6464 Nat Gas Code

download 6464 Nat Gas Code

of 223

Transcript of 6464 Nat Gas Code

  • 8/17/2019 6464 Nat Gas Code

    1/223

     

    Draft Israeli Standard SI 6464

     April 2016ICS CODE:

    Industrial natural gas consuming appliances -

    Safety Requirements for appliances application, workplace

    environment, testing and approval, natural gas supply pipework  

    This document is a proposal only

  • 8/17/2019 6464 Nat Gas Code

    2/223

    This standard was prepared by the following Expert Committees:

    Expert committee 40707  – Industrial Gas-Fired Appliance Applications - Appliances,

    comprised of the following members:

    Ran Cohen, Reuven Godali/ Boris Prokuprts , Amos Kamhine, Esra Levenberg (Chairman), Haim

    Melamed, Roi Shchori/ Ron Amir, Moshe Weingarten.

    Expert Committee 40708  – Industrial Gas-Fired Applications  – Workplace Environment,

    comprised of the following members:

     Armand Abramovici, Ashi Avizemer, Ilan Cohen, Ran Cohen (Chairman), Ariel Gazit/ Lior Wolich,

    Josef Jurborsky.

    Expert Committee 40709  – Industrial Gas-Fired Applications  – Testing and Approval,

    comprised of the following members:

     Adi Atsits/ Akiva Helman, Ziv Atias, Binyamin Budnitsky, Ran Cohen, Josef Jurborsky (Chairman),

     Amos Kamhine, Yariv Keidar.

    Expert Committee 40710  – Industrial Gas-Fired Applications  – Piping, comprised of the

    following members:

    Binyamin Budnitsky, Amos Bruckmayer, Akiva Helman, Yoni Leviel (Chairman), Haim Melamed,

    Amichai Pesah

  • 8/17/2019 6464 Nat Gas Code

    3/223

    Descriptors:

    natural gas, installations, industrial, hazardous areas classification, risk assessment, pipework

    systems

    Updating the Standard

    Israeli Standards are reviewed periodically at least every five years, in order to adapt them to

    scientific and technological developments. Users of Standards should ascertain that they are in

     possession of the latest edition of the Standard including its Amendments.

    A document appearing in the "Reshumot" (The Israeli Official Journal) as an Amendment may be

    a separate Amendment, or an Amendment incorporated into the Standard.

    Standard validity

    An Israeli Standard including revisions takes effect from its publication date in "Reshumot". 

    Whether the document or parts of it are Official should be checked. An Official Standard or

    Amendment (in whole or in part) takes effect 60 days following publication of the notice in the

    "Reshumot", unless the notice states otherwise for the effective date.

    S d d k

  • 8/17/2019 6464 Nat Gas Code

    4/223

    Foreword ................................................................................................................................................................. 5 

    Introduction to the Israeli Standard ......................................................................................................................... 6 

    1 Scope……………………………………………………………………………………………………7 

    2 Normative References ........................................................... ................................................................. ......... 9 

    3 Terms & Definitions ............................................................. ................................................................. ....... 13 

    4 Industrial Appliances Application (IAA) .............................................................. .................................... 2427 

    5 Workplace Environment ................................................................. .......................................................... 3946 

    6 Testing and Approval............................................................ ................................................................. ... 4756 

    7 Pipework ......................................................... ................................................................. ......................... 6673 

    8 Annexes (informative) .......................................................... ................................................................. . 97104 

    9 Annex checklists. ....................................................... ................................................................. .......... 106113 

    10 APPENDIX B MARCOGAZ STANDARD OVERVIEW ........................................................ .......... 107114 

    11 Abbreviation List ....................................................... ................................................................. .......... 108115 

  • 8/17/2019 6464 Nat Gas Code

    5/223

    Foreword

    The purpose of this standard is to allow the use of natural gas within the Israeli industry, by

    facilitating the connection of industrial factories to the natural gas supply system, while ensuring

    the safety of people, plant and property.

    The requirements relevant to the natural gas infrastructure (The transmission system, the

    distribution system and the supply system) are covered by the Israeli Standard SI 5664 (all parts).

    This standard covers requirements that are relevant to the Appliances Application within the

    industrial premises.

    The three main chapters of this standard are:

      Chapter 4 - Industrial Appliances Application (IAA)

    Specifying requirements relevant to each and every appliance (furnace, boiler, etc.)

    including all its sub-systems and accessories, and all its supporting systems.

      Chapter 5 - Safety of the workplace environment

    Specifying requirements relevant to the workplace environment of Industrial Appliances

    A li ti P idi f t d h lth i t f th l d ti

  • 8/17/2019 6464 Nat Gas Code

    6/223

    Introduction to the Israeli Standard

    This Israeli Standard is based on:

    (i)  International ISO and IEC standards and codes

    (ii)  Applicable directives and regulations in Europe;

    (iii)  Harmonized standards to these EU directives and regulations;

    (iv)   Non-harmonized standards and other Reference Documents such as technical

    guidelines;

    (v)  Rules and procedures of the IECEx System, International Ex-protection certification

    system for equipment, service facilities and personnel, based on IEC standards (see:

    www.iecex.com )

    The applicability of this Standard is methodologically divided into four chapters:

    (1)  Appliance Applications;

    (2)  Workplace Environment;

    (3)  Testing & Approval processes.

    (4)  Pipework system - design, construction, operation and maintenance.

    http://www.iecex.com/http://www.iecex.com/http://www.iecex.com/

  • 8/17/2019 6464 Nat Gas Code

    7/223

    1  ScopeThis Standard specifies safety requirements for new and existing natural gas systems that are part

    of industrial natural gas consuming appliances (hereafter I ndustri al Appli ance Appli cation), 

    Within these IAA's boundaries, the following are included:

    o  The Gas Train

    o  The burning system and the combustion air (or oxygen) system

    o  Burning Management System (BMS)

    o  Related accessories and auxiliary systems

    o  The integration with the process fed by the natural gas.

    o  Flue gas evacuation up to the stack's outlet.

    o  Pipework system (see definition 3.7.2)

    Note: The principles set out in this standard can be applied to Natural gas consuming appliances which

    are part of energy centers within hospitals, hotels, public facilities, etc., as far as they are applicable.

    These appliances and the fuel gas supply pipework may need to be assessed using other ISO or IEC or

    EN relevant standards that are not specified within this Israeli Standard1.

    This standard applies to the installation and operation of a range of natural gas Appliance

  • 8/17/2019 6464 Nat Gas Code

    8/223

    o  Furnaces

    o  Ovens

    driven by single, dual and multiple fuel burners.

    At a workplace and at its environment, several different risks could occur and be a danger for the

    safety and health of the employees or potential loss of assets.

    This standard applies to the systematic risk assessment of all the hazards at the working place and

    in the working environment, e.g. of the natural gas systems or CO, so that the risk, is reduced.

    This standard applies to the documentation relevant to the risk assessment information for the

    verification dossier. The following are not  included in the scope of this standard:

    o   Natural gas consuming appliances pertaining the domestic sector.

    o  Appliances solely driven by fuel oil, or other fuel gases, e.g LPG or biogas.

    o  Heating Recovery Steam Generators (HRSGs).

    o  Gas turbines, gas engines and CHP (Combined Heat and Power)

    o  Risks that are not the result of the conversion of the IAA to natural gas. (That is, risk

    assessment procedures to assess risks which are not  resulted from the natural gas systems,

    or the environment of these natural gas systems, are not included).

    o  Issues that are under the responsibility of a Ministry which is not:

  • 8/17/2019 6464 Nat Gas Code

    9/223

    2  Normative ReferencesThese references apply within this standard:

    Israeli Standards

    SI 5664-3 - Natural Gas Distribution System

    SI 12952-8 - Water-tube boilers and auxiliary installations –  part 8 –  Requirements for firing systems for

    liquid and gaseous fuels for the boiler

    SI 12953-7 - Shell boilers –  part 7: Requirements for firing systems for liquid and gaseous fuels for the

     boilers

    SI 16000 - Design for natural gas installations on industrial and commercial premises with respect to

    hazardous area classification and preparation of risk assessments

    SI 25000 - Hazardous area classification of natural gas installations

    SI 60079-10.1 - Explosive atmospheres - Part 10-1: Classification of areas - Explosive gas atmospheres

    SI 60079-14 - Explosive atmospheres - Part 14: Electrical installations design, selection and erection

    SI 60079-17 - Explosive atmospheres - Part 17: Electrical installations inspection and maintenance

    SI 60079-19 - Explosive atmospheres - Part 19: Equipment repair, overhaul and reclamation

    SI 67600 - Automatic forced draught burners for gaseous fuels

    SI 71555-1 - Polyethylene (PE) piping system for the supply of gaseous fuels: General

    SI 71555-2 - Polyethylene (PE) piping system for the supply of gaseous fuels: Pipes

    SI 71555 3 l h l ( ) i i f h l f f l i i

  • 8/17/2019 6464 Nat Gas Code

    10/223

    International Standards

    ISO/IEC 17020 - Conformity assessment - Requirements for the operation of various types of bodies

     performing inspection

    ISO/IEC 17025 - General requirements for the competence of testing and calibration laboratories

