- acceptance of equipment that came from the factory to the customer's site, consideration and elimination of comments on the configuration and quality of delivery
- technical advice and support (supervision) of work performed by specialists of the installation organization or the customer's operating personnel
- quality control of the completed installation
- checking the operation of mechanical interlocks (if necessary - adjustment in place)
- checking the operation of switching devices
In addition, chief engineers provide training for the customer's operating personnel - they acquaint them with the device and features of the new equipment.
Works on supervised installation occupy about 50% of the total volume of works, which are carried out by specialists of the engineering department. chief installation work are drawn up or in the form of an additional clause in the supply contract, while the cost of the service is included in total amount contract, or in the form of a separate contract for installation supervision.
High-quality supervision of installation can dramatically reduce the risk of errors during installation and commissioning of equipment, identify possible problems even before the equipment is put into operation, which ultimately improves the reliability of the electrical installation. Supervised installation eliminates many organizational and technical difficulties that inevitably arise during the installation of new, unfamiliar equipment.
When working with the majority of customers, RZVA specialists strongly recommend supervising the installation by the engineering department. The exception is regular customers and partners, whose specialists are well acquainted with RZVA equipment, maintain it for a long time, and have also undergone special training.
Tasks of the chief engineer at the facility:
1. Checking the availability of documentation
2. Checking the completeness of the equipment according to the packing lists
3. Checking the completeness of spare parts according to the documentation
4. Checking components, hardware, mounting elements and materials
5. Checking the integrity of the delivered equipment
6. Compliance of the foundation (floor) for the installation of cells
7. Control of installation of cells on the foundation (floor)
8. Quality control of installation during assembly, elimination of errors in all RZVA equipment as a whole
9. Visual control assembly and testing of equipment in general
10. Checking the serviceability of mechanical interlocks in the cells
11. Checking the rack-in/out of withdrawable elements
12. Checking the gaps in the contacts of the main circuits
13. Checking the quality of the rigid busbar assembly
14. Checking switches (operations VO) when supplying control current or from an external source.
15. Training of operating personnel in the features of equipment operation and its maintenance
16. Technical consulting of the customer's personnel in the process of their installation work.
Installation supervision is the installation of equipment directly by the supplier's managers. The working personnel is provided by the buyer, and the control of the main units is carried out by the specialists of the executing company.
What does the supplier guarantee?
The equipment supply company undertakes to provide full support for the project being implemented. According to the results of the performed activities, the buyer accepts the installations that are already fully prepared for launching into production.
Installation supervision is an activity during which the supplier assumes certain responsibilities. In his competence:
- conclude a contract for installation supervision;
- solve organizational issues of installation;
- ensure technical training project, its implementation;
- supervise employees;
- supply all equipment and additional spare parts if necessary;
- if the work is carried out by the supplier's specialists, it is his responsibility to hand over a fully working installation;
- bring the equipment to the declared capacity;
- complete the installation by drawing up an act on the work done and acceptance of the installation by the customer.
What is being done by the supplier?
Supervision works are activities for the supervision of each individual part of the installation procedure of the purchased equipment. Under the guidance of specialists, the customer's employees perform the entire installation complex. Adjustment, adjustment of the main parameters, their adjustment to the appropriate performance.
Upon completion, the batch of suitable products specified in the contract is handed over. Installation supervision is optimal choice installation of new technological solutions in existing production. The customer is released from routine duties. Often there is no way to look for relevant specialists who, after the commissioning of the facility, will no longer be required by the organization.
The management of the selling company has the most complete experience in the installation of complex technical products. All operations are perfected to the smallest detail, the staff is ready for unforeseen situations and malfunctions. There are own developments on the organization of work and the sequence of actions performed.
Equipment adjustment points
The supplier's responsibilities include installation supervision and commissioning, including a full cycle of monitoring the functioning of the assembled unit:
- compliance of the finished product with documentation, drawings is checked;
- the parameters of technological modes of operation are adjusted;
- the equipment is switched on for the first time;
- trial testing is carried out in an automatic cycle;
- control and verification of the produced trial batch of finished products;
- customer engineers and workers make adjustments under the guidance of the equipment supplier's specialists.
Responsibility for the quality of work lies entirely on the shoulders of the supplier. The customer and his specialists are only performers. Damage caused by incorrect assembly will be compensated by the seller. Faulty elements are replaced before the delivery of the object.
The documents
Before starting work, the facility is held on site. Fully coordinated actions are prescribed in the contract that suits the customer. It includes all items of work, deadlines, in addition, a preliminary cost is negotiated. Each project is unique and requires careful preparation documents by experts.
Often a design change is required due to unforeseen conditions. Corrections are made immediately, discussed with the customer. Completion of work is carried out in accordance with the completed documentation (certificate of installation supervision). After its signing, the object is delivered, and the buyer of equipment and services confirms the quality of the work performed.
Benefits of Hiring a Supplier
Often, at critical facilities, inexperienced specialists carry out installation supervision work. The definition of priority tasks is done incorrectly. The consequence of this approach is equipment downtime and additional costs to correct the situation.
Experienced customer specialists have already encountered such problems and know how to quickly deal with even the most difficult situation. A guarantee is given for the work done, which additionally insures the customer. After all, when the object is handed over on time, then everything goes according to the planned path of business development. This means that the payback from the modernization of the line will correspond to the declared indicators.
Mistakes can be avoided if you entrust the matter to professionals. Each step of the work will be documented. The delivery of the object will take place according to the stated requirements of the customer. Additional changes are possible during the installation in agreement with the supplier's specialists.
Subsequence
The work performed includes the following actions of the performer. Experienced specialists begin preparation with an inspection of the object. The analysis of the project by engineers is carried out, its compliance with real conditions is assessed. According to the results, measuring instruments are selected and technical means for marking the main points of equipment installation.
The requirements of GOSTs and other regulatory documents for the selected installation methods and the means used are compared. The qualifications of the customer's employees, the availability of permits, tolerances to height, cranes, and electrical work are checked. In case of non-compliance with the requirements, the technical means are recognized as unsuitable for the performance of work. If they were provided by the customer, they will be returned or replaced with serviceable equipment.
When all the nuances are agreed and documented, proceed to direct installation. Only after checking the work by the customer's employees is permission given to turn on the individual units first, then the complete installation. Achieving debugging of operating modes, training of technological personnel and technical services. The buyer receives documentation, applications, a list of spare parts with nomenclature for the order.
Installation supervision (supervision and organizational and technical management of equipment installation by its supplier/manufacturer or an authorized partner during installation works by the customer/contractor's specialists) and commissioning are carried out by the personnel of the commissioning site (PNU) of BPA LLC - a territorially distributed structural unit (Almetyevsk, Azov, Ufa, Nizhny Novgorod), as well as employees of the assembly production and service department (Lyubertsy, Moscow region), depending on the specifics of the equipment and systems supplied.
The list of activities performed during the production of installation supervision work should be regulated at the conclusion of the relevant contract in order to meet the needs of the customer as much as possible.
Commissioning work on the technical complex of instrumentation and automated process control systems is carried out in the following scope and sequence:
Preparatory work, including organizational and engineering preparation of work, including:
- Analysis of the working project documentation, selection of measuring instruments and tools, preparation of jobs
- Checking the conformity of the main specifications equipment to the requirements established in the passports and instructions of manufacturers (the results of the check are drawn up in a protocol, faulty technical means are transferred to the customer for repair or replacement)
- Coordination of forms of reporting documentation, etc.
The works of the first stage are carried out, as a rule, outside the installation area. Commissioning, combined with the installation of control, management and electrical devices, is carried out before the introduction of the operating mode and is carried out simultaneously with the installation of devices and automation equipment, including communication channels with peripheral subsystems.
