AS 3873-1995

1 - AS 3873-1995 PRESSURE EQUIPMENT-OPERATION AND MAINTENANCE
4 - PREFACE
5 - CONTENTS
8 - SECTION 1 SCOPE AND GENERAL
8 - 1.1 SCOPE
8 - 1.2 APPLICATION AND PURPOSE
8 - 1.2.1 Application
8 - 1.2.2 Purpose
8 - 1.3 REFERENCED DOCUMENTS
8 - 1.4 DEFINITIONS
8 - 1.4.1 Alter
9 - 1.4.2 Approved, approval
9 - 1.4.3 Boiler
9 - 1.4.4 Boiler, attended
9 - 1.4.5 Boiler, limited attendance
9 - 1.4.6 Boiler, unattended
9 - 1.4.7 Commissioning
9 - 1.4.8 Competent person
9 - 1.4.9 Equipment management system
9 - 1.4.10 Facility
9 - 1.4.11 Fired heater
9 - 1.4.12 Hazard
9 - 1.4.13 Hazard level
9 - 1.4.14 Hazardous substance
10 - 1.4.15 Hot work
10 - 1.4.16 In-service inspection body
10 - 1.4.17 Inspection body
10 - 1.4.18 Inspectors
10 - 1.4.19 Interlock
10 - 1.4.20 Maintain
10 - 1.4.21 Manufacturer
10 - 1.4.22 May
10 - 1.4.23 Operate
10 - 1.4.24 Operator
10 - 1.4.25 Owner
10 - 1.4.26 Owner-user
10 - 1.4.27 Pressure equipment
10 - 1.4.28 Pressure parts
10 - 1.4.29 Pressure piping
10 - 1.4.30 Pressure vessel
11 - 1.4.31 Process
11 - 1.4.32 Regulatory authority
11 - 1.4.33 Repair
11 - 1.4.34 Risk
11 - 1.4.35 Risk assessment
11 - 1.4.36 Shall
11 - 1.4.37 Should
11 - 1.4.38 Use
11 - 1.4.39 User
12 - SECTION 2 MANAGEMENT AND PERSONNEL
12 - 2.1 OWNER-USER'S RESPONSIBILITIES AND DUTIES
12 - 2.1.1 Owner-user
12 - 2.1.2 Owner-non-user
13 - 2.2 OWNER-USER'S SAFETY MANAGEMENT SYSTEM
13 - 2.2.1 General
13 - 2.2.2 Regulatory compliance
13 - 2.3 EQUIPMENT SUITABILITY
13 - 2.4 COMMISSIONING
13 - 2.4.1 Pre-start equipment check
14 - 2.4.2 Commissioning operations
14 - 2.5 WORKPLACE RISK ASSESSMENT
14 - 2.6 ORDERLINESS OF SYSTEM AND SURROUNDING AREA
15 - 2.7 PROCESS INFORMATION
15 - 2.7.1 Availability
15 - 2.7.2 Confidentiality
15 - 2.7.3 Fluids
15 - 2.8 OPERATOR AND MAINTENANCE PERSONNEL TRAINING
15 - 2.8.1 Extent of training
15 - 2.8.2 Refresher training
15 - 2.8.3 Training documentation
16 - 2.9 OPERATOR QUALIFICATIONS AND DUTIES
16 - 2.10 MAINTENANCE - QUALIFICATIONS AND DUTIES
16 - 2.10.1 General
16 - 2.10.2 Maintenance organization
16 - 2.11 CONTRACTOR'S QUALIFICATIONS AND DUTIES
16 - 2.11.1 General
17 - 2.11.2 Owner-user responsibilities
17 - 2.11.3 Contractor's responsibilities
17 - 2.12 EMPLOYEE PARTICIPATION AND CONSULTATION
17 - 2.13 MANAGEMENT OF CHANGE
19 - SECTION 3 GENERAL OPERATING AND MAINTENANCE PROCEDURES AND PRACTICES
19 - 3.1 GENERAL
19 - 3.1.1 Operating procedures
19 - 3.1.2 Review
19 - 3.1.3 Operating limits
19 - 3.1.4 Reporting
19 - 3.2 OPERATING PROCEDURES
20 - 3.3 OPERATIONAL SURVEILLANCE
21 - 3.4 SAFETY PRACTICES AND EMERGENCY PROCEDURES
21 - 3.4.1 General
21 - 3.4.2 Safety during maintenance
21 - 3.4.3 Isolation fittings
22 - 3.4.4 Emergency planning
22 - 3.4.5 Compliance audits
22 - 3.4.6 Safety information and records for pressure equipment used with hazardous substances
22 - 3.5 MAINTENANCE PROCEDURES
22 - 3.5.1 Maintenance program
22 - 3.5.2 Control system
22 - 3.5.3 Repairs and alterations
23 - 3.6 INSPECTION
23 - 3.7 INCIDENT INVESTIGATION
23 - 3.8 OUT-OF-SERVICE STORAGE
23 - 3.8.1 General
23 - 3.8.2 Disconnecting and removal
23 - 3.8.3 Dry storage
24 - 3.8.4 Wet storage
24 - 3.9 RECORDS
24 - 3.9.1 General
24 - 3.9.2 Access to records
