AS/NZS 3788:2006
Pressure equipment - In-service inspection
Aligns the Standard with current equipment integrity management and assessment practices and addresses some of the problems currently experienced in industry.
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AS/NZS 3788:2006 PRESSURE EQUIPMENT-IN-SERVICE INSPECTION
PREFACE
CONTENTS
SECTION 1 SCOPE AND GENERAL
1.1 SCOPE
1.2 APPLICATION
1.3 REFERENCED AND RELATED DOCUMENTS
1.3.1 Referenced documents
1.3.2 Related documents
1.4 DEFINITIONS
1.4.1 Inspector
1.4.2 Inspection body
1.4.3 Competent person
1.4.4 Inspection
1.4.5 Surveillance
1.4.6 Pressure equipment and ancillaries
1.4.7 Owner/User/Responsible person
1.4.8 Defects
1.4.9 In-service
1.5 RISK MANAGEMENT AND RISK BASED INSPECTION
1.6 SAFETY
1.7 SPECIAL CONDITIONS AND VARIATIONS
1.8 REFERENCED STANDARDS
SECTION 2 INSPECTION REQUIREMENTS
2.1 OBJECTIVES OF INSPECTION
2.2 ASSET INTEGRITY LIFE CYCLE
2.3 INSPECTION PROCESS
SECTION 3 INSPECTION PERSONNEL AND ADMINISTRATION
3.1 OWNER'S RESPONSIBILITIES
3.2 RESPONSIBILITIES AND CAPABILITIES OF PERSONS CARRYING OUT IN-SERVICE INSPECTION
3.2.1 General
3.2.2 Particular responsibilities
3.3 RESPONSIBILITIES OF INSPECTION BODIES
3.4 SUPPORT ORGANIZATIONS
SECTION 4 PRESSURE EQUIPMENT INSPECTION
4.1 GENERAL
4.2 COMMISSIONING OR RECOMMISSIONING INSPECTION
4.3 OPERATING SURVEILLANCE AND MONITORING
4.4 PERIODIC INSPECTION
4.4.1 Basis and types of inspection
4.4.2 Periodic inspection of pressure equipment
4.4.3 First inservice inspection
4.4.4 Intervals for periodic inspection
4.5 RISK BASED INSPECTION
4.6 INSPECTION OF IDLE PRESSURE EQUIPMENT
4.7 PRESSURERELIEF DEVICES
4.7.1 General
4.7.2 Commissioning and re-commissioning
4.7.3 On-line external visual inspection
4.7.4 Scheduled testing and maintenance
4.7.5 Testing and maintenance documentation
4.7.6 Re-adjustment and testing
4.7.7 Bursting discs
4.7.8 Rupture pin valves (buckling pin non-reclosing pressure relief device)
4.7.9 Fusible plugs
4.8 CONTROLS CRITICAL FOR SAFEGUARDING EQUIPMENT
4.8.1 Pressure-actuated devices
4.8.2 Temperature-actuated devices
4.8.3 Excess flow and back check valves
4.8.4 Quick-actuating closure interlocks and swing bolt doors
4.8.5 Relief valve isolation
4.9 INSTRUMENTATION AND CONTROLS
4.10 EMERGENCY SHUTDOWN SYSTEMS
4.11 AUTOMATIC FIRE-FIGHTING SYSTEMS USED TO PROTECT PRESSURE EQUIPMENT
4.12 LOW TEMPERATURE VESSELS
4.12.1 Vacuum-insulated vessels
4.12.2 Insulated, non-vacuum, non-jacketed vessels
4.12.3 Transportable vessels
4.13 PRESSURE PIPING
4.13.1 General
4.13.2 Intervals for periodic inspection of piping
SECTION 5 ASSESSMENT OF PRESSURE EQUIPMENT INTEGRITY
5.1 GENERAL
5.1.1 Scope of Section
5.1.2 Responsibility
5.1.3 Documentation
5.2 FITNESS FOR SERVICE ASSESSMENT
5.2.1 Introduction
5.2.2 Initial review
5.2.3 Investigation of defects
5.2.4 Thinning of walls
5.2.5 Cracking and crack-like defects
5.2.6 Volume type weld defects
5.2.7 Dents
5.2.8 Metallurgically damaged material
5.2.9 Leakage
5.2.10 Bulging
5.3 DETERMINATION OF REMAINING LIFE
5.4 DE-RATING
5.4.1 General
5.4.2 Presence of defects
5.4.3 Changed operating conditions
SECTION 6 REPAIRS, ALTERATIONS AND RE-RATING
6.1 GENERAL
6.1.1 General requirements
6.2 REPAIRS
6.2.1 Procedure and design
6.2.2 Minor repairs
6.2.3 Welder qualifications
6.2.4 Retrospectivity
6.3 RERATING
SECTION 7 INVESTIGATION OF DETERIORATION AND FAILURES
7.1 GENERAL
7.2 FAILURE ANALYSIS
7.3 RECORDING OF INCIDENTS AND FAILURES
SECTION 8 PRESSURE EQUIPMENT DOCUMENTATION AND IDENTIFICATION
8.1 INFORMATION FILES
8.2 REGISTER OF PRESSURE EQUIPMENT
8.3 PRESSURE EQUIPMENT IDENTIFICATION
8.3.1 General
8.3.2 Numbering systems
8.4 PRESSURE EQUIPMENT MARKING
8.4.1 General
8.4.2 Inadequate marking
8.5 PRESSURE EQUIPMENT DATA
8.5.1 General
8.5.2 Missing documentation
8.6 PRESSURE EQUIPMENT HISTORY
APPENDIX A - REFERENCED AND RELATED DOCUMENTS
A1 REFERENCED DOCUMENTS
A2 RELATED DOCUMENTS
APPENDIX B - RISK MANAGEMENT
B1 GENERAL
B2 RISK ANALYSIS AND MANAGEMENT TECHNIQUES
B2.1 General
B2.2 Hazard survey
B2.3 Hazard and operability study
B2.4 Reliability study
B2.5 System reliability and fault tree analysis
B2.6 Consequence analysis
B3 PERIODIC REVIEWS AND AUDITS
