts of the surface are deeply corroded compared to the rest of the surface. Ulcers can be in the form of shells deeply deep in the thickness of the metal, up to through destruction. The deepest ulcers are localized in places of deposition of salts and sediments. Any environment. 1,50 Enhance corrosion: insoluble salts, deposits, corrosion products, crevice effects, deformations. Pitting The local form of electrochemical corrosion, when a corrosion lesion is localized at individual points, penetrates deep into the metal, up to through destruction. Localization of pits can occur at the least corrosion-resistant points of the metal surface, where there is a violation of the oxide protective film (non-metallic inclusions, structural defects, etc.). It develops on steels of the austenitic and austenitic-ferritic class in neutral, slightly acidic and slightly alkaline environments, and on steels of the ferrite-pearlite class - in alkaline. Organic and inorganic chlorine compounds: HCl, Cl ^- . 1,67 Enhanced corrosion: O ₂ , H ₂ S, tensile loads, variable wetting areas. Intergranular and intergranular cracking The local type of corrosion is characterized by the destruction of metal along grain boundaries, while it quickly loses strength and ductility and is easily destroyed. This type of corrosion is especially susceptible to chromium and chromium-nickel steels, nickel and aluminum alloys. Sulfur, sulfur, tetrathionic, polythionic acids, sulfonic acids, sulfides, chlorides. 1,67 Increase corrosion: SO ₂ , S ₂ , ammonium salts, sulfonic acids, water, O ₂ , NH ₃ , polythionic acids. Knife A special case of intergranular corrosion, occurs exclusively in stabilized austenitic steels (i.e., containing alloying additives Ti or Nb), and usually occurs in a strip of metal directly adjacent to the weld. Sulfuric, sulfuric, perchloric, tetrathionic acids, polythionic acids, ammonium salts, sulfonic acids. 1,67 Increase corrosion: SO ₂ , S ₂ , ammonium salts, sulfonic acids, water, O ₂ NH ₃ , polythionic acids, residual tensile stresses. Crevice Local type of corrosion developing in areas of technical devices having such design features as cracks, gaps, etc. Any environment. 1,50 Threadlike A kind of crevice corrosion. It occurs on some metals having protective coatings, with defects in the form of pores, which act as gaps. Any environment. 1,50 Subsurface A type of corrosion that begins on a metal surface with a small area, but spreads deeper into the metal over a larger area. Corrosion products are concentrated in the depth (in the cavities) of the metal, causing it to swell and delaminate. Organic and inorganic acids, carbonates, chlorine compounds, various deposits of salts and corrosion products. 1,67 Enhances corrosion: various salt deposits.

Type of corrosion * Description of the corrosion process Corrosion determining media components K _and ^* Energized corrosion Type of corrosion caused by the simultaneous exposure to a corrosive environment and static tensile stresses. In this case, a corrosion crack can develop along the grain boundaries — intergranular cracking, or transcrystalline cracking along the grain body. Any environment. 1,67 Enhancing corrosion: the use of high-strength materials, H ₂ , H ₂ S, HCl Corrosion cracking A type of local corrosion that develops under the influence of a corrosive medium and tensile loads, and is initiated by any type of local surface lesion, which is a stress concentrator (ulcer, pitting, pore, etc.). Hydrogen sulfide, hydrogen chloride, organic and inorganic chlorine-containing and sulfur-containing compounds, hydrogen-containing gas, naphthenic acids, O ₂ , SO ₂ , S ₂ , V ₂ O ₅ , CO ₂ , CO. 1.75 Enhancing corrosion: high-strength steels, the presence of residual stresses, high content of base salts Alkaline cracking Type of electrochemical corrosion under the influence of a medium containing alkali, localized mainly in stressed areas of the metal and leading to its cracking. During alkaline cracking, nucleation of cracks occurs on the inner surface of the equipment walls in the zone with no deformation (brittle fracture), cracks have a strong branching of intergranular nature, there are no changes in mechanical properties. It occurs with an overdose of alkaline solutions intended for neutralization. Sodium hydroxide, sodium carbonate, ammonium hydroxide, diethanolamine (DEA), methyldiethanolamine (MDEA), ethanolamine (MEA). 1.75 Enhanced corrosion: chlorides, H ₂ S, CO ₂ , ammonium salts, high T, lack of t / o welds. Contact A type of electrochemical corrosion that develops upon the contact of metals having various electrochemical potentials. A metal having a lower electrochemical potential is subject to more intense dissolution (anode). Contact corrosion can occur on a metal of the same brand if mechanical stresses in it change its electrochemical characteristics, as well as if the parts are machined differently. Any environment. 1,67 Increase corrosion: O ₂ , oxygen-containing compounds, flow rates. Carbon Acid Corrosion Type of electrochemical corrosion under the influence of carbon dioxide (CO ₂ ) in the presence of moisture (more than 60%). The nature of the lesion is general and ulcerative corrosion (because along with the presence of poorly soluble corrosion products by carbonate and iron hydroxide, well-soluble iron bicarbonate is present). Fuel gas, steam-gas mixture of hydrocarbons, etc .. 1,67 Enhanced corrosion: high ↑ C _CO2 , low pH, high T (extreme).

