AS/NZS 3788:1996

1 - AS/NZS 3788:1996 PRESSURE EQUIPMENT - IN-SERVICE INSPECTION
4 - PREFACE
6 - CONTENTS
8 - SECTION 1 SCOPE AND GENERAL
8 - 1.1 SCOPE
8 - 1.2 APPLICATION
10 - 1.3 REFERENCED AND RELATED DOCUMENTS
10 - 1.3.1 Referenced documents
10 - 1.3.2 Related documents
10 - 1.4 DEFINITIONS
10 - 1.4.1 Alter
10 - 1.4.2 Boiler management system
10 - 1.4.3 Commissioning
10 - 1.4.4 Competent person
10 - 1.4.5 Dangerous occurrence
10 - 1.4.6 Defect
10 - 1.4.7 Hazard level
10 - 1.4.8 In-service inspection body
10 - 1.4.9 In-service inspector
10 - 1.4.10 Life assessment terms
11 - 1.4.11 Low-temperature vessels
11 - 1.4.12 May
11 - 1.4.13 Operate
11 - 1.4.14 Owner
11 - 1.4.15 Parties concerned
11 - 1.4.16 Pressure equipment
11 - 1.4.17 Pressures
11 - 1.4.18 Regulatory authority
11 - 1.4.19 Repair
11 - 1.4.20 Shall
11 - 1.4.21 Should
11 - 1.4.22 Space, confined
11 - 1.4.23 Use
11 - 1.4.24 Wastage
12 - 1.5 RISK MANAGEMENT
12 - 1.6 SAFETY
12 - 1.7 METHODS OF INSPECTION
12 - 1.8 SPECIAL CONDITIONS AND VARIATIONS
12 - 1.9 ALTERNATIVE STANDARDS
13 - SECTION 2 BASIC FEATURES OF INSPECTION
13 - 2.1 OBJECTIVES OF INSPECTION
13 - 2.2 ELEMENTS OF INSPECTION
13 - 2.3 STAGES OF INSPECTION
14 - 2.4 INSPECTION PROCESS
15 - SECTION 3 INSPECTION PERSONNEL AND ADMINISTRATION
15 - 3.1 OWNER'S RESPONSIBILITIES
15 - 3.2 IN-SERVICE INSPECTORS
15 - 3.3 OWNER INSPECTION SYSTEM
15 - 3.3.1 Requirements
16 - 3.4 SUPPORT ORGANIZATIONS
17 - SECTION 4 PRESSURE EQUIPMENT INSPECTION
17 - 4.1 GENERAL
17 - 4.2 COMMISSIONING OR RECOMMISSIONING INSPECTION
17 - 4.3 OPERATING SURVEILLANCE
18 - 4.4 PERIODIC INSPECTION
18 - 4.4.1 General
18 - 4.4.2 First in-service inspection
18 - 4.4.3 Frequency of periodic inspection
27 - 4.4.4 Preparation and planning
27 - 4.5 INSPECTION OF IDLE PRESSURE EQUIPMENT
27 - 4.6 PRESSURE-RELIEF DEVICES
27 - 4.6.1 General
28 - 4.6.2 Installation
28 - 4.6.3 Security of operation
28 - 4.6.4 In-service visual inspection
28 - 4.6.5 Valve maintenance or repairs
28 - 4.6.6 Spring-loaded, pilot-operated and dead weight pressure-relief valves
29 - 4.6.7 Bursting discs
30 - 4.6.8 Rupture pin valves (Buckling pin non-reclosing pressure relief device)
30 - 4.6.9 Fusible plugs
30 - 4.7 CONTROLS CRITICAL FOR SAFEGUARDING EQUIPMENT
30 - 4.7.1 Pressure-actuated devices
30 - 4.7.2 Temperature-actuated devices
30 - 4.7.3 Excess flow valves
30 - 4.7.4 Quick-actuating closure interlocks and swing bolt doors
30 - 4.7.5 Relief valve isolation interlocks
30 - 4.8 INSTRUMENTATION AND CONTROLS
31 - 4.9 EMERGENCY SHUTDOWN SYSTEMS
31 - 4.10 AUTOMATIC FIREFIGHTING SYSTEMS USED TO PROTECT PRESSURE EQUIPMENT
31 - 4.11 LOW TEMPERATURE VESSELS
31 - 4.11.1 Vacuum-insulated vessels
