TSG D0001-2009_English: PDF (TSGD0001-2009)
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Pressure pipe safety technology supervision regulation for industrial pressure pipe
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TSG D0001-2009
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| Standard ID | TSG D0001-2009 (TSGD0001-2009) | | Description (Translated English) | Pressure pipe safety technology supervision regulation for industrial pressure pipe [Quasi-Official / Academic version - scanned PDF, translated by Standard Committee / Research Institute in China] | | Sector / Industry | Special Equipment Industry Standard | | Classification of Chinese Standard | J74 | | Classification of International Standard | 23.040 | | Word Count Estimation | 53,550 | | Date of Issue | 2009-05-08 | | Date of Implementation | 2009-08-01 | | Drafting Organization | AQSIQ Special Equipment Safety Supervision Bureau | | Administrative Organization | ?State Environmental Protection Administration AQSIQ | | Regulation (derived from) | ?AQSIQ Announcement 2009 No.44 | | Summary | This standard applies to the process equipment along with the following conditions, industrial piping and auxiliary devices sector belongs to the district public works (hereinafter referred to as the pipe): (a) the maximum working pressure greater than or equal to 0. lMPa (gauge pressure, similarly hereinafter), (b) nominal diameter (Note 1) of greater than 25mm, (c) the transmission medium is a gas, steam, liquefied gases, maximum operating temperature is higher than or equal to its standard boiling point of liquids or combustible, explosive, toxic, corrosive liquid. |
TSG D0001-2009
Safety Technology Regulation for Special Equipment
Pressure Pipe Safety Technology Supervision Regulation for
Industrial Pressure Pipe
Issued by: General Administration of Quality Supervision, Inspection and
Quarantine of the People's Republic of China
May 8, 2009
Table of Contents
1 General Provisions ... 5
2 Pipe Elements ... 8
2.1 Basic Requirements ... 8
2.2 Materials ... 9
2.3 Application of Pipe Elements ... 10
3 Design ... 14
4 Installation ... 19
4.1 Basic Requirements ... 19
4.2 Welding and Heat Treatment ... 20
4.3 Site Manufacture and Installation ... 22
4.4 Visual Inspection and Non-destructive Testing of Welding Joint ... 23
4.5 Pressure Test and Leak Test ... 24
5 Application, Reconstruction and Maintenance ... 28
5.1 Application ... 28
5.2 Reconstruction ... 31
5.3 Maintenance and Repair ... 31
6 Periodic Inspections ... 32
7 Safety protection devices ... 34
7.1 Basic Requirements ... 34
7.2 Safety Relief Devices (Safety Valve and Bursting Disc Device) ... 36
7.3 Flame Arrester and ESV ... 37
7.4 Installation ... 39
7.5 Inspection and Maintenance ... 41
8 Supplementary Provisions ... 42
Annex A Gradation for Industrial Pressure Pipe and Classification of the
Toxicity, Corrosivity and Fire Hazard of its Medium ... 43
Annex B Quality Certificate of Pressure Pipe Elements ... 47
Annex C Design Documents of Pressure Pipes ... 48
Annex D Installation Quality Certificate of Pressure Pipes ... 51
Annex E Calculation of Safety Relief Devices ... 53
Pressure Pipe Safety Technology Supervision Regulation for
Industrial Pressure Pipe
1 General Provisions
Article 1 This regulation is formulated in line with the "Regulations on Safety Supervision
for Special Equipment", with a view to ensuring the safety operation of industrial pressure
pipe, ensuring the personal and property safety of the people and promoting the economic
development.
Article 2 This regulation is applicable to process plants, auxiliary equipment and industrial
pressure pipes (hereinafter referred to as "pipes") affiliated to the public works within the
battery limit. All the process plants, auxiliary equipment and pipes shall meet all of the
following requirements:
(1) Highest operating pressure is greater than or equal to 0.lMPa (gauge pressure, the
same below);
(2) Nominal diameter (NOTE 1) is greater than 25mm;
(3) Conveyance medium is gas, steam, liquefied gas, liquid whose highest operating
temperature is higher than or equal to its normal boiling point or combustible,
explosive, noxious and corrosive liquid.
Article 3 This regulation is applicable to the following pipe scope:
(1) Pipe elements, including pipe components (NOTE 2) and pipe support parts (NOTE
3);
(2) Joints between pipe elements, the first joint (weld, flange, sealing member and
fastener, etc.) connecting the pipe and equipment or device, and joints between the
pipes and non-pressure parts;
(3) Safety valves, bursting disc devices, flame arresters, emergency shutoff devices and
other safety protection systems used for the pipes.