    ISO/IEC 17065 Conformity assessment - Requirements for bodies certifying products, processes and

    services

    ISO/IEC 17100 - Conformity assessment - General requirements for accreditation bodies accrediting

    conformity assessment bodies

    ISO 3834-2 - Quality requirements for fusion welding of metallic materials -- Part 2: Comprehensive

    quality requirements

    ISO 12100 - Safety of machinery - General principles for design - Risk assessment and risk reduction

    ISO 31010 - Risk management - Risk assessment techniques

    IEC 61508-1 - Functional safety of electrical/electronic/programmable electronic safety-related systems -

    Part 1: General requirements

    IEC 61508-2 - Functional safety of electrical/electronic/programmable electronic safety-related systems -

    Part 2: Requirements for electrical/electronic/programmable electronic safety-related

    systems

    IEC 61508-3 - Functional safety of electrical/electronic/programmable electronic safety-related systems -

    Part 3: Software requirements

    IEC 61508-4 - Functional safety of electrical/electronic/programmable electronic safety-related systems -

    P t 4 D fi iti d bb i ti

  • 8/17/2019 6464 Nat Gas Code

    11/223

    European Standards

    EN 88-1 - Pressure regulators and associated safety devices for gas appliances - Part 1: Pressure

    regulators for inlet pressures up to and including 50 kPa

    EN 161 Automatic shut-off valves for gas burners and gas appliances

    EN 1127-1 - Explosive atmospheres - Explosion prevention and protection - Basic concepts and

    methodology

    EN 1643 Safety and control devices for gas burners and gas burning appliances. Valve proving

    systems for automatic shut-off valves

    EN 1854 - Pressure sensing devices for gas burners and gas burning appliances

    EN 10204 - Metallic products - Types of inspection documents

    EN 12067-2 - Gas/air controls for gas burners and gas burning appliances; Part2: electronic types

    EN 12583 - Gas Infrastructure - Compressor stations - Functional requirements

    EN 13480-1 - Metallic industrial piping - Part 1: General

    EN 13480-2 - Metallic industrial piping - Part 2: Materials

    EN 13480-3 - Metallic industrial piping - Part 3: Design and calculation

    EN 13480-4 - Metallic industrial piping - Part 4: Fabrication and installation

    EN 13480-5 - Metallic industrial piping - Part 5: Inspection and testing

    EN 13480-6 - Metallic industrial piping - Part 6: Additional requirements for buried piping

    CEN/TR 13480-7 - Metallic industrial piping - Part 7: Guidance on the use of conformity assessment

     procedures

    EN 13480 8 M t lli i d t i l i i P t 8 Additi l i t f l i d l i

  • 8/17/2019 6464 Nat Gas Code

    12/223

    National Standards and documents

    ASME B31.3 - Process Piping Guide

    ASTM A193 - Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature

    or High Pressure Service and Other Special Purpose Applications

    ASTM A194 - Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts

    for High Pressure or High Temperature Service, or Both

    ASTM F1962 - Standard Guide for Use of Maxi-Horizontal Directional Drilling for Placement of

    Polyethylene Pipe or Conduit Under Obstacles, Including River Crossings

    IGE/ UP/ 1 - Strength testing, tightness testing and direct purging of industrial and commercial gas

    installations

    IGEM/ UP/4  - Commissioning of gas-fired plant on industrial and commercial premises

    UK HSE HSG 253 - The safe isolation of plant and equipment

    PPI TR-46 - Guidelines for Use of Mini-Horizontal Directional Drilling for Placement of High

    Density Polyethylene Pipe

  • 8/17/2019 6464 Nat Gas Code

    13/223

    3  Terms & Definitions

    3.1  Industrial Appliance Application (IAA)

    An industrial natural gas consuming process installation using combustion air (or equivalent) and

    natural gas to feed any industrial process.

    The boundaries of the IAA are from the manual isolating valve (located most close downstream to

    the first control valve), and up to the release point of the Flue gas into the atmosphere, through

    any given exhaust system.

    3.1.1  Complete IAA (CIAA)

     New installed natural gas system, originally designed to operate on natural gas, which is a part of

    an IAA.

    3.1.2  Partial IAA (PIAA)

    Converted fuel (e.g, fuel oil, gas oil, LPG) to natural gas system, which is a part of an IAA.

    3 2 S t

  • 8/17/2019 6464 Nat Gas Code

    14/223

      an assembly referred to in the first indent, missing only

      the components to connect it on site or to sources of energy and motion,

      an assembly referred to in the first and second indents, ready to be installed and able to

    function as it stands

      only if mounted on a means of transport, or installed in a building or a structure,

      assemblies of machinery referred to in the first, second and third indents or partly

    completed machinery referred to partly completed machinery which, in order to achieve

    the same end, are arranged and controlled so that they function as an integral whole,

      an assembly of linked parts or components, at least one of which moves and which are

     joined together,

      intended for lifting loads and whose only power source is directly applied human effort

    3.6  Pipework

    Piping components intended for the transport of natural gas when connected together for

    integration into a pressure system. Piping includes in particular a pipe or system of pipes, tubing,

    fittings, expansion joints, hoses, or other pressure-bearing components as appropriate.

    3.6.1  IAA Piping

    Piping within the boundaries of the IAA itself, starting from the isolating valve, intended to

  • 8/17/2019 6464 Nat Gas Code

    15/223

    Figur e 3-1 –  Schematic presentation of the diff erence between I AA piping (defini tion 3.6.1) and Fuel

    Gas Supply Pipework (defi ni tion 3.6.2)

    3.7  Natural Gas

    See the definition in the Natural Gas Law.

  • 8/17/2019 6464 Nat Gas Code

    16/223

    3.9.3  Maximum Operating Pressure (MOP)

    The maximum pressure at which a system can be operated continuously under normal

    operating conditions.

     Note: Normal conditions are: no fault in any device or stream.

    [Source –  EN 15001]

    3.9.4  Strength Test Pressure (STP)

    The pressure applied to a system during strength testing

  • 8/17/2019 6464 Nat Gas Code

    17/223

    3.12  Purging

    Process for safety removing air or inert gas from pipework and/or pipeline components and

    replacing it with gas, or the reverse process. A distinction is made between the following:

    - Direct purging (e.g. purging of Air with Natural Gas)

    - Indirect purging (e.g. purging of Air with Inert gas and then purging it with NG)

    3.13  End-User

    The entity who is held legally responsible for the operation of the Industrial Appliances

    Application (e.g. installing, operating, adjusting, maintaining, cleaning, repairing or moving

    machinery) of the same to comply with any requirements of Israeli law and/or directives.

    3.14  Operator

    The person(s) installing, operating, adjusting, maintaining, cleaning, repairing or moving

    machinery.

    3.15  Employer

  • 8/17/2019 6464 Nat Gas Code

    18/223

    Connection, installation, commissioning, testing, repair and servicing of gas appliance

    installations shall be planned by a designer and performed by the Contractor.

    3.17  Competent Person

    An engineer who has proven professional experience and expertise of at least five (5) years in at

    least one of the following work fields:

      Mechanical knowledge related to the construction, installation and maintenance of

    gaseous fuels consuming IAA's.

      Electrical, PCE (Process Control Equipment) Instrumentation, SIS (Safety Instrumented

    System)

      Process skills related to heating systems / process engineering relevant to gaseous fuels

    consuming IAA's

      Explosive Environment relevant to gaseous fuels consuming IAA's

      Civil Engineering, HVAC engineering.

      Risk Assessment, (e.g, QRA, HAZID, HAZOP) relevant to gaseous fuels consuming

    IAA's

      Approval procedures in comparable sectors.

  • 8/17/2019 6464 Nat Gas Code

    19/223

    -  In Quantitative risk assessment   calculations of two components of risk  (R): the

    magnitude of the potential loss (L), and the probability (P) that the loss will occur, are

    needed

    - Qualitative risk assessment, based on the experiences and statistical values: A risk

    assessment team consists of different persons with different background knowledge.

    Specific information can be obtained from IEC 61508-5 (safety integrity) and also IEC

    61511-3.

    3.20  Assessment Team to conduct a risk assessment

    The examination relies on the Assessment Team from various disciplines with appropriate skills

    and experience who display intuition and good judgement.

    Recommended roles for team members are as follows:

      Study leader/ Risk Assessor: not closely associated with the design team and the

     project. Trained and experienced in leading HAZOP studies. Responsible for

    communications between project management and the HAZOP team. Plans the study.

    Agrees study team composition. Ensures the study team is supplied with a design

    representation package. Suggests guide words and guide word –  element/characteristic

    interpretations to be used in the study. Conducts the study. Ensures documentation of the

    l

  • 8/17/2019 6464 Nat Gas Code

    20/223

    [Source: Work inspection regulation (safety management plan), 2013 –  regulatory clarifications

    for the meaning of "acceptable risk" requirements]

    It is advised to also refer to the level of an acceptable risk in the relevant standards dealing with

    Risk assessment.