24 - 3.9.3 Relocation
25 - SECTION 4 SAFETY MANAGEMENT SYSTEM*
25 - 4.1 OWNER-USER'S RESPONSIBILITIES
25 - 4.2 SAFETY MANAGEMENT SYSTEM
25 - 4.3 CONTRACT REVIEW
26 - 4.4 DESIGN CHANGES OR ALTERATIONS
26 - 4.5 DOCUMENT CONTROL
26 - 4.6 PURCHASING
26 - 4.7 OWNER-USER SUPPLIED COMPONENTS
26 - 4.8 PRODUCT IDENTIFICATION AND TRACEABILITY
26 - 4.8.1 General
26 - 4.8.2 Identification
26 - 4.8.3 Traceability
26 - 4.9 PROCESS CONTROL
26 - 4.10 INSPECTION AND TESTING
27 - 4.11 INSPECTION MEASURING AND TEST EQUIPMENT
27 - 4.12 INSPECTION STATUS OF EQUIPMENT
27 - 4.13 NONCONFORMANCE
27 - 4.14 CORRECTIVE AND PREVENTIVE ACTION
27 - 4.15 HANDLING, STORAGE, PACKAGING AND DELIVERY OF PRESSURE EQUIPMENT
28 - 4.16 OPERATION AND MAINTENANCE RECORDS
28 - 4.17 INTERNAL AUDITS
28 - 4.18 SAFETY TRAINING
28 - 4.19 SERVICING
28 - 4.20 STATISTICAL TECHNIQUES
29 - SECTION 5 BOILERS
29 - 5.1 GENERAL
29 - 5.2 OPERATING AND MAINTENANCE INSTRUCTIONS
29 - 5.2.1 General
29 - 5.2.2 Sequence of operations
29 - 5.2.3 Pre-start equipment check
30 - 5.2.4 Operations check
30 - 5.2.5 Testing and checking programs
30 - 5.2.6 Daily checking and testing
31 - 5.2.7 Routine maintenance and testing
32 - 5.2.8 Periodic maintenance and testing
32 - 5.3 SHUTDOWN PROCEDURES
32 - 5.3.1 Shutdown procedure
32 - 5.3.2 Interlocks
33 - 5.4 TREATMENT OF WATER FOR BOILERS AND HEATERS
33 - 5.4.1 General
33 - 5.4.2 Water quality effects
33 - 5.5 BOILER VALVES AND FITTINGS
33 - 5.5.1 General
33 - 5.5.2 Pressure gauges (including monitors and sensors)
33 - 5.5.3 Water gauges
33 - 5.5.4 Safety valves
34 - 5.6 OPERATION OF FITTINGS AND ACCESSORIES
34 - 5.6.1 Blowdown equipment
34 - 5.6.2 Water-level control and security systems
34 - 5.6.3 Feedwater pumps
34 - 5.6.4 Soot blowers
35 - 5.7 FAILURE OF BOILER PRESSURE PARTS
36 - SECTION 6 PRESSURE VESSELS
36 - 6.1 GENERAL
36 - 6.2 VESSELS WITH QUICK-ACTUATING CLOSURES
36 - 6.2.1 General
36 - 6.2.2 Seating surface
36 - 6.2.3 Closure mechanisms
37 - 6.2.4 Interlock system
37 - 6.2.5 Procedures and documentation
37 - 6.2.6 Operating conditions
37 - 6.2.7 Repair procedures
38 - SECTION 7 PIPING SYSTEMS
38 - 7.1 GENERAL
38 - 7.2 INSPECTION
38 - 7.3 HYDRAULIC SHOCK
38 - 7.4 VENTING
39 - SECTION 8 FIRED HEATERS
39 - 8.1 GENERAL
39 - 8.2 OPERATION
39 - 8.2.1 General
39 - 8.2.2 Pre-start equipment check
39 - 8.2.3 Programs
39 - 8.2.4 Operational checks
40 - 8.3 ROUTINE MAINTENANCE AND TESTING
40 - 8.3.1 General
40 - 8.3.2 Routine maintenance
40 - 8.3.3 Typical procedure
40 - 8.4 PERIODIC MAINTENANCE AND INSPECTION
40 - 8.4.1 General
40 - 8.4.2 Periodic inspection
41 - 8.4.3 Periodic maintenance procedure
42 - APPENDIX A - LIST OF REFERENCED DOCUMENTS
43 - APPENDIX B - OWNER-USER'S DOCUMENTATION AND RECORDS
43 - B1 GENERAL
45 - APPENDIX C - RISK ASSESSMENT
45 - C1 GENERAL
45 - C2 MEANING OF RISK ASSESSMENT
45 - C3 PURPOSE OF RISK ASSESSMENT
46 - C4 APPLICATION
46 - C5 APPROPRIATE RISK ASSESSMENT
47 - C6 WHEN REQUIRED
47 - C7 PERSONS CONDUCTING ASSESSMENT
48 - C8 METHODOLOGY
48 - C9 HAZARD IDENTIFICATION
49 - C10 ASSESSMENT OF RISK
50 - C11 CONTROL OF RISK
51 - C12 RESULTS AND RESOLUTION OF THE ASSESSMENTS
51 - C13 IMPLEMENTATION OF ASSESSMENT ACTIONS
51 - C14 COMPLIANCE AUDITS
51 - C15 REPEAT ASSESSMENT
