Title
AS 3892-2001 Pressure equipment - Installation
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AS 3892
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AS 3892—2001
Australian Standard™
Pressure equipment—Installation
Licensed to Dawsons Maintenance Contractors Pty Ltd on 23 Aug 2001. Single user licence only. Storage, distribution or use on network prohibited.
This Australian Standard was prepared by Committee ME-001, Pressure Equipment.
It was approved on behalf of the Council of Standards Australia on 30 December
2000 and published on 27 February 2001.
The following interests are represented on Committee ME-001:
A.C.T. WorkCover
Australasian Corrosion Association
Australasian Institute of Engineer Surveyors
Australian Aluminium Council
Australian Building Codes Board
Australian Chamber of Commerce and Industry
Australian Industry Group
Australian Institute of Energy
Australian Institute of Petroleum
Australian Liquefied Petroleum Gas Association
Boiler and Pressure Vessel Manufacturers Association of Australia
Bureau of Steel Manufacturers of Australia
Department for Administrative and Information Services, S.A.
Department of Employment, Training and Industrial Relations, Qld
Department of Industries and Business, N.T.
Department of Infrastructure, Energy and Resources, Tas.
Department of Labour, New Zealand
Electricity Engineers Association, New Zealand
Electricity Supply Association of Australia
Institute of Materials Engineering Australasia
Institution of Engineers, Australia
Institution of Professional Engineers, New Zealand
National Association of Testing Authorities, Australia
New Zealand Engineering Federation
New Zealand Heavy Engineering Research Association
New Zealand Institute of Welding
New Zealand Petrochemical Users Group
Victorian WorkCover Authority
Welding Technology Institute of Australia
WorkCover N.S.W.
WorkSafe W.A.
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This Standard was issued in draft form for comment as DR 00262.
AS 3892—2001
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Australian Standard™
Pressure equipment—Installation
Originated as AS 3892—1991.
Previous edition 1995.
Third edition 2001.
COPYRIGHT
© Standards Australia International
All rights are reserved. No part of this work may be reproduced or copied in any form or by any
means, electronic or mechanical, including photocopying, without the written permission of the
publisher.
Published by Standards Australia International Ltd
GPO Box 5420, Sydney, NSW 2001, Australia
ISBN 0 7337 3748 X
AS 3892—2001
2
PREFACE
This Standard was prepared by the Joint Standards Australia/Standards New Zealand
Committee ME-001, Pressure Equipment to supersede AS 3892—1995, Pressure
equipment— Installation.
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This Standard is the result of a consensus among representatives on the Joint Committee to
produce it as an Australian Standard.
The first issue of this Standard consolidated, rationalized and extended the requirements
and recommendations in AS 1210, Pressure vessels, AS 1228, Pressure equipment—
Boilers, AS 2593, Boilers— Unattended and limited attendance and associated Standards. It
was part of a major program to restructure, unify and simplify the various Standards for
particular types of equipment and components in accordance with AS/NZS 1200, Pressure
equipment. AS/NZS 1200 covers requirements for land installations of boilers, pressure
vessels, pressure piping and associated matters.
The Committee recognized there was a need to specify requirements and give further
guidance to installers, purchasers and users on the installation of pressure equipment.
Existing Standards on boilers give some (but not consistent) guidance for their safe
installation, while pressure vessel Standards provide little information for their installation.
The objective of the Standard is to provide requirements for safe installation of pressure
equipment.
The main changes in this revision include the following:
(a)
A new section incorporating the requirements for the installation of pressure piping.
(b)
A new appendix giving guidance on the competency of installers.
(c)
A new appendix on management systems.
(d)
Alignment with Standardization Guide No. 17.1, Drafting of Standards that may be
referenced under occupational health and safety legislation.
This Standard provides the minimum installation requirements to ensure the initial and
continued safe and reliable performance of the pressure plant. In many circumstances,
additional requirements may be necessary for adequate performance or safety.
It is envisaged that experience gained in the use of the Standard will highlight areas that
need to be strengthened. It is intended that the Standard will be regularly reviewed and
revised as necessary to ensure it remains a useful document to all parties concerned and
provides safe and reliable pressure plant.