These works include the adjustment of individual elements and units of automated process control systems, including:
- Checking intrasystem communications and preparing for inclusion
- Checking the correct installation of cable connections, including the connection of contact sensor circuits, mechanism control circuits, etc. The check is carried out for compliance of the installation with the requirements of the manufacturer's instructions and working documentation
- Checking the correct marking, connection and phasing of electrical wiring
- Adjustment and control of the characteristics of actuators
- Setting up logical and temporal interconnections of signaling, protection, interlocking and control systems, checking the correctness of the signals passing
When performing work of the second stage, it is allowed to supply voltage to individual mounted units from test circuits and temporary power supply circuits in compliance with the organizational and technical measures provided for by safety regulations.
Start-up and adjustment works, providing pre-start technological operations, individual tests and complex testing of all equipment.
Commissioning works of the third stage include:
- Checking the functioning of application and system software
- Preliminary determination of the characteristics of the object, calculation and adjustment of the parameters of the equipment of automated systems, configuration of measuring transducers and software logic devices
- Adjustment and inclusion in the work of application programs in the scope of operational functions that ensure the mode of normal operation of the equipment
- Adjustment of control schemes and testing of electric drives of regulatory bodies, including software testing of equipment with testing of blocking schemes
- Adjustment of information measuring channels (discrete and analog)
- Setting up and conducting pre-start tests of the technological protection subsystem Bringing the settings of software and hardware, communication channels and application software to a state in which automated systems can be used in operation, while being carried out in a complex:
- Determining the compliance of the order of testing devices and elements of alarm, protection and control systems with the algorithms of working documentation with identifying the causes of failure or “false” operation, setting the necessary values for the operation of positional devices
- Definition of conformity bandwidth shut-off and control valves to the requirements of the technological process, the correct development of limit and limit switches, position and status sensors
- Determination of flow characteristics of regulating bodies and bringing them to the required rate using the adjustment elements available in the design
- Clarification of the static and dynamic characteristics of the object, adjustment of the values of the system settings
- Preparation for inclusion in the operation of systems to ensure integrated testing technological equipment
- Testing and determining the suitability of automated systems to ensure the operation of process equipment with a capacity that meets the standards for the development of design capacities in the initial period
- Job analysis automated systems
- Registration of production documentation, act of acceptance into operation of systems
- Making changes in one copy of the circuit diagrams from the set of working documentation based on the results of commissioning work agreed with the customer
Design work
The design department of the company consists of highly qualified and experienced personnel, provided modern equipment and specialized software for design, the necessary regulatory and methodological base, adapted to modern design and construction requirements. The main activity of the company in the field of design is aimed at the creation, reconstruction, technical re-equipment and expansion of automation and dispatching systems for oil production, oil refining, petrochemical, chemical and other industries. There is also a direction of designing electrical equipment for various purposes.
The proposed technical solutions are based on mass-produced equipment and software, both domestic and imported, that have been tested and confirmed by the relevant documents (certificates, permits for use in Russia):
- "Certificate of Conformity" of the State Standard of Russia;
- "Certificate of approval of the type of measuring instruments" of the State Standard of Russia;
- For equipment installed in hazardous areas "Certificate of explosion protection of electrical equipment";
- Permission of Rostekhnadzor (Gosgortekhnadzor) for use in the Russian Federation.
Engineering Services
Development of Application software for automated process control systems.
Each specific project is developed by the company's specialists based on the following basic principles:
The use of equipment and software based on standards and produced by leading manufacturers that have been operating in the market for a long time and steadily, having representative offices in Russia and providing high-quality support to buyers of their products.
Openness of technical solutions, allowing efficient sharing of equipment and software various developers.
Preparation of a detailed technical documentation, if necessary - training of the personnel of the enterprise to ensure the possibility of further development of the system by the forces of the customer's specialists.
Effective interaction with the APCS systems operating at the enterprise. Moreover, if the existing process control system is created on the basis of standard open approaches, it is possible to ensure its closest integration with the new information system - up to retransmission of control commands from the upper level of the system to the level of sensors.
The possibility of the fastest possible implementation of APCS systems, in particular, due to the fact that the technical solutions of the systems are modular and strictly structured.
High tech solutions
BPA LLC offers various solutions for optimizing the operation of automation systems - process control systems, process control systems and increasing the efficiency of your production:
Implementation of advanced process control systems APC (Advanced Process Control)
Implementation of the advanced process control (APC) system allows to increase the efficiency of process and facility management, improve process safety and enhance the ability of operators to control a large number of control loops.
The introduction of APC allows you to organize control over the management of a group of technological installations by one operator. Advanced Process Control (APC) - based on software tools a set of measures aimed at improving the efficiency of one or more technological installations by "non-technological" methods - by changing control algorithms. ARS is an add-on over the basic logic of the DCS. Using the infrastructure of your DCS, the APC software and hardware package significantly increases the utility of an asset.
APC is implemented on the basis of multi-parameter control using predictive models (Model Predictive Control - MPC). Traditionally, virtual analyzers (Soft Sensors) are implemented with APC systems to calculate non-measurable parameters of the control object. When introducing APC for each technological object (process), models of mass flows, heat balance, and a static model of measured parameters are developed.
Most modern packages already within the framework of the APC provide for a special technique for optimizing process control (basic level). The implementation of real-time optimization systems allows you to increase the profitability of APC projects. These systems can be aimed at optimizing the operation of an installation, a group of installations or technological complexes. The introduction of ADS is a fairly small additional investment when compared to the development of a modern DCS. The introduction of APC usually leads to an increase in plant productivity by several percent.
Supply of equipment for automation and power supply
The BPA company delivers turnkey process control systems, including the entire cycle of development, manufacturing, installation, commissioning and after-sales service(here are links to the relevant sections), as well as the supply of individual components, assemblies, spare parts.
At its production base in Lyubertsy, Moscow Region, BPA has an equipped and certified production of automation, control and electrical cabinets. The premises of the assembly production are equipped with a video surveillance system, through which it is possible to provide remote control over the assembly process, conduct final control, organize a video conference with performers and customers.
On the premises of the production base of the BPA, a warehouse is equipped for storing materials for current projects and placing a warehouse stock Supplies. The warehouse has a covered loading and unloading area, and warehouse loading equipment with a carrying capacity of up to 3 tons. If necessary, special equipment with a higher carrying capacity is called.
BPA practices various options for multimodal transportation (transportation by various modes of transport, including sea transportation and air delivery) of oversized cargo from anywhere in the world and delivers to all large and medium settlements, where the production bases of the Customers are located, both in the territory of the Russian Federation and in other countries. In some cases, in agreement with the Customer, it is possible to deliver oversized cargo and delivery to hard-to-reach places.
Production of switchboard equipment
BPA offers comprehensive services for the design, manufacture and supply of switchboard equipment for various purposes:
- NKU from idea to commissioning of the finished product,
- NKU for various purposes, standard and individual design,
- flexible approach when concluding contracts:
NKU "turnkey",
NKU from give-and-take raw materials,
assembly on site,
warranty and service maintenance of NKU.
The priority area of the company's activity is the development and implementation of modern low-voltage switchgears (LCD) of alternating and direct current with voltage up to 1 kV. The proposed switchboard equipment, along with high reliability and safety indicators, is more compact, convenient to use, has an improved design and takes into account the increased requirements of customers.
BPA main product line:
- NKU of distribution of alternating current (GRSHCH, VRU, SHCHR, ABP, SHCHSN;
- NKU distribution of direct current (SCPT, SHROT, SHOT, PPT, Complete SOPT);
- NKU control (cabinets for process control systems, metering cabinets, MCC engine control cabinets, control panels and control posts, test benches, server cabinets),
- combined cabinets (electrical + hydraulics or pneumatics)
- block-boxes with NKU.
