AS/NZS 3788:2001

1 - AS/NZS 3788:2001 PRESSURE EQUIPMENT-IN-SERVICE INSPECTION
4 - PREFACE
5 - CONTENTS
7 - SECTION 1 SCOPE AND GENERAL
7 - 1.1 SCOPE
7 - 1.2 APPLICATION
9 - 1.3 REFERENCED AND RELATED DOCUMENTS
9 - 1.3.1 Referenced documents
9 - 1.3.2 Related documents
9 - 1.4 DEFINITIONS
9 - 1.4.1 Pressure equipment and ancillaries
9 - 1.5 RISK MANAGEMENT AND RISK BASED INSPECTION
9 - 1.6 SAFETY
9 - 1.7 METHODS OF INSPECTION
10 - 1.8 SPECIAL CONDITIONS AND VARIATIONS
10 - 1.9 ALTERNATIVE STANDARDS
11 - SECTION 2 BASIC FEATURES OF INSPECTION
11 - 2.1 OBJECTIVES OF INSPECTION
11 - 2.2 ELEMENTS OF INSPECTION
11 - 2.3 STAGES OF INSPECTION
12 - 2.4 INSPECTION PROCESS
14 - SECTION 3 INSPECTION PERSONNEL AND ADMINISTRATION
14 - 3.1 OWNER’S RESPONSIBILITIES
14 - 3.2 IN-SERVICE INSPECTOR’S RESPONSIBILITIES AND CAPABILITIES
14 - 3.2.1 General
15 - 3.2.2 Particular responsibilities
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 (See Notes to Clause 4.4.4)
18 - 4.4.1 General
18 - 4.4.2 First in-service inspection
18 - 4.4.3 Guidelines for the periodic inspection of pressure equipment
18 - 4.4.4 Frequency of periodic inspection
28 - 4.5 INSPECTION OF IDLE PRESSURE EQUIPMENT
29 - 4.6 PRESSURE-RELIEF DEVICES
29 - 4.6.1 General
29 - 4.6.2 Installation
29 - 4.6.3 Security of operation
29 - 4.6.4 In-service visual inspection
29 - 4.6.5 Valve maintenance or repairs
30 - 4.6.6 Spring-loaded, pilot-operated and deadweight pressure-relief valves
31 - 4.6.7 Bursting discs
31 - 4.6.8 Rupture pin valves (Buckling pin non-reclosing pressure relief device)
32 - 4.6.9 Fusible plugs
32 - 4.7 CONTROLS CRITICAL FOR SAFEGUARDING EQUIPMENT
32 - 4.7.1 Pressure-actuated devices
32 - 4.7.2 Temperature-actuated devices
32 - 4.7.3 Excess flow and back check valves
32 - 4.7.4 Quick-actuating closure interlocks and swing bolt doors
32 - 4.7.5 Relief valve isolation interlocks
32 - 4.8 INSTRUMENTATION AND CONTROLS
32 - 4.9 EMERGENCY SHUTDOWN SYSTEMS
33 - 4.10 AUTOMATIC FIREFIGHTING SYSTEMS USED TO PROTECT PRESSURE EQUIPMENT
33 - 4.11 LOW TEMPERATURE VESSELS
33 - 4.11.1 Vacuum-insulated vessels
33 - 4.11.2 Insulated, non-vacuum, non-jacketed vessels
33 - 4.11.3 Transportable vessels
34 - SECTION 5 ASSESSMENT OF PRESSURE EQUIPMENT INTEGRITY
34 - 5.1 GENERAL
34 - 5.1.1 Scope of section
34 - 5.1.2 Responsibility
34 - 5.1.3 Documentation
34 - 5.2 ACCEPTANCE CRITERIA OF DEFECTS
34 - 5.2.1 Introduction
35 - 5.2.2 Initial review
35 - 5.2.3 Investigation of defects
36 - 5.2.4 Thinning of walls
36 - 5.2.5 Cracking
37 - 5.2.6 Planar type weld defects
37 - 5.2.7 Volume type weld defects
37 - 5.2.8 Dents
38 - 5.2.9 Metallurgically damaged material
38 - 5.2.10 Leakage
38 - 5.2.11 Bulging
38 - 5.3 DETERMINATION OF REMAINING LIFE