    3.22  Hazard and Operability Analysis (HAZOP)

    A structured and systematic technique for system examination and risk management. In particular,

    HAZOP is often used as a technique for identifying potential hazards in a system and identifying

    operability problems likely to lead to non-conforming products or system application. HAZOP is

     based on a theory that assumes risk events are caused by deviations from design or operating

    intentions. Identification of such deviations is facilitated by using sets of “guide words” as a

    systematic list of deviation perspectives. 

    Risks Assessments will be focused on the concept of change made to the factory. That means

    existing plants has to undertake risks assessments only for the partial IAA which have been newly

    adopted.

    3.23  Layer of Protection (LOPA)

    S d fi i i IEC 61511 3

  • 8/17/2019 6464 Nat Gas Code

    21/223

    3.27  SIF - Safety Instrument Function

    A function of a safety related system to reduce the risk in an application with the objective to

    achieve or keep a safe state. The safety function is always related to a safety loop, not to a

    component or device.

    3.28  SIL - Safety Integrity Level

    Discrete level (one out of four) for specifying the safety integrity requirements of the safety

    instrumented functions to be allocated to the safety instrumented systems. Safety integrity level 4

    has the highest level of safety integrity; safety integrity level 1 has the lowest

    3.29  Functional Safety

    A part of the overall safety concept. Functional safety may be achieved by instrumentation e. g.

     pressure transmitter, safety PLC, solenoid, actuator, valve, solenoids and others. Depends on the

    system the functional safety system prevent the plant and operators against hazards. The safety

    system can be triggered by different events like disoperation by human’s errors, hardware failures

    and environmental changes. Functional Safety is the capability of a safety system or other means

    to reduce risk, to execute the actions required for achieving or maintaining a safe state for the

  • 8/17/2019 6464 Nat Gas Code

    22/223

    3.32  Workplace Environment

    An environment where staff of the Employer is directly or indirectly in contact with when

    undertaking work where a potential hazard impact is given- The overall goal is, to create /

    construct a Working Environment without any hazards to safety and health to the staff. The

    Working Environment shall be safe and healthy in all tasks like construction, operation, testing

    and approval and maintenance.

    3.33  Testing and Approval Process

    A process as set forth in Chapter 6 of this Standard describing the criteria and requirements for

    achieving permission for both installation and operation of an IAA, towards granting a

    Serviceability approval

    3.34  Serviceability approval

    See the definition relevant to "Serviceability approval" ("תוניקת רושי ") in The Economic

    Arrangements Law –  accelerating industrial plants connection to the natural gas network, or "The

    Law of Arrangements" 

    ()"

  • 8/17/2019 6464 Nat Gas Code

    23/223

    3.38  Inspection Body (IB)

    A body that operates as defined by ISO/IEC 17020 and performs the requirements defined in the

    Gas Safety Law.

    3.39  Accreditation Body (ISRAC)

    The body which is defined by the Israeli law of arrangements as the body that issues

    accreditations to the Inspection Bodies against official rules and standards.

    3.40  Technical Expert

    An individual person, internal department, or external firm, corporation or company that either in

     person or through its representatives is engaged in and is responsible for the provision of services

    with respect to Testing and Approval Process as per Chapter 6 of this standard.

    3.41  Notified Body

    An international accredit certifier with a relevant scope to undetected assessments and approvals

    for acceptable Level 1 and 2 (see chapter 6.3).

  • 8/17/2019 6464 Nat Gas Code

    24/223

    4  Industrial Appliances Application (IAA)This section covers the requirements for technical installations of both new and existing IAAs

    which are to be connected to the NG (Natural Gas) grid. IAAs of new plants will be treated as

    Complete IAAs, whereas IAAs of existing plants will be treated as Partial IAAs.

    The General Requirements as defined in Chapter 4.2 of this Standard are mandatory requirements

    for both new and existing installations. Presumption of conformity is achieved when the Specific

    Requirements of chapter 4.3 and 4.4 are fulfilled.

    4.1  General Application Rules

    In order to achieve presumption of conformity all IAAs shall met the General Requirements.

    In addition to this, specific requirements

      set out in Chapter 4.3 for new plants with Complete IAAs -with the interface from gas

    main valve to the exhaust gas connection- shall be fulfilled.

      set out in Chapter 4.4 for existing plants with Partial IAAs  – with the interface from gas

    main valve to burner flange- shall be fulfilled.

  • 8/17/2019 6464 Nat Gas Code

    25/223

      ignition and re-ignition is smooth,

      cross-lighting is assured.

    Combustion

    Industrial Appliances Application shall be so constructed that, when used normally, flame stability

    is assured and combustion products do not contain unacceptable concentrations of substances

    harmful to health.

    Industrial Appliances Application shall be so constructed that, when used normally, there will beno accidental release of combustion products.

    Industrial Appliances Application connected to a flue gas for the dispersal of combustion products

    must be so constructed that in abnormal draught conditions there is no release of combustion

     products in a dangerous quantity into the room concerned.

    Temperatures

    Parts of Industrial Appliances Application which are intended to be placed in close proximity to

    the floor or other surfaces must not reach temperatures which present a danger in the surrounding

    area.

    The surface temperature of knobs and levers of appliances intended to be manipulated must not

     present a danger to the user.

  • 8/17/2019 6464 Nat Gas Code

    26/223

      Industrial Appliances Application shall be designed and constructed as to obviate hazards

    of electrical origin. In the area in which it applies, compliance with the safety objectives

    in respect of electrical hazards laid down in chapter  4.3.114.3.11. 

    Materials

    Materials must be appropriate for their intended purpose and must withstand the technical,

    chemical and thermal conditions to which they will foreseeably be subjected. The properties of

    materials that are important for safety must be confirmed to the End-User by the manufacturer or

    the supplier of the Industrial Appliances Application.

    Fittings for natural gas handling systems

    Fittings intended to be part of an Industrial Appliances Application shall be so designed and built

    as to fulfil correctly their intended purpose when incorporated in accordance with the instructions

    for installation. The instructions for installation, adjustment, operation and maintenance must be

     provided with the fittings concerned.

    4.2.1  Requirements for natural gas related machinery within the IAA

    The requirements are applicable to following products such as:

  • 8/17/2019 6464 Nat Gas Code

    27/223

      If the appliance is covered within a specific safety standard and complies with the

    requirements specified in this standard, the Study Leader/ Risk Assessor shall consider it

    during the procedure of the Risk Assessment.

      Determine the limits of the machinery / Industrial Appliances Application, which include

    the intended use and any reasonably foreseeable misuse thereof;

      Identify the hazards that can be generated by the natural gas related machinery / Industrial

    Appliances Application and the associated hazardous situations;

      Estimate the risks, taking into account the severity of the possible injury or damage to

    health and the probability of its occurrence;

      Evaluate the risks, with a view to determining whether risk reduction is required;

      Eliminate the hazards or reduce the risks associated with these hazards by application of

     protective measures, in the order of priority established in section

    4.2.2.1  Functional Safety devices (SIL Loops)

    Any claim of functional safety for a component, subsystem or system shall be evaluated against

    the recognized functional safety standards IEC 61508. A certified product, like transmitter, valve

    etc., can then be claimed to be Functionally Safe to a particular Safety Integrity Level (SIL) in a

    specific range of applications.

  • 8/17/2019 6464 Nat Gas Code

    28/223

    4.2.2.2  Devices for explosive atmospheres

    Devices for use in potentially explosive atmospheres are divided into three groups. Devices for

    Group II stand for explosive gases. Whereby Group I will be not considered because it will

    applicable for coal mining category I and category III for environment with dust.

     Note:

    If the IAA is placed in potentially explosive dusty atmosphere - the relevant arguments should be

    considered and applied

    4.2.3  Design and construction of natural gas pipework and pressure equipment within

    the boundary of the IAA

    The aim is to minimize the hazards that are caused by the NG pipework and pressure equipment

    within the boundary of the IAA, and the corresponding accessories. Therefore it establishes

    requirements for the design and manufacture of NG supply equipment with a maximum allowable

     pressure greater than 0.5 barg.

    The NG equipment shall be designed, manufactured and checked, and if applicable equipped and

    installed, in such a way as to ensure its safety when put into service in accordance with the

    manufacturer’s instructions, or in reasonably foreseeable conditions.

  • 8/17/2019 6464 Nat Gas Code

    29/223

    Additional requirements relevant to those NG consuming IAAs that are not covered under this

    clause, shall be certified according to the PED directive, as applicable.

    4.2.4  Technical instructions for IAAs

    For all used equipment or natural gas related machinery installed within the boundaries of the

    Industrial Appliances Application, technical instructions intended for the installer/ operator shall

     be available upon installation, commissioning, operation and maintenance, and shall contain all

    the instructions for installation, operation, adjustment and servicing required to ensure that

    machinery or equipment within the boundaries of the Industrial Appliances Application is used

    correctly within the limits of safe operation. In particular, the instructions must specify explicitly

    for each single machinery or equipment consuming any type of fuel:

      The type of fuel which can be used including, for standard fuels, its required

    specifications as typically used for such fuel.

