Standard
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AS 3873-2001
[Current]Pressure equipment — Operation and maintenance
Specifies minimum requirements and guidance on the operation and maintenance of boilers, pressure vessels, associated control and safety equipment, piping and auxiliaries, and in the execution of such work. Covers actions required by the owner-user from initial receipt of the equipment on-site until final disposal. Applies to commissioning, operation, maintenance, routine inspection, storage and disposal, together with specific requirements for safety management systems, including where appropriate risk assessment. Applies to pressure equipment covered by AS/NZS 1200. The requirements do not apply to all hazard levels of pressure equipment.
Published: 06/03/2001
Pages: 65
Table of contents
Cited references
Content history
Table of contents
Header
About this publication
Preface
1 Scope and general
1.1 Scope
1.2 Application and objective
1.2.1 Application
1.2.2 Objective
1.3 Referenced documents
1.4 Definitions
2 Management and personnel
2.1 General
2.2 Safety management system
2.3 Documentation for safety management systems
2.4 Commissioning operations
2.5 Risk management
2.6 Process information
2.6.1 Availability
2.6.2 Process contents
2.7 Operator and maintenance personnel training
2.7.1 Training
2.7.2 Refresher training
2.7.3 Training and competency documentation
2.8 Operation and maintenance
2.9 Maintenance system
2.9.1 General
2.9.2 Maintenance organization
2.10 Contractors
2.11 Personnel participation and consultation
2.12 Management of change
2.13 Records
2.13.1 General
2.13.2 Access to records
2.13.3 Relocation
2.14 Incident investigation
3 General operating and maintenance procedures and practices
3.1 General
3.1.1 Operating procedures
3.1.2 Review
3.1.3 Operating limits
3.1.4 Reporting
3.2 Operating procedures
3.2.1 General
3.2.2 Pre-start equipment check
3.3 Operational surveillance
3.4 Safety practices and emergency procedures
3.4.1 General
3.4.2 Safety during maintenance
3.4.2.1 General
3.4.2.2 Entry into pressure equipment
3.4.2.3 Entry into flues and furnaces
3.4.2.4 Hot work on pressure equipment systems
3.4.2.5 Static electricity
3.4.2.6 Cooling pressure parts by hosing
3.4.3 Safe isolation
3.4.4 Emergency planning
3.4.5 Safety practices and emergency procedures
3.4.6 Safety information and records for pressure equipment used with hazardous substances
3.5 Orderliness of system and surrounding area
3.6 Maintenance procedures
3.6.1 Maintenance program
3.6.2 Control system
3.6.3 Repairs and alterations
3.6.4 Temporary and emergency repairs
3.7 Inspection
3.8 Out-of-service storage
3.8.1 General
3.8.2 Disconnecting and removal
3.8.3 Dry storage
3.8.4 Wet storage
3.9 Disposal
4 Boilers
4.1 General
4.2 Operating and maintenance instructions
4.2.1 General
4.2.2 Sequence of operations
4.2.3 Pre-start equipment check
4.2.4 Operations check
4.2.5 Testing and checking programs
4.2.5.1 General
4.2.5.2 Programs
4.2.5.3 Routine and periodic testing and maintenance
4.2.6 Daily checking and testing
4.2.6.1 General
4.2.6.2 Checks
4.2.6.3 Log
4.2.7 Routine maintenance and testing
4.2.7.1 General
4.2.7.2 Routine maintenance
4.2.7.3 Typical procedure
4.2.7.4 Records
4.2.7.5 Changes to procedure
4.2.8 Periodic maintenance and testing
4.2.8.1 General
4.2.8.2 Periodic inspection
4.2.8.3 Cleaning
4.2.8.4 Periodic maintenance procedure
4.3 Shutdown procedures
4.3.1 Shutdown procedure
4.3.2 Interlocks
4.4 Treatment of water for boilers and heaters
4.4.1 General
4.4.2 Water quality effects
4.5 Boiler valves and fittings
4.5.1 General