Type of corrosion * Description of the corrosion process Corrosion determining media components K _and ^* Low-temperature hydrogen sulfide and hydrogen sulfide corrosion cracking Type of electrochemical corrosion of a metal under the influence of moisture saturated with hydrogen sulfide. It is accompanied by hydrogenation and further cracking of the metal (TFR). The destruction of the metal is of two types: through cracking (occurs suddenly and has a pronounced local character) and delamination (bubbling). Hydrogen sulfide in solution is a dibasic acid. The nature of the corrosion damage is general and ulcerative. Hydrogen sulfide in the presence of moisture, NaCl and other chlorides, sulfur-containing organic and inorganic components. 1.75 Increase corrosion: O ₂ , H ₂ , chlorides, HCl, FeS, (due to chemical interaction with H ₂ S and Sample H ₂ SO ₄ ), S ₂ , S ^- , CO ₂ , sulfites, thiosulfates, pH <6 , with max ~ 4, and amplifying. At pH> 8, increased T (max at 40 ° C). Hydration is promoted by: hydrides of elements As, S, P, Se, Te, Bi, pH <6, ions - HS ^- , S ^2- , chlorides, CO ₂ , H ₂ . Hydrochloric sulfide A type of electrochemical corrosion of a metal due to the combined action of hydrogen chloride and hydrogen sulfide in the presence of condensed moisture. The nature of the corrosion damage is corrosion in the form of small and wide closely spaced flat bottom ulcers for carbon, low alloy steels and cast iron. With an increase in the concentration of HCl to 0.07 n and a temperature of up to 120 ° C, the nature of the corrosion damage is uniform. For austenitic and austenitic-ferritic steels - pitting and CKR (chloride corrosion cracking) in the presence of tensile residual stresses. Organic and inorganic chlorine and sulfur compounds, HCl, ammonium chloride, chlorine derivatives, organic nitrogen compounds. 1.80 Enhanced corrosion: H ₂ S, O ₂ , S ₂ , Fe ³⁺ , nitrogen and chlorine-containing components of hydrocarbon raw materials, NH ₃ , high T, high content of HCl, pH = 3.5 ÷ 7. Carbonyl A type of chemical corrosion occurring at elevated temperatures (140-300 ° C) and pressures (200-300 at) in media containing carbon monoxide (CO). At high temperatures, CO with iron iron forms volatile pentacarbonyl Fe (CO) ₅ , which leads to loosening of the metal surface with the formation of deep (up to 5 mm) ulcers. The most dangerous temperature range for carbonyl corrosion is 140-250 ° C. At temperatures below 90 ° C and above 300 ° C, iron does not interact with CO. At temperatures> 250 ° C, carbon monoxide decomposes to form soot on the metal surface: 2CO → CO ₂ + C, which leads to carburization and embrittlement of low alloy steels. Carbon monoxide (CO), hydrogen and unsaturated hydrocarbons (OGH), higher organic acids: naphthenic, carbonic propionic, aldehydes, alcohols. 1,50 Enhanced Corrosion: H ₂ S, High P. Gas Type of chemical corrosion of metals in a gaseous medium with a minimum moisture content (less than 0.1%) or its absence at high temperatures. The basis of this process is the oxidation of iron by oxygen of the working medium of the apparatus with the formation of iron oxides: FeO, Fe ₂ O ₃ , Fe ₃ O ₄ , as well as with decarburization of the metal, which reduces the mechanical strength of the metal, especially the fatigue limit. A characteristic feature of the process is the formation and continuous growth of solid reaction products (scale) on the surface of the layer. Gaseous media containing: O ₂ , H ₂ , CO ₂ CO, SO ₂ , HCl. 1.80 Enhanced corrosion: high T and high O ₂ content.

Type of corrosion * Description of the corrosion process Corrosion determining media components K _and ^* High-temperature hydrogen sulfide (HTSC) A type of chemical corrosion associated with the oxidation of metal by hydrogen sulfide at high temperatures (over 260 ° C) in the absence of moisture. It is accompanied by the chemical interaction of iron with hydrogen sulfide to produce hydrogen, as well as decarburization of carbide compounds, as a result of which methane is formed in the metal structure, metal swelling, embrittlement, and cracking along grain boundaries occur, which is accompanied by the precipitation of whole metal blocks Hydrogen sulfide, sulfur, a hydrogen-containing gas, sulfur-containing organic and inorganic components, mercaptans. 1.80 Increase corrosion: high content of H ₂ S, high T, H ₂ , mercaptans, suspended particles, sulphide scale, deposits of resins, coke, turbulence, O ₂ , steam. High Temperature Sulfur A type of chemical corrosion associated with high-temperature metal oxidation by heating sulfur dioxide, which is accompanied by the appearance of aggressive sulfur dioxide (SO ₂ ) in them. During its interaction with ferrous iron, a layered scale is formed, consisting of FeS, FeO, Fe ₃ O ₄ . This leads to a local increase in temperature and the development of local corrosion lesions in the form of deep ulcers, smallpox, leading to local damage. In the interaction of SO ₂ with cast iron, internal oxidation occurs, its volume increases ("growth of cast iron"), which leads to warping, cracking and destruction. When interacting with nickel-containing steels, nickel is oxidized with the formation of dross NiS, NiO and H _2, and strength is lost, causing intergranular destruction of the metal. Heating and exhaust gases, flue gases, sulfur, pyrite, H ₂ S, sulfur-containing organic and inorganic compounds. 1,67 Enhanced corrosion: increased content of SO ₂ , O ₂ and H ₂ S, H ₂ , excess air, sulfates, oxide compounds, coke, high T, surface defects (sunsets, films, inclusions). High temperature vanadium A type of chemical corrosion associated with the intensification of high-temperature oxidation of a metal under the influence of a strong oxidizing agent of vanadium pentoxide (V ₂ O ₅ ). V ₂ O ₅ forms vanadates of Fe and Cr, with low melting points. The metal loses its strength, causing avalanche intergranular destruction of the metal at temperatures of 700-800 ° C. Heating and exhaust gases, flue gases, sulfur, pyrite, H ₂ S, sulfur-containing organic and inorganic compounds. 1.80 Increase corrosion: Na ₂ SO ₄ , NaOH, Na ₂ CO ₃ , Mo ₂ O ₃ , Wo ₂ O ₃ , fluorides, Bi compounds, lead.