The terms ‘normative’ and ‘informative’ have been used in this Standard to define the
application of the appendix to which they apply. A ‘normative’ appendix is an integral part
of a Standard, whereas an ‘informative’ appendix is only for information and guidance.
3
AS 3892—2001
CONTENTS
Page
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SECTION 1 SCOPE AND GENERAL
1.1 SCOPE......................................................................................................................... 5
1.2 OBJECTIVE ................................................................................................................ 5
1.3 APPLICATION ........................................................................................................... 5
1.4 REFERENCED DOCUMENTS................................................................................... 6
1.5 DEFINITIONS............................................................................................................. 6
SECTION 2 GENERAL REQUIREMENTS
2.1 COMPLIANCE............................................................................................................ 7
2.2 SAFETY DURING INSTALLATION......................................................................... 7
2.3 PROTECTION OF EQUIPMENT ............................................................................. 10
2.4 MANAGEMENT SYSTEMS .................................................................................... 10
SECTION 3 INSTALLATION, ORGANIZATION AND PERSONNEL
3.1 GENERAL REQUIREMENTS.................................................................................. 11
3.2 INSTALLATION ...................................................................................................... 11
SECTION 4 INSTALLATION OF BOILERS
4.1 HOUSING ................................................................................................................. 12
4.2 FOUNDATIONS AND SUPPORTS.......................................................................... 12
4.3 LOCATION AND ACCESS...................................................................................... 13
4.4 SETTINGS ................................................................................................................ 15
4.5 LIGHTING ................................................................................................................ 15
4.6 VENTILATION......................................................................................................... 15
4.7 NOISE CONTROL .................................................................................................... 16
4.8 CONTROL ROOMS.................................................................................................. 16
4.9 PROVISION FOR OUTDOOR INSTALLATION .................................................... 16
4.10 FEEDWATER TREATMENT AND SUPPLY PLANT ............................................ 17
4.11 BLOWDOWN SYSTEMS......................................................................................... 17
4.12 BOILER FLUE GAS EXHAUST SYSTEMS............................................................ 18
4.13 SOLID FUEL AND ASH STORAGE, AND HANDLING AND DUST
COLLECTION EQUIPMENT ................................................................................... 21
4.14 GAS AND OIL EQUIPMENT................................................................................... 23
4.15 ASSOCIATED PROTECTIVE AND EMERGENCY SYSTEMS ............................. 23
4.16 ELECTRICAL INSTALLATION.............................................................................. 24
4.17 ERECTION................................................................................................................ 24
4.18 COMMUNICATION FACILITY .............................................................................. 24
4.19 FINAL CONDITION AND HOUSEKEEPING ......................................................... 24
4.20 PRECOMMISSIONING INSPECTION .................................................................... 24
SECTION 5 INSTALLATION OF PRESSURE VESSELS
5.1 SITING ...................................................................................................................... 26
5.2 FOUNDATIONS AND SUPPORTS.......................................................................... 26
5.3 LOCATION AND ACCESS...................................................................................... 26
5.4 LIGHTING ................................................................................................................ 27
5.5 VENTILATION......................................................................................................... 27
5.6 NOISE CONTROL .................................................................................................... 27
5.7 ELECTRICAL INSTALLATION.............................................................................. 28
5.8 ERECTION................................................................................................................ 28
AS 3892—2001
4
Page
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5.9 CORROSION PROTECTION ................................................................................... 28
5.10 INSULATION ........................................................................................................... 28
5.11 PRECOMMISSIONING INSPECTION .................................................................... 28
SECTION 6 INSTALLATION OF PRESSURE PIPING
6.1 GENERAL................................................................................................................. 30
6.2 PIPING ...................................................................................................................... 30
