Pressure vessels

Steam boilers

Piping

Remarks

Scope of

application

Every item of pressure-bearing equipment (incl. fittings) is assigned to a defined inspection scheme (“regime”) which sets out the inspection intervals plus the type and scope of the Recurring Inspections. The authorized agency (“competent body“) can order a variant scheme “Z” in special cases (e.g. in the case of time-dependent risks that are difficult to assess or in the case of special materials).

¹ Deviations require the consent of the authorized agency

1.         Scheme K (SK or DK)

2.         Scheme V (SV or DV)

3.         Scheme D1 (DR)

4.         Scheme O1 (OT è cylindrical, vertical, single walls, and flat bottom)

5.         Scheme O2 (OT è cylindrical, vertical, double walls, and flat bottom)

6.         Scheme D2 (DR or OT if not dealt with in D1, O1 or O2)

7.         Scheme L (SL, DL, IL)

8.         Scheme T (fittings)

9.         Scheme Z (special pressure vessels)

Responsibility

No details

Official

supervision

Ministry of Labor and Social Affairs

Implementation of inspection

By the following nominated by the Ministry of Labor and Social Affairs

§   independent test institutes, and

§   operator test centers (see also “Documentation”)

Additional inspections (NDT) by specialists with certification under EN 473, Level 2

Documentation

Extension of the inspection intervals only subject to the existence of documents relating to the pressure-bearing equipment, for example relating to the operating mode, any repairs/changes, and inspection results. No details are given in the existing text about a universal obligation to retain documentation.

Inspections

Initial inspection

No details

External inspection

Pressure-bearing equipment

Visual inspection of the pressure-bearing equipment or pipe from the outside, including fittings (in the case of piping, esp. expansion joints, spring hangers, mountings, etc.)

This is supplemented where appropriate by NDT (the usual situation in the case of piping). Checking of refractory linings, e.g. by means of thermography. There are special requirements for the external inspection of insulated, coated, and earth-covered pressure-bearing equipment/piping. In this respect, an inspection program is produced in advance by the authorized agency in consultation with the operator.

Fittings/accessories

In the case of safety-related fittings, inspection of their condition and operability is carried out. In the case of measurement & control safety facilities, this is done by checking the entire measurement & control circuit (sensors, actuators) )è definition of an inspection program by the authorized agency. Inspection is implemented by an Inspector or maintenance company (according to Regulation T0103). Recurring Inspections can be carried out in the context of maintenance. Other fittings are checked for their (external) condition by the operator.

Internal

inspection

Internal Examination (IE)

Visual inspection. Examination of general condition, especially with regard to corrosion phenomena. Alternatively, this can be replaced by nondestructive testing procedures (NDT) if an Internal Examination is impossible¹.

Inspection of liquid distributors by the opening of inspection apertures (complete approval within 12 years by successive opening of the inspection apertures at each Internal Examination). Replacement of built-in components at defined intervals in the case of steam boilers and firing chambers irrespective of findings). Checking of coatings, refractory linings, etc.

Simplification in the case of pressure vessel systems operated in parallel (use of analogy). Additional examinations required (as per Annex 2 of Regulation T0102) in the case of pressure-bearing equipment / piping where there is a risk of creep.

Surface examination

For special pressure-bearing vessels (e.g. steam and water containers of boiler systems) at defined intervals that differ from the Recurring Inspection intervals or by agreement with the authorized agency. Only for materials in Category “CP” (see Regulation T 0203) where d_d > 30 mm and J_m > 300°C. Examination of all weld seam surfaces and heat-affected zones that come into contact with the medium as per Regulation T 0203.

¹ Definition of procedure, scope of inspection, and measuring points by the authorized agency in consultation with the operator

Press. insp.

Pressure tests (as per Regulation T0240) only if no Internal Examinations are possible.

Insp. in spec. cases

No details

Intervals

Re 1:    Every 2 years è Can be extended to 4-year intervals after the 3rd inspection¹

Re 2:    Every 4 years è Can be extended to 8-year intervals after the 2nd inspection, and thereafter to 12-year intervals if NDT OK¹

Re 3:    Every 6 years è Can be extended to 8-year intervals after the 2nd inspection if NDT OK¹

Re 4:    Every year è Can be extended to 6-year intervals after the 4th inspection if NDT OK²
Every 4 years (IE) è Can be extended by harmonization with inspection intervals of other inspected elements with longer intervals¹
Every 6 years (External Examination (EE) and wall-thickness measurements)
Every 12 years (interval for other inspected elements) è Can be extended to 18-year intervals after the 2nd inspection

Re 5:    Every year è Can be extended to 6-year intervals after the 4th inspection if bottom examination² OK
Every 6 years (EE; IE only if defects found in EE, pressure-bearing equipment out of service or corrosive media)