NOTE 1: The nominal diameter is the inside nominal diameter and nominal dimension, the code is usually indicated in DN.
NOTE 2: Pipe components are used to connect or assemble the pressure-bearing and enclosed pipe systems, including pipes, pipe
fittings, flanges, sealing members, fasteners, valves, safety protection systems, compensators, flexible joints, pressure hoses,
filters (such as Y-shape and T-shape), throttling devices (such as orifice plates) in the pipes and segregators.
NOTE 3: Pipe support parts, including steeves, spring supporters and hangers, diagonal bars, balance weights, elastic bolts,
support bars, chains, guideways, cradles, bases, rollers, brackets, sliding supports, lifting eyes, hangers, clasps, pipe clips,
U-clamps and plywoods.
Article 4 The following pipes shall comply with provisions specified in other relevant safety
technology regulations:
(1) Pipes whose nominal pressure is above 42MPa;
(2) Non-metallic pipes.
Article 5 This regulation is not applicable to the following pipes:
(1) Pipes special for the electrical equipment and telecommunication;
(2) Power pipes;
(3) Pipes for military equipment and nuclear facilities;
(4) Pipes for offshore installations and pipes down the mine;
(5) Pipes special for mobile equipment like railway locomotives, automotives, ships and
aerospace crafts;
(6) Pipes for petroleum, natural gas and terrestrial heat exploration and excavation
devices;
(7) Long-distance (oil-gas) pipes and oil/gas field gathering pipes;
(8) Pipes for town and municipal utilities;
(9) Pipes belonging to the body of refrigeration and air conditioning equipment as well as
pipes special for heating and ventilation;
(10) Other pipes within the scope specified in "Regulations on Safety Technology for
Special Equipment".
Article 6 Manufacturing of the pipe elements and the design, installation (including the field
fabrication, the same below), reconstruction, maintenance, application and inspection/testing
shall be in accordance with this regulation.
The quality and technical supervision departments (hereinafter referred to as "quality
inspection departments") at all levels are responsible for the safety supervision of pipes and
for the supervision of the implementation of this regulation.
Article 7 This regulation specifies basic safety requirements for the pipes, other provisions
(such as technical standards and internal enterprise provisions) shall not be lower than the
requirements of this regulation.
Safety management personnel and operators of pipes shall obtain corresponding "Special
Equipment Operator Certificate".
2 Pipe Elements
2.1 Basic Requirements
Article 14 The design pressure of standard parts of the pipe elements shall be in accordance
with the requirements specified in the relevant safety technology regulations and their
corresponding standards. Non-standard pipe elements shall also be provided with design
calculations and drawings.
Article 15 Manufacturing organizations of pipe elements shall obtain "Manufacture License
for Special Equipment" and shall accept the supervision and inspection for their product
manufacturing process by the special equipment inspection and testing institutions in light of
the relevant safety technology regulations.
Article 16 Manufacturing of the pipe elements shall be provided with design (technical)
documents and manufacturing process documents and also shall meet the requirements in the
relevant safety technology regulations and their corresponding standards.
Article 17 Manufacturing of the pipe components shall be in accordance with provisions
specified in the relevant safety technology regulations and their corresponding standards. As
for the welding (including the repair welding) in the manufacturing process, welding
procedure qualified through assessment shall be adopted and welders with qualification
certificate shall be responsible for the welding. Welding procedure qualification and welder
performance qualification tests shall be in accordance with the requirements specified in the
relevant safety technology regulations and their corresponding standards.
Article 18 Manufacturing organizations of pipe elements shall provide product quality
certificate documents stamped with their quality inspection seals according to the supply
batches of the pipe elements. As for those pipe elements supervised and inspected, they still
shall be provided with supervision and testing certificate issued by the special equipment
inspection and testing institutions.
Quality certificate documents of the pipe components include product qualification certificate
and quality certificate. Product qualification certificate usually covers the product name, serial
number, specification type and voluntary standards, etc. (for specific format, see Annex B).
The quality certificate usually includes the following contents except for those contents
included in the product qualification certificate:
(1) Chemical compositions of the materials;
(2) Mechanical properties of the materials and welding joints;
(3) Heat treatment state;
(4) Results of non-destructive testing;
(5) Pressure test results (applicable to the relevant safety technology regulations and their
corresponding standards or those specified in the contract);
(6) Type test results (applicable to those requiring type test);
(7) Other inspection items specified in the product standards or contract;
(8) Quality certificates of outsourced semi-finished products or finished products.