31 - 4.11.2 Insulated, non-vacuum, non-jacketed vessels
31 - 4.11.3 Transportable vessels
32 - SECTION 5 ASSESSMENT OF PRESSURE EQUIPMENT INTEGRITY
32 - 5.1 GENERAL
32 - 5.1.1 Scope of section
32 - 5.1.2 Responsibility
32 - 5.1.3 Documentation
32 - 5.2 ACCEPTANCE CRITERIA OF DEFECTS
32 - 5.2.1 Introduction
33 - 5.2.2 Initial review
33 - 5.2.3 Investigation of defects
33 - 5.2.4 Thinning of walls
34 - 5.2.5 Cracking
35 - 5.2.6 Planar type weld defects
35 - 5.2.7 Volume type weld defects
35 - 5.2.8 Dents
35 - 5.2.9 Metallurgically damaged material
36 - 5.2.10 Leakage
36 - 5.2.11 Bulging
36 - 5.3 DETERMINATION OF SAFE REMAINING LIFE
36 - 5.3.1 General
36 - 5.3.2 Investigation Method
37 - 5.3.3 Fatigue
37 - 5.3.4 Creep
38 - 5.3.5 Combined creep and fatigue
38 - 5.3.6 Wastage
38 - 5.3.7 Combined creep, fatigue and wastage
39 - 5.3.8 Review of design life of pressure equipment of advanced design and construction
39 - 5.3.9 Inspection prior to end of safe life
39 - 5.4 DETERMINATION OF MAXIMUM ALLOWABLE WORKING PRESSURE
39 - 5.4.1 Introduction
39 - 5.4.2 Presence of defects
40 - 5.4.3 Changed operating conditions
40 - 5.5 RELATED DOCUMENTS
41 - SECTION 6 REPAIRS, ALTERATIONS AND RE-RATING
41 - 6.1 GENERAL
41 - 6.2 REPAIRS, REPLACEMENTS AND ALTERATIONS
41 - 6.2.1 Procedure and design
41 - 6.2.2 Minor repairs
42 - 6.2.3 Welder qualifications
42 - 6.2.4 Inspection
42 - 6.3 RE-RATING
43 - SECTION 7 INVESTIGATION OF DETERIORATION AND FAILURES
43 - 7.1 GENERAL
43 - 7.2 FAILURE ANALYSIS
43 - 7.2.1 General
43 - 7.2.2 Failure analysis data
44 - 7.3 REPORTING OF INCIDENTS AND FAILURES
49 - SECTION 8 DOCUMENTATION AND RECORDS
49 - 8.1 GENERAL
49 - 8.2 PRESSURE EQUIPMENT REGISTER
49 - 8.3 PRESSURE EQUIPMENT DATA
50 - 8.4 PRESSURE EQUIPMENT HISTORY
50 - 8.5 PRESSURE PIPING
51 - APPENDIX A - LIST OF REFERENCED DOCUMENTS
55 - APPENDIX B - RISK MANAGEMENT
55 - B1 GENERAL
55 - B2 RISK ANALYSIS AND MANAGEMENT TECHNIQUES
55 - B2.1 Hazard survey
55 - B2.2 Hazard and operability study
55 - B2.3 Reliability study
55 - B2.4 System reliability and fault tree analysis
55 - B2.5 Consequence analysis
55 - B2.6 Risk assessment
55 - B3 AUDITS
56 - B4 USE OF RISK MANAGEMENT
57 - APPENDIX C - SAFETY DURING INSPECTION
57 - C1 GENERAL
57 - C2 HAZARDOUS SUBSTANCES
57 - C3 INSPECTION EQUIPMENT
57 - C4 SAFETY AND PROTECTIVE EQUIPMENT
58 - C5 ISOLATION AND TAGGING
60 - APPENDIX D - METHODS OF NSPECTION
60 - D1 SCOPE
60 - D2 METHODS
60 - D3 DOCUMENTATION
60 - D4 SURFACE PREPARATION
60 - D5 COMPETENCE
60 - D6 VISUAL EXAMINATION
60 - D6.1 General
60 - D6.2 External visual examination
61 - D6.3 Internal visual examination
62 - D7 THICKNESS TESTING
62 - D8 RADIOGRAPHIC EXAMINATION
62 - D9 ULTRASONIC EXAMINATION