Re 6:    Every 4 years è Can be extended by harmonization with inspection intervals of other inspected elements with longer intervals if no corrosion is anticipated
Every 6 years (interval for other inspected elements) è Can normally be extended to 12-year intervals after the 2nd inspection

Re 7:    Shortest interval of the associated pressure vessel but not < 4 years (the extended inspection intervals of the connected pressure vessels must also apply to the pipe(s))

Re 8:    Every year (for non-pressure-releasing safety facilities) è Interval can be extended or shortened by the authorized agency
Every 4 years (for other safety facilities)³

Re 9:    Defined individually by the authorized agency⁴

¹ Extension of the inspection intervals only in the case of satisfaction of defined preconditions set out in Annex 2 to Regulation T 0102 / 97-02 (e.g. no use of materials at risk from brittle fracture, additional checks, and documented repairs)

² Examination of the displacement at the bottom edge and displacement in the cylindrical part

³ Intervals for inspection of sensors are defined individually by the authorized agency

⁴ Normally on the basis of an inspection schedule of the operator

Pressure vessels

Steam boilers

Piping

Remarks

Scope of

application¹

Inspection group classification is based on the Pressure Equipment Directive (PED):

1. Gases, liquefied/dissolved gasses, vapors²

a)    Fluids in Group I, Categories III and IV (with special regulations for unstable gases and storage containers for propane, butane, liquid oxygen, N₂O at defined volume)

b)    Fluids in Group 2, Categories III and IV (with special regulations for compressed air containers and containers for N₂, Ar, He, and carbon dioxide)

2. Liquids³

a)    Liquids in Group 1, Categories I - III where V > 1 liter and
PS×V > 400 bar×liter (⁴)

b)    Liquids in Group 2, Categories I and II where V > 10 liter (⁴)

Inspection group classification is based on the Pressure Equipment Directive (PED):

Hot water and steam generators (fired or heated in other ways)

where TS > 110°C and V > 2 liter (⁴), categorization in Categories III and IV

Inspection group classification is based on the Pressure Equipment Directive (PED):

1. Gases, liquefied/dissolved gasses, vapors²

a)    Fluids in Group I, Categories II and III (with special regulations for unstable gases); including piping where PS×V > 200 bar×liter (⁴)

b)    Fluids in Group 2, Categories II and III; including piping where PS×V > 1000 bar×liter (⁴)

2. Liquids³

a)    Liquids in Group I, Categories II and III; including piping where PS×V > 400 bar×liter (⁴)

b)    Liquids in Group 2, Category II, including piping where PS×V > 10000 bar×liter (⁴)
(Exception for initial inspection: water piping)

¹ The categories are according to the charts in Annex II to the Pressure Equipment Directive (PED) (see also Article 3 of the PED).

² Vapor pressure > 0.5 bar gauge pressure at TS

³ Vapor pressure < 0.5 bar gauge pressure at TS

⁴ V = enclosed volume

Responsibility

No details

Official

supervision

Ministry of Labor and Social Affairs

Implementation of inspection

By the following nominated by the Ministry of Labor and Social Affairs

§   independent test institutes, and

§   operator test centers (see also “Documentation”)

with accreditation under EN 45004

Documentation

In order for the inspection intervals to be extended, a qualified independent or operator-owned test center should be available to the operator with at least one attached expert on Level 3¹ and a linked administration for the inventory of pressure-bearing equipment and all inspection-related data.

¹ No further comment is given on the classification in the original text on which this is based.

Inspections

Initial inspection

No details about type or scope. Initial inspection required for the pressure-bearing equipment listed under “Scope of application”

External inspection

Process apparatus¹

Every 4 years

The second and subsequent inspection intervals can be extended² to max. 8 years. This interval can be extended again to 12 years if a NDT was carried out after 8 years.

Storage containers¹

Every 6 years

The second and subsequent inspection intervals can be extended² to max. 12 years.

Every 2 years

The third and subsequent inspection intervals can be extended² to 4 years.

Every 4 years

The second and subsequent inspection intervals can be extended² to max. 8 years.

¹The same inspection interval applies in principle to the safety-related fittings as to the associated apparatus.

In the case of sensors for safety-related fittings, the inspection interval must be defined individually by the test institute or the operator test center.

Non-releasing excess pressure safety facilities must be inspected after 1 year at the latest, other safety-related fittings after 4 years at the latest.

²Extension of the inspection intervals only in the case of satisfaction of defined preconditions (e.g. no use of materials at risk from brittle fracture, additional checks, and documented repairs). For pressure-bearing equipment, subject to certain technical preconditions, the inspection intervals can be set on the basis of RBI (risk based inspections).

Internal

inspection

Pressure test

Insp. in spec. cases

No details