Pipe support parts shall be provided with product quality certificate documents according to
the provisions stipulated in the relevant safety technology regulations and their corresponding
standards.
Product qualification certificates and quality certificates shall be stamped by quality
inspection personnel and quality assurance engineer of the manufacturing organization.
Article 19 Pipe components shall be signed and marked piece by piece. The marking contents
generally include code or brand of the manufacturing organization, license sign, material
(grade, specification and furnace batch number), and product code. In addition, they also shall
be in accordance with the requirements specified in the relevant safety technology regulations
and their corresponding standards. If the product specification is too small to mark all
contents, then labels may be adopted or partial contents may be omitted in terms of
corresponding requirements. It shall be able to trace back to the product quality certificate
document from the product markings.
Article 20 As for valves for the pipes, not only the requirements stipulated in this regulation,
but also those in other safety technology regulations shall be complied with.
2.2 Materials
Article 21 Selection of materials for pipe components shall meet the following basic
requirements and in the design, appropriate materials shall be selected according to specific
working conditions and media:
(1) Be in line with the provisions stated in the corresponding material standards; in the
application aspect, it shall be in line with the provisions in the relevant pipe safety
technology regulations;
(2) Elongation of metal materials shall not be lower than 14% and materials shall be
provided with sufficient anti-brittle failure capability at the lowest service
temperature. When metal materials whose elongation is lower than 14% must be
applied on grounds of specific causes, necessary protective measures must be able to
be taken;
NOTE 4: Definition of severe cyclic condition is specified in GB/T 20801.3-2006 "Pressure Piping Code - Industrial
Piping - Part 3: Design and Calculation".
(2) Service temperature of spherical-graphite cast iron shall be higher than -20℃ and be
lower than or equal to 350℃.
Article 25 Gray cast iron and malleable cast iron pipe components may be applied in the
following conditions. However, safety protection measures against superheat, thermal shock,
vibration and misoperation must be adopted;
(1) Service temperature of gray cast iron shall be higher than or equal to -10℃, but shall
be lower than or equal to 230℃. The design pressure shall be less than or equal to
2.0MPa;
(2) Service temperature of malleable cast iron shall be higher than -20℃ and be lower
than or equal to 300℃. The design pressure shall be less than or equal to 2.0MPa;
(3) When the gray cast iron and malleable cast iron are used for combustible medium,
their service temperature shall be higher than or equal to 150℃ and the design
pressure shall be less than or equal to 1.0MPa.
Article 26 As for the application of carbon structural steel pipe components (pressure parts),
not only those provisions stipulated in Article 27 of this regulation, but also those specified
below shall be met:
(1) Carbon structural steels shall not be applied to class GC1 pipes;
(2) Boiling steel and semi-killed steel shall not be applied to noxious and combustible
medium pipes; their design pressure shall be less than or equal to 1.6MPa and service
temperature shall be lower than or equal to 200℃ but shall not be lower than 0℃;
(3) Q215A, Q235A and other class A killed steels shall not be applied to noxious and
combustible medium pipes; their design pressure shall be less than or equal to
1.6MPa and service temperature shall be lower than or equal to 350℃. The lowest
service temperature shall be in accordance with those specified in GB/T
20801.1-2006 "Pressure Piping Code - Industrial Piping - Part 1: General";
(4) Q215B, Q235B and other class B killed steels shall not be applied to utmost and
highly imperil and noxious medium pipes; their design pressure shall be less than or
equal to 3.0MPa and service temperature shall be lower than or equal to 350℃. The
lowest service temperature shall be in accordance with those specified in GB/T
20801.1.
Article 27 As for carbon structural steels applied to pipe components, their welding thickness
shall meet the following requirements:
(1) Requirements for pipe material grade table, antiseptic treatment and heat insulation as
well as for sweeping and cleaning, and pipe painting;
(2) Technical requirements for pipe elements;
(3) When pipe elements are adopted in the engineering design, requirements for
engineering design service life shall be considered;
(4) Technical requirements for manufacture and installation (including welding) of pipes;
(5) Testing and inspection requirements.
Article 38 Pipe drawing list and pipe layout shall be sealed with design license stamp of the
design organization.
Article 39 Pipe data sheet, pipe material grade table, equipment layout, pipe layout, strength
calculation and pipe stress analysis calculation as well as other major design drawings and
documents shall be provided with three step signatures, namely, designer, checker and
examiner. In addition, the pipe material grade table and pipe stress analysis calculation of
class GC1 pipes also shall be signed by the design approver.