38 - 5.3.1 General
39 - 5.3.2 Investigation Method
40 - 5.3.3 Fatigue
40 - 5.3.4 Creep
41 - 5.3.5 Combined creep and fatigue
41 - 5.3.6 Wastage
41 - 5.3.7 Combined creep, fatigue and wastage
41 - 5.3.8 Review of design life of pressure equipment of advanced design and construction
42 - 5.3.9 Inspection prior to end of remaining life
42 - 5.4 DETERMINATION OF MAXIMUM ALLOWABLE WORKING PRESSURE
42 - 5.4.1 Introduction
42 - 5.4.2 Presence of defects
43 - 5.4.3 Changed operating conditions
43 - 5.5 RELATED DOCUMENTS
44 - SECTION 6 REPAIRS, ALTERATIONS AND RE-RATING
44 - 6.1 GENERAL
44 - 6.2 REPAIRS, REPLACEMENTS AND ALTERATIONS
44 - 6.2.1 Procedure and design
44 - 6.2.2 Minor repairs
45 - 6.2.3 Welder qualifications
45 - 6.2.4 Inspection
45 - 6.3 RE-RATING
46 - SECTION 7 INVESTIGATION OF DETERIORATION AND FAILURES
46 - 7.1 GENERAL
46 - 7.2 FAILURE ANALYSIS
46 - 7.2.1 General
46 - 7.2.2 Failure analysis data
47 - 7.3 RECORDING OF INCIDENTS AND FAILURES
52 - SECTION 8 PRESSURE EQUIPMENT IDENTIFICATION AND REGISTRATION DOCUMENTATION AND RECORDS
52 - 8.1 GENERAL
52 - 8.2 PRESSURE EQUIPMENT REGISTER
52 - 8.3 PRESSURE EQUIPMENT DATA
53 - 8.4 PRESSURE EQUIPMENT HISTORY
53 - 8.5 PRESSURE PIPING
54 - APPENDIX A - LIST OF REFERENCED DOCUMENTS
58 - APPENDIX B - RISK MANAGEMENT
58 - B1 GENERAL
58 - B2 RISK ANALYSIS AND MANAGEMENT TECHNIQUES
58 - B2.1 Hazard survey
58 - B2.2 Hazard and operability study
58 - B2.3 Reliability study
58 - B2.4 System reliability and fault tree analysis
59 - B2.5 Consequence analysis
59 - B2.6 Risk assessment
59 - B3 AUDITS
59 - B4 USE OF RISK MANAGEMENT
59 - B5 RISK BASED INSPECTION
61 - APPENDIX C - SAFETY DURING INSPECTION
61 - C1 GENERAL
61 - C2 HAZARDOUS SUBSTANCES
61 - C3 INSPECTION EQUIPMENT
62 - C4 SAFETY AND PROTECTIVE EQUIPMENT
62 - C5 ISOLATION AND TAGGING
64 - APPENDIX D - METHODS OF INSPECTION
64 - D1 SCOPE
64 - D2 METHODS
64 - D3 DOCUMENTATION
64 - D4 SURFACE PREPARATION
64 - D5 COMPETENCE
64 - D6 VISUAL EXAMINATION
64 - D6.1 General
65 - D6.2 External visual examination
65 - D6.3 Internal visual examination
66 - D7 THICKNESS TESTING
66 - D8 RADIOGRAPHIC EXAMINATION
67 - D9 ULTRASONIC EXAMINATION
67 - D10 MAGNETIC PARTICLE EXAMINATION
67 - D11 PENETRANT EXAMINATION
67 - D12 INFRARED THERMOGRAPHY
67 - D13 OTHER NON-DESTRUCTIVE EXAMINATION METHODS
67 - D14 METALLURGICAL TESTING
67 - D14.1 Material identification
68 - D14.2 Hardness
68 - D14.3 Microscopy and replication
68 - D15 HYDROSTATIC PRESSURE TEST
68 - D15.1 General
69 - D15.2 Test pressure
69 - D15.3 Test medium
69 - D15.4 Test temperature
69 - D15.5 Hydrostatic test procedure
70 - D15.6 Reporting of results
71 - D16 PNEUMATIC PRESSURE TEST
71 - D16.1 Application
71 - D16.2 General precautions