4.5.2 Pressure gauges (including monitors and sensors)
4.5.3 Water gauges
4.5.4 Safety valves
4.6 Operation of fittings and accessories
4.6.1 Blowdown equipment
4.6.2 Water-level control and security systems
4.6.3 Feedwater pumps
4.6.4 Soot blowers
4.7 Failure of boiler pressure parts
5 Pressure vessels
5.1 General
5.2 Vessels with quick-actuating closures
5.2.1 General
5.2.2 Seating surface
5.2.3 Closure mechanisms
5.2.4 Interlock system
5.2.5 Procedures and documentation
5.2.6 Operating conditions
5.2.7 Repair procedures
6 Piping systems
6.1 General
6.2 Inspection
6.3 Hydraulic shock
6.4 Venting
7 Fired heaters
7.1 General
7.2 Operation
7.2.1 General
7.2.2 Pre-start equipment check
7.2.3 Operating procedures
7.2.4 Operational checks
7.2.4.1 General
7.2.4.2 Checks
7.2.4.3 Log
7.3 Routine maintenance and testing
7.3.1 General
7.3.2 Routine maintenance
7.3.3 Typical procedure
7.4 Periodic maintenance and inspection
7.4.1 General
7.4.2 Periodic inspection
7.4.3 Periodic maintenance procedure
Appendix A
Appendix B
B1 General
B2 Safety management system—Components
B3 Design changes or alterations
B4 Document and data control
B5 Purchasing
B6 Supplied components
B7 Product identification and traceability
B7.1 General
B7.2 Identification
B7.3 Traceability
B8 Process control
B9 Inspection and testing
B10 Inspection measuring and test equipment
B11 Inspection status of equipment
B12 Nonconformance
B13 Corrective and preventive action
B14 Handling, storage, packaging and delivery of pressure equipment
B15 Operation and maintenance records
B16 Internal audits
B17 Safety management system training
B18 Servicing
B19 Statistical techniques
Appendix C
Appendix D
D1 General
D2 Meaning of risk assessment
D3 Purpose of risk assessment
D4 Application
D5 Appropriate risk assessment
D6 When recommended
D7 Conducting risk assessment
D8 Methodology
D9 Hazard identification
D10 Assessment of risk
D11 Control of risk
D12 Results and resolution of the assessments
D13 Compliance audits
D14 Repeat assessment
D15 Documentation and record
Appendix E
E1 General
E2 Unattended boiler operation
E3 Training and skills for all categories
E4 Additional training requirements for Category 2
E5 Training and experience for Category 3
E6 Special additional training for power (utility) boilers (Category 4)
Appendix F
F1 General
F2 Assessment of competency
F3 Evidence of competence
Appendix G
G1 Dry storage—Boilers and process equipment
G2 Wet storage
G2.1 Boilers
G2.2 Process equipment
Appendix H
H1 Recommissioning procedure
H2 Pre-pressure-raising checks
H3 Filling the boiler
H4 Firing
H5 Pressure raising
H6 Safety valves
H7 Turbine drives
H8 Precautions
Appendix I
I1 Water treatment methods
I2 Purpose of treatment
I3 Water characteristics
I4 Closed water systems
I5 Water quality effects
I5.1 General
I5.2 Deposits
I5.3 Scale
I5.4 Foam
I5.4.1 General
I5.4.2 Causes of foaming
I5.4.3 Causes of priming
I5.5 Corrosion
Appendix J
J1 General
J2 Low-water condition
J3 Vital parts
Appendix K
K1 Shortage of water
K2 Furnace distortion
K3 Incomplete combustion
K4 Gas-side corrosion
K4.1 Low temperature gas-side corrosion
K4.2 High temperature gas-side corrosion
K5 Cracking of tube ends and tubeplates in fire-tube boilers
K6 Corrosion fatigue
K7 External corrosion
K8 Erosion
K9 Flue gas explosion
Cited references in this standard
[Current]
Gas cylinder test stations, Part 3: Transportable gas cylinders — Periodic inspection and testing of composite cylinders (ISO 11623:2015, MOD)
[Current]
Gas cylinder test stations, Part 1: General requirements, inspection and tests — Gas cylinders
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