Standard
Track updates
AS/NZS 3788:2006
[Current]Pressure equipment — In-service inspection
Specifies minimum requirements for the inspection, repair and alteration of in-service boilers, pressure vessels, piping, safety equipment and associated controls, and gives guidance on the execution of such activities. These inspections include the initial inspection after installation and prior to commissioning. Information is also given to facilitate grounds for agreement between the interested parties in establishing appropriate inspection intervals and procedures for pressure equipment.
Published: 27/07/2006
Pages: 194
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
1.3 Referenced and related documents
1.3.1 Referenced documents
1.3.2 Related documents
1.4 Definitions
1.5 Risk management and risk based inspection
1.6 Safety
1.7 Special conditions and variations
1.8 Referenced Standards
2 Inspection requirements
2.1 Objectives of inspection
2.2 Asset integrity life cycle
2.3 Inspection process
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
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
4.4.1.1 General
4.4.1.2 External inspection
4.4.1.3 Internal inspection
4.4.2 Periodic inspection of pressure equipment
4.4.3 First in-service inspection
4.4.4 Intervals for periodic inspection
4.4.4.1 Inspection intervals
4.4.4.2 Wastage rate
4.4.4.3 Determination of inspection interval
4.4.4.3.1 General
4.4.4.3.2 Criteria
4.4.4.4 Extension of inspection intervals
4.4.4.5 Special cases
4.5 Risk based inspection
4.6 Inspection of idle pressure equipment
4.7 Pressure-relief 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
4.7.4.1 General
4.7.4.2 Test interval
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
4.13.2.1 External inspection interval—Piping
4.13.2.2 Internal inspection interval—Piping
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
5.2.5.1 General
5.2.5.2 Assessment of fitness for service
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
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 Re-rating
7 Investigation of deterioration and failures
7.1 General
7.2 Failure analysis
7.3 Recording of incidents and failures
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
A1 Referenced documents
A2 Related documents
Appendix B
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
C1 General
C2 Hazardous substances
C3 Inspection equipment
C4 Safety and protective equipment
C5 Isolation and tagging
Appendix D
D1 Scope
D2 Methods
D3 Documentation
D4 Surface preparation
D5 Competence
D6 Visual examination (VT)
D6.1 General
D6.2 External visual examination
D6.2.1 Above ground pressure equipment
D6.2.2 Buried or mounded pressure equipment
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 non-destructive 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
E1 General
E2 Materials of construction
E3 Inspection
E3.1 Inspection intervals
E3.1.1 In-service inspection
E3.1.2 Operator surveillance
E3.2 Visual examination
E3.2.1 General
E3.2.2 External visual examination
E3.2.3 Internal visual inspection
E3.2.4 Thickness testing
E3.2.5 Inspection of baffles welded to the shell
E3.3 Non-destructive examination
E3.3.1 General
E3.3.2 Transportable vessels involved in accident
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
F1 Pre-shutdown 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
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
H1 General
H2 Shell and tube heat exchangers
H3 Air-cooled heat exchangers
H4 Plate heat exchangers
H5 Report
Appendix I
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 Non-destructive 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
J1 General
J2 Inspection of pressure components
J3 Inspection of fireside components
J4 External inspection
J5 Testing
Appendix K
Appendix L
L1 General
L2 Decommissioning
L3 External inspection
L4 Internal inspection
L5 Preservation procedure
L6 Monitoring of pressure equipment standing idle
L7 Recommissioning
Appendix M
M1 General
M2 Corrosion
M2.1 General (uniform) corrosion
M2.2 Localized corrosion
M2.3 Galvanic corrosion
M2.4 Velocity-related 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
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
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 crack-like defects
O6.6.1 Definition of problem
O6.6.2 Calculation of critical crack size
O6.6.2.1 Crack A
O6.6.2.2 Crack B
O6.6.2.3 Cracks C and D
O6.6.2.4 Crack C
O6.6.2.5 Crack D
O6.6.2.6 Effect of design stress
O6.6.2.7 Crack growth due to fatigue at crack A
Appendix P
P1 General
P2 Guidance on test interval
Appendix Q
Q1 Inspection
Q2 Records
Appendix R
R1 External inspection of pressure vessels without cathodic protection
R2 External inspection of pressure vessels with cathodic protection
R3 Records
Appendix S
S1 General
S2 Inspection and repair
Appendix T
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
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
V1 General
V2 Evidence of competency
V3 Key knowledge and competency areas
Appendix W
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
W3.8.1 Shell
W3.8.2 Ends
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
X1 General
X2 Pressure gauges
X3 Test procedure
X4 Pass/fail criteria
Appendix Y
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
Y5.2.1 Stirling boilers
Y5.2.2 WIF boilers
Y5.2.2.1 Water starvation
Y5.2.2.2 Cracking around feed water inlet
Y5.3 Fire tube boilers
Y5.3.1 Locomotive boilers
Y5.3.1.1 General
Y5.3.1.2 Trip inspection
Y5.3.1.3 Interim inspection
Y5.3.1.4 Annual inspection
Y5.3.1.5 Full internal inspection
Y5.3.2 Agricultural and road engines
Y6 Testing
Y6.1 Hydrostatic testing
Y6.2 Ultrasonic testing
Y7 Repairs
Y8 Records
Appendix Z
Z1 Scope
Z2 Foundations and structures
Z3 Inspection
Z4 Inspection interval
Z5 Reinforced concrete foundations and structures
Z6 Metallic structures
Z7 Bolts
Cited references in this standard
[Current]
Site testing of protective coatings, Method 1: Non-conductive coatings — Continuity testing — High voltage (brush) method
[Current]
Site testing of protective coatings, Method 2: Non-conductive coatings — Continuity testing — Wet sponge method
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Assurance of product quality, Part 1: Pressure equipment manufacture
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