      The fuel supply pressure limits required at one specifically identifiable point within the

    Industrial Appliances Application including the boundaries of upper and lower limit

     pressure during operation under nominal load and during shut-down.

      The minimum requirements for supply with fresh air or any combustion gas either

    naturally aspirated or supplied by means of any peripheral device including the

    minimum flow of fresh air or combustion air required under maximum load.

  • 8/17/2019 6464 Nat Gas Code

    30/223

    4.3  Specific Requirements for Complete Industrial Appliances Application

    (IAAs)

    This chapter applies to Complete IAAs which include an IThE/Steam boiler or any other industrial

    fuel-consuming appliances as described in the scope of this standard and is constructed and built

    as completely new.

    4.3.1  Risk Assessment

    For safety issues that are not covered within the applicable safety standards, a complementary

    Risk Assessment shall be done.

    A risk assessment of the Complete IAA shall be conducted by the assessment team as defined in

    chapter 4.3.

    The risk assessment team can choose one of the following standards for performing a risk

    assessment:

      ISO 12100 shall be applied for Complete IAA, e.g. for a dedicated burner, pump, etc. This

    risk assessment is an iterative process with different possibilities for reducing the risk to

    an acceptable tolerance level.

    Note:

    This International Standard specifies basic terminology, principles and a methodology for

  • 8/17/2019 6464 Nat Gas Code

    31/223

      Other methods for performing RA are available and specified in IEC 61511-3 (such as

    LOPA, ALRPA and others)

    4.3.2  Natural Gas Pipe Connection (see definition3.6.13.6.1) 

    All natural gas connections within the boundaries of the Complete IAA shall be designed and

    constructed in line with the applicable standard as referenced below, used under design operating

    conditions.

    Connection and pipework shall comply with all parts of EN 13480 or EN 15001 as far as

    applicable.

    In addition to the aforesaid, the classification of the piping systems is always in minimum

    category II or equivalent based on EN 13480-1 “Classification of piping”.

    Category I or lower systems are not accepted by Industrial Appliance Application (IAA).

    Requirements regarding multiple burner's connection as defined in SI 74600-2 for IThE and for

    steam boilers in SI 12952-8 and SI 12953-7 shall additionally be applied.

     Natural Gas pipes with a diameter greater as DN 50 shall be welded with welder certificates as

    defined in EN 13480.

    Threaded connections of natural gas pipes up to DN 50 are permitted. In general screwed and

    flange connections are required. Pipe fitting and compensators shall be suitable and proofed.

  • 8/17/2019 6464 Nat Gas Code

    32/223

    For categories 1 to 3 the approval procedure is described in several modules. It is always possible

    to use modules from a higher but not from a lower category.

    All gas supply pipes and accessories belonging to category II or higher involves the collaboration

    of an IB irrespective of the used module.

    In detail the modules A to H1 are described in PED 97/23/EEC.

    Gas pressure equipment or assemblies which are in conformity with the standards named in the

    chapter Specific Requirements shall be presumed to be in conformity with these essential safety

    requirements.

    4.3.3  Combustion Air Connection

    The construction of the combustion air pipework shall be so designed and built as to fulfil

    correctly their intended purpose. The air supply to any combustion device within the boundaries

    of the Complete IAA shall be designed unrestricted. If shut-off valves are installed, these devices

    shall be safely controlled. The location of the combustion air intake shall be such as to prevent

    entry of exhaust.

    The ventilation of the building and thereby the Complete IAA shall be such as to allow an

    adequate supply of process /combustion air to reach the combustion units under all circumstances

    and conditions.

  • 8/17/2019 6464 Nat Gas Code

    33/223

    Electronic gas/air ratio controls shall comply with EN 12067-2 if applicable.

    Mechanical gas/air ratio controls are permitted. The mechanical gas/air ratio need not to be

    monitored if once during the initial adjustment limits were fixed and cannot be removed

    afterwards.

    If the requirements of these standards cannot be complied with (e.g, EN 88-1 or EN 12067-2

    cannot be applied for CHPs), other equivalent safety levels can be applied.

    The design of the natural gas/air ratio control has to consider process conditions as well as fuel

    and combustion air properties.

    The air mass flow rate shall always be in a ratio with the fuel mass flow in order to ensure safe

    ignition and that throughout the operating range, a stable and safe combustion is maintained at

    each individual burner. The ratio needs not be the same value at all operational conditions.

    In addition to the above stated, the gas/air ratio shall comply with SI 74600-2, SI 67600, EN 267,

    SI 12953-7 and SI 12952-8.

    Defect or malfunction should effect that the system will tend towards higher excess air or proceed

    to lockout if the gas/air ratio results in an unsafe condition.

    4.3.5  Burner

    4.3.5.1  Forced draught Gas Burner

  • 8/17/2019 6464 Nat Gas Code

    34/223

    Any other multi fuel Industrial thermoprocessing equipment (IThE) including the burner shall

    comply with SI 74600-2.

    4.3.5.4  Burners which are not referenced to within the above normative

    standards

    Burners manufactured according to standards outside the list in clause 4.3.5 shall be approved

    according to Risk Assessment procedure, to be approved by the IB.

    The additional requirements for the alternating operation between various fuels shall be

    considered. In cases of doubts an additional risk analysis for the alternating operation shall be

    conducted and considered

    Any other multi fuel Industrial IThE including the burner shall comply with SI 74600-2.

    4.3.6  IThE –  Safety for combustion and fuel handling systems

    4.3.6.1  Industrial thermoprocessing equipment

    Industrial thermoprocessing equipment (IThE) within the boundaries of the Complete IAA shall

    comply with SI 74600-2

    4.3.6.2  Water-tube boilers

    Water-tube boilers and auxiliary installations with volumes in excess of 2 liters for the generation

  • 8/17/2019 6464 Nat Gas Code

    35/223

    4.3.7.2  Flue Gas passages leak tightness

    The leak tightness of the flue gas evacuation connection and pipework within the boundaries of

    the Complete IAA shall be proven according to an approved method, e. g. EN 13611.

    Note: The IThE or any other industrial gas-consuming appliances as described in the scope of this

    standard shall be included in the leak tightness test as far as applicable.

    4.3.8  Stacks fed by several firings

    4.3.8.1  General

    The stack shall be designed according to the applicable standards, such as, SI 67600, SI 74600-2,

    SI 12952-8, SI 12953-7, in order to ensure proper exhausting of flue gases and safe operation of

    the burning system.

    4.3.8.2  Common Stack

    If a common stack exists the prescribed risk assessment as laid down in chapter  4.3.14.3.1 shall

    include the possible hazards related to a common stack.

    In general flue gas flows from several firings entering a common duct shall be constructed in such

    a way that,

      during all operating conditions the stack pressure shall variate in an acceptable tolerance

  • 8/17/2019 6464 Nat Gas Code

    36/223

    If nothing else is defined the forced ventilation mass flow shall content the combustion room, all

    flue gas passages up to entering the stack (total volume) in such a way that the total volume is

    5 times changed prior any firing system start-up. A minimum purging time is defined with 30 sec.

    After any false-start, cutout during normal or abnormal situation, the above mentioned procedure

    shall be repeated before any re firing start-up.

    Manually operated firings shall consist as well an adequate/effective purging. This shall be

    ensured with adequate timing relay.

    In some special cases for IThE the purging conditions can variate from the aforesaid. In thesecases, SI 74600-2 shall be considered. 

    4.3.10  Purging or venting of natural gas

    4.3.10.1  Natural gas venting from All IAAs

    Venting of natural gas released from all IAAs shall be into a safe location according to an

    approved procedure and shall comply with the safety measures and procedures specified in

    IGE / UP / 1. 

    4.3.10.2  Natural gas venting from IAAs operating at pressure higher than 16 barg

    Venting of Natural Gas of IAAs operating at pressures higher than 16 barg shall comply with the

  • 8/17/2019 6464 Nat Gas Code

    37/223

    (1)  Other parts of the overall safety of a system are mechanical safeguards or organization

     procedures are partly considered by these standards, In most situations, safety is achieved

     by a number of systems which rely on many technologies ( for example mechanical,

    hydraulic, pneumatic, electrical, electronic, programmable electronic). This standard also

     provides a framework within which safety-related systems based on other technologies 

    (2)  The electric safety is not part of the functional safety standard. 

    IAA, which complies with the Functional Safety requirements as specified in SI 67600 or SI74600 shall be presumed to be in conformity with these essential safety requirements.

    4.4  Specific Requirements for Partial IAAs

    This chapter applies for Partial IAAs, which shall be a part of an existing IThE/Steam boiler or

    any other industrial fuel-consuming appliances as described in the scope of this standard.

    Mainly converted IAAs from LPG/Fuel Oil to natural gas are covered by this chapter.

    Generally it will be assumed, that the given Technical Characteristics of the existing IThE/Steam

     boiler, or any other industrial fuel-consuming appliances as described in the scope, remain

    unchanged. The new Partial IAA shall be matched to the existing IThE/Steam boiler by ensuring

    full technical and safety compatibility. If the Technical Characteristics cannot be kept additional

  • 8/17/2019 6464 Nat Gas Code

    38/223

    4.4.5  Burner

    4.4.5.1  Forced draught Gas Burner

    The requirement in clause 4.3.5.1 shall apply in this clause.