Type of corrosion ^* Description of the corrosion process Corrosion determining media components K _and ^* High temperature hydrogen corrosion and hydrogen cracking The chemical type of corrosion that results from the interaction of hydrogen with the carbide component of steel at elevated temperatures (from 200 ° C) and pressures (from 300 MPa) in environments containing hydrogen. Decarburization of steel occurs: Hydrogen, water-containing gases, (WASH), hydrocarbon gases (UVG). 1.80 Increase corrosion: increase in T, P, H ₂ , the presence of H ₂ S, ammonium hydrosulfide. Fe ₃ C + 2H ₂ ↔ 3Fe + CH ₄ with the formation of methane in the internal volumes of the metal mainly along the grain boundaries. Due to the large size of the methane molecule, it cannot diffuse inside the metal and, accumulating at the grain boundaries, leads to high pressure and subsequent cracking. As a result of hydrogen corrosion, the metal surface loses its metallic luster (matte), its strength decreases, and blisters (filled with methane) can form in the surface layer. This process has a certain incubation period during which the equipment can be operated safely, it all depends on pressure and temperature, the higher they are, the less the incubation period. Corrosion Cavitation Local destruction of metal due to the simultaneous corrosion and impact of the external environment. The mechanism of corrosion cavitation is close to the mechanism of corrosion fatigue. However, unlike the latter, its action is limited to microzones commensurate with the dimensions of the individual components of the metal structure (grain, inclusions, etc.). Shock repetitive jets of the medium (water hammer), leading to pulsating stresses of the surface layer. The type of destruction in this case is deep caverns. Any environment. 1,67 Enhanced corrosion: reduced strength of steels, the presence of saturated saline solutions, the presence of residual stresses, deformations, solid particles (catalyst, pollution, etc.). Corrosion erosion Local destruction of metal due to the simultaneous exposure to a corrosive environment and abrasive mechanical or abrasive particles. 1,50 Fretting corrosion Local destruction of the metal due to the simultaneous exposure to the corrosive environment and vibration. 1,67 Note: * Accepted designations: T - temperature, p - pressure, pH - characteristic of acidity (hydrogen indicator of the medium).

The excess of the quantity (volume% or mass%) of the main aggressive components from the values established by the regulation is taken into account using the correction factor ψ shown in table 6.

Table 6. Coefficient taking into account the excess of the amount of the main aggressive components from the components established by the regulations. Correction factor Excess of the amount of the main aggressive components from those established by the regulations, vol.% Or mass.% Does not exceed 0 ÷ 0.005 0.005 ÷ 0.01 0.01 ÷ 0.1 0.1 ÷ 0.5 0.5 ÷ 1.0 1,0 ÷ 1,5 1.5 ÷ 3.0 More than 3.0 ψ 0 0.5 0.8 1,0 1,5 2.0 2,5 3.0 3,5

There may be cases when aggressive components appear in the circulating media, the presence of which is not provided for by the regulation, which is associated with the non-compliance of the supplied raw materials with the requirements of technical documentation. Such aggressive components can be: magnesium chloride and calcium chloride, carboxylic acids, and other oxygen-containing substances, tarry substances, naphthenic acids, mechanical impurities, nitrogenous compounds, organochlorine compounds, mercaptans, polysulfides, residual sulfur and others.

The presence of these components can lead to an increase in the corrosive effect of the medium on the material from which the technical devices are made. The impact factor of unaccounted components is taken into account using the coefficient of enhancement of the corrosion activity of the medium (K _s ), the numerical values of which are given in table 7.

Table 7. Accounting for changes in corrosivity of the medium, Ks. Unaccounted environmental components K _s Nitrogen compounds (ammonia, amines) 0.17 Oxygen and oxygen-containing substances (resinous compounds, carboxylic, naphthenic acids, etc.) 0.33 Sulfides, disulfides, polysulfides 0.33 Mercaptans 0.33 Carbon oxides, Co, Co ₂ 0.50 Sulphates, So ₃ ^2- , SO ₄ ^2- 0.50 Salts, MgCl ₂ ; CaCl ₂ 0.50 Hydrogen, H ₂ 0.60 Hydrogen sulfide, H ₂ s 0.67 Chlorine-containing compounds, Cl ^- 0.67 Mineral impurities (V, Na, Ca, Mg, etc.) 0.67 Mechanical impurities (fine particles of sand, clay, other hard rocks, rust, scale, crystallized salts) 0.67

Thus, having determined the corrosion activity score of the medium according to formula (1) and taking into account the data in table 8., it is possible to evaluate the corrosion factor of the technological environment with the establishment of an assessment of the possibility of operation of the technical device under consideration.

Table 8. Assessment of the corrosive effects of the technological environment. Factor Analysis Area Factor parameter The value of factors taking into account the corrosive effects of the technological environment. Group criterion. The rank of the technical device. The value of the factor at which the operation of the technical specifications is not recommended. The maximum permissible value of the factor at which the operation of the technical specifications is possible. The value of the factor at which the operation is allowed. The value of the factor at which the operation of the technical specifications is allowed. I rank II rank III rank IV rank Corrosive effects of media ball > 80.0 25.0 ÷ 80.0 5.0 ÷ 25.0 ≤5.0 Note: * The value of the point of corrosion activity is greater than 1. Therefore, the higher the value of the point obtained, the less reliable the technical device and its higher rank in terms of the factor of the corrosive effect of the medium.