6.3 JOINTS...................................................................................................................... 31
6.4 SUPPORTS ............................................................................................................... 32
6.5 IN-LINE EQUIPMENT ............................................................................................. 33
6.6 TESTING................................................................................................................... 34
6.7 CLEANING OF PIPEWORK .................................................................................... 34
6.8 THERMAL INSULATION AND PROTECTION ..................................................... 34
6.9 IDENTIFICATION.................................................................................................... 34
SECTION 7 INSTALLATION OF ASSOCIATED SERVICES, FITTINGS AND PIPING
7.1 CONNECTION TO SERVICES ................................................................................ 35
7.2 FITTINGS AND PIPING........................................................................................... 35
7.3 LOCATION OF FITTINGS AND PIPING................................................................ 35
7.4 PROTECTION OF FITTINGS AGAINST INTERFERENCE................................... 35
7.5 PROTECTION AGAINST DAMAGE....................................................................... 35
7.6 DRAINAGE PIPING ................................................................................................. 35
7.7 SAFETY DEVICE DISCHARGE PIPING ................................................................ 36
7.8 ISOLATION OF INTERCONNECTED PRESSURE EQUIPMENT......................... 37
7.9 OUTDOOR INSTALLATION................................................................................... 37
APPENDICES
A
LIST OF REFERENCED DOCUMENTS ................................................................. 38
B
GUIDE FOR A METHODOLOGY OF INCIDENT INVESTIGATION ................... 40
C
GUIDE FOR MANAGEMENT SYSTEMS FOR THE INSTALLATION OF
PRESSURE EQUIPMENT ........................................................................................ 41
D
GUIDE FOR ASSESSING THE COMPETENCY OF INSTALLERS ...................... 44
E
GUIDE FOR THE DESIGN OF BOILER BLOWDOWN TANKS ........................... 45
5
AS 3892—2001
STANDARDS AUSTRALIA
Australian Standard
Pressure equipment—Installation
S EC TION
1
S C OP E
AND
G E NER A L
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1.1 SCOPE
This Standard specifies the requirements for, and gives guidance on, the installation of
pressure equipment (boilers, pressure vessels and pressure piping), control, and safety
equipment constructed in accordance with AS/NZS 1200 and Standards referenced therein,
together with other relevant Standards.
NOTES:
1
No requirements can be written in sufficient detail to cover all aspects of installation for the
great variety of pressure equipment. Each installer should ensure that the quality of the
installation is in accordance with all applicable requirements and is adequate for continued
safe performance of the equipment. This may require further work to be undertaken and the
seeking of expert advice.
2
‘Duty of care’ is now prescribed on employers and employees regardless of regulation or
standards. This Standard does not supersede ‘duty of care’.
3
Users of this Standard are reminded that it has no legal authority in its own right, but may
acquire legal standing if adopted by government or any other authority having jurisdiction, or
if specified as part of a commercial contract.
1.2 OBJECTIVE
This Standard is intended to—
(a)
establish uniform minimum requirements for the installation of pressure equipment to
ensure safe performance and protection of personnel, equipment and the environment;
and
(b)
provide information and guidance for suppliers, installers, purchasers and various
authorities.
1.3 APPLICATION
This Standard applies to, but is not limited to, the following pressure equipment:
(a)
Static boilers (including superheaters, economizers, reheaters and air heaters) but
excluding domestic pressure cookers, domestic coffee machines and similar boilers.
(b)
Static fired and unfired pressure vessels (including industrial fired heaters, water
heaters, feedwater heaters, heat exchangers and other similar equipment).
(c)
Pressure piping assembled on or off-site.
(d)
Associated auxiliaries, e.g. boiler combustion equipment, fuel storage and handling
equipment, combustion air and flue gas systems, feed and circulating pumps.
(e)
Associated appurtenances, e.g. safety valves, pressure gauges, water gauges,
blowdown systems, feedwater controllers, soot blowers, steam and water valves, and
bursting discs.
(f)
Associated pressure equipment control systems.
(g)
Associated piping.
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© Standards Australia
AS 3892—2001
6
1.4 REFERENCED DOCUMENTS
A list of documents referred to in this Standard is given in Appendix A.
1.5 DEFINITIONS
For the purpose of this Standard, the definitions given in AS/NZS 1200 and those below
apply.
1.5.1 Competent person
A person who has acquired, through training, qualification, or experience, or a combination
of these, the knowledge and skills enabling that person to perform the task required.
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1.5.2 Installation (the process of)
The placing into position or erection of pressure equipment, the fitting of associated
appurtenances and auxiliaries, and associated checks in preparation for commissioning and
operation at a construction site or plant site. It includes reinstallation, relocation and
re-erection of equipment.