    4.4.5.2  Atmospheric Gas Burner

    The requirement in clause 4.3.5.2 shall apply in this clause.

    4.4.5.3  Multi fuel burner

    The requirement in clause 4.3.5.3 shall apply in this clause.

    4.4.5.4  Burners which are not referenced to within the above normative

    standards

    The requirement in clause 4.3.5.4 shall apply in this clause.

    4.4.6  Electrical Installation

    Any electrical installation of industrial appliance application and its protective circuits shall be

    installed and proven in accordance with Israel Electricity Law and its corresponding directives.

    All electrical enclosures, components and cabling shall be suitable for the environment.

  • 8/17/2019 6464 Nat Gas Code

    39/223

    4.4.11  Functional Safety of a Partial IAA, related to natural gas use

    The requirement in clause 4.3.12 shall apply in this clause.

    Note: Any approval previously issued to the IAA for operation by a fuel other than natural gas, is

    not valid and shall be re-issued for the natural gas operation.

  • 8/17/2019 6464 Nat Gas Code

    40/223

    5 Workplace Environment

    During the planning of a new plant or new facility or a modification of an existing plant / facility,

    latest upon completion before the work starts, a “Working Environment Impact Assessment”

    (WEIA) has to be performed for the “complete IAA” (see clause 4.3) or the changes done by the

    “partial IAA” (see clause 4.4) to assess the hazards of safety and Health for the workers which are

    caused by the changes resulted by the conversion to natural gas, only.

    During the WEIA the influence of the existing part of a plant / facility has to be considered because this part could have an influence to the new installed IAA. After the assessment, the

    employer and operators knows the hazards of the working place or working task and shall take the

    necessary measures to eliminate them.

    During the WEIA process, it will be checked if the requirements for safety and health of changed

     part will be fulfilled and the explosion protective study and documentation will be created of this

    outcome. Also the influence of the environment has be checked during the WEIA process.

    One part the WEIA analysis is to check the test certificates of the installed technical safety

    equipment but not a function test.

    It is not part of the WEIA analyses to check if the technical equipment fulfills the requirements of

    chapter 4 of this standard. This is to be done during the approval process described in chapter 6 of

  • 8/17/2019 6464 Nat Gas Code

    41/223

    Hereby, “complete IAA” or “ partial IAA” equipment are considered the same. Meaning, unsafe

    “existing equipment” shall be changed or refitted to a safe level. 

    For every workplace and working task a WEIA shall be realized. One part of the WEIA is the

    “new equipment” the other part is the “existing equipment” with his hazards to safety and health

    for the workers at the work.

    The working environment could be checked during the planning / Construction phase used the

    checklist of hazards and method to assess the risk.

    If an explosive atmosphere occurs, a special risk assessment (see clause 5.3.35.3.2) has to performto define EX-Zones. This special risk assessment shall be performed during the planning phase

    and immediately before operation of the equipment / plant starts.

    5.2  Requirements for a working environment impact assessment (WEIA)

    The general requirements for a WEIA are described in the Occupational Safety and Health

    Regulation.

    The general way to performing risk assessments (e.g, WEIA) is described in ISO 31010:2009.

    At the ISO 31010:2009 no checklist with specific hazardous factors and no method to assess the

    risk are defined. A checklist with hazardous factors and a risk matrix is defined in this standard.

    A WEIA involves the following steps:

  • 8/17/2019 6464 Nat Gas Code

    42/223

    risk assessment of safety and health (OSH) of work environment exists (and that it includes the

    checklist of hazardous factors as specified in clause 8.2.3). The employer has to verify that the

    recommendations of the safety and health of work (OSH) risk assessment are being implemented.

    5.2.2  Methods of Risk Assessment

    Risks Assessments shall be focused on the concept of change made to the factory. That means

    existing plants has to undertake risks assessments only for the partial IAA which have been newly

    adopted. 

    Every risk at a working-place or a working task has to be assed. If the risk is too big (orange or

    red), the employer shall take measure to eliminate the risk to a minimum, an ALARP (as low as

    reasonably practicable) Process could define.

    In ISO 31010:2009 no specific method to assess the risk is given. The following table is a practice

    example given in this standard.

    ALARP stands for "as low as reasonably practicable", and is a term often used in the milieu of

    safety-critical and safety-involved systems. The ALARP principle is that the residual risk shall be

    as low as reasonably practicable.

    For a risk to be ALARP it must be possible to demonstrate that the cost involved in reducing the

    risk further would be grossly disproportionate to the benefit gained. The ALARP principle arises

    https://en.wikipedia.org/wiki/Safety-criticalhttps://en.wikipedia.org/wiki/Safety-involvedhttps://en.wikipedia.org/wiki/Riskhttps://en.wikipedia.org/wiki/Riskhttps://en.wikipedia.org/wiki/Safety-involvedhttps://en.wikipedia.org/wiki/Safety-critical

  • 8/17/2019 6464 Nat Gas Code

    43/223

    The working environment could be checked during the planning / construction phase used the

    checklist of hazards and method to assess the risk.

    5.2.3  Aim –  and arrangements hierarchy

  • 8/17/2019 6464 Nat Gas Code

    44/223

    5.3  Requirements to define EX-Zones

    Minimum requirements for the safety and health protection of workers potentially at risk fromexplosive atmospheres. “Explosive atmosphere” means a mixture with air, under atmospheric

    conditions, of flammable substances in the form of gases, vapors, mists or dusts in which, after

    ignition has occurred, combustion spreads to the entire unburned mixture.

    These general requirements are valid for gaseous atmospheres. Environments where dust

    atmospheres may occur are not covered by the present requirement. Mechanical incidents are not

    considered at the moment in the requirement.

    The requirements to define EX-Zones are described as follows:

    Only approved equipment can be used.

    5.3.1  Classification of Zones

    Classification of zones shall be performed in accordance with the requirements of SI 60079-10.1.

    Other equivalent Israeli Standards, e.g. SI 25000, SI 16000 or other equivalent National foreign

    Standards can also be used.

    5.3.2  Prevention of and protection against explosion

    With a view to preventing, within the Occupational Safety and Health Regulation) and providing

  • 8/17/2019 6464 Nat Gas Code

    45/223

      the installations, substances used, processes, and their possible interactions,

      the scale of the anticipated effects.

    Explosion risks shall be assessed overall.

    Places which are or can be connected via openings to places in which explosive atmospheres may

    occur, shall be taken into account in assessing explosion risks.

    5.3.4  Verification dossier

    An explosion protection document (verification dossier) based on a “explosion risk assessment”shall be issued for all places in which explosive atmospheres may occur.

    In addition it shall contain the following information and documents:

      Area classification documents as required by SI 60079-10.1 with plans showing the

    classification and extent of the hazardous areas including the zoning

      Optional assessment of consequences of ignition

      Where applicable gas classification in relation to the group or subgroup of the electrical

    equipment

      Temperature class or ignition temperature of the gas or vapour involved

      External influences and ambient temperature.

    In regards to the equipment, which is built into the installation, the following information has to

     be included in the verification dossier:

  • 8/17/2019 6464 Nat Gas Code

    46/223

      Installer’s/qualified person’s declaration 

      Plans for follow-up testing and approval

    5.3.5  Defining Ex-Zones

    As described in clauses  נמצ . 4.2.4.1 andשגי ה! מקור ההפניה ל שגי ה! מקור ההפניה ל

    .4.2.4.2, the requirements to define Ex-Zones are defined in IEC 60079-10-1נמצ .

    IEC 60079-10-1 allows the application of national standards to define Ex-Zones, e.g. SI 25000.

    5.3.6  Ventilation of Ex-Zones

    The definition of Ex-Zones depends on the ventilation of the area where a dangerous explosive

    atmosphere can occur. It makes a big different if you use a natural ventilation or a mechanical

    ventilation. During mechanical ventilation the opening in the building, the air temperature and the

    wind direction and wind speed has an influence of the efficiency of the ventilation.

    The calculation of the wall openings by natural ventilation is described in IEC 60079-10-1. There

    are all factors described with an influence of the ventilation.

    The kind of ventilation and the right calculation of the ventilation have a great impact of the

    definition of the Ex-Zones, see clause 5.3.55.3.5. 

  • 8/17/2019 6464 Nat Gas Code

    47/223

    5.6  Electrical Installation in explosive atmospheres

    Any installations shall comply with IEC 60079-14: Explosive atmospheres - Part 14: ElectricalInstallations design, selection and erection.

    A comparison between the International and European schemes for zoning is brought in the

    following table 1, for information only.

    Table 1 –  Conversion table Zoning to EPL level versus EXPLOSIVE ENVI RONMENT

    Zone IEC - Equipment Protection Level (EPL) EXPLOSIVE ENVIRONMENT

    Category (2014/34/EU)

    0 Ga II1G

    1 Ga or Gb II1G or II2G

    2 Ga, Gb or Gc II1G, II2G or II3G

    20 Da II1D

    21 Da or Db II1D or II2D

  • 8/17/2019 6464 Nat Gas Code

    48/223

    6 Testing and Approval

    6.1  General

    This chapter outlines the process of Testing and Approval of any IAA.