NKU design:
- modular NKU, with plug-in or fixed devices,
- sectioning up to 4b,
- degree of protection up to IP66,
- explosion-proof or conventional.
NKU are made on the basis of high-quality components from leading manufacturers:
- cabinet shells: Rittal, ABB, Schneider Electric, Siemens, Eaton
- devices: ABB, Schneider-Electric, Siemens, Eaton
- electrical installation equipment: Phoenix Contact, Wago, etc.
Characteristics of BPA production:
- production and storage facilities 855 sq.m (Lyubrtsy)
- certification of production at Schneider Electric, ABB and Eaton for compliance with Western requirements for NKU manufacturers,
- a system of stage-by-stage quality control of products,
- high-quality tools and production equipment,
- certification of manufactured equipment (certificates of GOS R and Customs Union)
The high quality of the assembly work of the BPA is based on the following principles:
- professional staff;
- high-quality production equipment and tools;
- modern approach to the organization of the production of works;
- quality control at different stages of production, finished electrical equipment is necessarily tested and verified by our own electrical laboratory.
Construction and installation works
To perform construction and installation works (SMR) in the structure of LLC "BPA" organized Assembly management, represented by construction and installation sites, geographically located in the cities. Ufa, Azov (Rostov region) and Saratov.
The sites are fully equipped with competent, certified personnel, machines, mechanisms, tools and devices for the performance of work. Welding personnel and equipment used are certified by the National Welding Control Agency (NAKS).
The main volumes of construction and installation works are carried out by BPA LLC at the facilities of electric power industry, oil and gas production, oil refining, transportation of oil and oil products, chemical, petrochemical and other industries.
The profile works for the personnel of the installation sites are:
- Installation of instrumentation and A, electric installation work on various technological installations oil refineries, including the construction of outdoor cable racks;
- Electrical installation work of automation equipment, telemechanics, relay protection, power electrical equipment of 10/6/0.4 kV substations;
- Installation of instrumentation and A in tank farms, tank farms, racks and terminals, including systems for commercial accounting of oil and oil products, means of providing fire safety, gas analysis systems;
- Installation of instrumentation and A, power electrical equipment, electrical work during the development of oil and gas fields (including the construction of 6 kV overhead lines);
- Installation of instrumentation and A, power electrical equipment, complex systems security, electrical work of other industrial installations.
The management of BPA LLC is carrying out systematic work on sectoral diversification and expansion of the types of construction and installation works performed by the Assembly Department on its own.
Installation supervision and commissioning
LLC "BPA" performs installation, connection and commissioning of equipment, as well as commissioning - a set of works performed during the preparation and conduct of individual tests and comprehensive testing of equipment.
All work is carried out by BPA specialists. The activities carried out as part of the installation supervision work are regulated at the conclusion of the contract with the ability to determine the format and conditions for their implementation, fully satisfying the requirements of the customer.
Qualitatively performed installation supervision work can dramatically reduce the risk of errors during installation and commissioning and further operation of the equipment, identify possible problems even before the equipment is put into operation, which ultimately improves the reliability of the equipment and, as a result, excludes downtime equipment.
Installation supervision work carried out by authorized organizations eliminates many of the organizational and technical difficulties that inevitably arise during the installation of new, unfamiliar equipment.
When working with customers, most equipment suppliers strongly recommend that installation supervision be performed by authorized specialists. An exception may be customers and partners whose specialists are well acquainted with the supplied equipment, maintain it for a long time and have undergone special training.
It should be borne in mind that when performing work on their own, the customer assumes all the risks associated both with their implementation and in the future with the operation of the equipment.
When supplying equipment, two options are possible:
- installation supervision is included in the cost of equipment;
- installation supervision works are paid and performed under a separate contract.
Both in the first and in the second case, it is necessary to obtain in advance the information necessary for the installation, connection and verification of equipment, such as:
- dimensions, weight of equipment;
- method of installation and installation of equipment in place;
- used tool, equipment;
- used technical fluids;
- necessary communications;
- requirements for operating personnel.
Timely preparation reduces downtime during work and ensures that equipment reaches production capacity in a timely manner.
For any questions regarding the conditions for performing installation supervision, please contact the equipment supplier or its service center.
If the service center of your supplier is our company or your supplier is not able to perform high-quality installation supervision, our specialists are ready to answer all your questions.
Measurement and testing of electrical equipment up to 35kV
The electrotechnical laboratory is designed to carry out measurements and tests in order to determine the state electrical networks, equipment, devices. One of the main conditions for the stable operation of the power supply system is its regular Maintenance and carrying out all necessary electrical measurements.
Conducting electrical measurements by specialists of electrical laboratories allows you to establish the causes of the presence of external voltage on the cases of various devices, monitor their performance, measure the insulation resistance of wires, check the integrity of the ground circuit, check the protection operation and measure the resistance to the spread of current of the ground loop) and lightning protection, ringing of cables, equipment and much more on a contractual basis.. On time.
It should be noted that testing and measurements are necessary not only when emergency, but also when installing new electrical equipment (acceptance measurements and tests), as well as during its operation for preventive purposes (control measurements and tests). Control tests allow timely detection and elimination of the probability of equipment failure.
All work is carried out at a high level, we treat the performance of our duties responsibly and professionally.
After the electrical measurements and tests are completed, the specialists of the electrical laboratory, processing the results, draw up a technical report on electrical measurements of a certain form and issue a standard protocol of the established sample and, in case of malfunctions, a defective statement.
The activities of the electrical laboratory are licensed. Used devices are checked and certified in the State Metrological Service
Service maintenance
To ensure service and warranty maintenance of equipment purchased from BPA LLC or supplied by other manufacturers or suppliers, our company has its own service department and spare parts warehouse. The work is carried out by highly qualified specialists in accordance with the requirements of regulatory and technical documents using various diagnostic equipment.
The main tasks of the service department for the maintenance of equipment of the company "BPA"
- service maintenance, repair and adjustment of various low-voltage switchgear (SCSN, SCPT, MSB, SHROT, PPT, SHPOBR and others);
- service, repair and adjustment of frequency converters (Danfoss, Vacon, Rockwell Automation and others);
- service maintenance, repair and adjustment of various automated process control systems;
- service maintenance, repair and adjustment of monitoring systems for transformer equipment of various manufacturers;
- retrofit of NKU and circuit breakers manufactured by Schneider Electric and ABB;
- service, repair, commissioning of rectifiers, inverters and UPS by GUTOR Electronic LLC (Schneider Electric);
- warranty and post-warranty repair of equipment manufactured by the assembly production of the BPA company;
- supply of spare parts and accessories for equipment manufactured by assembly production or supplied by BPA LLC;
- providing technical support operation and maintenance of equipment supplied by BPA LLC;
- inspection, fault detection of equipment supplied by BPA LLC;
- on-site training of the customer's personnel.
Benefits of the BPA Service Department:
- Extensive experience in the maintenance of electrical equipment and equipment repair;
- Experienced professionals who are regularly trained and certified in training centers equipment manufacturers;
- The service department of the company has the necessary fleet of specialized equipment for service and other work;
- Conducting a technical examination of equipment with the issuance of recommendations for further operation, maintenance and repair of equipment;
- Carrying out service and repair work in accordance with the regulations of manufacturers and your needs;
- Providing advice to clients on the choice of equipment for solving specific problems;
- Availability own production and service center allows to carry out repair and maintenance of equipment of almost any complexity.
Project management
During the period of operation of BPA LLC, an effective strategy for managing various projects was developed, taking into account international experience. In addition to standard procedures, such as project planning, risk minimization, team efficiency improvement, there is an internal control service that allows timely corrective actions to be taken on the management system of a specific project.