NOTE: Some portion of the installation may occur at the manufacturer’s works.
1.5.3 Installation
A complete assembly of pressure equipment in a location.
1.5.4 May
Indicates the existence of an option.
1.5.5 Purchaser
A body corporate, firm or person, who buys the pressure equipment from the manufacturer.
NOTE: It may include the owner or user.
1.5.6 Shall
Indicates that a statement is mandatory.
1.5.7 Should
Indicates a recommendation.
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7
S EC TION
2
GENER A L
AS 3892—2001
R EQ U IR EMENTS
2.1 COMPLIANCE
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The completed installation shall comply with this Standard. Where appropriate, the
following should be observed:
(a)
Drawings and specifications.
(b)
The recommendations of the suppliers or manufacturers of the pressure equipment,
associated appurtenances and auxiliaries.
(c)
Requirements of local government by-laws and ordinances, and other bodies or
agencies. These may include one or more aspects of the following:
(i)
Gas supply
e.g. AS 5601 (AG 601) and AS 3814 (AG 501).
(ii)
Fuel oil supply
e.g. AS 1940.
(iii) Electricity supply
e.g. AS/NZS 3000.
(iv)
Liquefied gas installations
Liquid petroleum gas (LPG) installations, e.g. AS/NZS 1596, anhydrous
ammonia installations, e.g. AS 2022, liquefied natural gas (LNG) installations,
e.g. AS 3961.
(v)
Major hazard facilities
Examples of relevant documents include Control of Major Hazard Facilities
National Standard [NOHSC:1014(1996)] and National Code of Practice
[NOHSC:2016(1996)].
2.2 SAFETY DURING INSTALLATION
2.2.1 General
During the installation, appropriate safety requirements shall be observed. The provision of
a clear set of safe working procedures for the prevention of hazardous incidents during
installation, appropriate to the complexity, should be available.
These procedures should ensure the following:
(a)
Provision of a safe working environment for the installation.
(b)
Development and maintenance of a written plan of action regarding safety practices.
(c)
Development and implementation of an installation layout analysis. Review for the
development of other elements of safety practices and emergency procedures.
(d)
Provision of a communication facility, such as a telephone service or equivalent.
(e)
Provision of whatever illumination of the working areas is considered necessary for
safe working.
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AS 3892—2001
(f)
Instigation of an assessment of the possible hazards involved with the installation of
the pressure equipment. The areas of risk should include but not be limited to the
following:
(i)
Pressure plant location.
(ii)
Fuel handling system design.
(iii) Fire protection provisions.
(iv)
Explosion relief provisions.
(v)
Equipment failure.
NOTE: See Appendix B for a guide methodology of incident investigation.
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2.2.2 Orderliness of systems and surrounding area
The pressure equipment system and its surrounding area shall be kept in a clean, safe and
tidy condition.
This, typically, should include—
(a)
the removal of all excess equipment and materials (including flammable and
combustible materials) from the area;
(b)
the removal of all substances and obstacles from stairways, platforms, roads and
access areas that could cause a hazard to personnel; and
(c)
the removal or isolation of spillages of solid, liquid and gaseous fuels, ash and dust.
2.2.3 Entry into pressure equipment systems
All the appropriate requirements of AS 2865 and additional specific site requirements shall
be undertaken before entering a confined space.
2.2.4 Entry into flues and furnaces
Safety procedures for entry into flues or furnaces shall be similar to those for entry into
pressure equipment systems (see Clause 2.2.3).
2.2.5 Hot work on pressure equipment systems
All hot work, such as oxy-cutting, welding and grinding, shall be carried out in accordance
with safe working procedures to control risk of fire, explosion, collapse, or other damage to
equipment or persons, in compliance with AS 1674.1, AS 1674.2 and AS 2865.
Prior to the commencement of hot work, a hot work permit shall be obtained or, if no hot
work permit system exists, written permission shall be obtained from the owner or the
owner’s representative.
The permit should document the fire prevention and protection requirements that have been
provided prior to beginning the hot work operations. It should indicate the date(s)
authorized for hot work, the duration of the permit and identify the object on which hot
work is to be performed. The permit should be kept on file until completion of the hot work
operations, or in the event of an emergency arising or an incident happening, until an
investigation is completed.
