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AS/NZS 3788-1996 pressure equipment - in-service inspection

Standard Number:  AS/NZS 3788-1996
Title:  pressure equipment - in-service inspection
Language:  English
Status:  Withdrawn
Publisher:  Australia Standards(AS)
Price:  
Number of Pages:139  

Preface:   
Description:Specifies requirements and criteria for the periodic inspection, repair and alteration of in-service boilers, pressure vessels, piping, safety equipment and associated controls. Criteria are given for the selection of intervals between internal and external inspection of boilers, pressure vessels, and piping. Criteria for the assessment of defects and deterioration are included. Guidance on repairs, modifications, and re-rating are given. Provision is made for owners to carry out their own inspections.  
Catalog:Document Contents
AS/NZS 3788:1996 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 Alter
1.4.2 Boiler management system
1.4.3 Commissioning
1.4.4 Competent person
1.4.5 Dangerous occurrence
1.4.6 Defect
1.4.7 Hazard level
1.4.8 In-service inspection body
1.4.9 In-service inspector
1.4.10 Life assessment terms
1.4.11 Low-temperature vessels
1.4.12 May
1.4.13 Operate
1.4.14 Owner
1.4.15 Parties concerned
1.4.16 Pressure equipment
1.4.17 Pressures
1.4.18 Regulatory authority
1.4.19 Repair
1.4.20 Shall
1.4.21 Should
1.4.22 Space, confined
1.4.23 Use
1.4.24 Wastage
1.5 RISK MANAGEMENT
1.6 SAFETY
1.7 METHODS OF INSPECTION
1.8 SPECIAL CONDITIONS AND VARIATIONS
1.9 ALTERNATIVE STANDARDS
SECTION 2 BASIC FEATURES OF INSPECTION
2.1 OBJECTIVES OF INSPECTION
2.2 ELEMENTS OF INSPECTION
2.3 STAGES OF INSPECTION
2.4 INSPECTION PROCESS
SECTION 3 INSPECTION PERSONNEL AND ADMINISTRATION
3.1 OWNER'S RESPONSIBILITIES
3.2 IN-SERVICE INSPECTORS
3.3 OWNER INSPECTION SYSTEM
3.3.1 Requirements
3.4 SUPPORT ORGANIZATIONS
SECTION 4 PRESSURE EQUIPMENT INSPECTION
4.1 GENERAL
4.2 COMMISSIONING OR RECOMMISSIONING INSPECTION
4.3 OPERATING SURVEILLANCE
4.4 PERIODIC INSPECTION
4.4.1 General
4.4.2 First in-service inspection
4.4.3 Frequency of periodic inspection
4.4.4 Preparation and planning
4.5 INSPECTION OF IDLE PRESSURE EQUIPMENT
4.6 PRESSURE-RELIEF DEVICES
4.6.1 General
4.6.2 Installation
4.6.3 Security of operation
4.6.4 In-service visual inspection
4.6.5 Valve maintenance or repairs
4.6.6 Spring-loaded, pilot-operated and dead weight pressure-relief valves
4.6.7 Bursting discs
4.6.8 Rupture pin valves (Buckling pin non-reclosing pressure relief device)
4.6.9 Fusible plugs
4.7 CONTROLS CRITICAL FOR SAFEGUARDING EQUIPMENT
4.7.1 Pressure-actuated devices
4.7.2 Temperature-actuated devices
4.7.3 Excess flow valves
4.7.4 Quick-actuating closure interlocks and swing bolt doors
4.7.5 Relief valve isolation interlocks
4.8 INSTRUMENTATION AND CONTROLS
4.9 EMERGENCY SHUTDOWN SYSTEMS