B4 USE OF RISK MANAGEMENT
B5 RISK BASED INSPECTION
APPENDIX C - SAFETY DURING INSPECTION
C1 GENERAL
C2 HAZARDOUS SUBSTANCES
C3 INSPECTION EQUIPMENT
C4 SAFETY AND PROTECTIVE EQUIPMENT
C5 ISOLATION AND TAGGING
APPENDIX D - METHODS OF INSPECTION
D1 SCOPE
D2 METHODS
D3 DOCUMENTATION
D4 SURFACE PREPARATION
D5 COMPETENCE
D6 VISUAL EXAMINATION (VT)
D6.1 General
D6.2 External visual examination
D6.3 Internal visual examination
D7 THICKNESS TESTING
D8 RADIOGRAPHIC EXAMINATION (RT)
D9 ULTRASONIC EXAMINATION (UT)
D10 MAGNETIC PARTICLE EXAMINATION (MT)
D11 PENETRANT EXAMINATION (PT)
D12 INFRARED THERMOGRAPHY
D13 OTHER NONDESTRUCTIVE EXAMINATION METHODS
D14 METALLURGICAL TESTING
D14.1 Material identification
D14.2 Hardness
D14.3 Microscopy and replication
D15 HYDROSTATIC PRESSURE TEST
D15.1 General
D15.2 Test pressure
D15.3 Test medium
D15.4 Test temperature
D15.5 Hydrostatic test procedure
D15.6 Reporting of results
D16 PNEUMATIC PRESSURE TEST
D16.1 Application
D16.2 General precautions
D16.3 Examination of welds
D16.4 Test temperature
D16.5 Test pressure
D16.6 Test procedure
D16.7 Reporting of results
D17 COMBINED HYDROSTATIC/PNEUMATIC TEST
D18 LEAK TESTING
D18.1 General
D18.2 Pneumatic leak testing of low temperature vessels
D19 DESTRUCTIVE TESTING
D20 INSPECTION OF INTERNAL LININGS
APPENDIX E - INSPECTION AND REPAIR OF TRANSPORTABLE VESSELS
E1 GENERAL
E2 MATERIALS OF CONSTRUCTION
E3 INSPECTION
E3.1 Inspection intervals
E3.2 Visual examination
E3.3 Non-destructive examination
E3.4 Ancillary equipment
E4 REPAIRS, ALTERATION AND RERATING OF TRANSPORTABLE VESSELS
E4.1 General
E4.2 Repairs
E4.3 Non-destructive examination
E4.4 Repair after accident
E4.5 Post weld heat treatment
APPENDIX F - INSPECTION OF BOILERS
F1 PRESHUTDOWN INSPECTION
F2 SHUTDOWN PROCEDURE
F3 PREPARATION FOR SHUTDOWN INSPECTION
F4 SHUTDOWN INSPECTION
F5 INSPECTION OF BOILER MANAGEMENT SYSTEMS
F6 INSPECTION DURING RECOMMISSIONING
F7 BOILER ANCILLARY EQUIPMENT
F8 REPORT
APPENDIX G - INSPECTION OF UNFIRED PRESSURE VESSELS-STATIONARY
G1 GENERAL
G2 AIR RECEIVERS
G3 PRESSURIZED STORAGE VESSELS
G4 LP GAS STORAGE VESSELS
G5 PROCESS VESSELS
G6 AUXILIARY VESSELS
G7 AUTOCLAVES
G8 STEAM JACKETED VESSELS
G9 REPORT
APPENDIX H - INSPECTION OF HEAT EXCHANGERS, COOLERS AND CONDENSERS
H1 GENERAL
H2 SHELL AND TUBE HEAT EXCHANGERS
H3 AIRCOOLED HEAT EXCHANGERS
H4 PLATE HEAT EXCHANGERS
H5 REPORT
APPENDIX I - INSPECTION OF PRESSURE PIPING
I1 GENERAL
I2 PIPING INTEGRITY PROGRAMS
I3 POSSIBLE MODES AND CAUSES OF FAILURE
I4 INSPECTION INTERVALS
I5 DATA AND HISTORY RECORDS
I5.1 Data
I5.2 History records
I6 VISUAL INSPECTION
I6.1 General external visual inspection
I6.2 Inspection during operation and shutdown
I6.3 Inspection during outage and start-up
I7 NONDESTRUCTIVE TESTING (NDT)
I8 THE EFFECTS OF CREEP AND THERMAL FATIGUE ON PIPING
I8.1 Creep
I8.2 Thermal fatigue
I8.3 Combined creep and thermal fatigue
I9 BURIED PIPING
I10 RISK-DIRECTED OR RISK-BASED APPROACHES TO PIPING INTEGRITY
I11 MANAGEMENT OF PIPING NDT SCOPE
I12 ONGOING THICKNESS TESTING PROGRAMS
APPENDIX J - INSPECTION OF FIRED HEATERS
J1 GENERAL
J2 INSPECTION OF PRESSURE COMPONENTS
J3 INSPECTION OF FIRESIDE COMPONENTS
J4 EXTERNAL INSPECTION
J5 TESTING
APPENDIX K - EXAMPLE INSPECTION REPORTS
APPENDIX L - PRESERVATION AND INSPECTION OF IDLE PRESSURE EQUIPMENT
L1 GENERAL
L2 DECOMMISSIONING
L3 EXTERNAL INSPECTION
L4 INTERNAL INSPECTION
L5 PRESERVATION PROCEDURE
L6 MONITORING OF PRESSURE EQUIPMENT STANDING IDLE
L7 RECOMMISSIONING
APPENDIX M - COMMON MODES AND CAUSES OF DETERIORATION AND FAILURE
M1 GENERAL
M2 CORROSION
M2.1 General (uniform) corrosion
M2.2 Localized corrosion
M2.3 Galvanic corrosion
M2.4 Velocityrelated corrosion
M2.5 Intergranular corrosion
M2.6 Dealloying
M2.7 Corrosion induced cracking
M2.8 High temperature corrosion
M3 HYDROGEN BLISTERING
M4 HYDROGEN SULPHIDE CRACKING
M5 FATIGUE
M6 DISTORTION BY OVERHEATING
M7 CREEP
M8 BRITTLE FRACTURE
M9 LIQUID METAL EMBRITTLEMENT
M10 OVER-PRESSURIZATION
M11 OVERLOADING
M12 EARTHQUAKES, EARTH SETTLEMENT AND WIND LOADING
M13 MECHANICAL DAMAGE
M14 EROSION
M14.1 Internal
M14.2 External
M15 FAULTY MATERIAL
APPENDIX N - ASSESSMENT OF LOCALIZED WALL THINNING OF CYLINDRICAL, CONICAL, AND SPHERICAL SHELLS
