Pressure vessels

Steam boilers

Piping

Remarks

Scope of

application¹

Pressure equipment, that does not fall under Art. 3, par. 3 and with
PS² > 0,5 barg

Pipelines, that do not fall in
Art. 3, par. 3, with PS² > 0,5 barg and which are provided for the transportation of inflammable, easily inflammable, highly inflammable, corrosive or toxic fluids

¹ Pressure equipment outside the limits listed before has to be inspected by the user at his own responsibility, if there are effects that cause damages.

² “PS” = pressure setting of safety equipment (not necessarily identical with defintion of “maximum allowable pressure” in the Pressure Equipment Directive (PED))

Responsibility

The operator is responsible for functionally appropriate, safe operation and inspection at the correct intervals.

Official

supervision

By the regional authorities responsible for occupational health & safety

Implementation of inspection

Depending on hazard potential:

1. Low hazard potential equipment è Competent personell (nominated by the user)

2. High hazard potential equipment è Accredited inspection bodies (“Zugelassene Überwachungsstellen” -
                                                                        “ZÜS”) or user inspectorates

Responsibility for inspection according to the conformity evaluation criteria of PED (table number - Annex II, category, possibly with additional regulations). Responsibility is different for initial and periodic inspection.

Documentation

The pressure vessel document relating to the initial inspection and the inspection certificates for the periodic inspections must be kept by the operator at the operating location.

Inspections¹

Initial inspection

Inspection of the plant / component concerning proper condition of

§   documentation (in particular with respect to lawful placement on the market) and marking

§   equipment, especially safety equipment

§   external condition (in particular with respect to assembly and installation)

External inspection

Every 2 years:

Visual inspection => check on fittings (only in the case of apparatus heated by fire, flue gas or electricity)

Every year:

Visual inspection, check on fittings, and functional test

Every 5 years:

Visual inspection of the piping, check on fittings and functional test

¹Important changes in german regulation:

The operator has to determine the intervals by performing a hazard analysis.

The inspection intervals listed before are maximum values. They are only relevant for pressure equipment with high hazard potential (inspection by accredited inspection bodies necessary).

Inspection of explosion-proof for all equipment every 3 years

Internal

inspection

Every 5 years:

Visual inspection of the internal chamber;

Non-destructive test methods possible

Every 3 years

Visual inspection of the internal chambers and of all elements of the steam boiler system;

Non-destructive test methods possible

Not applicable

Strength test

Every 10 years:

In most cases a deformation and leak check with a water or gas gauge pressure test;

Non-destructive test methods possible

Every 9 years:

In most cases a deformation and leak check with a water gauge pressure test;

Non-destructive test methods possible

Every 5 years:

In most cases a deformation and leak check with a water or gas gauge pressure test;

Non-destructive test methods possible

Insp. in spec. cases

Prior to recommissioning following extensive changes to the pressure equipment, following damage, and also in the case of special order by the authority

Pressure vessels

Steam boilers

Piping

Remarks

Scope of

application

Recurring obligation of inspection for all pressure systems with what are referred to as “relevant fluids”¹, which in the case of failure present a danger to personnel due to the excess pressure.

These chiefly include:

§       Individual pressure vessels and systems of multiple pressure vessels

§       Piping and sections of piping

§       Protective facilities relating to piping and/or pressure vessels

Exclusions comprise transport containers and the pressure vessels listed separately in the regulations.

¹Relevant fluids:

§     Steam (irrespective of the pressure)

§     Gases and liquefied gases with a gauge pressure greater than 0.5 bar

Responsibility

The operator is responsible for ensuring that the inspection schedule (see “Documentation”) covers all relevant parts of the pressure system and that the inspections are carried out.

An external specialist can be consulted where appropriate.

Official

supervision

Supervision of operators with large pressure vessel systems is carried out by the national authority for health and (occupational) safety, the Health and Safety Executive (HSE), with headquarters in London.

Most vessels in offices and commercial buildings are the responsibility of environmental protection officers from local factory inspectorates.

Implementation of inspection

Anyone who is in possession of recognition for the purposes of carrying out Recurring Inspections.

Recognition is effected by the HSE and is dependent on the size and complexity of the pressure vessel system. The following are differentiated:

1.        Systems of low importance - minor systems:
inspection by the operator's own engineers

2.        Systems of medium importance - intermediate systems:
inspection by external engineers with links to other specialists (materials technology, nondestructive testing)

3.        Systems of high importance - major systems:
as item 2, but accreditation is recommended (under BS EN 45004)¹

In most cases, implementation is by test inspectors who belong to their own test associations. There are several test associations and operator test organizations.