The structure of the company has a project-oriented structure, which allows creating a cohesive team for each project, focused on completing the project on time with optimal quality. The presence of a large number of branches allows you to optimize logistics costs, which leads to increased efficiency and simplifies communication with the customer.
To manage large and / or technically complex projects, the project team is strengthened by the chief project engineers, which makes it possible to increase the speed of solving technical issues that inevitably arise during the implementation of such projects.
The presence in the company of a full range of departments from the design department to construction and installation departments and close ties between departments at the horizontal level makes it possible to implement turnkey projects, as well as improve the quality of work, due to a better understanding of mutual advantages and needs.
Industrial Safety Management
Hazard and operability analysis “HAZOP”
BPA LLC conducts HAZOP studies on a mandatory basis when implementing its projects at the design and survey, construction and commissioning stages. BPA LLC conducts a training course within its subsidiaries, which includes the theoretical and practical foundations of the “HAZOP” Hazard and Operability Analysis method based on GOST R 51901.11-2005.
Analysis of the danger and operability of technological systems "HAZOP" is one of the most common methods of risk analysis.
Risk analysis is a structured process, the purpose of which is to determine both the likelihood and magnitude of adverse consequences of the activity, object or system under investigation. Harm to people, property or the environment is considered as an adverse effect.
Risk analysis is an integral part of the risk management process, during which both qualitative and quantitative methods of risk analysis are applied.
HAZOP / HAZID and other methods of qualitative analysis of technological processes are widely used in foreign practice of safety justification and are reflected in the FNP " General rules explosion safety …”, RD -03-418-01, GOST R 51901.11-2005 (IEC 61882:2001), etc.
General contract
General contracting is one of the most versatile services in the field of construction and installation works, which implies a whole range of organizational and management work, including full control of the facility on the rights of the Customer and with full responsibility to him. BPA LLC provides general contracting services both of a narrowly focused nature and as part of a full-scale individual or commercial construction of the very high level difficulties.
Main goals
General contracting is centralized management the entire range of work at the construction site in strict accordance with the approved working documentation and schedule, including:
- organization of interaction between own structural divisions;
- clear coordination of the activities of subcontractors performing the stages specified in the subcontract agreement;
- invitation of specialized third-party specialists;
- close cooperation with regulatory and auditing authorities.
The general contractor is responsible for the quality of all work performed both on its own and with the involvement of subcontractors, assuming all possible risks of the project as a whole.
Main functions
Acting as a general contractor, we offer the provision of a full range of design, engineering and construction services, including:
- technical consulting and design expertise;
- carrying out the necessary range of geodetic surveys;
- development of design and technical and budget documentation with optimization best solutions;
- search and engagement of specialized subcontractors with a proven track record for construction work;
- provision of logistics services for the provision of the facility necessary materials and resources;
- organization of interaction between subcontractors and permission conflict situations;
- constant technological and quality control over each stage of work with the signing of intermediate acceptance certificates;
- strict compliance with the requirements of fire safety, labor protection, environmental standards;
- coordination of the work performed in the state control bodies;
- control of financial flows within the approved cost estimate;
- carrying out current and full settlements with involved third-party organizations and persons;
- preparation of a complete set of documentation for the completion of construction; putting the object into operation.
Thanks to a well-developed concept, general contracting services provided by BPA LLC allow implementing the most complex turnkey projects within the time frame precisely stipulated by contractual obligations and in compliance with approved building codes and requirements with a guarantee High Quality all work done.
You can get comprehensive information about general contracting services in the complex or in the segment of construction work selected by the customer by contacting the specialists of BPA LLC.
On-site consulting;
Installation supervision is a set of expert and consulting services. The composition of these services is individual for each project and is carefully coordinated with the Customer.
Installation supervision is a control measure on the part of Mashinostroitelny Engineering LLC for compliance with the correct assembly, installation and connection of equipment. These works are carried out by our representative both independently and together with a specialist of the Customer's enterprise or contractor organization. Supervision works include:
General technical and technological control of equipment installation;
On-site consulting;
Provision and maintenance of technical documentation;
Theoretical and practical training of the customer's personnel;
Quality control in the production of commissioning.
Installation supervision is accompanied by the presence and visits of our specialists to the facility.
Commissioning works by nature and purpose are a continuation of installation work and the final link in the creation of new industries. After their completion, the constructed facility can be presented for commissioning.
Commissioning works include:
Control of adjustment of the moving part of metal structures;
Carrying out diagnostics of electrical equipment and automation cabinets;
Regime and adjustment tests are a set of measures aimed at bringing equipment to design conditions, as well as ensuring the economical operation of this equipment;
Preparation of acceptance documents.
Mashinostroitelny Engineering LLC performs the whole range of works related to the start-up and adjustment of the installed equipment and is carried out during the preparation and conduct of individual tests and during the complex testing of equipment. The term “equipment” covers all technological system object.
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FEDERAL AGENCY FOR TECHNICAL REGULATION AND METROLOGY
NATIONAL
STANDARD
RUSSIAN
FEDERATION
General specifications
Official edition
|
Standartinform |
Foreword
1 DESIGNED BY OPEN joint stock company Taganrog boiler plant "Krasny Kotelshchik" (JSC TKZ "Krasny Kotelshchik") and the Open Joint Stock Company "Scientific and Production Association for Research and Design of Power Equipment named after A.I. I.I. Polzunova (JSC NPO CKTI)
2 INTRODUCED by the Technical Committee for Standardization TK 244 "Energy Stationary Equipment"
3 APPROVED AND PUT INTO EFFECT by Order of the Federal Agency for Technical Regulation and Metrology No. 1485-st dated November 06, 2014
4 INTRODUCED FOR THE FIRST TIME
The rules for the application of this standard are established in GOST R 1.0-2012 (section 8). Information about changes to this standard is published in the annual (as of January 1 of the current year) information index "National Standards", and the official text of changes and amendments - in the monthly information index "National Standards". In case of revision (replacement) or cancellation of this standard, a corresponding notice will be published in the next issue of the information index "National Standards". Relevant information, notification and texts are also placed in information system general use - on the official website of the Federal Agency for Technical Regulation and Metrology on the Internet (gost.ru)
© Standartinform, 2015
This International Standard may not, in whole or in part, be reproduced, duplicated or distributed as official publication without the permission of the Federal Agency for Technical Regulation and Metrology
manufacturer, followed by cleaning the places of correction and carrying out control for the absence of cracks.
When grinding with an abrasive wheel, the stripping marks should be directed along the edges.
4.5.2.3 The edges and ends of parts after mechanical cutting should not have cracks; sharp edges and burrs must be blunted. Irregularities and burrs larger than 0.5 mm are not allowed, blockages should not exceed 1 mm.
4.5.3 Impacts on carbon and low-alloy steel, as well as cutting it with scissors, punching holes in it and other similar operations at temperatures below minus 25 °C are not allowed.
4.6 Requirements for assembly and welding of steel structures
4.6.1 General basic requirements for assembly and welding of structures must comply with the requirements of GOST 5264, GOST 8713, GOST 14771, GOST 11534 and GOST 23518, special requirements for assembly and welding of steel structures of boilers must comply with the requirements of this standard.
4.6.2 Fitters and welders who have been trained and certified in accordance with the requirements of Rostekhnadzor and who have the appropriate entries in the certificate for the right to perform these operations are allowed to perform work on the assembly and welding of steel structures of boilers. Before starting work on the manufacture of metal structures, the manufacturer is obliged to certify welding technologies in accordance with the requirements of Rostekhnadzor.