4.10 AUTOMATIC FIREFIGHTING SYSTEMS USED TO PROTECT PRESSURE EQUIPMENT
4.11 LOW TEMPERATURE VESSELS
4.11.1 Vacuum-insulated vessels
4.11.2 Insulated, non-vacuum, non-jacketed vessels
4.11.3 Transportable vessels
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 ACCEPTANCE CRITERIA OF DEFECTS
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
5.2.6 Planar type weld defects
5.2.7 Volume type weld defects
5.2.8 Dents
5.2.9 Metallurgically damaged material
5.2.10 Leakage
5.2.11 Bulging
5.3 DETERMINATION OF SAFE REMAINING LIFE
5.3.1 General
5.3.2 Investigation Method
5.3.3 Fatigue
5.3.4 Creep
5.3.5 Combined creep and fatigue
5.3.6 Wastage
5.3.7 Combined creep, fatigue and wastage
5.3.8 Review of design life of pressure equipment of advanced design and construction
5.3.9 Inspection prior to end of safe life
5.4 DETERMINATION OF MAXIMUM ALLOWABLE WORKING PRESSURE
5.4.1 Introduction
5.4.2 Presence of defects
5.4.3 Changed operating conditions
5.5 RELATED DOCUMENTS
SECTION 6 REPAIRS, ALTERATIONS AND RE-RATING
6.1 GENERAL
6.2 REPAIRS, REPLACEMENTS AND ALTERATIONS
6.2.1 Procedure and design
6.2.2 Minor repairs
6.2.3 Welder qualifications
6.2.4 Inspection
6.3 RE-RATING
SECTION 7 INVESTIGATION OF DETERIORATION AND FAILURES
7.1 GENERAL
7.2 FAILURE ANALYSIS
7.2.1 General
7.2.2 Failure analysis data
7.3 REPORTING OF INCIDENTS AND FAILURES
SECTION 8 DOCUMENTATION AND RECORDS
8.1 GENERAL
8.2 PRESSURE EQUIPMENT REGISTER
8.3 PRESSURE EQUIPMENT DATA
8.4 PRESSURE EQUIPMENT HISTORY
8.5 PRESSURE PIPING
APPENDIX A - LIST OF REFERENCED DOCUMENTS
APPENDIX B - RISK MANAGEMENT
B1 GENERAL
B2 RISK ANALYSIS AND MANAGEMENT TECHNIQUES
B2.1 Hazard survey
B2.2 Hazard and operability study
B2.3 Reliability study
B2.4 System reliability and fault tree analysis
B2.5 Consequence analysis
B2.6 Risk assessment
B3 AUDITS
B4 USE OF RISK MANAGEMENT
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 NSPECTION
D1 SCOPE
D2 METHODS
D3 DOCUMENTATION
D4 SURFACE PREPARATION
D5 COMPETENCE
D6 VISUAL EXAMINATION
D6.1 General
D6.2 External visual examination
D6.3 Internal visual examination
D7 THICKNESS TESTING
D8 RADIOGRAPHIC EXAMINATION
D9 ULTRASONIC EXAMINATION
D10 MAGNETIC PARTICLE EXAMINATION
D11 PENETRANT EXAMINATION
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 - INSPECTION AND REPAIR OF TRANSPORTABLE VESSELS
E1 GENERAL
E2 MATERIALS OF CONSTRUCTION
E3 INSPECTION
E3.1 Inspection frequency
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 Postweld heat treatment
APPENDIX F - INSPECTION OF BOILERS
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 -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 REPORT
APPENDIX H - INSPECTION OF HEAT EXCHANGERS, COOLERS AND CONDENSERS
H1 GENERAL
H2 SHELL AND TUBE HEAT EXCHANGERS
H3 AIR-COOLED HEAT EXCHANGERS
H4 PLATE HEAT EXCHANGERS
APPENDIX I - INSPECTION OF PRESSURE PIPING