N1 GENERAL
N2 NOTATION
N3 ASSESSMENT PROCEDURE
N3.1 Method
N3.2 Definition of thinned area
N3.3 Minimum calculated thickness
N3.4 Characteristic shell length (Ls)
N3.5 Mean thickness of trapezoidal patches
N3.6 Allowable minimum thickness
N3.7 Acceptability of thinning
N4 TREATMENT OF THINNED AREAS
N5 EXAMPLE OF ASSESSMENT OF LOCALLY THINNED WALL
N5.1 Example with no weld in thinned area
N5.2 Example with weld in thinned area
N5.3 Example of Dm for corroded area within a vessel
APPENDIX O - ASSESSMENT OF PLANAR DEFECTS
O1 GENERAL
O2 ASSESSMENT
O2.1 General
O2.2 Original equipment design data
O2.3 Maintenance and operating history
O2.4 Material property data
O2.5 Flaw characterization
O3 FITNESS FOR SERVICE ASSESSMENT CONCEPTS
O3.1 Subcritical crack growth
O3.2 Leak before break analysis
O3.3 Remaining life
O4 REMEDIATION CONCEPTS
O4.1 Removal or repair of the crack
O4.2 Use of a crack arresting detail or device
O4.3 Performing physical changes
O4.4 Isolation on change of environment
O5 DOCUMENTATION REQUIREMENTS
O6 SIMPLIFIED FRACTURE MECHANICS
O6.1 General
O6.2 Notation
O6.3 Critical crack size (ac)
O6.4 Crack growth due to fatigue
O6.5 Safety factors
O6.6 Examples of application of simplified fracture mechanics for assessing cracklike defects
APPENDIX P - PRESSURE RELIEF VALVES-SUPPLEMENTARY INFORMATION
P1 GENERAL
P2 GUIDANCE ON TEST INTERVAL
APPENDIX Q - INSPECTION OF PRESSURE EQUIPMENT WITH QUICK-ACTUATING CLOSURES AND SWING BOLT DOORS
Q1 INSPECTION
Q2 RECORDS
APPENDIX R - INSPECTION OF BURIED OR MOUNDED PRESSURE VESSELS
R1 EXTERNAL INSPECTION OF PRESSURE VESSELS WITHOUT CATHODIC PROTECTION
R2 EXTERNAL INSPECTION OF PRESSURE VESSELS WITH CATHODIC PROTECTION
R3 RECORDS
APPENDIX S - INSPECTION OF DEAERATORS
S1 GENERAL
S2 INSPECTION AND REPAIR
APPENDIX T - INSPECTION OF STORAGE TANKS TO API 620 OR EQUIVALENT
T1 SCOPE
T2 AMBIENT TEMPERATURE AND HEATED TANKS
¿T3 LOW TEMPERATURE STORAGE TANKS (tanks normally operating below ¿10¿C)
T3.1 Internal inspection of low temperature storage tanks
T3.2 External inspection of low temperature storage tanks
APPENDIX U - REMAINING LIFE ASSESSMENT
U1 BACKGROUND
U2 FACTORS AFFECTING REMAINING LIFE
U3 THREE STAGE REMAINING LIFE ASSESSMENT
U3.1 General
U3.2 Stage 1-Review of remaining life-design based
U3.3 Stage 2-Review of remaining life-operational data and history based
U3.4 Stage 3-Review of remaining life-testing and inspection based
U4 PRESSURE PIPING
U5 REMAINING LIFE ASSESSMENT
U5.1 Investigation method
U5.2 Fatigue
U5.3 Creep
U5.4 Combined creep and fatigue
U5.5 Wastage or general corrosion
U5.6 Combined creep, fatigue and wastage
U5.7 Review of design life of pressure equipment of advanced design and construction
U5.8 Inspection prior to end of remaining life
U6 WORKED EXAMPLE OF A THREE-STAGE REMAINING LIFE ASSESSMENT
APPENDIX V - COMPETENCY OF IN-SERVICE INSPECTION BODIES AND PERSONNEL
V1 GENERAL
V2 EVIDENCE OF COMPETENCY
V3 KEY KNOWLEDGE AND COMPETENCY AREAS
APPENDIX W - INSPECTION OF DRUMS FOR TRANSPORT OF LIQUEFIED GAS
W1 APPLICATION
W2 PERIODIC INSPECTION AND TESTING
W3 EXTERNAL EXAMINATION
W3.1 General
W3.2 Bulge
W3.3 Burn
W3.4 Dents
W3.5 Cuts and gouges
W3.6 Isolated pits
W3.7 Chain pitting and line corrosion
W3.8 General corrosion
W3.9 Gas leakage
W3.10 Fire damage
W4 INTERNAL EXAMINATION
W5 CLEANING
W6 WEIGHING
W7 MARKING
W8 RECORDING
W9 PLUGS AND VALVES
APPENDIX X - TESTING OF SOFT SEATED POP ACTION RELIEF VALVES FOR LIQUEFIABLE GAS SERVICE
X1 GENERAL
X2 PRESSURE GAUGES
X3 TEST PROCEDURE
X4 PASS/FAIL CRITERIA
APPENDIX Y - INSPECTION OF HERITAGE BOILERS AND PRESSURE VESSELS
Y1 INTRODUCTION
Y2 TYPES OF EQUIPMENT AND RESPONSIBILITIES
Y3 TYPE FAULTS
Y3.1 Cracking of lap joints and use of test grooves
Y3.2 Radial cracking
Y4 OPERATIONAL ISSUES
Y4.1 Caustic cracking and water treatment
Y4.2 Mud, scale and restricted circulation
Y4.3 Stayed areas
Y4.4 Fusible plugs
Y4.5 Gauge glasses and other fittings
Y5 EQUIPMENT ISSUES
Y5.1 Pressure vessels
Y5.2 Water tube boilers
Y5.3 Fire tube boilers
Y6 TESTING
Y6.1 Hydrostatic testing
Y6.2 Ultrasonic testing
Y7 REPAIRS
Y8 RECORDS
APPENDIX Z - INSPECTION OF FOUNDATIONS AND STRUCTURES
Z1 SCOPE
Z2 FOUNDATIONS AND STRUCTURES
Z3 INSPECTION