The ranking parameters of technical devices by the factor of general corrosion are set depending on two components:

- corrosion rates;

- residual life by the factor of general corrosion and are determined according to table 9.

Table 9. Assessment of the possibility of exploitation by the factor of general corrosion. No. p / p Factor Analysis Area Factor Parameter * The importance of factors taking into account general corrosion. Group criterion. The rank of the technical device. The value of the factor at which the operation of the technical specifications is not recommended. The maximum permissible value of the factor at which the operation of the technical specifications is possible. The value of the factor at which the operation is allowed. The value of the factor at which the operation of the technical specifications is allowed. I rank II rank III rank IV rank one Actual corrosion rate taken into account C _v , mm / year - > 0.5 0.1 ÷ 0.5 ≤0.1 2 Total Corrosion Residual Resource T _or years 0 ÷ 3 3 ÷ 5 5 ÷ 10 > 10 Note: * The calculation of the corrosion rate and residual life is carried out according to the technical documentation for the ranked type of technical devices.

When ranking technical devices according to the duration of operation, in accordance with established practice and the current Rules, the operation of technical devices can be divided into two consecutive periods: the first is determined by the framework established by the design organization or the manufacturer; the second - is determined by the period (or periods) established by the conclusions of expert organizations within the framework of their industrial safety examinations.

Technical devices that have not developed a regulatory period are evaluated by factors related to compliance with the requirements of the technical documentation on the ongoing survey and the requirements of technological regulations.

Technical devices that have developed a standard operating life, already on this factor fall into the zone of increased attention. Factors that determine the state of a technical device include: the results of electronic safety (examination of industrial safety), funds raised during technical diagnostics, the resource established during examination of industrial safety, and other factors.

The assessment of the possibility of operating technical devices by the duration factor is carried out in accordance with the instructions given in table 10 for technical devices:

- those who have not developed a standard operating life in accordance with paragraphs 1, 2 of table 10.

- those who have developed the standard life in accordance with paragraphs 3, 4, 5 of table 10.

Table 10. Evaluation of the possibility of operation by the factor of the duration of operation. No. p / p Operating time Factor parameter The value of factors taking into account the duration of operation. Group criterion. The rank of the technical device. The value of the factor at which the operation of the technical specifications is not recommended. The maximum permissible value of the factor at which the operation of the technical specifications is possible. The value of the factor at which the operation is allowed. The value of the factor at which the operation of the technical specifications is allowed. I rank II rank III rank IV rank one Factor taking into account the standard life (T) during routine inspections t, year - - <3 3 ÷ T 2 Factor taking into account the standard life (T) without routine inspections t, year - 0 ÷ T - - 3 Factor that determines work beyond the standard operating life The number of implemented types of control in EPB ** - 0 ÷ 3 3 ÷ 5 > 5 four The presence and results of EPB ** EPB operation prohibited - - - 5 EPB not performed - - - Note: * When analyzing the factor that determines the operation of technical devices with an extended service life, the recommended types of control during electronic safety measures should be taken according to table 11. ** If several examinations have been performed, the results of the latter are accepted for consideration.

Table 11. Types of non-destructive testing in EPB. The parameter that takes into account the types of control during electronic safety measures Types of control of the technical condition of equipment during EPB ^* BUT IN GN / PI UZT School AE TC MG FUR VD Note: * BUT - external examination; IN - internal inspection; GI - hydro or pneumatic testing; UZT - ultrasonic thickness measurement; Secondary school - weld inspection using ultrasonic testing - ultrasonic testing, MP - magnetic particle inspection, PV - penetrating substance control, RG - X-ray control, MMPM - metal magnetic memory control, VT - eddy current control; AE - acoustic emission control; TK - thermal control; MG - metallographic studies; FUR - measurement of mechanical properties; VD - vibrodiagnostic control.

The adopted four-level expert assessment of the situation related to the duration of operation fully corresponds to the ranks accepted in this manual.

The ranking of technical devices taking into account the identified defects should be based on information on the time of occurrence of defects, on the cause of the formation of defects (design error, metallurgical defect, poorly performed repairs, technological or operational violations), on the parameters of defects, and also on the assessment of the consequences caused by the presence of defects.

For each technical device, when ranking it by defectiveness, it is necessary to determine the most characteristic situation for this defect, shown in table 12:

- Eliminated defect - defect eliminated after the repair (in accordance with the technical documentation) with the subsequent 100% control of the defective area.

- Non-eliminated defects - a defect that has not been eliminated after detection, or that has been eliminated in violation of the requirements of the technical documentation and subsequently not checked.

- A removable defect is a defect, the elimination of which is technically possible and economically feasible.

- Fatal defect - a defect, the elimination of which is technically impossible or economically inexpedient.

- A defect that is not prone to development is a defect that is unlikely to develop during the normal course of the process, or the rate of development is negligible to assess the possibility of operation until the next scheduled shutdown for repair.

- A defect prone to development is a defect, the rate of development of which is an indicator for assessing the possibility of operation until the next scheduled stop for repairs.

- A critically dangerous defect is a defect in the presence of which the operation of a technical device is either impossible without the introduction of strict restrictions, or is completely unacceptable. This category includes defects that create a threat of collapse of structures, loss of bearing capacity of individual elements, etc.

An assessment of the possibility of operating a technical device taking into account defectiveness is given in table 12.