    The End-user shall separately submit for each IAA an individual application for approval through

    an "Approval Application Form" (see clause 6.4.1.3) before installing and operating these IAAs

    (Serviceability approval).

    This chapter deals with Partial and Complete IAAs using natural gas burning appliance. The IAAs

    mainly consist out of a complete self-contained package of burner, piping, valves and control

    equipment.

    The specific requirements for the different stages of testing and approval (Stage I: Approval for

    installation, and Stage II: Approval for operation - Serviceability Approval) are illustrated in Fig.

    Fi gure 6-1 Figure 6-1and Fi gure 6-2 Figure 6-2. 

     Note:

    The goal of this chapter is to make sure that the End-User understands the regulatory and technical

  • 8/17/2019 6464 Nat Gas Code

    49/223

    Following an examination of these available certifications by the IB, the IB shall determine the

    acceptability level (see below).

    These criteria are based on the fact that the majority of IAAs probably have some form of

    certification within the European Community (EC).

    Acceptability Level 1:

    IAA products/systems are certified to International or to European standards (IEC, ISO, EN) by an

    appropriate certified party (e. g. Notified Body or product certification body), for the type and sizeof appliance or plant for which certification is practicable.

    Acceptability Level 2:

    Self-declaration by the manufacturer(s), demonstrating the conformity of the IAA to essential

    requirements of the relevant EC Directives/Standards, is ensured. Based on evidence of technical

    documentation provided in spot checks, these declarations shall be validated by a Competent

    Body, and approved by the IB, according to ISRAC criteria.

    Acceptability Level 3:

    IAAs for which neither certification (Level 1) nor declaration (Level 2) exists, based on

  • 8/17/2019 6464 Nat Gas Code

    50/223

    Further proof of suitability can be:

      EC Type examination certificates such as corresponding to Pressure Equipment Directive

    97/23/EC will be repealed from the 19 July 2016 by the new PED Directive 2014/68/EU,

    Gas Appliance Directive 2009/142/EC, Construction Product Regulation 305/2011 , EMC

    Directive 2004/108/EC Low Voltage Directive 2006/95/EC will be repealed from the 20

    April 2016 by the new LVD Directive 2014/35/EU; Machinery Directive 2006/42/EC.

      Significant Type test reports according to the applicable desired normative issued by ISO

    EN 17025 appointed laboratoryWhere the manufacturer is required to present a self-declaration of conformity, it shall be issued

    according to the requirements of ISO 17050 (parts 1 and 2). 

     Note:  EC Declaration of Conformity  - The EC Declaration of Conformity must contain all relevant

    information to identify the Union harmonization legislation according to which it is issued, as

    well as the manufacturer, the authorized representative, the notified body if applicable, the

     product, and where appropriate a reference to harmonized standards or other technical

     specifications.

     By drawing up and signing the EC Declaration of Conformity, the manufacturer assumes

    responsibility for the compliance of the product. The CE marking indicates the conformity of the

     product with the Union legislation applying to the product and providing for CE marking.

    CE marking

    The CE marking is a key indicator (but not proof) of a product’s compliance with EU legislation

  • 8/17/2019 6464 Nat Gas Code

    51/223

    Exemplary important criteria to be considered for this application and approval procedure are

    given in the following standards:

    i)  Mechanical part of the piping shall be tested at least by EN 13480-5 or EN 15001.

    ii)  PCE (Process Control Equipment) and SIS (Safety Instrumented System) shall betested at least by IEC 61508 and by IEC 61511

    iii)  Process engineering shall be tested by SI 74600-2, SI 67600, SI 12953-7 and SI

    12952-8

    iv)  Explosive environment check list in SI 60079 (parts 10.1, 14 and 17)

     Note: Further standards applicable to the approval procedure are listed in Chapter 2 and shall be

    taken into consideration, if relevant.

    The approval process includes two different stages, resulting in:

    1.  Approval for Installation (Stage 1)

    2.  Approval for Operation - Serviceability Approval (Stage 2)

    The consecutive production stage shall be covered by periodic surveillance, maintenance and

  • 8/17/2019 6464 Nat Gas Code

    52/223

    6.4.1  Stage 1 –  Approval for installation

    General scheme of the procedure for Stage 1 is given in Figure 6-1:

    Technical Expert

    Technical data sheets and design documents

    Permit Application Form,incl. Technical Documents

    IB

    compiles 

    GAP reportcreates 

    End-user  

    Contractor  

    End-user  

    compiles 

  • 8/17/2019 6464 Nat Gas Code

    53/223

    The End User shall operate the IAA according to the manufacturer(s) manuals and relevant

    standards.

    The End User shall provide the relevant test plans and documents (ITP, and/or V&VP) to be

    approved by the IB.

    Once the End-user has engaged an IB he shall complete both Stages for Approval (1/ Installation

    and 2/ Operation - Serviceability Approval) with this IB. For the re-approval after five years

    (stage 3) the End-user is free to engage another IB.

    Code/Standard deviations are forbidden to bypass, unless it is demonstrated that the same safety

    level is kept (e.g, by performing a risk assessment).

    6.4.1.2  Technical Documents

    Before compiling the Approval Application Form, the End-User shall assort the relevant technicaldocuments according to his selected IAA and the corresponding applicable standards. Normally,

    the Contractor and/or a Technical expert would support this task.

    The End User shall keep the documentation through the life cycle of the IAA.

    The Technical Documents shall demonstrate that the IAA including its product/system, complies

    with applicable standards.

  • 8/17/2019 6464 Nat Gas Code

    54/223

    6.4.1.4.2 Gap Report for IAAs that comply with former versions of the applicable standards

    For IAAs which comply with the requirements of former versions of the applicable standards, the

    manufacturer shall provide a demonstration of compliance with the former version of the

    applicable standard and deliver a gap report specifying the gaps between the new and former

    versions of these applicable standards through a self-declaration.

    If there is no manufacturer, a Technical Expert shall provide an approved the gap analysis.

    The gaps shall be resolved according to the requirements in clause 6.4.1.4.1.Once the gaps are resolved, a second demonstration of compliance to the new version of the

    applicable standards shall be delivered through a self-declaration.

    6.4.1.5  Approval for Installation (IB)

    Approval for Installation is granted only for new equipment.

    If all GAPs (according to the gap report issued by the IB) have been successfully fulfilled, the IBshall issue to the End-User an Approval for Installation. 

    The IB shall use a standardized template when issuing an approval for installation to the End

    User.

  • 8/17/2019 6464 Nat Gas Code

    55/223

    6.4.2  Stage 2 –  Approval for operation

    6.4.2.1  General

    The End-user needs to assure that:

      installation and commissioning,

      (safety) validation,

      operation, maintenance and repair,

    are carried out according to the requirements of the Standards. Further on the instructions (e. g.

    safety manual) given by the supplier and the safety documentation delivered by the components

    suppliers/vendors have to be observed.

    During validation testing, the End-user shall verify that the safety of general functions can be

    executed as required by the Specification.

  • 8/17/2019 6464 Nat Gas Code

    56/223

    General scheme of the procedure for Stage 2 is given in Figure 6-2:

    Punch List andTest Report

    IBTest Protocol including

    permission for HC

    IB

    Supervisesinstallation (piping),functional tests and

    cold commissioning

    compiles 

    Contractor

    Technical Expert

    End-user

    Installation (piping)

    Functional Test

    Cold Commissioning

    Hot Commissioning

    creates 

    Conductsinstallation (piping),functional tests andcold commissioning

  • 8/17/2019 6464 Nat Gas Code

    57/223

    6.4.2.2  Installation, Functional Testing and Cold Commissioning

    Once the Installation approval is issued (Stage 1), the IB shall accompany Stage 2 (Serviceability

    Approval) following these steps:

      installation (piping)

      functional testing

      cold commissioning

      hot commissioning.

    Figure 6-3 presents an example of the process as given in standard IEC 62337.

    Figur e 6-3 General scheme for Commissioni ng of electrical, i nstrumentation and contr ol systems in the

    process industry [source: I EC 62337]

    Installation

    Completion

    Installation

    Functional test

    Completion

    mechanical

    Cold Hot

    CommissioningOperation

    Performance

    Test

    Final acceptance

    Permission for

    "gassing up"

  • 8/17/2019 6464 Nat Gas Code

    58/223

      assessment of the fuel gas connection and it´s possible leakages. Measurement methods

    and instruments are to be found in Chapter 4.3 in the relevant subchapter (4.3.2

    Connection).

      a general assessment of the appliance installation against the workplace environment

    safety requirements.

    It should be emphasized, that all on-site Testing and Approvals/ validations made by IB are visual

    Testing and Approvals and are limited to witnessing of the performed tests (e.g, SAT  –   SiteAcceptance Tests). The tests themselves shall be performed solely by the End- user or its

    appointed Technical Expert.