62 - D10 MAGNETIC PARTICLE EXAMINATION
62 - D11 PENETRANT EXAMINATION
63 - D12 INFRARED THERMOGRAPHY
63 - D13 OTHER NON-DESTRUCTIVE EXAMINATION METHODS
63 - D14 METALLURGICAL TESTING
63 - D14.1 Material identification
63 - D14.2 Hardness
64 - D14.3 Microscopy and replication
64 - D15 HYDROSTATIC PRESSURE TEST
64 - D15.1 General
64 - D15.2 Test pressure
64 - D15.3 Test medium
64 - D15.4 Test temperature
65 - D15.5 Hydrostatic test procedure
65 - D15.6 Reporting of results
66 - D16 PNEUMATIC PRESSURE TEST
66 - D16.1 Application
66 - D16.2 General precautions
67 - D16.3 Examination of welds
67 - D16.4 Test temperature
67 - D16.5 Test pressure
68 - D16.6 Test procedure
68 - D16.7 Reporting of results
68 - D17 COMBINED HYDROSTATIC/PNEUMATIC TEST
69 - D18 LEAK TESTING
69 - D18.1 General
69 - D18.2 Pneumatic leak testing of low temperature vessels
69 - D19 DESTRUCTIVE TESTING
69 - D20 INSPECTION OF INTERNAL LININGS
71 - APPENDIX E - INSPECTION AND REPAIR OF TRANSPORTABLE VESSELS
71 - E1 GENERAL
71 - E2 MATERIALS OF CONSTRUCTION
72 - E3 INSPECTION
72 - E3.1 Inspection frequency
72 - E3.2 Visual examination
74 - E3.3 Non-destructive examination
76 - E3.4 Ancillary equipment
76 - E4 REPAIRS, ALTERATION AND RERATING OF TRANSPORTABLE VESSELS
76 - E4.1 General
76 - E4.2 Repairs
77 - E4.3 Non-destructive examination
77 - E4.4 Repair after accident
77 - E4.5 Postweld heat treatment
78 - APPENDIX F - INSPECTION OF BOILERS
78 - F1 PRE-SHUTDOWN INSPECTION
78 - F2 SHUTDOWN PROCEDURE
78 - F3 PREPARATION FOR SHUTDOWN INSPECTION
79 - F4 SHUTDOWN INSPECTION
80 - F5 INSPECTION OF BOILER MANAGEMENT SYSTEMS
80 - F6 INSPECTION DURING RECOMMISSIONING
80 - F7 BOILER ANCILLARY EQUIPMENT
80 - F8 REPORT
81 - APPENDIX G -INSPECTION OF UNFIRED PRESSURE VESSELS - STATIONARY
81 - G1 GENERAL
81 - G2 AIR RECEIVERS
81 - G3 PRESSURIZED STORAGE VESSELS
81 - G4 LP GAS STORAGE VESSELS
82 - G5 PROCESS VESSELS
82 - G6 AUXILIARY VESSELS
82 - G7 AUTOCLAVES
82 - G8 REPORT
83 - APPENDIX H - INSPECTION OF HEAT EXCHANGERS, COOLERS AND CONDENSERS
83 - H1 GENERAL
83 - H2 SHELL AND TUBE HEAT EXCHANGERS
83 - H3 AIR-COOLED HEAT EXCHANGERS
84 - H4 PLATE HEAT EXCHANGERS
85 - APPENDIX I - INSPECTION OF PRESSURE PIPING
85 - I1 GENERAL
85 - I2 PIPING OF HAZARD LEVELS A AND B
85 - I3 POSSIBLE MODES OF FAILURE
86 - I4 INSPECTION PERIODS
86 - I5 DATA AND HISTORY RECORDS
86 - I5.1 Data
87 - I5.2 History records
87 - I6 INSPECTION
87 - I6.1 General external visual inspection
88 - I6.2 Inspection during operation and shutdown
89 - I6.3 Inspection during outage and start-up
89 - I7 NON-DESTRUCTIVE EXAMINATION
91 - I8 THE EFFECTS OF CREEP AND THERMAL FATIGUE ON PIPING
91 - I8.1 Creep
91 - I8.2 Thermal fatigue
91 - I8.3 Combined creep and thermal fatigue