Table 12. Assessment of the possibility of operating a technical device taking into account defectiveness. No. p / p Defective situation Evaluation of the possibility of operation, taking into account the defectiveness factor. Group criterion. The rank of the technical device. The value of the factor at which the operation of the technical specifications is not recommended. The maximum permissible value of the factor at which the operation of the technical specifications is possible. The value of the factor at which the operation is allowed. The value of the factor at which the operation of the technical specifications is allowed. I rank II rank III rank IV rank one No defects • 2.1 Identifiable removable defects that are not inclined to development - not resolved • 2.2 Fatal defects that are not prone to development were identified - not resolved • 3 Defects not inclined to development are revealed - eliminated • 4.1 Identifiable developmental defects identified - not resolved • 4.2 Identified inconsistent defects prone to development - not resolved • 5 Identified defects prone to development - fixed • 6 Critically dangerous fatal defects detected • Note: * The rank of technical devices for the considered factors is indexed by •.

The four-level expert assessment of the situation adopted in the section, taking into account the possibility of operating equipment with one or another degree of defectiveness, fully corresponds to the ranks accepted in this manual.

The ranking of technical devices associated with changes that have occurred during the operation is due to the fact that a significant number of technical devices are operated for a sufficiently long period during which various kinds of changes are recorded, ranging from changes in operating conditions by pressure, temperature and environment to global reconstructions.

Changes in the technical structure during operation can have a significant impact on industrial safety, which must be taken into account by ranking.

Changes that have occurred with the technical device during operation should be taken into account using the following parameters and indicators:

Changes in operating conditions (table 13).

Table 13. Consideration of the factor of changes in operating conditions that occur with equipment during operation. No. p / p Possible situation related to changes during operation Evaluation of the possibility of operation, taking into account the factor of changing operating conditions. Group criterion. The rank of the technical device. The value of the factor at which the operation of the technical specifications is not recommended. The maximum permissible value of the factor at which the operation of the technical specifications is possible. The value of the factor at which the operation is allowed. The value of the factor at which the operation of the technical specifications is allowed. I rank II rank III rank IV rank one Pressure and temperature reduction • 2 Pressure and temperature increase with documented evidence • 3 Pressure and temperature increase in the absence of justification • four The increase in process parameters • 5 Changing the technological environment Set by the factor of the corrosive effects of the technological environment. 6 No change • Note: * The rank of technical devices for the considered factors is indexed by •.

Preservation (de-preservation) (table 14).

Table 14. Consideration of the factor of conservation (de-conservation). No. p / p Possible situation related to changes during operation Evaluation of the possibility of exploitation, taking into account the factor of conservation (re-conservation). Group criterion. The rank of the technical device. The value of the factor at which the operation of the technical specifications is not recommended. The maximum permissible value of the factor at which the operation of the technical specifications is possible. The value of the factor at which the operation is allowed. The value of the factor at which the operation of the technical specifications is allowed. I rank II rank III rank IV rank one Preservation according to the requirements of the rules • 2 Preservation in violation of the rules • 3 Decommissioning without deregistration and conservation • four Depreservation in accordance with the requirements of the rules • 5 Depreservation in violation of the rules • 6 Commissioning after a break of more than 12 months • 7 No change • Note: * The rank of technical devices for the considered factors is indexed by •.

Design changes (table 15).

Table 15 Taking into account the factor of design changes. No. p / p Possible situation related to changes during operation Evaluation of the possibility of operation, taking into account the factor of structural changes. Group criterion. The rank of the technical device. The value of the factor at which the operation of the technical specifications is not recommended. The maximum permissible value of the factor at which the operation of the technical specifications is possible. The value of the factor at which the operation is allowed. The value of the factor at which the operation of the technical specifications is allowed. I rank II rank III rank IV rank one Partial modification of load-bearing structures (availability of design and other documentation) • 2 Partial modification of load-bearing structures (lack of design and other documentation) • 3 Insertion of additional devices (project availability) • four Insertion of additional devices (without project) • 5 Operation unchanged • Note: * The rank of technical devices for the considered factors is indexed by •.

Description and availability of calculations (table 16).

Table 16. Consideration of a factor that takes into account the presence and characteristics of the calculations. No. p / p Possible situation related to changes during operation Assessment of the possibility of operation, taking into account the factor of availability and characteristics of the calculations. Group criterion. The rank of the technical device. The value of the factor at which the operation of the technical specifications is not recommended. The maximum permissible value of the factor at which the operation of the technical specifications is possible. The value of the factor at which the operation is allowed. The value of the factor at which the operation of the technical specifications is allowed. I rank II rank III rank IV rank one No calculations • 2 Calculations partially satisfying the requirements of GOST • 3 Calculations satisfying the requirements of GOST • four The availability of settlements is not provided for by the requirements of the rules • Note: * The rank of technical devices for the considered factors is indexed by •.

Changes in the strength characteristics and properties of materials of structural elements (table 17).

Table 17. Consideration of the factor of change in strength characteristics and properties of materials of structural elements. No. p / p Possible situation related to changes during operation Evaluation of the possibility of exploitation, taking into account the factor of change in material design. Group criterion. The rank of the technical device. The value of the factor at which the operation of the technical specifications is not recommended. The maximum permissible value of the factor at which the operation of the technical specifications is possible. The value of the factor at which the operation is allowed. The value of the factor at which the operation of the technical specifications is allowed. I rank II rank III rank IV rank one Conforms to the project (standard) • 2 Does not comply with the project (standard) • 3 Lack of data •

The adopted four-level expert assessment of the situation during changes occurring with the equipment during operation fully corresponds to the ranks accepted in this manual.

To determine the rank of the technical device, the matrix form of analysis of the final information of the aggregate factors determining the degree of possibility of the safe operation of technical devices was used (see table 1).

Working with the matrix provides for the inclusion in the appropriate cells of the fields of the matrix of the results obtained by expert evaluation of each factor. Accordingly, the maximum value determines the established rank. The result obtained in this way can be adjusted upon receipt of additional information obtained in the process of industrial safety examination when analyzing the influence of one or another factor.