I1 GENERAL
I2 PIPING OF HAZARD LEVELS A AND B
I3 POSSIBLE MODES OF FAILURE
I4 INSPECTION PERIODS
I5 DATA AND HISTORY RECORDS
I5.1 Data
I5.2 History records
I6 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 EXAMINATION
I8 THE EFFECTS OF CREEP AND THERMAL FATIGUE ON PIPING
I8.1 Creep
I8.2 Thermal fatigue
I8.3 Combined creep and thermal fatigue
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 - TYPICAL INSPECTION REPORTS IN ACCORDANCE WITH AS 3788
APPENDIX L - PRESERVATION AND INSPECTION OF IDLE PRESSURE EQUIPMENT
L1 GENERAL
L2 DECOMMISSIONING
L3 EXTERNAL INSPECTION
L4 PRESERVATION PROCEDURE
L5 MONITORING OF PRESSURE EQUIPMENT STANDING IDLE
L6 RECOMMISSIONING
APPENDIX M - COMMON MODES AND CAUSES OF DETERIORATION AND FAILURE
M1 GENERAL
M2 CORROSION
M2.1 Groups of corrosion
M2.2 Forms of corrosion
M3 HYDROGEN BLISTERING
M4 HYDROGEN SULFIDE CRACKING
M5 FATIGUE
M6 DISTORTION BY OVERHEATING
M7 CREEP
M8 EMBRITTLEMENT
M9 OVERPRESSURIZATION
M10 OVERLOADING
M11 EARTHQUAKES, EARTH SETTLEMENT AND WIND LOADING
M12 MECHANICAL DAMAGE
M13 EROSION
M13.1 Internal
M13.2 External
APPENDIX N - ASSESSMENT OF LOCALIZED WALL THINNING OF CYLINDRICAL, CONICAL, AND SPHERICAL...
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
N3.5 Mean thickness of trapezoidal patches
N3.6 Acceptability of thinning
N4 ALLOWABLE MINIMUM THICKNESS
N5 TREATMENT OF THINNED AREAS
N6 EXAMPLE OF ASSESSMENT OF LOCALLY THINNED WALL
N6.1 Problem
N6.2 Example with no weld in thinned area
N6.2 Example with weld in thinned area
APPENDIX O - ASSESSMENT OF PLANAR DEFECTS
O1 GENERAL
O2 NOTATION
O3 CRITICAL CRACK SIZE
O4 CRACK GROWTH DUE TO FATIGUE
O5 SAFETY FACTORS
O6 FURTHER CONSIDERATIONS
O7 EXAMPLES OF APPLICATION OF SIMPLIFIED FRACTURE MECHANICS FOR ASSESSING CRACK-LIKE DEFE...
O7.1 Definition of problem
O7.2 Calculation of critical crack size
APPENDIX P - TYPICAL MAINTENANCE REPORT - PRESSURE-RELIEF VALVES
APPENDIX Q - INSPECTION OF PRESSURE EQUIPMENT WITH QUICK-ACTUATING CLOSURES AND SWING BOL...
Q1 INSPECTION
Q2 RECORDS
APPENDIX R - EXTERNAL 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
S3 RELATED DOCUMENT
APPENDIX T - INSPECTION OF STORAGE TANKS TO ANSI/API 620 OR EQUIVALENT
T1 SCOPE
T2 AMBIENT TEMPERATURE AND HEATED TANKS
T3 LOW TEMPERATURE STORAGE TANKS
T3.1 Internal inspection of low temperature storage tanks
T3.2 External inspection of low temperature storage tanks
T4 RELATED DOCUMENTS
APPENDIX U - COST EFFECTIVE REMAINING LIFE ASSESSMENT
U1 BACKGROUND
U2 FACTORS AFFECTING REMAINING LIFE
U3 THREE STAGE REMAINING LIFE ASSESSMENT
U4 WORKED EXAMPLE OF A THREE-STAGE REMAINING LIFE ASSESSMENT
APPENDIX V - KEY COMPETENCIES FOR IN-SERVICE INSPECTORS
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 WEIGHTING
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
  
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