Z4 INSPECTION INTERVAL
Z5 REINFORCED CONCRETE FOUNDATIONS AND STRUCTURES
Z6 METALLIC STRUCTURES
Z7 BOLTS
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References
Specification for design and construction of ferrous piping installations for and in connection with land boilers
Pressure equipment - Inspection bodies and personnel
Related Information
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: 3.8.3
Citation context:Repairs, alterations and re-rating of in-service pressure equipment shall comply with AS/NZS 3788 and this code or be acceptable to an inspection body.
Approved Code Of Practice For The Design, Safe Operation, Maintenance And Servicing Of Boilers, 2000 Edition Incorporating Amendment 1:2004
Ministry: WorkSafe New Zealand
Section: 1.29.7
Citation context:Inspection periods may only be extended beyond those in columns 4 and 5, table 4.1 of AS NZS 3788 and table 1.2 above, where these have been approved by the Secretary in writing, …
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: 3.2.5
Citation context:All pressure equipment shall be installed so that the isolation requirements of clause C.5 of AS/NZS 3788, and/or clause 3.4.3 of AS 3873 can be met.
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: 3.7.3
Citation context:All pressure equipment shall be installed so that the isolation requirements of clause C.5 of AS/NZS 3788, and/or clause 3.4.3 of AS 3873 can be met.
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: 3.7.3(3)
Citation context:In-service equipment ... (3) Controllers of pressure equipment which: (a) Contains catalysts; or (b) Is not specifically covered in table 4.1 of AS/NZS 3788 or schedule A: shall consult with an inspection body on the inspection periods for the equipment.
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: 3.7.5(1)
Citation context:Inspection periods may be extended beyond those specified in columns 4 and 5, table 4.1 of AS/NZS 3788 or schedule A of this code, only where a controller’s ITP for the equipment concerned has been recognised by the Secretary.
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: 3.8.2(1)
Citation context:Records shall be kept of the operation, maintenance, repair, alteration and servicing of pressure equipment in accordance with AS/NZS 3788 and this code. These shall include ...
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: 3.8.4
Citation context:The safe remaining life of pressure equipment shall be determined in accordance with this code and AS/NZS 3788 or by equivalent methods acceptable to an inspection body.
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: 7.7.7(c)
Citation context:Turbine ancillary systems, coming within the scope of the PECPR Regulations, shall be inspected and tested in accordance with AS/NZS 3788 and this code of practice.
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: Appendix E1
Citation context:Pressure relief devices shall be serviced, maintained, tested and inspected in accordance with AS/NZS 3788 except as modified by this appendix.
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: Appendix E2
Citation context:Controllers shall ensure that records for pressure relief devices are maintained in accordance with the requirements of AS/NZS 3788.
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: Appendix F1.1
Citation context:In-service pressure equipment which is not excluded by the PECPR Regulations or, covered by an exemption notice issued under the regulations, shall be inspected following commissioning and thereafter inspected periodically in accordance with AS/NZS 3788 e
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: Appendix F2.2
Citation context:Where inspection periods are derived from Table 4.1, AS/NZS 3788, controllers shall have a management system for equipment that satisfies the requirements of Section 3, AS/NZS 3788 and this appendix. This shall be either a documented operating and mainten
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: Appendix F5.1
Citation context:First yearly inspections shall be carried out where indicated by table 4.1, AS/NZS 3788 and these shall include both internal and external inspections.