It is allowed to perform tacking of parts made of steel grades 12MX and 12XM without preheating if electrodes of the E50A type are used for these purposes.
4.6.3 Minimum distance between axes of adjacent butt joints welded joints constituent parts, as a rule, should be at least 400 mm. Location areas and types of butt joints should be indicated in the drawings.
4.6.4 Jointing of elements of composite sections, as a rule, should be carried out before the general welding of the structure; in some cases, welding of such joints in the assembled assembly unit may be allowed with the permission of the author of the project.
4.6.5 Additional joining of elements of load-bearing welded structures, not provided for in the drawing, can only be carried out with the permission of the author of the project. Docking of minor, mastered and frequently encountered elements at a given enterprise can be carried out according to the manufacturer's documentation.
4.6.6 Welded joints of design elements of steel structures shall be marked with the welder's personal stamp in a conspicuous place, at a distance of 20-40 mm from the weld. An assembly element welded by one welder is branded once. When welding elements by several welders, the seams are branded by each welder along the boundaries of the welding area. Welds subject to non-destructive testing are branded at the beginning and at the end of the weld, except for welds up to 1 m long, which are branded once at the beginning or at the end of the weld.
4.6.7 Giving fillet welds a concave profile with a smooth transition to the base metal, as well as making butt welds without reinforcement, if provided for by the drawings, should be carried out, as a rule, with an appropriate selection of welding modes and an appropriate arrangement of the parts to be welded. In necessary cases, it is allowed to process the seams with an abrasive wheel, or use another method of processing.
4.6.8 The beginning and end of the butt weld, as well as the fillet weld performed by the machine, should be led out of the welded parts to the lead strips, which should have a groove similar to the weld being performed, and be installed in the same plane with the welded parts close to their edges. The accuracy of the installation of the lead plates is the same as when assembling elements for welding. At the end of welding, the lead plates are removed by mechanical or oxygen cutting with a thorough cleaning of the ends of the seams.
Note - In the necessary cases provided for by the technological documentation, it is allowed to use manual arc or mechanized welding for re-welding of welds made by automatic submerged arc welding.
4.6.9 The location, design and dimensions of the seams must comply with GOST 5264, GOST 8713, GOST 14771, GOST 11534, GOST 23518, GOST 15164 and the design and technological documentation of the manufacturer.
4.6.10 The quality of welds performed at the enterprise for welding and mounting fixtures, slinging parts, scaffold fastening parts and similar elements should not be lower than the quality of the main structural welds.
4.6.11 Welding should be carried out, as a rule, at a positive ambient temperature.
Where necessary, electrical arc welding without preheating, it can be carried out at a negative outside temperature, which should not be the one indicated in Table 5 below.
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Table 5 - Minimum outdoor temperatures for welding |
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Note - Welding in carbon dioxide at a negative temperature is not applicable. |
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4.6.12 At an ambient temperature below that specified in Table 6, manual, semi-automatic and automatic welding of steel structures with a temporary resistance of up to 540 MPa inclusive should be carried out with preheating. Heating is carried out over the entire thickness of the metal up to 120-180 ° C at a width of at least 100 mm on both sides of the joint and at a length of at least 300 mm on both sides of the weld boundaries (for open welds).
4.6.13 Welding of steel structures with a tensile strength of more than 540 to 590 MPa should be carried out at a temperature not lower than minus 15 °С with a steel thickness of up to 16 mm and not lower than 0 °С with a steel thickness of more than 16 to 25 mm. At lower temperatures, welding of steel of the specified thicknesses should be carried out with preheating to a temperature of 120-160 °C.
For steel thicknesses over 25 mm, preheating must be carried out in all cases, regardless of the ambient temperature.
4.6.14 Mechanized submerged arc welding of a structure may be performed without preheating in the following cases:
from carbon steels:
up to 30 mm thick at a temperature not lower than minus 30 °С;
at thicknesses over 30 mm at a temperature not lower than minus 20 °C;
from low alloy steel:
thickness up to 30 mm at a temperature not lower than minus 20 °C;
at thicknesses over 30 mm at a temperature not lower than minus 10 °C;
4.6.15 Mechanized welding at temperatures below those specified in 4.6.14 should be carried out only in modes that provide an increase in heat input and a decrease in the cooling rate.
4.6.16 At a steel temperature below minus 5 °C, welding should be carried out from the beginning to the end of the weld without interruption, except for the time required to change the electrode or electrode wire and clean the weld at the place where welding is resumed.
It is not allowed to stop welding before the weld of the required size is completed and it is not allowed to leave individual sections of the weld unwelded. In the event of a forced termination of welding, the process should be resumed after heating the steel in accordance with the technological process developed for the structures to be welded.
4.6.17 Welding of structures made of heat-resistant steels, regardless of the ambient temperature, should be carried out with preliminary and concomitant heating in accordance with the requirements of Table 6.
4.6.18 Welded butt joints made of heat-resistant steels are subject to heat treatment (tempering) in accordance with the requirements of Table 7.
The requirements of Table 7 also apply to fillet and tee welds.
with the size of the leg of the seam:
for steels 12МХ, 12ХМ, 15ХМ - more than 15 mm; for steel 12X1MF - more than 10 mm.
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Table 7 - Heat treatment modes for welded joints made of heat-resistant steels |
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Notes: 1 When welding various grades of steel, the tempering mode determines the greatest indicators in terms of duration and temperature. 2 The assignment of heat treatment modes in cases not provided for by this standard is made according to the technical documentation for the product. |
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4.6.19 At the end of welding, all technological devices must be removed, followed by welding and cleaning of the tack spots, the welded seams of the structure must be cleaned from slag, spatter, metal sagging. It is allowed not to clean surfaces from metal splashes that are not subject to painting during installation, are difficult to access for external inspection, and do not affect marketable condition, as well as the surfaces of auxiliary elements used for packaging and transportation.
4.7 Requirements for the assembly of steel structures
4.7.1 The elements of the frame columns, assembled at the installation, when transferring loads by tight contact, must be supplied with milled ends.
4.7.2 Only those elements and parts of steel structures that meet the requirements of this standard and are accepted by the quality control department or the foreman should be allowed to assemble. The results of the control should be noted in a special journal or other relevant reporting documentation adopted at the enterprise.
4.7.3 The assembly must be carried out according to the drawings and technological documentation, providing for the necessary accuracy of the assembly and the preservation of the geometric shape.
4.8 Test assembly requirements
4.8.1 The need for and the scope of the control assembly of products are determined by the working drawings on the metal structures of the boilers.
4.8.2 During the control assembly of field joints of columns, posts, beams, shields, trusses, it is allowed to shift the edges of the joined elements up to 0.1 of their thickness, but not more than 2 mm, if there are no other instructions in the design documents.
The gap between the parts in the joints, for which the project provides for a tight fit, should not exceed 0.5 mm. In this case, a probe of this thickness should not pass between the trimmed surfaces of the parts.
4.8.3 Control assembly of oversized items such as long shields, spatial sheet structures (bunkers, shafts and other load-bearing elements) must be carried out in accordance with the requirements of design and technological documents.
This checks:
Coincidence of connecting and mounting dimensions;
Compliance of dimensions and tolerances for assembly with the requirements of drawings and normative and technical documentation.
4.8.4 Upon completion of the test assembly, the relative position of the mating elements must be fixed by punching or drawing marks. All structures that have passed the control assembly must be stamped with the Quality Control Department.
4.8.5 After the test assembly, an act must be drawn up according to the form adopted by the manufacturer.
5 Requirements for bolt holes
5.1 Nominal bolt hole diameters various kinds and accuracy classes A, B and C according to GOST 1759.0, as well as high-strength bolts according to GOST R 52643 and GOST R 52644 are accepted in accordance with the current normative documents 1 and working documentation.