Article 40 The design pressure of pipes shall not be less than the pressure that may encounter
in operation under the harshest pressure-temperature combination operating condition.
When pipe operating condition exceeds the design condition, provisions related to the
allowable overpressure in GB/T 20801 shall be complied with.
Article 41 Selection of the applicable pressure of pipe components shall meet the following
requirements:
(1) Applicable pressure of pipe elements such as flange and valve shall meet the
requirements for pressure-temperature rating corresponding to the design temperature
specified in the relevant standard;
(2) Applicable pressure of straight pipes, miter elbows, elbows, stop plate, nonstandard
flanges and branch connection pipe fittings shall be determined through calculation
according to GB/T 20801;
(3) Applicable pressure of the sockets and threaded pipe fittings shall be determined
according to the straight pipe wall thickness specified in the relevant standard;
(4) Applicable pressure of butt-welded pipe fittings and branch pipe bases shall be
determined through calculation according to GB/T 20801. If it is incapable of
calculation, then the pressure may be determined by the verification test.
If the applicable pressure of pipe components cannot be determined according to those
specified in Items (1)~(4), then it may also be determined by service experience, stress
analysis, type test and other methods. However, it shall be evaluated by the technical
organizations or technical institutions entrusted by GAQSIQ.
Article 42 The design temperature of pipes shall be determined according to the temperature
that may occur in operation under the harshest pressure-temperature combination operating
condition.
Article 43 When the ambient temperature is lower than 0℃, there shall be measures to
prevent external surfaces of cut-off valves, control valves, safety protection devices and other
moving parts of the pipe components from being frozen.
Article 44 When the outer wall temperature of the metal pipes is affected by the atmospheric
environment conditions, the lowest ambient temperature considered in the design of pressure
pipes may be the lowest monthly mean temperature value in recent years according to the
local meteorological data (NOTE 9).
NOTE 9: The lowest monthly mean temperature refers to the sum of the lowest temperature among days of the month divided by
the number of days in the month.
Article 45 Strength calculation of the pipe components shall be in accordance with those
specified in GB/T 20801. As for those pipes which are connected with pumps and other
rotating equipment, or are used in high temperature and high pressure, or whose circulation
equivalent amount is larger than 7000, or which require in the engineering design, then stress
analysis shall be carried out for them.
Article 46 In the stress analysis of pipes, the impact of the following various loads and the
interplay between the loads and forces generated by other reasons shall be taken into account:
(1) Media pressure, pipe deadweight (including thermal-insulating layers, pipe
components and media weight) and other sustained loads;
(2) Temporary loads such as wind load, seismic load and impact counterforce on pipes
when valves close and cause the pressure raise instantly or when the discharge valve
opens;
(3) Temperature difference loads, alternating or non-alternating loads on the pipes
generated by displacement of fixed supporters and hangers or terminals.
Article 47 Axial stress of pipes shall meet the following requirements:
(1) Axial stress of pipes under the sustained load combination operating condition shall
be less than or equal to the permissible material stress under the highest operating
temperature;
NOTE 11: It shall not be adopted for flanges or in conditions that other components with slight permanent deformation may pose
leakage or fault.
Article 51 Design and selection of the pipe components shall be in accordance with those
specified in GB/T 20801.
Article 52 The design of flanges, gaskets and fasteners of the pressure pipes shall be in
accordance with those specified in HG 20592~20635-1997 "Steel Pipe Flanges, gaskets And
Fasteners" and other relevant standards.
Article 53 In order to guarantee the sealing requirements of the flange joints, the design shall
comply with the following principles:
(1) Slip-on flange shall not be used for pipes with frequent temperature changes,
especially when flanges are not heat insulated;
(2) When flanged connection is adopted for pipes in severe cyclic condition, butt-welded
neck flanges shall be adopted;
(3) Expanded joint flanges and threaded flange shall not be used for class GC1 pipes and
in environment of super-strong corrosivity;
(4) Flared flanging joints shall not be used in severe cyclic condition;
(5) Fasteners of flanged connection shall meet the sealing requirements of gaskets under
pretension and operation conditions. The low intensity fasteners shall not be used for
flange joints under severe cyclic condition;
(6) Gaskets shall be selected according to the liquid property, service temperature,
pressure and flange sealing surface as well as other factors. The sealing loads of the
gaskets shall be matched with the flange pressure rating, tight surface types and
surface roughness as well as the fasteners;
(7) As for class GC1 pipes and pipes with noxious and combustible medium, fastening
loads and procedures of their flange joints shall be specified in order to ensure the
sealability of the flange joints.