    The test equipment shall be provided by the responsible End user or its appointed Technical

    Expert. The IB shall check that the test equipment is suitable and calibrated as per regulation

    and/or manufacturers guideline. However, the IB is at any time free to decide to make use of its

    own measurement equipment.

    After a successful performance of the installation (piping), functional tests and cold

    commissioning, the IB shall compile a Test Protocol and, if positive, shall issue, alongside that

    Test Protocol, a written approval for Hot Commissioning.

  • 8/17/2019 6464 Nat Gas Code

    59/223

    If needed Boiler

    EN 12953-7

  • 8/17/2019 6464 Nat Gas Code

    60/223

    6.4.2.5  Maintenance and Operation Tests (by the End User)

    Once “Approval for Operation (Serviceability Approval)” has been issued, the operation stage

    (Stage 3) shall start and maintenance tests shall be undertaken by the End User. The intervals of

    the maintenance tests may depend on the possible hazards which occurred during risk assessment

    of the appliance installation and the workplace environment, based on the engineering documents

    or based on the requirements of certain standards.

    The requirements under this clause shall be performed according to the relevant standards quoted

    in this standard, manuals provided by the equipment manufacturer(s) and good engineering practice, which were approved by the IB, when the “Approval for Operation  (Serviceability

    Approval)” has been issued. 

    Below are some examples for periodic maintenance:

      The test plan for the periodic maintenance shall contain the assessment of the natural gas

    connection and it´s possible leakages. Measurement methods and instruments are to be

    found in Chapter 4.3 in the relevant subchapter (4.3.2 Connection).

      The test plan for the periodic maintenance shall contain a general assessment of the

    appliance installation against the workplace environment safety requirements.

      The test plan for the periodic maintenance shall contain a general test of any leakages.

  • 8/17/2019 6464 Nat Gas Code

    61/223

    The equipment used for the maintenance (e.g, portable testing equipment, tools and the

    mechanical equipment) shall be compatible for the environment in which it is being operated (e.g,

    explosive atmosphere), or, the environment shall be such that allows the use of other type of

    equipment.

    6.4.2.5.2 Additional requirements to be submitted to / or the IB4 

    6.4.3  Safety test for the renewal of the "Serviceability approval" (see 3.34) in IAAsalready consuming natural gas ("Gassed up" plants, see 3.36)

    Within a period of 36 months, starting the date of publication of this Israeli Standard in official

    records, "Gassed Up" plants shall undergo a safety test, for renewal of their "Serviceability

    approval".

    For the renewal of their "Serviceability approval", IAAs that already installed and consume

    natural gas, shall be tested by the IB for compliance with the following requirements:

    6.4.3.1  Gap analysis

    A gap analysis, testing the compliance of the IAA with the safety requirements specified in SI

    74600-2, shall be performed. Following this analysis, a gap report shall be prepared (by the

    Technical Expert approved by the IB), specifying the requirements which are not complied with,

  • 8/17/2019 6464 Nat Gas Code

    62/223

    6.4.3.3  Maintenance level of the natural gas systems

    The natural gas systems shall be adequately maintained.

    All actions performed to keep these systems adequately maintained, shall be documented, as per

    the requirement in chapter 6.

    Note: Clause 6.4.3 and its sub-clauses are valid only during 36 months starting the date of

     publication of this Israeli Standard in official records. 

    6.5  General administrative and technical items for application form

    The following information shall be provided by the End-user.

    Administrative information is mandatory for all IAAs, and specific technical information

    depends on the type of IAA and shall be provided according to the relevance.

    6.5.1  General information

      Business Name & Address:

      Contact name & number:

      Qualified Agents details:

      Design Standard (relevant standard for each of the components)

  • 8/17/2019 6464 Nat Gas Code

    63/223

    o  BOM (Bill of Material) where can be seen major information like Isolation valves

    (number, size, make & model) etc.

    o  Take into account the information in Technical Document see chapter 6.5.2

      Flue:

    o  Type (natural or forced):

    o  Size:

    o  Shared/dedicated:

    o

      Termination Point:  Use:

    o  Indicate pattern of use (hours per day/days per week)

    o  Process performance data (heating up time, throughput):

      Gas Supply:

    o  Supply Pressure:

    o  Inlet pipework size:

    o  Material type of the piping

    o  Flow rate (Nm3/hr)

    o  Design and operating pressures and temperatures

      If Dual or Multi Fuel burners:

  • 8/17/2019 6464 Nat Gas Code

    64/223

      A general description of the electrical equipment, PCE instrument and of the SIS,

      Design and manufacturing drawings plus diagrams of components, sub-assemblies,

    circuits, etc.,

      Descriptions and explanations needed to understand the above mentioned drawings and

    diagrams plus the operation of the electrical equipment,

      A list of the Standards used, in full or in part, and a description of the solutions employed

    to meet the safety aspects of this directive when Standards have not been applied.

      The results of the design calculations and of checks carried out, etc. (if relevant to thesafety of the appliance),

      Test reports (in fact, the test reports which may be available, established by a Technical

    Expert).

      The overall drawing of the machinery/system and drawings of the control circuits, as well

    as the pertinent descriptions and explanations necessary for understanding the operation

    of the machinery, full detailed drawings, accompanied by any calculation notes, test

    results, etc.

      Ventilation assessments as per relevant installation standards, of production halls, and

    confined spaces relevant to the appliance and its peripherals, Certificates, etc., required to

    check the conformity of the machinery with the essential health and safety requirements,

  • 8/17/2019 6464 Nat Gas Code

    65/223

      Checklists (with relevancy of the specific IAA)

      The vendor shall carry out necessary research and tests on components, fittings or the

    completed machinery, system to determine whether by its design or construction it is

    capable of being assembled and put into service safely. The relevant reports and results

    shall be included alongside the technical documents.

      Electrical diagrams with BOM (Bill of Material)

    o  If needed that the electrical equipment meets the expected mechanical

    requirements in such a way that persons and property are not endangered;o  That the electrical equipment shall be resistant to non-mechanical influences in

    expected environmental conditions, in such a way that persons and property are

    not endangered;

    6.5.3  Work place environment

    In order to identify the potential hazard in the working environment, the IB shall verify that an

    updated version of a document that summarizes the Risk assessment of safety and health (OSH) of

    work environment exists (and that this document includes the checklist of hazardous factors as

    specified in clause 8.2.38.2.3).

    A systematic check about safety and health related problems at a workplace or working tasked for

  • 8/17/2019 6464 Nat Gas Code

    66/223

      Safety and emergency breakouts of electric and gas supply in connection to the

    appliance/process.

      Any additional information that can help the understanding of the appliance.

    6.6  Labelling and Marking

    A marking approval shall be readily available in the vicinity of the main valve of the plant, with

    the following information:

      The name of the inspection body (IB)

      The test number and date

      Periodic test details (the dates of the last test and the up-coming test)

      The approved IAAs

    If there are several approvals, each shall be placed in the vicinity of the applicable valve.

    A readable copy of the approval shall be visible in the work environment at all times.

  • 8/17/2019 6464 Nat Gas Code

    67/223

    7 Pipework

    7.1  General

    7.1.1  The system design shall be according to the EN 15001 (series) or the ASME B31.3 (Latest

    Editions) requirements. Hazardous Area Classification shall be carried out as per the

    requirements of the SI 25000 or SI 60079-10.1. Buried sections of PE pipe on systems

    whose precedent code is ASME B31.3 shall be designed as per the requirements set by theSI 5664 Part 3.

    7.1.2  Before the End User can install and subsequently operate an Industrial Gas Installation

    system, the End User shall apply for an approval and such approval shall be granted prior

    to commencement of any installation related activity.

    7.1.3  Exemptions may be granted by the Inspection Body only upon written request by the End

    User subject to agreed restrictions and conditions. Exemptions shall be considered on a

    case-by-case basis and a given exemption can be withdrawn if:

    7.1.3.1 The data furnished by the End User to obtain it, appear to be incorrect or

  • 8/17/2019 6464 Nat Gas Code

    68/223

    7.2  Design of the system

    7.2.1  Detailed Design

    7.2.1.1  The system boundary is described in Annex 7.3

    7.2.1.2  The design shall provide a complete and comprehensive summary of all design related

    data and criteria applicable to the proposed Industrial Gas application system such as:

      Reference to the design code, guidelines, technical specifications and all addendato these.

      Relevant engineering decisions, their rationality, choice of design-related

     parameters and any other variables having impact on the design.

      Software used for design and analyses.

      Decisive design factors derived from the route survey, environmental, corrosion

    and protection philosophy, specific operating criteria, required lifetime for the

     pipeline, etc.

    7.2.1.3  Code deviations shall not be accepted by the IB.

    7.2.1.4  This design should include a description and drawing that shows the boundary limits of

    this project. These boundary limits should note the upstream provider as well as the

  • 8/17/2019 6464 Nat Gas Code

    69/223

     plant and be taken into consideration for the pipeline design, particularly taking into

    account possible hazards to the NG system due to the surrounding areas.

    7.2.1.8  Above ground installations such as an inlet valve station or a PRMS etc. shall be fitted

    with a sunshade. Welded sections of pipework, without mechanical fittings or

    instrumentations, originally designed to withstand solar radiation input is exempt from

    this requirement.