5.2 The formation of holes is carried out at the manufacturer by drilling or punching. Hole punching is not allowed in design connections, as well as those specified in the working documentation.
5.3 Maximum deviations of hole diameters from design ones depending on the method of formation and type of bolted connection are given in Table 8.
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Table 8 - Limit deviations of hole diameters |
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Note - The diameter of the punched holes on the die side must not exceed the nominal diameter of the holes by more than 1.5 mm. The use of punched holes in design connections is not allowed. |
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5.4 Control and general assembly of structures with field bolted connections should be carried out at the manufacturer, if this is specified in the working documentation.
6 Safety requirements
6.1 Requirements for safety and industrial sanitation when performing all work on the manufacture of steel structures and their parts must comply with the instructions of the manufacturer, developed in accordance with the requirements of GOST 12.2.003, GOST 12.3.002, GOST 12.3.003, GOST 12.3.004 , GOST 12.3.005, GOST 12.3.009, GOST R 53001, GOST 12.2.008 and the Rules of the Gosgortekhnadzor of Russia.
6.2 Ventilation, air conditioning and air heating systems of production, storage and auxiliary buildings must comply with GOST 12.4.021 and provide meteorological conditions and cleanliness of the air environment at permanent workplaces, in the working and serviced area, corresponding to sanitary standards and GOST 12.1.005.
6.3 Machine tools, machine tools and equipment must meet the requirements of GOST 12.2.009, GOST 12.2.029.
7 Completeness
7.1 The completeness of delivery of steel structures must comply with the requirements of the standard for general technical specifications for boilers.
7.2 The scope of delivery of steel structures shall include installation drawings and shipping documentation.
8 Acceptance rules
8.1 Acceptance of steel structures, as well as operational control during their manufacture, should be carried out by the technical control department of the manufacturer in accordance with the requirements of design, technological and regulatory and technical documentation, as well as this standard.
8.2 Rolled steel for steel structures of boilers at the manufacturer of steel structures before being put into production must pass technical control, including:
Visual control of accompanying documentation (certificates, passports);
Visual control of packaging and labeling;
External technical inspection and measuring control of rolled steel.
In this case, marking and sorting of rolled products should be carried out.
8.3 When controlling the accompanying documentation, the following is checked:
Availability of all data and technical characteristics of the rental;
Compliance of the technical data specified in the certificate with the requirements of the documentation for the supply of rolled products.
8.4 During the control of packaging and labeling, the following is checked:
For rolled steel - compliance of packaging and marking with the requirements of GOST 7566;
For fencing pipes - compliance with the requirements of GOST 13663.
8.5 When accepting finished products, the following is checked:
Completeness of steel structures for compliance with the requirements of design documentation;
Proper use of materials;
Compliance of permissible deviations of product dimensions with the requirements of technical documentation;
The correctness of the operational marking and branding of products (including according to 4.8.4. and control samples), as well as the marking of finished products and transport marking;
The volume and quality of the control assembly;
The correctness of packaging, coloring and conservation, as well as the availability of shipping documentation.
In addition, when accepting finished products, the following are carried out:
External technical inspection and measurement control;
Operational control of welded joints;
Control tests.
8.6 Each finished product must be stamped with the quality control department.
9 Control methods
9.1 The scope and methods of control of steel structures must comply with the requirements of this standard and technical documentation.
9.2 Control methods for rolled steel supplied to the enterprise for the manufacture of steel structures and their parts, as well as control of packaging and marking of rolled steel must comply with the requirements of GOST 7566, GOST 380 and standards for the range.
9.3 During external technical inspection and measurement control, the dimensions, shape and quality of the surface of rolled steel, their compliance with the requirements of standards, specifications and this standard are checked.
9.4 Quality control of welded joints
9.4.1 Quality control of welded joints of steel structures should be carried out by the methods provided for by GOST 3242.
9.4.2 Methods for controlling the mechanical properties of welded joints in steel structures should
9.4.3 The radiographic method for testing welded joints in steel structures must comply with the requirements of GOST 7512.
9.4.4 Methods of ultrasonic testing (US) of welded seams of steel structures must comply with the requirements of GOST 14782.
9.4.5 Sampling methods for determining the chemical composition of welds in steel structures must comply with the requirements of GOST 7122.
9.4.6 Quality control of welded joints to be checked must be carried out after heat treatment of the product.
Note - Re-inspection of butt welds is allowed not to be carried out in case of heat treatment and ultrasonic testing of these welds until the final welding of the product.
9.4.7 The results of inspection of welded joints of design elements shall be recorded in the relevant documentation.
9.4.8 Welded joints are subject to visual control and measurement, regardless of the dimensions of the parts to be welded, the steel grade and the welding method.
Visual inspection checks for:
1) compliance of the assembly and welding of steel structures with the requirements of 4.6.4-4.6.17, including the presence of the Quality Control Department stamp of acceptance of the assembly for welding and the welder's brand;
2) compliance with the specified geometric dimensions; at the same time, the seams of critical design elements of steel structures are subject to continuous control, and the seams of secondary non-design elements are subject to selective control (in an amount of at least 20%);
3) surface quality of welds; on appearance seams must have: a smooth surface (for automatic welding);
a finely flaky surface (with a flake height within the tolerance for the dimensions of the weld according to the relevant standards);
without sagging - for other types of welding;
smooth transition to the base metal - for all types of welding;
4) in multilayer welds, the size of the depressions between two adjacent beads when welding in the lower position should not exceed:
for manual arc welding - 1 mm;
for automatic and semi-automatic welding in carbon dioxide environment, as well as for automatic submerged arc welding - 2 mm;
for welding in a different spatial position - 2 and 3 mm, respectively, without reducing the leg of the seam.
Before visual inspection, the welds and the adjacent surface of the base metal to a width of 20 mm on both sides of the weld must be cleaned. Visual inspection should be carried out in sufficient light. Doubtful places should be viewed through a magnifying glass.
The method of visual control is established by the Quality Control Department of the manufacturer. Visual inspection must precede all other inspections.
9.4.9 Testing of seams that ensure the density (tightness) of the structure: bunker sheathing panels, boxes and others is carried out in accordance with the requirements of working drawings. Control is carried out according to the documentation of the manufacturer.
9.4.10 Welded butt joints of tensioned, bent and tension-bent load-bearing elements of the frame and ceiling, as well as critical design elements, must be subjected to control by one of the non-destructive methods:
1) continuous - when delivered to areas with a cold climate or for facilities with a high level of responsibility;
2) selective, but not less than 20% of the length of the seams - when delivered to areas with a temperate climate and a normal level of responsibility of the structure; selective control is carried out mainly in the places of intersection of the seams and in places with signs of defects.
Notes:
1 The need and scope of non-destructive testing are established by the drawings.
2 In cases where it is impossible to carry out testing by non-destructive methods, the presence of defects in welds can be determined by macrosections made from lead strips.
9.4.11 The following are not allowed in welded joints:
cracks of all types and directions located in the weld metal, along the fusion line and in the near-weld zone of the base metal;
lack of penetration (non-fusion) located near the surface along the cross section of the welded joint; pores arranged in the form of a continuous grid or chains; uncertified craters and burns; fistulas;
undercuts at the transition points of the seam to the base metal; surges and leaks.
9.4.12 In appearance, the seams of welded joints must meet the requirements of 9.4.8 of this standard and have no sagging, burns, narrowing, breaks, as well as a sharp transition to the base metal;
undercuts of the base metal are allowed with a depth of not more than 0.5 mm with a steel thickness of 2 to 10 mm and no more than 1 mm with a steel thickness of more than 10 mm; all craters must be sealed.