Article 54 Design and selection of the pipe supporters and hangers shall be in accordance
with those specified in GB/T 20801. The following principles shall be complied with during
the design:
(1) Ensure all the pipe supporters and hangers be provided with adequate strength and
stiffness;
(2) As for the design of pipe supporters and hangers and pipe connection members,
oversize local bending stress shall not be generated at the connections and pipes shall
not be deformed. In cyclic load condition, stress concentration at the connections may
be reduced.
Article 55 Emission and treatment of combustible, noxious or mordant harmful media shall
be in accordance with those specified in the relevant national standards.
Article 56 As for pipe systems with utmost noxious or highly imperil media and combustible
liquid, leak test shall be carried out for them after the installation and construction are
completed. Specific requirements for leak test shall be stipulated in the design documents.
4 Installation
4.1 Basic Requirements
Article 57 Pipe installation organization shall obtain special equipment installation license
and shall be responsible for the installation quality of pipes.
Article 58 Before the pipes are installed, the installation organization shall fill in
"Announcement on Installation, Reconstruction and Maintenance of Special Equipment" and
inform the quality and technical supervision departments responsible for pipe application and
registration (hereinafter referred to as "application and register authority") in the pipe
installation site in written form and accept their supervision and inspection as required.
Non-destructive testing institutions are not members of the installation organizations and are
not directly entrusted by them. Before the installation, they also shall inform the application
and register authority in site in writing and accept its supervision and inspection as required.
Article 59 Before the pipe installation and construction, the installation organization shall
develop technical documents for pipe installation, such as construction design and
construction scheme. Pipe installation work may be carried out until they are approved by the
end users (or the technical directors of their entrusting party). Installation quality of pipes
shall meet those specified in GB/T 20801 and design documents.
Article 60 Supervision and inspection institutions shall perform according to the provisions
specified in the pressure pipe installation, supervision and inspection rules. After the pipe
installation is completed, the supervision and inspection institutions shall issue the installation,
supervision and inspection certificate and reports in time in order to serve as the reference for
final acceptance of pipe installation engineering and the application registration.
Article 61 After the pipe installation is completed, the installation organization and
non-destructive testing organization shall solely arrange the pipe installation and inspection
data, and submit installation quality certificate documents to pipe end users (or technical
directors of the entrusting party), who shall be responsible for preservation of these
documents within the pipe service life.
Article 64 Ammeters, voltmeters and other instruments and meters of the welding equipment
as well as welding parameter adjustment devices shall be periodically verified and inspected,
or else, they shall not be used for the welding of the pipe pressure parts.
Article 65 Welding environment in the construction site shall be controlled strictly. Ambient
temperature for the welding shall ensure adequate temperature needed for the welding and the
welder's skill operation unaffected. If the weldment surfaces are damp or if there is no
protective measures for welders and weldments during rain, snow and wind period, then
welding shall not be carried out.
Article 66 Positions of the pipe welding joints, groove processing, cleaning and inspection,
weldment assembly and weld preheating shall meet the requirements of GB/T20801. The pipe
welding joints shall be set in convenient for welding and heat treatment and away from the
area of stress concentration as much as possible. The weldments, except pretensioned or
precompressed craters of the pipe specified in the design documents, shall not be assembled
by force.
Article 67 As for the single-welded butt joints of class GC1 pipes, pipes whose design
temperature is lower than or equal to -20℃, alloy-steel pipes with larger hardening tendency,
stainless steel and non-ferrous metal pipes, argon arc welding shall be adopted for their root
pass welding and there shall be no arc scratch on their surfaces.
Article 68 Before and during the welding process of titanium materials, groove pollution
shall be prevented. Surface color shall be inspected once every pass welding is completed. It
shall be removed immediately if unqualified, and re-welding shall be conducted. Surface
color may be inspected with reference to the relevant standards.
Article 69 Welder identification symbols shall be marked near the welding joints after the
joint welding is completed. When the welder identification symbols cannot be marked
directly on the pipe pressure parts, they may be indicated on the pipe isometric diagram
instead.
Article 70 Repair of unqualified welding joints shall conform to the following requirements:
(1) The reasons for defects shall be analyzed and the corresponding repair measures shall
be put forward before the repair;
(2) The repair welding shall be conducted by qualified welders using welding procedures
which are qualified through assessment.
(3) When the same position (the filler metal overlapped position in the repair welding) is
repaired for more than two times, then the adjustment of welding procedures must be
considered. Repair measures shall be reestablished. The repair shall not be conducted
until being approved by the technical directors of the welding organization;
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