The ranking of technical devices by hazard factor is based on the provisions of Federal Law No. 116 of the Federal Law “On Industrial Safety of Hazardous Production Facilities”, taking into account the amendments of 03/04/2013, as well as NTD for the safe operation of technical devices are presented in table 18.

Table 18. Hazard ranking of technical devices. Rank Pressure, MPa (kgf / cm ² ) Temperature ° C Working environment I Over 0.07 (0.7) Whatever Explosive, fire hazardous, 1st, 2nd hazard classes according to GOST 12.1.007 II Over 0.07 (0.7) to 4.0 (40) Below - 70, above 400 Over 4.0 (40) Whatever Up to 0.07 (0.7) Whatever III Over 0.07 (0.7) to 1.6 (16) From - 70 to - 20 Any, with the exception of those indicated for I and II ranks 200 to 400 Over 1.6 (16) to 4.0 (40) From - 70 to 400 IV Over 0.07 (0.7) to 1.6 (16) From - 20 to 200 Up to 0.07 (0.7) Whatever

When creating any system of technical diagnostics, it is necessary to choose the scope, types and means of technical diagnostics, that is, determine the level of technical control. The determining factor in determining the level of control is the established rank (tables 1, 18).

A joint examination of the rank according to table 1, which determines the possibility of operating a technical device, and the rank according to table 18, which determines the danger during its operation, allows you to classify the required level of control, ensuring the necessary industrial safety.

The definition of the level of control is presented in matrix form (table 19).

Table 19. Matrix for selecting the scope of technical diagnostics and the type of non-destructive testing of vessels and apparatuses. Grade TU
Hazard rank IV III II I IV A A A B III A A B C II A B C D I B C D E

Working with the matrix involves determining the level by the appropriate cell indicated by letter indices: A, B, C, D, E, characterizing the volume, methods, means and frequency of technical control.

The frequency and methods of control of technical devices are established on the basis of a previously determined level of control, as well as the frequency of overhauls.

The frequency of control is two-level:

- 1st level - control of technical devices during a stop for major repairs.

- 2nd level - control of technical devices in operation mode.

Table 20 presents the minimum required control volume for vessels and apparatuses for overhaul, depending on the level of control.

Table 20. Control methods for vessels and apparatuses in major repairs. Control level Scope of control in overhaul Control methods* BUT IN** UZT School HB MG *** AE **** GI (PI) A • • • 1 time in 8 years B • • • • • C • • • • • • D • • • • • • E • • • • • • • **** Note: * BUT - external examination; IN - internal inspection; UZT - control of the thickness of structural elements; SSH - control of welds and heat-affected zone; HB - measurement of hardness; MG - metallographic studies; AE - acoustic emission control; GI (PI) - hydraulic (pneumatic) tests. ** For a two-year interval between overhauls, internal inspection can be replaced by alternative types of control for levels “A”, “B”, “C” with a three-year interval for levels “A” and “B”. Replacement can be carried out subject to the approval of the Control Program by a specialized organization. *** The need for metallographic studies is determined by the experts conducting the ranking depending on the operating conditions that can cause a change in the physicomechanical properties of materials of structural elements. **** For levels “A” ÷ “D”, AE control is carried out as an accompanying control for PI. ***** Designation indicating the need for this type of control.

In addition to the works indicated in table 20, the following works can be carried out for overhaul (the need for conducting is determined by the specialists conducting the ranking depending on the operating conditions and the requirements of the technical documentation):

- Studies of physical and mechanical properties.

- Analysis of the chemical composition of the materials used.

- Calibration calculation for strength.

- Determination of residual life.

- Calculation and control of tightening forces of flange joints.

When conducting an overhaul of an industrial safety examination, the scope of control is determined by the organization conducting the examination, but it should be no less than the amount indicated in Table 20 and in the regulatory and technical documentation.

Tables 21-23 show the minimum required frequency and amount of control for vessels and apparatuses in operation, depending on the level of control and the interval between overhauls.

In addition to the frequency and scope of control specified in tables 21-23, situational consideration of the frequency and methods of control is possible.

Table 21. Frequency and control methods for vessels and apparatuses in operation for a two-year interval between overhauls. Control level Scope of control in operating mode Number of months since last overhaul 6 12 eighteen 24 A BUT BUT BUT Overhaul B BUT BUT BUT C BUT BUT, UZT BUT D BUT BUT, UZT, SSh, TK * BUT E BUT, UZT, AE ** BUT, UZT, SSH, TK, AE BUT, UZT, AE Note: * Thermal control is carried out once a month for lined vessels and apparatuses and with a periodicity according to table 6.2 for vessels and apparatuses with a wall temperature of more than 250 ° C. ** Acoustic emission control is carried out on the basis of factors determining the level of control “E”. Such factors may be - the factor of the corrosive effect of the medium and the factor associated with the defectiveness of the technical device.

Table 22. Frequency and control methods for vessels and apparatuses in operation for a three-year interval between overhauls. Control level Scope of control in operating mode Number of months since last overhaul 6 12 eighteen 24 thirty 36 A BUT BUT BUT BUT BUT Overhaul B BUT BUT BUT, UZT BUT BUT C BUT BUT BUT, UZT, SSH, TC BUT BUT D BUT BUT, UZT, SSH, TC BUT BUT, UZT, SSH, TC BUT E BUT, UZT, AE BUT, UZT, SSh, TK *, AE ** BUT, UZT, AE BUT, UZT, SSH, TK, AE BUT, UZT, AE Note: * Thermal control is carried out once a month for lined vessels and apparatuses and with a periodicity according to table 6.3 for vessels and apparatuses with a wall temperature of more than 250 ° C. ** Acoustic emission control is carried out on the basis of factors determining the level of control “E”. Such factors may be - the factor of the corrosive effect of the medium and the factor associated with the defectiveness of the technical device.