The following discontinuities in the seams of welded joints are allowed, which are detected by physical inspection methods, except for ultrasonic testing:
lack of penetration over the cross section of welds in joints available for welding from both sides, up to 5% of the metal thickness, but not more than 2 mm, with a lack of penetration length of not more than 50 mm, with a distance between them of at least 250 mm and a total length of lack of penetration sections of not more than 200 mm for 1 m seam;
lack of penetration at the root of the seam in joints without backings, available for welding only on one side, up to 15% of the thickness of the metal, but not more than 3 mm;
separate slag inclusions or pores or accumulations of their sizes in diameter not more than 10% of the thickness of the welded metal, but not more than 3 mm;
slag inclusions or pores located in a chain along the seam, with their total length not exceeding 200 mm per 1 m of the seam;
accumulation of gas pores and slag inclusions in separate sections of the weld in an amount of not more than 5 pcs. per 1 cm 2 of the weld area with a diameter of one defect not more than 1.5 mm.
The equivalent area of a single defect in ultrasound is taken according to Table 9.
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Table 9 - Equivalent area of a single defect |
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Notes: 1 A chain of slag inclusions is considered to be defects located along one line, in an amount of at least three with a distance between them not exceeding three times the length of the longest slag inclusion from among those included in the chain. 2 When calculating pores, individual pores with a size of 0.2 mm in any section of the weld, as well as larger pores located in the reinforcement of the weld, may not be taken into account. |
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9.4.13 If unacceptable defects are detected during selective ultrasonic flaw detection, X-ray diffraction and gamma graphy, then it is necessary to carry out additional control of defective joints at a distance equal to twice the length of the tested section of this joint, mainly in places located near the defective section. If during additional control unacceptable defects are found, then the entire seam and doubtful areas of other seams are subjected to control.
Identified defective areas of welds shall be corrected in accordance with 9.4.15 and re-checked.
9.4.14 Welded butt joints of structural design elements are subject to mechanical testing. Control, including the norms for the selection of control plates, is carried out according to the documentation of the manufacturer. Control or test plates should be made as a continuation of the welded seam of the product, for which lead strips can be used. For mechanical testing it is allowed to use control plates welded by welders during certification. In this case, the control and production welded joints must be identical.
GOST P 56204-2014
Impact strength tests are carried out with thicknesses of the welded metal over 12 mm.
The seams of the control plates, welded, as an exception, separately, must be welded by the same welder using the same modes, electrodes and equipment as when welding the product. The dimensions of blanks (plates), as well as the shape and dimensions of the samples, and the method of cutting them from blanks must comply with GOST 6996.
In this case, the following types of tests of the welded joint should be carried out:
for tension - two samples;
for impact bending with a notch in the center of the seam - three samples.
for bending (bending) - two samples;
on the hardness of the heat-affected zone in welded joints of low-alloy steel - at least at three points on one sample, while the hardness should not exceed 250 HB.
The tensile strength a b must not be less than the lower value of the tensile strength of the base metal, established by the standard or specifications for a given steel grade in the same heat treatment mode.
The bend angle and impact strength of welded joints must not be less than those specified in Table 10.
The mechanical properties of specimens of welded joints shall be determined as the arithmetic mean of the results obtained from testing individual specimens.
Tests are considered unsatisfactory if at least one of the samples results are obtained that are lower than the established standards by more than 10%, and for impact strength by 0.2 M J / m 2 (2 kgf m / cm 2). If the results are unsatisfactory, the tests are repeated on a double number of samples cut from the same control joint or welded product. Repeated control is carried out only for the type of mechanical tests for which unsatisfactory results were obtained.
If during the repeated test, at least one of the samples received unsatisfactory results, the overall result for this type of test is considered unsatisfactory, and the seams are unsuitable.
In case of unsatisfactory test results, the defective seam must be removed mechanically or by air-arc gouging, produced according to the manufacturer's documentation. The qualification of the welder and the quality of the welding consumables must be additionally checked. For steel grades 12Kh1MF, 12MH and 12KhM, after air-arc gouging, it is necessary to perform surface treatment by mechanical means to remove the oxidized layer and control the sample surfaces for the absence of cracks.
9.4.15 Correction of defective welds is carried out according to the manufacturer's documentation in agreement with the QCD. In this case, seams with cracks and other defects exceeding the allowable ones (see 7.4.12) are removed at a distance exceeding the length of the defective area by 20 mm (10 mm on each side), and after checking the quality of the defect removal, they are welded again.
Seam breaks, constrictions and craters are welded. The undercuts of the base metal, exceeding the allowable ones, are cleaned and welded, followed by cleaning, which ensures a smooth transition from the deposited metal to the base one. Any correction of defects by undermarking is prohibited. Corrected defects, welds or parts of them must be re-accepted by the Quality Control Department.
For all steel grades, repairing the defective area more than three times is not allowed.
9.5 Methods of control and permissible deviations of linear and angular dimensions, shapes
and location of surfaces of steel structures and their elements
9.5.1 Methods for monitoring the linear and angular dimensions of steel structures and their elements should include the use of standard measuring instruments and should correspond in terms of accuracy
comply with drawing requirements.
The control methods used must also ensure the accuracy of measuring linear and angular dimensions with the errors provided for by the relevant regulatory and technical documentation.
9.5.2 Limit deviations (±) of the dimensions of parts made from sheet and shaped steel should not exceed those indicated in Table 11.
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Table 11 - Limit deviations in the dimensions of rolled parts |
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Note - The maximum deviations indicated in Table 12 are allowed for parts made of sheet and shaped steel with a thickness of up to 20 mm; for thicknesses over 20 mm, the tolerances must be increased by 50%. |
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9.3.1 The difference in diagonals (±) of sheet parts, depending on their value, should not exceed that specified in Table 12.
9.5.4 The displacement (±) of the axes of the holes in the parts from the nominal location shall not exceed that specified in Table 13.
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Table 13 - Permissible deviations of the axes of holes in parts |
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9.5.5 Limit deviations (±) of overall dimensions and the difference in diagonals of finished assembly units of steel structures should not exceed those specified in Table 14.
GOST P 56204-2014
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Table 14 - Permissible deviations of the overall dimensions of parts |
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9.5.6 The maximum deviations of the dimensions of assembly units and parts of steel structures, which are not specified in the technical documentation, regardless of the thickness of the metal and the technological method of manufacture, must be no more than: for holes - according to H16; for shafts - according to hi6; the rest - by
9.5.7 Limit deviations of the dimensions of parts and elements should not be summed up. Technological process must exclude the accumulation of allowable deviations that make it impossible to assemble the structure as a whole without adjustment.
9.5.8 Limit deviations of the shape and location of surfaces in assembly units and parts should not exceed those specified in Table 15.
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Table 15 - Form limit deviations |
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GOST P 56204-2014
Introduction
The national standard was prepared by OAO TKZ Krasny Kotelshchik and OAO NPO CKTI. This standard is one of the normative documents included in the evidence base confirming the action technical regulation Customs Union "On the safety of equipment operating under excessive pressure" (TR TS 032/2013).
Note - The limit deviations of the dimensions specified in 9.5.8, 9.5.9 and 9.5.10 refer to the shipping elements of steel structures.
9.5.9 Limit deviations of the dimensions, shape and location of the surfaces of elements of steel structures of a composite section (columns, beams, crossbars and other elements) should not exceed those indicated in tables 16-19.
Table 16 - Limit deviations of element dimensions
Name
Tolerances (±)
DL within the tolerance for the height L of the profile L, not more than 0.01L
L within the tolerance for the height L of the profile L within the double tolerance for the width of the shelf
flatness
L within the tolerance for the height L of the profile DL within the double tolerance for the width of the shelf
L within the tolerance for the height L of the profile L within the double tolerance for the width of the shelf.