93 - APPENDIX J - INSPECTION OF FIRED HEATERS
93 - J1 GENERAL
93 - J2 INSPECTION OF PRESSURE COMPONENTS
94 - J3 INSPECTION OF FIRESIDE COMPONENTS
94 - J4 EXTERNAL INSPECTION
94 - J5 TESTING
95 - APPENDIX K - TYPICAL INSPECTION REPORTS IN ACCORDANCE WITH AS 3788
97 - APPENDIX L - PRESERVATION AND INSPECTION OF IDLE PRESSURE EQUIPMENT
97 - L1 GENERAL
97 - L2 DECOMMISSIONING
97 - L3 EXTERNAL INSPECTION
97 - L4 PRESERVATION PROCEDURE
98 - L5 MONITORING OF PRESSURE EQUIPMENT STANDING IDLE
98 - L6 RECOMMISSIONING
99 - APPENDIX M - COMMON MODES AND CAUSES OF DETERIORATION AND FAILURE
99 - M1 GENERAL
99 - M2 CORROSION
99 - M2.1 Groups of corrosion
99 - M2.2 Forms of corrosion
100 - M3 HYDROGEN BLISTERING
101 - M4 HYDROGEN SULFIDE CRACKING
101 - M5 FATIGUE
101 - M6 DISTORTION BY OVERHEATING
101 - M7 CREEP
101 - M8 EMBRITTLEMENT
102 - M9 OVERPRESSURIZATION
102 - M10 OVERLOADING
102 - M11 EARTHQUAKES, EARTH SETTLEMENT AND WIND LOADING
102 - M12 MECHANICAL DAMAGE
102 - M13 EROSION
102 - M13.1 Internal
102 - M13.2 External
106 - APPENDIX N - ASSESSMENT OF LOCALIZED WALL THINNING OF CYLINDRICAL, CONICAL, AND SPHERICAL SHELLS
106 - N1 GENERAL
106 - N2 NOTATION
107 - N3 ASSESSMENT PROCEDURE
107 - N3.1 Method
107 - N3.2 Definition of thinned area
107 - N3.3 Minimum calculated thickness
108 - N3.4 Characteristic shell length
108 - N3.5 Mean thickness of trapezoidal patches
109 - N3.6 Acceptability of thinning
109 - N4 ALLOWABLE MINIMUM THICKNESS
110 - N5 TREATMENT OF THINNED AREAS
110 - N6 EXAMPLE OF ASSESSMENT OF LOCALLY THINNED WALL
110 - N6.1 Problem
110 - N6.2 Example with no weld in thinned area
112 - N6.2 Example with weld in thinned area
116 - APPENDIX O - ASSESSMENT OF PLANAR DEFECTS
116 - O1 GENERAL
116 - O2 NOTATION
117 - O3 CRITICAL CRACK SIZE
120 - O4 CRACK GROWTH DUE TO FATIGUE
121 - O5 SAFETY FACTORS
121 - O6 FURTHER CONSIDERATIONS
121 - O7 EXAMPLES OF APPLICATION OF SIMPLIFIED FRACTURE MECHANICS FOR ASSESSING CRACK-LIKE DEFECTS
121 - O7.1 Definition of problem
122 - O7.2 Calculation of critical crack size
127 - APPENDIX P - TYPICAL MAINTENANCE REPORT - PRESSURE-RELIEF VALVES
128 - APPENDIX Q - INSPECTION OF PRESSURE EQUIPMENT WITH QUICK-ACTUATING CLOSURES AND SWING BOLT DOORS
128 - Q1 INSPECTION
128 - Q2 RECORDS
129 - APPENDIX R - EXTERNAL INSPECTION OF BURIED OR MOUNDED PRESSURE VESSELS
129 - R1 EXTERNAL INSPECTION OF PRESSURE VESSELS WITHOUT CATHODIC PROTECTION
129 - R2 EXTERNAL INSPECTION OF PRESSURE VESSELS WITH CATHODIC PROTECTION
129 - R3 RECORDS
130 - APPENDIX S - INSPECTION OF DEAERATORS
130 - S1 GENERAL
130 - S2 INSPECTION AND REPAIR
130 - S3 RELATED DOCUMENT
131 - APPENDIX T - INSPECTION OF STORAGE TANKS TO ANSI/API 620 OR EQUIVALENT