Table 23. Frequency and control methods for vessels and apparatuses in operation for a four-year interval between overhauls. Control level Scope of control in operating mode Number of months since last overhaul 6 12 eighteen 24 thirty 36 42 48 A BUT BUT BUT BUT BUT BUT BUT Overhaul B BUT BUT BUT BUT, UZT BUT BUT BUT C BUT BUT BUT BUT, UZT, SSh, TK * BUT BUT BUT D BUT BUT, UZT, SSH, TC BUT BUT, UZT, SSH, TC BUT BUT, UZT, SSH, TC BUT E BUT, UZT, AE ** BUT, UZT, SSH, TK, AE BUT, UZT, AE BUT, UZT, SSH, TK, AE BUT, UZT, AE BUT, UZT, SSH, TK, AE BUT, UZT, AE Note: * Thermal control is carried out once a month for lined vessels and apparatuses and with periodicity according to table 24 for vessels and apparatuses with a wall temperature of more than 250 ° C. ** Acoustic emission control is carried out on the basis of factors determining the level of control “E”. Such factors may be - the factor of the corrosive effect of the medium and the factor associated with the defectiveness of the technical device.

Table 24. presents the minimum required control volume for pipelines for overhaul, depending on the level of control.

Table 24. Control methods for pipelines in major repairs. Control level Scope of control in overhaul Control methods* BUT IN** UZT School HB MG *** AE **** GI (PI) A • • • 1 time in 8 years B • • • • • C • • • • • • D • • • • • • E • • • • • • • **** Note: * BUT - external examination; IN - internal inspection; UZT - control of the thickness of structural elements; SSH - control of welds and heat-affected zone;

HB - measurement of hardness; MG - metallographic studies; AE - acoustic emission control; GI (PI) - hydraulic (pneumatic) tests. ** Subject to the possibility of access to the inner surface. *** The need for metallographic studies is determined by the experts conducting the ranking depending on the operating conditions that can cause a change in the physicomechanical properties of materials of structural elements. **** For levels “A” ÷ “D”, AE control is carried out as an accompanying control for PI. ***** Designation indicating the need for this type of control.

In addition to the works indicated in table 24, the following works can be carried out for overhaul (the need for carrying out is determined by the specialists conducting the ranking depending on the operating conditions and the requirements of the technical documentation):

- Studies of physical and mechanical properties.

- Analysis of the chemical composition of the materials used.

- Calibration calculation for strength.

- Determination of residual life.

- Calculation and control of tightening forces of flange joints.

When conducting an overhaul of an industrial safety examination, the scope of control is determined by the organization conducting the examination, but at the same time it should be no less than the amount indicated in table 25 and in the normative and technical documentation.

Tables 25-27 show the minimum required frequency and amount of control for vessels and apparatuses in operation, depending on the level of control and the interval between overhauls.

In addition to the frequency and scope of control specified in tables 25-27, a situational consideration of the frequency and methods of control is possible.

Table 25. Frequency and control methods for pipelines in operation for a two-year interval between overhauls. Control level Scope of control in operating mode Number of months since last overhaul 6 12 eighteen 24 A BUT BUT BUT Overhaul B BUT BUT but C BUT BUT BUT D BUT BUT, UZT, TC * BUT E BUT, UZT, AE ** BUT, UZT, SSH, TK, AE BUT, UZT, AE Note: * Thermal control is carried out once a month for lined vessels and apparatuses and with a periodicity according to table 26 for vessels and apparatuses with a wall temperature of more than 250 ° C. ** Acoustic emission control is carried out on the basis of factors determining the level of control “E”. Such factors may be - the factor of the corrosive effect of the medium and the factor associated with the defectiveness of the technical device.

Table 26. Frequency and inspection methods for pipelines in operation for a three-year interval between overhauls. Control level Scope of control in operating mode Number of months since last overhaul 6 12 eighteen 24 thirty 36 A BUT BUT BUT BUT BUT Overhaul B BUT BUT BUT BUT BUT C BUT BUT BUT, UZT BUT BUT D BUT BUT BUT, UZT, SSh, TK * BUT BUT E BUT, UZT, AE BUT, UZT, AE ** BUT, UZT, SSH, TK, AE BUT, UZT, AE BUT, UZT, AE Note: * Thermal control is carried out once a month for lined vessels and apparatuses and with a periodicity according to table 26 for vessels and apparatuses with a wall temperature of more than 250 ° C. * Acoustic emission control is carried out on the basis of factors determining the level of control “E”. Such factors may be - the factor of the corrosive effect of the medium and the factor associated with the defectiveness of the technical device.

Table 27. Frequency and inspection methods for pipelines in operation for a four-year interval between overhauls. Control level Scope of control in operating mode Number of months since last overhaul 6 12 eighteen 24 thirty 36 42 48 A BUT BUT BUT BUT BUT BUT BUT Overhaul B BUT BUT BUT BUT, UZT BUT BUT BUT C BUT BUT BUT BUT, UZT, SS BUT BUT BUT D BUT BUT, UZT BUT BUT, UZT, SSh, TK * BUT BUT, UZT BUT E BUT, UZT, AE ** BUT, UZT, AE BUT, UZT, AE BUT, UZT, SSH, TK, AE BUT, UZT, AE BUT, UZT, AE BUT, UZT, AE Note: * Thermal control is carried out once a month for lined vessels and apparatuses and with a periodicity in accordance with table 27 for vessels and apparatuses with a wall temperature of more than 250 ° C. ** Acoustic emission control is carried out on the basis of factors determining the level of control “E”. Such factors may be - the factor of the corrosive effect of the medium and the factor associated with the defectiveness of the technical device.