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Table 17 - Limit deviations of the form of sections of elements |
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GOST P 56204-2014
NATIONAL STANDARD OF THE RUSSIAN FEDERATION
BOILERS STATIONARY STEEL STRUCTURES
General specifications
Steam and hot-water stationary boilers. steel structures. General operating specification
Introduction date - 2015-09-01
1 area of use
This standard applies to steel structures of stationary boilers, waste heat boilers, hot water and power technology boilers (hereinafter referred to as boilers) and establishes their classification, technical requirements, as well as the rules for control, acceptance, completeness, rules for packaging, labeling, transportation, storage and manufacturer's warranty steel structures.
The standard can be extended to steel structures of other power equipment, if there are no special requirements for them.
The standard is intended for enterprises and organizations that design and manufacture steel structures of boilers.
This standard uses normative references to the following standards:
3.2 According to the conditions of construction and operation: open and semi-open layouts of boilers; closed boilers.
3.3 By level of responsibility:
increased - for thermal power plants with an installed capacity of more than 150 MW; normal - for other stations and boiler houses.
3.4 According to the type of fuel used in boilers solid fuel boilers;
boilers operating on liquid or gaseous fuels; boilers (utilizers) using technological media.
3.5 By type of element connections: welded;
on bolts.
4 General technical requirements
4.1 Steel structures of boilers must be manufactured in accordance with the requirements of this standard according to the working documentation approved by the developer and accepted for production by the manufacturer.
Working documentation for structures should be developed in accordance with the current regulatory documents in this area. The production technology must be regulated by technological documentation approved in the manner prescribed by the manufacturer.
It is allowed to manufacture steel structures of boilers in accordance with the requirements of other regulatory documents after agreement with the customer.
4.1.1 Material requirements
In the standards or specifications for structures of specific types, materials for structures and connections should be used, the requirements for which are established in the working documentation developed in accordance with the current regulatory documents. Materials must comply with the requirements of standards or specifications for their manufacture.
4.2 Requirements for basic materials (rolled steel)
4.2.1 General rules for acceptance, packaging, marking and paperwork for rolled steel supplied for the manufacture of steel structures must comply with the requirements of GOST 7566. If the data of the certificate does not comply with the standard, the rolled steel must be rejected and reclamation documentation must be drawn up for it.
4.2.2 Incoming materials, semi-finished products and purchased products must comply with the standards and specifications for their manufacture and supply.
4.2.3 Prior to the launch of rolled products into production, the presence of the marking and its compliance with the certificates must be checked.
In the absence of certificates, the manufacturer is obliged to subject the rolled products to all types of tests provided for the required steel grade. Rolled products are allowed to be put into production if the data obtained during the testing process is not lower than those guaranteed by standards and specifications.
4.2.4 When cutting off a part of a beam, sheet, strip, pipe, and other blanks, the marking must be preserved or restored on the remaining part. The marking must be encircled with indelible ink.
4.2.5 Rolled steel should be stored, as a rule, indoors with stacking in stable piles. When storing rolled steel without a canopy, metal should be laid with a slope that provides water flow.
4.2.6 Steel flat pads and spacers used in stacks should have edges with rounded corners without burrs and blockages. When performing loading and unloading operations and lifting and transport operations, it is necessary to use devices that exclude the formation of residual deformations and crushing of steel.
4.3 Requirements for welding consumables
4.3.1 In this standard, for welding consumables used in the manufacture of steel
ny structures, referred: electrodes, welding wire, flux, gases and liquids.
4.3.2 Welding consumables supplied to the steel structure manufacturer must be supplied in accordance with applicable standards and specifications and pass incoming inspection and testing in accordance with the requirements of GOST 24297.
4.3.3 Welding consumables used for manual arc, semi-automatic and automatic welding of steel structure elements must comply with the requirements of the current standards and the data in Table 1.
4.3.4 Welding consumables should be stored separately by brands and lots in a heated and dry room. Flux should be stored in a closed container.
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* Application at temperatures from 0 to plus 150 °C is allowed. It is allowed to use other welding consumables with the appropriate technical and economic justification. |
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4.4 Requirements for straightening, bending and marking of rolled steel
4.4.1 Straightening of rolled steel and parts made from it should be carried out, as a rule, on rollers and presses using mechanized devices and brackets, and straightening of small parts - on a plate with a smoother. Editing by imposing false welding beads is not allowed.
Note - For universal and strip steel with a rib curvature twice as high as indicated in table 2, straightening of rolled products by heating with a gas burner flame from the side of the convex edge is allowed. Hot straightening is allowed only at a temperature of at least 700 °C.
4.4.2 Hot and cold bending of parts must be carried out according to the manufacturer's technological documentation on rollers and presses, and in some cases (for small parts) it can be done manually.
4.4.3 After completion of hot straightening and bending, the cooling rate of parts must exclude hardening, warping, residual stresses, cracks, tears. Intensive cooling is not allowed.
4.4.4 After bending and straightening, the parts must not have cracks. Separate nicks, dents and other surface defects are allowed that do not take the thickness of the rolled product beyond the limits of the minus permissible deviation. Inspection of parts after bending and straightening should be carried out in accordance with
compliance with the requirements of design and technological documentation.
4.4.5 For design and critical elements made of rolled steel, cold straightening and bending is permissible if the steel deformation (radius of curvature and deflection) does not exceed the limits specified in Table 2.
Radius of curvature R, not less than
Deflection f,
Note-L - length of the concave part; S is the thickness of the sheet (strip); b,b i, bg -h - height; a - side; d is the diameter.
With smaller radii of curvature and larger deflections (than specified in Table 2), straightening and working of steel by pressure should be carried out in a hot state in the temperature range from 700 °C to 1100 °C in compliance with the requirements of 4.4.3.
4.4.6 The internal radii of rounding of sheet parts when bending them on edge bending machines should not be less than those indicated in table 3.
4.4.7 Marking should be carried out according to the technology that provides the necessary accuracy of work. The allowances for linear edge shortenings from welding taken into account when marking should be indicated in the technological documentation.
4.5 Requirements for cutting and edging
4.5.1 Cutting of shaped and sheet metal should be carried out according to technological documentation, as a rule, using scissors, saws, dies, as well as gas cutting machines or semi-automatic machines.
Manual gas cutting is allowed in some cases provided for by the technological process.
4.5.2 The edges and ends of shaped and sheet products after thermal cutting must be cleaned of burrs, slag, sagging and metal splashes.
GOST P 56204-2014
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The cut surfaces must be processed in accordance with the requirements of table 4. Table 4 - Requirements for the processing of cut surfaces |
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Notes: 1 Machining refers to gouging, milling, abrasive tooling, grinding and other processing methods that remove the oxidized layer and surface defects until blackness is removed. 2 The “+” sign means that mechanical processing is mandatory, the “-” sign means mechanical processing no work required._ |
4.5.2.1 The edges and ends of parts after mechanical cutting should not have cracks, sharp edges and burrs should be blunted. Burrs and blockages should not be more than 1 mm.
4.5.2.2 The ends of shaped and sheet products must be cut and processed in accordance with the requirements of the drawings. In the absence of such requirements, the ends must be cut at right angles; deviation from perpendicularity D (drawing) of end A relative to surface B is allowed no more than 15% of the thickness of the rolled product, but no more than 3 mm for thicknesses over 20 mm.
If the cut surface roughness does not comply with the requirements of 4.5.2 and 4.5.2.1, it is allowed to correct individual places and snags by smooth cleaning, in the amount of not more than two per 1 m of the cut length.
It is allowed to correct the edges with snags by welding according to the technology of the enterprise -
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