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: Appendix F6
Citation context:AS/NZS 3788 is cited extensively in Appendix F6.
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: Appendix F7.1(1)
Citation context:‘Extended periods’ of inspection as noted in 4.4.3.2 and 4.4.3.3(b), AS/NZS 3788 shall only be approved by an inspection body where the controller’s ITP has been recognised by the Secretary. The maximum ‘extended periods’ permitted are shown in column 6 o
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: Appendix F7.3(b)(v)
Citation context:... It is in conformance with the requirements of AS/NZS 3788 for extended inspection periods; and ...
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: Appendix F8
Citation context:Further extended periods of inspection as described in 4.4.3.3(c), AS/NZS 3788 shall only be approved by an inspection body where: (1) The controller’s ITP covering the equipment has been recognised by the Secretary; and (2) The requirements of 4.4.3.3(c)
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: Appendix J7.3
Citation context:... This shall include the vessel, fittings, piping and structural supports and any requirements of AS/NZS 3788. ...
Approved Code Of Practice For Pressure Equipment (Excluding Boilers) 2001
Ministry: WorkSafe New Zealand
Section: Schedule C
Citation context:AS/NZS 3788 (latest edition) is listed as a referenced standard
Approved Code Of Practice For The Design, Safe Operation, Maintenance And Servicing Of Boilers, 2000 Edition Incorporating Amendment 1:2004
Ministry: WorkSafe New Zealand
Section: 1.29.3
Citation context:In-service boilers shall be inspected and tested in accordance with the Health and Safety in Employment (Pressure Equipment, Cranes and Passenger Ropeways) Regulations 1999, AS/NZS 3788 and other relevant requirements of this code. The equipment inspector
Approved Code Of Practice For The Design, Safe Operation, Maintenance And Servicing Of Boilers, 2000 Edition Incorporating Amendment 1:2004
Ministry: WorkSafe New Zealand
Section: 1.29.4
Citation context:Inspection periods for in-service boilers shall be in accordance with AS/NZS 3788 except as modified by ….
Approved Code Of Practice For The Design, Safe Operation, Maintenance And Servicing Of Boilers, 2000 Edition Incorporating Amendment 1:2004
Ministry: WorkSafe New Zealand
Section: Appendix A2
Citation context:AS/NZS 3788 Pressure equipment - In-service inspection.
Approved Code Of Practice For The Design, Safe Operation, Maintenance And Servicing Of Boilers, 2000 Edition Incorporating Amendment 1:2004
Ministry: WorkSafe New Zealand
Section: 1.15.1
Citation context:Controllers responsible for safety valves shall ensure that records for safety valves are maintained in accordance with the requirements of AS/NZS 3788
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AS/NZS 3788:2006 PRESSURE EQUIPMENT-IN-SERVICE INSPECTION
PREFACE
CONTENTS
SECTION 1 SCOPE AND GENERAL
1.1 SCOPE
1.2 APPLICATION
1.3 REFERENCED AND RELATED DOCUMENTS
1.3.1 Referenced documents
1.3.2 Related documents
1.4 DEFINITIONS
1.4.1 Inspector
1.4.2 Inspection body
1.4.3 Competent person
1.4.4 Inspection
1.4.5 Surveillance
1.4.6 Pressure equipment and ancillaries
1.4.7 Owner/User/Responsible person
1.4.8 Defects
1.4.9 In-service
1.5 RISK MANAGEMENT AND RISK BASED INSPECTION
1.6 SAFETY
1.7 SPECIAL CONDITIONS AND VARIATIONS
1.8 REFERENCED STANDARDS
SECTION 2 INSPECTION REQUIREMENTS
2.1 OBJECTIVES OF INSPECTION
2.2 ASSET INTEGRITY LIFE CYCLE
2.3 INSPECTION PROCESS
SECTION 3 INSPECTION PERSONNEL AND ADMINISTRATION
3.1 OWNER'S RESPONSIBILITIES
3.2 RESPONSIBILITIES AND CAPABILITIES OF PERSONS CARRYING OUT IN-SERVICE INSPECTION
3.2.1 General
3.2.2 Particular responsibilities
3.3 RESPONSIBILITIES OF INSPECTION BODIES
3.4 SUPPORT ORGANIZATIONS
SECTION 4 PRESSURE EQUIPMENT INSPECTION