¹ Alongside the inspection of systems of high impor-tance, it is recommended that engineers with accreditation under
BS EN 45004 draw up or certify inspection schedules (§ 43 ACoP).

ACoP - Approved Code Of Practice

Documentation

Issue of a written inspection schedule by the operator or external specialists

The suitability of the inspection schedule must be confirmed by a test engineer with accreditation under BS EN 45004 (see above), chiefly with regard to the nature and frequency of the examinations, and where appropriate in respect of required special examination methods also.

The operator receives the inspection result in written form.

Inspections¹

Initial inspection

External inspection

Internal inspection

Pressure-test

No fixed inspection cycles prescribed; the recurring inspections are carried out by taking account of the inspection schedule.

Depending on the inspection result, the inspection schedule must be inspected for validity and where appropriate adapted to the new circumstances.

In the case of systems that present a danger due to their condition, the supervisory agency (enforcing authority) must be informed.

¹ The individual types of inspection are not explicitly differentiated in the original text on which this is based.

Insp. in spec. cases

No details

Pressure vessels

Steam boilers

Piping

Remarks

Scope of

application¹

Inspection group classification according to the contained substance (Group 1/Group 2 fluid), aggregate condition (liquid/gaseous), product of pressure and capacity (PS×V in bar×liter), operating temperature, and type of pressure vessel

Examples of pressure vessels with obligation of Recurring Inspection:

Group 1 fluid:        PS×V > 1000

Group 2 fluid:        Gases where TS £ 120°C and PS×V > 3000;
Gases where TS > 120°C and PS×V > 1000

Autoclaves:            PS×V > 200

Pressure vessels for generating hot water and steam

Inspection group classification according to apparatus type, operating gauge pressure, operating temperature, product of pressure and capacity, firing type, and heat output

Examples of pressure vessels with obligation of Recurring Inspection:

Steam boilers

PS > 10 bar or PS×V > 500 bar×liter (²)

Water boilers

Gas/liquid-fired and TS £ 120°C: Q > 10 MW (³)

Gas/liquid-fired and TS > 120°C: Q > 1 MW (³)

Solid fuel: Q > 1 MW

Tube-bundle water heaters

Internal diameter of tubes > 38 mm or

PS > 16 bar or PS×V > 750 bar×liter (²)

Inspection group classification according to the fluid conveyed (Group 1 fluid, Group 2 fluid), the inspection group of the connected pressure vessels, and dimensioning criteria (e.g. design for creep or fatigue stress)

¹ TUKES (see “Official supervision”) maintains and updates a list of pressure systems subject to recurring inspection

² V = minimum water volume contained in the systemund Schutzeinrichtungen) die „relevante Fluide“ (Dampf ohne Druckeinschränkung, Gase und verflüssigte Gase > 0,5 bar)

³ Q = firing heat output

Responsibility

The operator of the pressure-bearing system is responsible for carrying out Recurring Inspections at the correct intervals.

Commissioning of the test institute is by the operator.

Official

supervision

By the state authority TUKES, with headquarters in Helsinki

Implementation of inspection

By two independent test institutions recognized by TUKES:

§     INSPECTA OY

§     POLARTEST OY

The test institutions are required to send information to TUKES about the recurring inspections carried out.

Documentation¹

§     Certificate of conformity

§     Operating instructions

§     Workshop drawings

§     Design data (e.g. operating data, corrosion factors)

§     Material certificates

§     Welding information and information incl. certificates relating to NDT and heat treatment

¹ The documents listed only involve the design and manufacturing documentation required for pressure vessels with Recurring Inspections. No details are given in the source text with regard to any inspection documents.

Inspections

Initial inspection

Prior to commissioning:

Inspection as to whether the pressure vessel system can be safely commissioned. Inspection is effected in the context of the commissioning phase.

No details

External inspection

Every 4 years:

Inspection as to whether the pressure vessel system is operated safely

Every 2 years:

Inspection as to whether the pressure vessel system is operated safely

Internal

inspection

Every 4 years:

Visual inspection of the condition in the internal chamber

Pressure test

Every 8 years:

Check for deformation and leaks in the case of x 1.3 operating gauge pressure

Insp. in spec. cases

As necessary, following changes in the operating mode or repairs