    7.2.1.9  All above ground installations or pipes shall be suitably protected from mechanical impact

    (e.g. using bollards or the like).

    7.2.1.10  The detailed design shall include the following items that firmly establish the system

     parameters, installation and operating criteria and limitations. This shall address the

    following, but not limited to:

      List of design personnel names, roles and initials.

      Basis of Design and project specific introduction.

      Overall design philosophy and statements of code compliance.

      A list of the codes applied and the precedence code.

      Design pressure and operating pressure ranges(The MIP provided by the

    upstream supplier shall be lower than the design pressure).

    Design and operational temperatures(Design temperatures shall be at least -10 to

  • 8/17/2019 6464 Nat Gas Code

    70/223

      All tie-in interfaces between the upstream provider and the inlet valve station

    should be above ground and flanged, if applicable

      Consideration shall be made for the future connections e.g. safe connection to a

    gassed up system and the inclusion of a double block and bleed configuration,

    etc.

      Insulation Joints (IJ) and/or Insulating Flange Kits shall be installed above

    ground. Insulation Joints should be installed in the Horizontal position only. If

    this requirement cannot be met, the IJ shall withstand the maximum inducedstress allowed.

      If required according to the results of the HAZID, the plant inlet valve station

    shall be equipped with a Fail Close remotely operated valve and a pressure

    indicator transmitter. A temperature transmitter shall be considered by the

    designer based on the upstream equipment and supply conditions. The inlet valve

    station shall not be visible from the public domain.

      Wall thickness calculations have to take into account, at least 1 mm of corrosion

    allowance.

      Design drawings, Isometrics and an aerial photo (Tatza) with the pipe route,

    valve station, gas consumers etc., superimposed.

  • 8/17/2019 6464 Nat Gas Code

    71/223

    o  Backfilling (including compaction requirements) of buried pipes; the

    report shall specify any parameters necessary for stress analysis of

    the system to be conducted appropriately.

    o  The foundation design of any new pipe supports or pipe bridges.

    o  Any HDDs to be conducted.

      Drawings capturing any recommendations outlined in the Geotechnical Report

      HDD shall be designed according to the requirements of PPI (Plastic Pipe

    Institute) TR-46 or ASTM F-1962 as applicable.

      Pipe Protection measures (concrete coating, saddles, vehicle crash protection

    etc.)

      Risk assessment including HAZID

      Fire and Gas assessment and mapping. Any pit, building or room containing a

    gas piping installation has to be ventilated to prevent the accumulation of gas

    such as could occur from minor gas escapes and achieve the desired hazardous

    area zone type.

      Electrical basis of design and drawings.

      Control and Instrumentation basis of design and drawings.

  • 8/17/2019 6464 Nat Gas Code

    72/223

    o  Load case table (Sustained, Expansion, Occasional, Operational,

    Hydrostatic and Fatigue).

    o  Ancillary pipework including bypasses and vent lines.

    o  Electronic copies of the output files.

    o  Restraint summary report inclusive of the forces and moments at

    each support type.

    o  Code compliance summary report.

    o  Stress isometrics generated by the software.

      Pressure Test Plan which shall include the following:

    o  A table containing the various test sections (numbered and color

    coded), design and test pressures, test medium and test duration.

    o  General Arrangement Drawing or Pipe Isometrics indicating the

    highlighted test sections in color and cross referenced with the table

    detailed above.

    o  Only one golden weld is permitted. Any Additional golden weld

    shall be approved by the IB.  The designer's procedure for testing

    which includes his requirements for the performance of the test. The

  • 8/17/2019 6464 Nat Gas Code

    73/223

    7.2.2  The IB Review Process

    7.2.2.1  The IB shall review the design for content and shall be allowed to reject the design out ofhand, should the package quality not meet the required standards.

    7.2.2.2  In the event that the package is rejected as such, the End User shall have the right to

    reissue the package upon revision as described above. This reissuance shall include a

    specific table of changes made to the package that will assure that the package is robust.

    This revised package shall also be approved by the experienced and independent

    international design firm prior to submission for IB review, if applicable.

    7.2.2.3  Upon initial acceptance of the design package, the IB shall carry out a design review and

    issue an approval or design comments. These design comments shall be provided in a

    tabular format to the End User for response.

    7.2.2.4  Responses to these comments shall be provided to the IB within the table format to assure

    tracking of the comments. Revised documentation shall be provided in the format asdescribed above. Changes from previous submissions shall be indicated on all revised

    documents submitted.

    7.2.2.5  The tracking of this design review stage shall be carried out strictly through the table and

    therefore, it is advised that a highly detailed response be provided within the table along

    with a specific mention of the location of the document within the revised package.

  • 8/17/2019 6464 Nat Gas Code

    74/223

    7.3  Procurement

    7.3.1  Manufacturing of the System

    7.3.1.1  The procurement process shall be based on the approved design package.

    7.3.1.2  The End User shall obtain all materials from reputable suppliers.

    7.3.1.3  End User shall establish acceptance criteria associated with suppliers and demonstrate that

    these are met through conducting a pre-qualification process.

    7.3.1.4  This process of approval by the End User shall be fully documented for the possible audit by the IB.

    7.3.1.5  Procured pipes shall be hydrostatically pressure tested at the mill.

    7.3.1.6  Procured valves shall be antistatic and fire safe and certified accordingly, Ball valves shall

     be of a solid ball type. The UK HSE HSG 253 (the safe isolation of plant and equipment)

    document shall be used for determining the type of valves intended for the specific

     purpose and use.

    7.3.1.7  The use of unlisted components is not permitted in systems that have been designed

    according to the requirements of ASME B31.3.

    7 3 2 Lawful code

  • 8/17/2019 6464 Nat Gas Code

    75/223

    7.3.3.2  Steel

    Each component, pipe, fittings and part shall have its own unique manufacturing, inspection and

    test certificate which shall be presented to the IB. Components on design pressure systems above

    16 barg shall be supplied with an EN 10204 3.2 inspection certificate unless the end user has a

     previous positive record with the specific components supplier and was prior approved by the

    inspection body, then EN 10204 3.1 inspection certificate shall be used. The Technical Expert

    shall accept the definitive material certificate by signing off the original documents. The

    certificates of components fabricated/manufactured from other certified parent components shall

     be provided with the certificate of the parent component.

    Note  –  For new installations, the inspector should use the following table:

  • 8/17/2019 6464 Nat Gas Code

    76/223

    Notes:

    (1)  Drawing and calculation shall be submitted by the supplier prior to the production for

    INGL approval.

    (2)  Drawing shall be submitted by the supplier prior to the production for INGL approval

    (3)  For bolts diameter ≥ 3", 3.2 Certificate is required. The bolts and Nuts shall comply with

    ASTM A193 B7 for the bolts and A194 2H for the nuts. The bolts shall be supplied with

    cadmium plated as preference or with hot deep zinc galvanized as alternative to be

    approved by the Company.

    7.3.4  Traceability

    7.3.4.1  PE

    Each PE pipe and fitting shall have a fully traceable history of its manufacturing process and

    acceptance testing.

    7.3.4.2  Steel

    Each pipe or piping component shall have a fully traceable history inclusive of its marking

    certificate and all steps of its manufacturing process and acceptance testing

  • 8/17/2019 6464 Nat Gas Code

    77/223

      Corrosion coating for Flanges, Tees, valves and any other components

      As a minimum, the following data shall be reviewed:

      Chemical composition of base materials in compliance with chosen material

    grade.

      Mechanical properties of base materials based testing as per the relevant code.

      Destructive tests may include: tensile testing (longitudinal and transverse),

    fracture toughness, hardness (Charpy V, CTOD), lamination detection, bending,

    etc.  Mechanical properties of all welds inclusive of HAZ (Heat Affected Zone).

      Mechanical properties after bending, forging, heat treatment, forming of base

    materials.

      Corrosion sensitivity of end product. Accelerated corrosion testing of weld, HAZ

    and base material sample.

      Dimensions.

      Measurements of wall thickness, pipe straightness, pipe body ovality, pipe end

    ovality.

  • 8/17/2019 6464 Nat Gas Code

    78/223

    7.4  Construction

    7.4.1  Construction of the system

    Upon completion of the above items, the End User may commence with the construction

    document's submittal. The IB will review and provide comments to the issues stated above. End

    User shall provide response to these comments in a timely manner. No construction activity

    should take place prior to resolving all comments to the satisfaction of the IB. The construction

     procedures review process may be timely and should be taken into account when developing the

    schedule. In a sufficient time prior to construction, the End User shall provide the following

    information:

    7.4.1.1  Quality Management System procedure

    The End User shall be responsible to supply the IB with a detailed Quality Management System

    Plan. This plan shall be assessed by the IB on its safety aspects through a formal and systematic

    review of the installation plan with the objective of hazard identification and execution concerns.

    The plan shall provide full details of the pipeline installation aspects with emphasis on

    management of personnel safety and pipeline integrity control during all phases of the installation.

    Procedures shall be developed for all specific installation aspects such as the pipe laying, pipe

  • 8/17/