4.1 GENERAL
4.2 COMMISSIONING OR RECOMMISSIONING INSPECTION
4.3 OPERATING SURVEILLANCE AND MONITORING
4.4 PERIODIC INSPECTION
4.4.1 Basis and types of inspection
4.4.2 Periodic inspection of pressure equipment
4.4.3 First inservice inspection
4.4.4 Intervals for periodic inspection
4.5 RISK BASED INSPECTION
4.6 INSPECTION OF IDLE PRESSURE EQUIPMENT
4.7 PRESSURERELIEF DEVICES
4.7.1 General
4.7.2 Commissioning and re-commissioning
4.7.3 On-line external visual inspection
4.7.4 Scheduled testing and maintenance
4.7.5 Testing and maintenance documentation
4.7.6 Re-adjustment and testing
4.7.7 Bursting discs
4.7.8 Rupture pin valves (buckling pin non-reclosing pressure relief device)
4.7.9 Fusible plugs
4.8 CONTROLS CRITICAL FOR SAFEGUARDING EQUIPMENT
4.8.1 Pressure-actuated devices
4.8.2 Temperature-actuated devices
4.8.3 Excess flow and back check valves
4.8.4 Quick-actuating closure interlocks and swing bolt doors
4.8.5 Relief valve isolation
4.9 INSTRUMENTATION AND CONTROLS
4.10 EMERGENCY SHUTDOWN SYSTEMS
4.11 AUTOMATIC FIRE-FIGHTING SYSTEMS USED TO PROTECT PRESSURE EQUIPMENT
4.12 LOW TEMPERATURE VESSELS
4.12.1 Vacuum-insulated vessels
4.12.2 Insulated, non-vacuum, non-jacketed vessels
4.12.3 Transportable vessels
4.13 PRESSURE PIPING
4.13.1 General
4.13.2 Intervals for periodic inspection of piping
SECTION 5 ASSESSMENT OF PRESSURE EQUIPMENT INTEGRITY
5.1 GENERAL
5.1.1 Scope of Section
5.1.2 Responsibility
5.1.3 Documentation
5.2 FITNESS FOR SERVICE ASSESSMENT
5.2.1 Introduction
5.2.2 Initial review
5.2.3 Investigation of defects
5.2.4 Thinning of walls
5.2.5 Cracking and crack-like defects
5.2.6 Volume type weld defects
5.2.7 Dents
5.2.8 Metallurgically damaged material
5.2.9 Leakage
5.2.10 Bulging
5.3 DETERMINATION OF REMAINING LIFE
5.4 DE-RATING
5.4.1 General
5.4.2 Presence of defects
5.4.3 Changed operating conditions
SECTION 6 REPAIRS, ALTERATIONS AND RE-RATING
6.1 GENERAL
6.1.1 General requirements
6.2 REPAIRS
6.2.1 Procedure and design
6.2.2 Minor repairs
6.2.3 Welder qualifications
6.2.4 Retrospectivity
6.3 RERATING
SECTION 7 INVESTIGATION OF DETERIORATION AND FAILURES
7.1 GENERAL
7.2 FAILURE ANALYSIS
7.3 RECORDING OF INCIDENTS AND FAILURES
SECTION 8 PRESSURE EQUIPMENT DOCUMENTATION AND IDENTIFICATION
8.1 INFORMATION FILES
8.2 REGISTER OF PRESSURE EQUIPMENT
8.3 PRESSURE EQUIPMENT IDENTIFICATION
8.3.1 General
8.3.2 Numbering systems
8.4 PRESSURE EQUIPMENT MARKING
8.4.1 General
8.4.2 Inadequate marking
8.5 PRESSURE EQUIPMENT DATA
8.5.1 General
8.5.2 Missing documentation
8.6 PRESSURE EQUIPMENT HISTORY
APPENDIX A - REFERENCED AND RELATED DOCUMENTS
A1 REFERENCED DOCUMENTS
A2 RELATED DOCUMENTS
APPENDIX B - RISK MANAGEMENT
B1 GENERAL
B2 RISK ANALYSIS AND MANAGEMENT TECHNIQUES
B2.1 General
B2.2 Hazard survey
B2.3 Hazard and operability study
B2.4 Reliability study
B2.5 System reliability and fault tree analysis
B2.6 Consequence analysis
B3 PERIODIC REVIEWS AND AUDITS
B4 USE OF RISK MANAGEMENT
B5 RISK BASED INSPECTION
APPENDIX C - SAFETY DURING INSPECTION
C1 GENERAL
C2 HAZARDOUS SUBSTANCES
C3 INSPECTION EQUIPMENT
C4 SAFETY AND PROTECTIVE EQUIPMENT
C5 ISOLATION AND TAGGING
APPENDIX D - METHODS OF INSPECTION
D1 SCOPE
D2 METHODS
D3 DOCUMENTATION
D4 SURFACE PREPARATION
D5 COMPETENCE
D6 VISUAL EXAMINATION (VT)
D6.1 General
D6.2 External visual examination
D6.3 Internal visual examination
D7 THICKNESS TESTING
D8 RADIOGRAPHIC EXAMINATION (RT)
D9 ULTRASONIC EXAMINATION (UT)
D10 MAGNETIC PARTICLE EXAMINATION (MT)
D11 PENETRANT EXAMINATION (PT)
D12 INFRARED THERMOGRAPHY
D13 OTHER NONDESTRUCTIVE EXAMINATION METHODS
D14 METALLURGICAL TESTING
D14.1 Material identification
D14.2 Hardness
D14.3 Microscopy and replication
D15 HYDROSTATIC PRESSURE TEST
D15.1 General
D15.2 Test pressure
D15.3 Test medium
D15.4 Test temperature
D15.5 Hydrostatic test procedure
D15.6 Reporting of results