72 - D16.3 Examination of welds
72 - D16.4 Test temperature
73 - D16.5 Test pressure
73 - D16.6 Test procedure
73 - D16.7 Reporting of results
74 - D17 COMBINED HYDROSTATIC/PNEUMATIC TEST
74 - D18 LEAK TESTING
74 - D18.1 General
74 - D18.2 Pneumatic leak testing of low temperature vessels
74 - D19 DESTRUCTIVE TESTING
75 - D20 INSPECTION OF INTERNAL LININGS
76 - APPENDIX E - INSPECTION AND REPAIR OF TRANSPORTABLE VESSELS
76 - E1 GENERAL
77 - E2 MATERIALS OF CONSTRUCTION
77 - E3 INSPECTION
77 - E3.1 Inspection frequency
77 - E3.2 Visual examination
79 - E3.3 Non-destructive examination
81 - E3.4 Ancillary equipment
82 - E4 REPAIRS, ALTERATION AND RERATING OF TRANSPORTABLE VESSELS
82 - E4.1 General
82 - E4.2 Repairs
83 - E4.3 Non-destructive examination
83 - E4.4 Repair after accident
83 - E4.5 Postweld heat treatment
84 - APPENDIX F - INSPECTION OF BOILERS
84 - F1 PRE-SHUTDOWN INSPECTION
84 - F2 SHUTDOWN PROCEDURE
84 - F3 PREPARATION FOR SHUTDOWN INSPECTION
85 - F4 SHUTDOWN INSPECTION
86 - F5 INSPECTION OF BOILER MANAGEMENT SYSTEMS
86 - F6 INSPECTION DURING RECOMMISSIONING
86 - F7 BOILER ANCILLARY EQUIPMENT
86 - F8 REPORT
87 - APPENDIX G - INSPECTION OF UNFIRED PRESSURE VESSELS-STATIONARY
87 - G1 GENERAL
87 - G2 AIR RECEIVERS
87 - G3 PRESSURIZED STORAGE VESSELS
87 - G4 LP GAS STORAGE VESSELS
88 - G5 PROCESS VESSELS
88 - G6 AUXILIARY VESSELS
88 - G7 AUTOCLAVES
88 - G8 REPORT
89 - APPENDIX H - INSPECTION OF HEAT EXCHANGERS, COOLERS AND CONDENSERS
89 - H1 GENERAL
89 - H2 SHELL AND TUBE HEAT EXCHANGERS
90 - H3 AIR-COOLED HEAT EXCHANGERS
90 - H4 PLATE HEAT EXCHANGERS
91 - APPENDIX I - INSPECTION OF PRESSURE PIPING
91 - I1 GENERAL
91 - I2 PIPING OF HAZARD LEVELS A AND B
92 - I3 POSSIBLE MODES AND CAUSES OF FAILURE
92 - I4 INSPECTION PERIODS
92 - I5 DATA AND HISTORY RECORDS
92 - I5.1 Data
93 - I5.2 History records
93 - I6 INSPECTION
93 - I6.1 General external visual inspection
95 - I6.2 Inspection during operation and shutdown
96 - I6.3 Inspection during outage and start-up
96 - I7 NON-DESTRUCTIVE EXAMINATION
98 - I8 THE EFFECTS OF CREEP AND THERMAL FATIGUE ON PIPING
98 - I8.1 Creep
99 - I8.2 Thermal fatigue
99 - I8.3 Combined creep and thermal fatigue
100 - I9 BURIED PIPING
101 - APPENDIX J - INSPECTION OF FIRED HEATERS
101 - J1 GENERAL
101 - J2 INSPECTION OF PRESSURE COMPONENTS
102 - J3 INSPECTION OF FIRESIDE COMPONENTS
102 - J4 EXTERNAL INSPECTION
103 - J5 TESTING
104 - APPENDIX K - TYPICAL INSPECTION REPORTS IN ACCORDANCE WITH THIS STANDARD
106 - APPENDIX L - PRESERVATION AND INSPECTION OF IDLE PRESSURE EQUIPMENT
106 - L1 GENERAL
106 - L2 DECOMMISSIONING
106 - L3 EXTERNAL INSPECTION
106 - L4 PRESERVATION PROCEDURE
107 - L5 MONITORING OF PRESSURE EQUIPMENT STANDING IDLE