52 - C16 DOCUMENTATION AND RECORD
52 - C17 RELATED DOCUMENTS
53 - APPENDIX D - TYPICAL TRAINING AND SKILL REQUIREMENTS OF BOILER OPERATORS
53 - D1 GENERAL
53 - D2 UNATTENDED BOILER OPERATION
53 - D3 TRAINING AND SKILLS FOR ALL CATEGORIES
54 - D4 ADDITIONAL TRAINING REQUIREMENTS FOR CATEGORY 2
54 - D5 TRAINING AND EXPERIENCE FOR CATEGORY 3
54 - D6 SPECIAL ADDITIONAL TRAINING FOR POWER (UTILITY) BOILERS (CATEGORY 4)
55 - APPENDIX E - STORAGE PROCEDURES
55 - E1 DRY STORAGE
55 - E2 WET STORAGE
55 - E2.1 Boilers
55 - E2.2 Special precautions
55 - E2.3 Process equipment
56 - APPENDIX F - TYPICAL PROCEDURE FOR STARTING UP A BOILER AFTER A MAJOR OVERHAUL
56 - F1 RECOMMISSIONING PROCEDURE
57 - F2 PRE-PRESSURE-RAISING CHECKS
57 - F3 FILLING THE BOILER
57 - F4 FIRING
57 - F5 PRESSURE RAISING
58 - F6 SAFETY VALVES
58 - F7 TURBINE DRIVES
58 - F8 PRECAUTIONS
59 - APPENDIX G - TYPICAL REQUIREMENTS FOR FEEDWATER AND BOILER WATER QUALITY
59 - G1 WATER TREATMENT METHODS
59 - G2 PURPOSE OF TREATMENT
59 - G3 WATER CHARACTERISTICS
60 - G4 CLOSED WATER SYSTEMS
61 - G5 WATER QUALITY EFFECTS
61 - G5.1 General
61 - G5.2 Deposits
62 - G5.3 Scale
62 - G5.4 Foam
62 - G5.5 Corrosion
63 - APPENDIX H - TYPICAL EMERGENCY PROCEDURE FOR LOSS OF WATER OR LOW-WATER CONDITION IN A BOILER
63 - H1 GENERAL
63 - H2 LOW-WATER CONDITION
64 - H3 VITAL PARTS
65 - APPENDIX I - SOME MODES OF FAILURE OF BOILERS
65 - I1 SHORTAGE OF WATER
65 - I2 FURNACE DISTORTION
65 - I3 INCOMPLETE COMBUSTION
66 - I4 GAS-SIDE CORROSION
66 - I4.1 Low temperature gas-side corrosion
66 - I4.2 High temperature gas-side corrosion
66 - I5 CRACKING OF TUBE ENDS AND TUBEPLATES IN FIRE-TUBE BOILERS
66 - I6 CORROSION FATIGUE
66 - I7 EXTERNAL CORROSION
66 - I8 EROSION
67 - I9 FLUE GAS EXPLOSION
68 - APPENDIX J - TYPICAL EXAMPLE OF A GENERIC RISK ASSESSMENT FOR AUTOMOTIVE FUEL PRESSURE VESSELS*
68 - J1 EQUIPMENT IDENTIFICATION
68 - J2 HAZARD IDENTIFICATION
68 - J3 RISK ASSESSMENT
69 - J4 RISK CONTROL

Specifies requirements and provides 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.

This Standard specifies the requirements and gives guidance on the operation and maintenance of boilers, pressure vessels, associated control and safety equipment, piping and auxiliaries, (e.g. boiler fuel handling and firing equipment, heaters, fans, pumps, feedwater treatment and the like) and gives guidance in the execution of such work. It also covers actions required by the owner-user from initial receipt of the equipment on-site until final disposal.This Standard applies to commissioning, operation, maintenance, routine inspection, storage and disposal. It includes specific requirements for safety management systems, including where appropriate risk assessment.Requirements cannot be written in sufficient detail to cover all aspects of the above. Each owner-user is responsible for taking necessary action to ensure the continued safe operation of the pressure equipment. This may require the seeking of outside expert advice.This Standard applies to pressure equipment covered by AS/NZS 1200. However, all the requirements do not apply to all hazard levels of pressure equipment.

First published as AS 3873-1991.
Second edition 1995.