D16 PNEUMATIC PRESSURE TEST
D16.1 Application
D16.2 General precautions
D16.3 Examination of welds
D16.4 Test temperature
D16.5 Test pressure
D16.6 Test procedure
D16.7 Reporting of results
D17 COMBINED HYDROSTATIC/PNEUMATIC TEST
D18 LEAK TESTING
D18.1 General
D18.2 Pneumatic leak testing of low temperature vessels
D19 DESTRUCTIVE TESTING
D20 INSPECTION OF INTERNAL LININGS
APPENDIX E - INSPECTION AND REPAIR OF TRANSPORTABLE VESSELS
E1 GENERAL
E2 MATERIALS OF CONSTRUCTION
E3 INSPECTION
E3.1 Inspection intervals
E3.2 Visual examination
E3.3 Non-destructive examination
E3.4 Ancillary equipment
E4 REPAIRS, ALTERATION AND RERATING OF TRANSPORTABLE VESSELS
E4.1 General
E4.2 Repairs
E4.3 Non-destructive examination
E4.4 Repair after accident
E4.5 Post weld heat treatment
APPENDIX F - INSPECTION OF BOILERS
F1 PRESHUTDOWN INSPECTION
F2 SHUTDOWN PROCEDURE
F3 PREPARATION FOR SHUTDOWN INSPECTION
F4 SHUTDOWN INSPECTION
F5 INSPECTION OF BOILER MANAGEMENT SYSTEMS
F6 INSPECTION DURING RECOMMISSIONING
F7 BOILER ANCILLARY EQUIPMENT
F8 REPORT
APPENDIX G - INSPECTION OF UNFIRED PRESSURE VESSELS-STATIONARY
G1 GENERAL
G2 AIR RECEIVERS
G3 PRESSURIZED STORAGE VESSELS
G4 LP GAS STORAGE VESSELS
G5 PROCESS VESSELS
G6 AUXILIARY VESSELS
G7 AUTOCLAVES
G8 STEAM JACKETED VESSELS
G9 REPORT
APPENDIX H - INSPECTION OF HEAT EXCHANGERS, COOLERS AND CONDENSERS
H1 GENERAL
H2 SHELL AND TUBE HEAT EXCHANGERS
H3 AIRCOOLED HEAT EXCHANGERS
H4 PLATE HEAT EXCHANGERS
H5 REPORT
APPENDIX I - INSPECTION OF PRESSURE PIPING
I1 GENERAL
I2 PIPING INTEGRITY PROGRAMS
I3 POSSIBLE MODES AND CAUSES OF FAILURE
I4 INSPECTION INTERVALS
I5 DATA AND HISTORY RECORDS
I5.1 Data
I5.2 History records
I6 VISUAL INSPECTION
I6.1 General external visual inspection
I6.2 Inspection during operation and shutdown
I6.3 Inspection during outage and start-up
I7 NONDESTRUCTIVE TESTING (NDT)
I8 THE EFFECTS OF CREEP AND THERMAL FATIGUE ON PIPING
I8.1 Creep
I8.2 Thermal fatigue
I8.3 Combined creep and thermal fatigue
I9 BURIED PIPING
I10 RISK-DIRECTED OR RISK-BASED APPROACHES TO PIPING INTEGRITY
I11 MANAGEMENT OF PIPING NDT SCOPE
I12 ONGOING THICKNESS TESTING PROGRAMS
APPENDIX J - INSPECTION OF FIRED HEATERS
J1 GENERAL
J2 INSPECTION OF PRESSURE COMPONENTS
J3 INSPECTION OF FIRESIDE COMPONENTS
J4 EXTERNAL INSPECTION
J5 TESTING
APPENDIX K - EXAMPLE INSPECTION REPORTS
APPENDIX L - PRESERVATION AND INSPECTION OF IDLE PRESSURE EQUIPMENT
L1 GENERAL
L2 DECOMMISSIONING
L3 EXTERNAL INSPECTION
L4 INTERNAL INSPECTION
L5 PRESERVATION PROCEDURE
L6 MONITORING OF PRESSURE EQUIPMENT STANDING IDLE
L7 RECOMMISSIONING
APPENDIX M - COMMON MODES AND CAUSES OF DETERIORATION AND FAILURE
M1 GENERAL
M2 CORROSION
M2.1 General (uniform) corrosion
M2.2 Localized corrosion
M2.3 Galvanic corrosion
M2.4 Velocityrelated corrosion
M2.5 Intergranular corrosion
M2.6 Dealloying
M2.7 Corrosion induced cracking
M2.8 High temperature corrosion
M3 HYDROGEN BLISTERING
M4 HYDROGEN SULPHIDE CRACKING
M5 FATIGUE
M6 DISTORTION BY OVERHEATING
M7 CREEP
M8 BRITTLE FRACTURE
M9 LIQUID METAL EMBRITTLEMENT
M10 OVER-PRESSURIZATION
M11 OVERLOADING
M12 EARTHQUAKES, EARTH SETTLEMENT AND WIND LOADING
M13 MECHANICAL DAMAGE
M14 EROSION
M14.1 Internal
M14.2 External
M15 FAULTY MATERIAL
APPENDIX N - ASSESSMENT OF LOCALIZED WALL THINNING OF CYLINDRICAL, CONICAL, AND SPHERICAL SHELLS
N1 GENERAL
N2 NOTATION
N3 ASSESSMENT PROCEDURE
N3.1 Method
N3.2 Definition of thinned area
N3.3 Minimum calculated thickness
N3.4 Characteristic shell length (Ls)
N3.5 Mean thickness of trapezoidal patches
N3.6 Allowable minimum thickness
N3.7 Acceptability of thinning
N4 TREATMENT OF THINNED AREAS
N5 EXAMPLE OF ASSESSMENT OF LOCALLY THINNED WALL
N5.1 Example with no weld in thinned area
N5.2 Example with weld in thinned area
N5.3 Example of Dm for corroded area within a vessel
APPENDIX O - ASSESSMENT OF PLANAR DEFECTS
O1 GENERAL
O2 ASSESSMENT