107 - L6 RECOMMISSIONING
108 - APPENDIX M - COMMON MODES AND CAUSES OF DETERIORATION AND FAILURE
108 - M1 GENERAL
108 - M2 CORROSION
108 - M2.1 Groups of corrosion
108 - M2.2 Forms of corrosion
110 - M3 HYDROGEN BLISTERING
110 - M4 HYDROGEN SULPHIDE CRACKING
110 - M5 FATIGUE
111 - M6 DISTORTION BY OVERHEATING
111 - M7 CREEP
111 - M8 BRITTLE FRACTURE
111 - M9 LIQUID METAL EMBRITTLEMENT
111 - M10 OVERPRESSURIZATION
111 - M11 OVERLOADING
112 - M12 EARTHQUAKES, EARTH SETTLEMENT AND WIND LOADING
112 - M13 MECHANICAL DAMAGE
112 - M14 EROSION
112 - M14.1 Internal
112 - M14.2 External
116 - APPENDIX N - ASSESSMENT OF LOCALIZED WALL THINNING OF CYLINDRICAL, CONICAL, AND SPHERICAL SHELLS
116 - N1 GENERAL
116 - N2 NOTATION
117 - N3 ASSESSMENT PROCEDURE
117 - N3.1 Method
117 - N3.2 Definition of thinned area
118 - N3.3 Minimum calculated thickness
118 - N3.4 Characteristic shell length (Ls)
119 - N3.5 Mean thickness of trapezoidal patches
119 - N3.6 Acceptability of thinning
120 - N4 ALLOWABLE MINIMUM THICKNESS
120 - N5 TREATMENT OF THINNED AREAS
120 - N6 EXAMPLE OF ASSESSMENT OF LOCALLY THINNED WALL
120 - N6.1 Problem
121 - N7 Example with no weld in thinned area
122 - N7.1 Example with weld in thinned area
125 - N7.2 Example of Dm for corroded area within a vessel
126 - APPENDIX O - ASSESSMENT OF PLANAR DEFECTS
126 - O1 GENERAL
126 - O2 NOTATION
127 - O3 CRITICAL CRACK SIZE (ac)
131 - O4 CRACK GROWTH DUE TO FATIGUE
132 - O5 SAFETY FACTORS
132 - O6 FURTHER CONSIDERATIONS
132 - O7 EXAMPLES OF APPLICATION OF SIMPLIFIED FRACTURE MECHANICS FOR ASSESSING CRACK-LIKE DEFECTS
132 - O7.1 Definition of problem
133 - O7.2 Calculation of critical crack size
139 - APPENDIX P - TYPICAL MAINTENANCE REPORT-PRESSURE-RELIEF VALVES
140 - APPENDIX Q - INSPECTION OF PRESSURE EQUIPMENT WITH QUICK-ACTUATING CLOSURES AND SWING BOLT DOORS
140 - Q1 INSPECTION
140 - Q2 RECORDS
141 - APPENDIX R - EXTERNAL INSPECTION OF BURIED OR MOUNDED PRESSURE VESSELS
141 - R1 EXTERNAL INSPECTION OF PRESSURE VESSELS WITHOUT CATHODIC PROTECTION
141 - R2 EXTERNAL INSPECTION OF PRESSURE VESSELS WITH CATHODIC PROTECTION
141 - R3 RECORDS
142 - APPENDIX S - INSPECTION OF DEAERATORS
142 - S1 GENERAL
142 - S2 INSPECTION AND REPAIR
143 - S3 RELATED DOCUMENT
144 - APPENDIX T - INSPECTION OF STORAGE TANKS TO ANSI/API 620 OR EQUIVALENT
144 - T1 SCOPE
144 - T2 AMBIENT TEMPERATURE AND HEATED TANKS
144 - T3 LOW TEMPERATURE STORAGE TANKS (tanks normally operating below -10°C)
144 - T3.1 Internal inspection of low temperature storage tanks
145 - T3.2 External inspection of low temperature storage tanks
146 - T4 RELATED DOCUMENTS
147 - APPENDIX U - COST EFFECTIVE REMAINING LIFE ASSESSMENT
147 - U1 BACKGROUND
147 - U2 FACTORS AFFECTING REMAINING LIFE