131 - T1 SCOPE
131 - T2 AMBIENT TEMPERATURE AND HEATED TANKS
131 - T3 LOW TEMPERATURE STORAGE TANKS
131 - T3.1 Internal inspection of low temperature storage tanks
132 - T3.2 External inspection of low temperature storage tanks
132 - T4 RELATED DOCUMENTS
134 - APPENDIX U - COST EFFECTIVE REMAINING LIFE ASSESSMENT
134 - U1 BACKGROUND
134 - U2 FACTORS AFFECTING REMAINING LIFE
134 - U3 THREE STAGE REMAINING LIFE ASSESSMENT
136 - U4 WORKED EXAMPLE OF A THREE-STAGE REMAINING LIFE ASSESSMENT
140 - APPENDIX V - KEY COMPETENCIES FOR IN-SERVICE INSPECTORS
141 - APPENDIX W - INSPECTION OF DRUMS FOR TRANSPORT OF LIQUEFIED GAS
141 - W1 APPLICATION
141 - W2 PERIODIC INSPECTION AND TESTING
141 - W3 EXTERNAL EXAMINATION
141 - W3.1 General
141 - W3.2 Bulge
141 - W3.3 Burn
141 - W3.4 Dents
142 - W3.5 Cuts and gouges
142 - W3.6 Isolated pits
142 - W3.7 Chain pitting and line corrosion
143 - W3.8 General corrosion
143 - W3.9 Gas leakage
144 - W3.10 Fire damage
144 - W4 INTERNAL EXAMINATION
144 - W5 CLEANING
144 - W6 WEIGHTING
144 - W7 MARKING
144 - W8 RECORDING
145 - W9 PLUGS AND VALVES
146 - APPENDIX X - TESTING OF SOFT SEATED POP ACTION RELIEF VALVES FOR LIQUEFIABLE GAS SERVICE
146 - X1 GENERAL
146 - X2 PRESSURE GAUGES
146 - X3 TEST PROCEDURE
146 - X4 PASS/FAIL CRITERIA

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.

This Standard specifies the requirements for the inspection, repair and alteration of in-service boilers, pressure vessels, piping, safety equipment and associated controls (hereinafter referred to as pressure equipment), and gives guidance in the execution of such inspection. It includes the initial inspection after installation and prior to commissioning. The inspection flow diagram (see Figure 1.1) illustrates the various types of inspection covered by this Standard. This Standard provides information for regulatory authorities, owners, and inspectors to facilitate grounds for agreement, and the establishment of uniform minimum requirements for in-service inspections, including inspection frequencies and procedures, to ensure safe and economic operation. Information is provided for the assessment of defects and deterioration of pressure equipment.NOTE: No rules can be written in sufficient detail to cover all aspects of the inspection of in-service pressure equipment. Each owner is responsible for ensuring that the extent and frequency of inspection is adequate for the continued safe operation of the pressure equipment. This may require the seeking of expert outside advice.This Standard may be used by inspection bodies and owners to set minimum standards of in-service inspection.

First published as AS 3788-1990.
Revised and redesignated AS/NZS 3788:1996.