O2.1 General
O2.2 Original equipment design data
O2.3 Maintenance and operating history
O2.4 Material property data
O2.5 Flaw characterization
O3 FITNESS FOR SERVICE ASSESSMENT CONCEPTS
O3.1 Subcritical crack growth
O3.2 Leak before break analysis
O3.3 Remaining life
O4 REMEDIATION CONCEPTS
O4.1 Removal or repair of the crack
O4.2 Use of a crack arresting detail or device
O4.3 Performing physical changes
O4.4 Isolation on change of environment
O5 DOCUMENTATION REQUIREMENTS
O6 SIMPLIFIED FRACTURE MECHANICS
O6.1 General
O6.2 Notation
O6.3 Critical crack size (ac)
O6.4 Crack growth due to fatigue
O6.5 Safety factors
O6.6 Examples of application of simplified fracture mechanics for assessing cracklike defects
APPENDIX P - PRESSURE RELIEF VALVES-SUPPLEMENTARY INFORMATION
P1 GENERAL
P2 GUIDANCE ON TEST INTERVAL
APPENDIX Q - INSPECTION OF PRESSURE EQUIPMENT WITH QUICK-ACTUATING CLOSURES AND SWING BOLT DOORS
Q1 INSPECTION
Q2 RECORDS
APPENDIX R - INSPECTION OF BURIED OR MOUNDED PRESSURE VESSELS
R1 EXTERNAL INSPECTION OF PRESSURE VESSELS WITHOUT CATHODIC PROTECTION
R2 EXTERNAL INSPECTION OF PRESSURE VESSELS WITH CATHODIC PROTECTION
R3 RECORDS
APPENDIX S - INSPECTION OF DEAERATORS
S1 GENERAL
S2 INSPECTION AND REPAIR
APPENDIX T - INSPECTION OF STORAGE TANKS TO API 620 OR EQUIVALENT
T1 SCOPE
T2 AMBIENT TEMPERATURE AND HEATED TANKS
¿T3 LOW TEMPERATURE STORAGE TANKS (tanks normally operating below ¿10¿C)
T3.1 Internal inspection of low temperature storage tanks
T3.2 External inspection of low temperature storage tanks
APPENDIX U - REMAINING LIFE ASSESSMENT
U1 BACKGROUND
U2 FACTORS AFFECTING REMAINING LIFE
U3 THREE STAGE REMAINING LIFE ASSESSMENT
U3.1 General
U3.2 Stage 1-Review of remaining life-design based
U3.3 Stage 2-Review of remaining life-operational data and history based
U3.4 Stage 3-Review of remaining life-testing and inspection based
U4 PRESSURE PIPING
U5 REMAINING LIFE ASSESSMENT
U5.1 Investigation method
U5.2 Fatigue
U5.3 Creep
U5.4 Combined creep and fatigue
U5.5 Wastage or general corrosion
U5.6 Combined creep, fatigue and wastage
U5.7 Review of design life of pressure equipment of advanced design and construction
U5.8 Inspection prior to end of remaining life
U6 WORKED EXAMPLE OF A THREE-STAGE REMAINING LIFE ASSESSMENT
APPENDIX V - COMPETENCY OF IN-SERVICE INSPECTION BODIES AND PERSONNEL
V1 GENERAL
V2 EVIDENCE OF COMPETENCY
V3 KEY KNOWLEDGE AND COMPETENCY AREAS
APPENDIX W - INSPECTION OF DRUMS FOR TRANSPORT OF LIQUEFIED GAS
W1 APPLICATION
W2 PERIODIC INSPECTION AND TESTING
W3 EXTERNAL EXAMINATION
W3.1 General
W3.2 Bulge
W3.3 Burn
W3.4 Dents
W3.5 Cuts and gouges
W3.6 Isolated pits
W3.7 Chain pitting and line corrosion
W3.8 General corrosion
W3.9 Gas leakage
W3.10 Fire damage
W4 INTERNAL EXAMINATION
W5 CLEANING
W6 WEIGHING
W7 MARKING
W8 RECORDING
W9 PLUGS AND VALVES
APPENDIX X - TESTING OF SOFT SEATED POP ACTION RELIEF VALVES FOR LIQUEFIABLE GAS SERVICE
X1 GENERAL
X2 PRESSURE GAUGES
X3 TEST PROCEDURE
X4 PASS/FAIL CRITERIA
APPENDIX Y - INSPECTION OF HERITAGE BOILERS AND PRESSURE VESSELS
Y1 INTRODUCTION
Y2 TYPES OF EQUIPMENT AND RESPONSIBILITIES
Y3 TYPE FAULTS
Y3.1 Cracking of lap joints and use of test grooves
Y3.2 Radial cracking
Y4 OPERATIONAL ISSUES
Y4.1 Caustic cracking and water treatment
Y4.2 Mud, scale and restricted circulation
Y4.3 Stayed areas
Y4.4 Fusible plugs
Y4.5 Gauge glasses and other fittings
Y5 EQUIPMENT ISSUES
Y5.1 Pressure vessels
Y5.2 Water tube boilers
Y5.3 Fire tube boilers
Y6 TESTING
Y6.1 Hydrostatic testing
Y6.2 Ultrasonic testing
Y7 REPAIRS
Y8 RECORDS
APPENDIX Z - INSPECTION OF FOUNDATIONS AND STRUCTURES
Z1 SCOPE
Z2 FOUNDATIONS AND STRUCTURES
Z3 INSPECTION
Z4 INSPECTION INTERVAL
Z5 REINFORCED CONCRETE FOUNDATIONS AND STRUCTURES
Z6 METALLIC STRUCTURES
Z7 BOLTS
Previous versions
AS/NZS 3788:2006
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