147 - U3 THREE STAGE REMAINING LIFE ASSESSMENT
149 - U4 WORKED EXAMPLE OF A THREE-STAGE REMAINING LIFE ASSESSMENT
153 - APPENDIX V - KEY COMPETENCIES FOR IN-SERVICE INSPECTORS
154 - APPENDIX W - INSPECTION OF DRUMS FOR TRANSPORT OF LIQUEFIED GAS
154 - W1 APPLICATION
154 - W2 PERIODIC INSPECTION AND TESTING
154 - W3 EXTERNAL EXAMINATION
154 - W3.1 General
154 - W3.2 Bulge
154 - W3.3 Burn
155 - W3.4 Dents
155 - W3.5 Cuts and gouges
155 - W3.6 Isolated pits
156 - W3.7 Chain pitting and line corrosion
156 - W3.8 General corrosion
157 - W3.9 Gas leakage
157 - W3.10 Fire damage
157 - W4 INTERNAL EXAMINATION
158 - W5 CLEANING
158 - W6 WEIGHING
158 - W7 MARKING
158 - W8 RECORDING
158 - W9 PLUGS AND VALVES
159 - APPENDIX X - TESTING OF SOFT SEATED POP ACTION RELIEF VALVES FOR LIQUEFIABLE GAS SERVICE
159 - X1 GENERAL
159 - X2 PRESSURE GAUGES
159 - X3 TEST PROCEDURE
159 - X4 PASS/FAIL CRITERIA
160 - APPENDIX Y - IN-SERVICE INSPECTION AND RECORD KEEPING FOR STEAM LOCOMOTIVE, TRACTION ENGINE AND PORTABLE STEAM ENGINE .....
160 - Y1 GENERAL
160 - Y2 ORGANIZATION AND PERSONNEL
160 - Y3 RESPONSIBILITIES
160 - Y4 IN-SERVICE INSPECTION
160 - Y4.1 Trip inspections
160 - Y4.2 Washout requirements and water treatment
161 - Y4.3 Interim inspections
161 - Y4.4 Annual inspection
161 - Y4.5 Full internal inspection
161 - Y4.6 Hydrostatic testing
162 - Y4.7 Boilers in long-term storage
162 - Y4.8 Cracking of asymmetrical seams and the need for test grooves
163 - Y5 RECORDS
163 - Y6 LOGBOOK AND INSPECTION RECORDS

Provides requirements for the inspection, repair and alteration of in-service boilers, pressure vessels, piping, safety equipment and associated controls. It also provides guidance in the execution of such inspections. These inspections include the initial inspection after installation and prior to commissioning. Information is also given to facilitate grounds for agreement between appropriate regulatory authorities, owners and inspectors in establishing uniform minimum requirements for in-service 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 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 assist in assuring safe and economic operation. Information is provided for the assessment of defects and deterioration of pressure equipment.NOTES: 1 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 appropriate and adequate for the continued safe and economic operation of the pressure equipment. This may require the seeking of expert outside advice.2 Duty of Care is now prescribed on employers and employees regardless of regulation or standards. This Standard does not supersede such Duty of Care.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.
Third edition 2001.