Presented in the description of tables 1-27 illustrate the achievement of the technical result with the technical problem posed by this invention, and are also examples of the implementation of the claimed method, showing the possibility of implementing this method as an invention.

The data of the tables and the description as a whole show the effectiveness of this method, aimed at improving industrial safety during the operation of technical devices and equipment of technological plants of chemical, petrochemical and oil refining complexes.

Claims (10)

1. A method for ranking technical devices that are part of industrial facilities for the chemical, petrochemical and oil refining industries, based on the distribution of technical devices by the degree of their technical danger due to possible failure during operation, including (a) analysis of regulatory requirements on technical devices and recording information about their characteristics in the information database; (b) an assessment of the technical condition of technical devices at different periods of their operation, taking into account their technical condition before the start of operation, (c) the formation of a common information database on the actual technical condition of devices at different periods of time and the dynamics of development of a technical condition in the future based on information, obtained during the assessment of the technical condition at stages (a) and (b), while the evaluation conducts the technical genetics of the state of technical devices to obtain data on their technical condition for previous period of time, conduct a technical diagnosis of their condition for the current period of time, conduct a technical forecast of their condition for the subsequent period of their operation, and with technical genetics determine the design features of technical devices taking into account the changes made to their design, their installation, materials used, and operating conditions , data on their strength, failures in work, accidents and their causes, and also take into account the results of the survey for the previous period of time, when technical These diagnostics carry out a survey of the corrosion state, determine the degree of corrosion exposure to them during operation, taking into account the influence of temperature, pressure, exposure to hazardous aggressive environments, the presence of defects, the establishment of the causes of their occurrence, the influence of all these factors on the operation of technical devices, and during technical diagnostics take into account the results of the technical genetics, then carry out the technical forecast of the technical condition of the technical devices, in which dividing the possibility of their further safe operation on the basis of data obtained during technical genetics and technical diagnostics of them, and taking into account their available safety margin, fatigue, degree of corrosion failure, (g) further, technical devices included in the equipment manufacturing complex are selected from the total number, assigned to the category of weak links, the most prone to degradation processes that reduce their operational reliability, establish the reasons that reduce their performance, ( e) further, on the basis of an expert-point assessment using the matrix form of analysis, information obtained on the degree of reliability and safety of operation, a numerical value of the hazard rating from 1 to 4 is assigned to one or another device under investigation, depending on their technical condition based on the results obtained during technical genetics, technical diagnostics, technical forecasting, moreover, critically hazardous technical devices that allow operation after restoration are considered to be the first rank of danger Repair work, performing periodic or comprehensive continuous monitoring of their technical condition, or is taken out of operation, hazardous technical devices that allow operation with restrictions or periodic monitoring of their technical condition are classified as hazardous; the third hazard class includes potentially hazardous technical devices that allow for operation with simultaneous monitoring of their technical condition during the overhaul period, by the fourth at the rank of danger include technical devices, which allow for further use without any restrictions, and further depending on the assigned technical device hazard rank set the level, the volume and frequency of non-destructive testing conducted by the technical condition of the technical device. 2. The method according to p. 1, characterized in that the matrix with which the matrix analysis is carried out is formed by entering the results obtained by expert evaluation into its corresponding cells. 3. The method according to p. 2, characterized in that the factors affecting the possibility and period of operation of technical devices and the assignment of a hazard class to them include the corrosive effects of aggressive and technological environments, defectiveness (the presence of various detected defects), residual life corrosion rate, the presence of general corrosion, the duration of operation, the presence of changes in technical devices during their operation. 4. The method according to p. 3, characterized in that when ranking according to the corrosion factor, the values of the results in the form of points, obtained taking into account the influence of all internal and external factors on the technical condition of technical devices, determine the established hazard level. 5. The method according to p. 4, characterized in that when identifying defects take into account the registration time of the defect, the type of defect, the cause of the defect, their frequency and consequences caused by the occurrence of the defect. 6. The method according to p. 5, characterized in that when establishing the operational capability and assigning a hazard rating to a technical device, the estimated life for it, the mileage or its life in excess of the estimated value established for it are taken into account. 7. The method according to p. 6, characterized in that the rank of the technical device with an operating life beyond the calculated one is determined by the number of non-destructive tests performed, which include external and internal visual inspection, ultrasonic testing, including ultrasonic thickness measurement, magnetic particle inspection, acoustic emission control, control of penetrating chemicals, x-ray control, thermal control, metallographic studies, measurement of mechanical properties, control by m gnitnoy memory, eddy current testing. 8. The method according to p. 7, characterized in that the changes in technical devices that have occurred in the previous period of their operation are determined, taking into account the change in the conditions of their operation, including temperature, pressure, working process medium, change in the strength characteristics of their individual structural elements and material properties, from which they are made, the change in corrosion rate under altered operating conditions. 9. The method according to p. 8, characterized in that, depending on the established hazard level of the technical device after ranking, taking into account the results obtained from the results of the matrix analysis system, determine the volume and level of non-destructive testing of the technical condition of technical devices and equipment as a whole. 10. The method according to p. 9, characterized in that the technical devices, regardless of the period of operation with an extended interval between overhauls, are subject to established control in a volume that may include external and internal visual inspection, ultrasonic inspection, including ultrasonic thickness gauge, magnetic particle inspection, acoustic emission control, penetrating chemicals control, x-ray control, thermal control, metallographic studies, measurement of mechanical properties tv, magnetic memory control method, eddy current testing.