2.2.6 Static electricity
Where static electricity may be generated by the process or work, suitable precautions shall
be instigated, and the static electricity should be discharged in accordance with
AS/NZS 1020.
2.2.7 Cooling pressure parts by hosing
Except in an emergency, no pressure part should be hosed with cold water to reduce its
temperature quickly, otherwise major, immediate or unforeseen damage may occur.
© Standards Australia
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9
AS 3892—2001
2.2.8 Isolation from an existing system
Where it is necessary to connect to an existing operating system, suitable provisions shall
be made to isolate all pressure sources from the new work until completion of the
installation. The provisions shall be located between the vessel and each connected source
of pressure.
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Isolation of all connecting parts of the system shall be undertaken by the following:
(a)
One stop valve and a blanking plate.
(b)
Two stop valves with an atmospheric vent between; both stop valves shall be chained
and padlocked in the closed position. The keys shall be retained by the appropriate
personnel.
(c)
The removal of a section of interconnecting pipework.
2.2.9 Isolation from liquid-filled equipment
Provisions for isolation shall be located between the equipment and each connected source
of pressure. Isolation procedures for liquid-filled pressure equipment shall not cause
excessive pressure build-up.
This may be achieved by —
(a)
pressure protection devices remaining in service when liquid-filled pressure
equipment is isolated;
(b)
liquid-filled pressure equipment being partially drained to allow for thermal
expansion; or
(c)
pressure equipment being depressurized and vented, and the provision of blanks on
the pipe flanges immediately upstream and downstream of any removed pipe section
or equipment.
Caution is required when draining or venting to prevent failure due to vacuum.
2.2.10 Risk management
Risk assessment shall be performed which identifies hazards that may arise from, and
during, the installation of pressure equipment and its interaction with any existing system.
See AS 3873 and AS/NZS 4360.
The risk assessment should be reviewed where changes are made to the existing pressure
equipment system and new equipment is added to the system.
Risk documentation with reference to hazard analysis risk assessments and changes should
be retained for a period of at least two years. Such documentation should be appropriate to
the complexity of the system and should comply with the risk assessment statements
included in the relevant pressure equipment Standards.
2.2.11 Control of risk
Measures to control risks to an acceptable low level should be implemented or adequate
safeguards to minimize the possibility of accidents should be provided.
A procedure for the timely investigation and analysis of any problem arising from the
installation of pressure equipment should be established and for the instigation of the
necessary corrective action. Each corrective action should be documented to identify that
action has been taken and is effective, and the relevant notification given.
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© Standards Australia
AS 3892—2001
10
2.3 PROTECTION OF EQUIPMENT
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The management system, automatic control system and other operating or safety, or both,
systems for pressure equipment shall be adequately protected during installation.
Conditions which may cause deterioration or damage include the following:
(a)
Weather conditions.
(b)
Dust or atmospheric pollutants.
(c)
Unauthorized tampering. Security facilities should be provided for outdoor
installations.
(d)
Any physical cause, such as impact by forklift trucks, cranes or from materials being
lifted and shifted.
2.4 MANAGEMENT SYSTEMS
A management system for the installation of pressure equipment should be implemented
and maintained to satisfy the needs and objectives of the organization and be appropriate to
the equipment to be installed and the processes, size and structure of the organization.
The management system may be used by the organization to demonstrate its ability to meet
the installation requirements.
NOTE: A guide to management systems for installation of pressure equipment is given in
Appendix C.
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AS 3892—2001
S E C T ION 3
INS T A L LAT IO N ,
OR GAN IZAT ION A ND P ER S ONNE L
3.1 GENERAL REQUIREMENTS
3.1.1 General
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The scope of the installation shall be defined to ensure that the equipment and services
provided by the installer achieve the desired outcome, and where appropriate, comply with
the relevant requirements of this Standard.
Organizations or personnel consulted on the design, installation coordination and other
technical or safety aspects of the installation, should have the necessary qualifications,
competence and experience to provide engineering advice that will ensure compliance with
all of the relevant Standards and specifications.
When various parts of the installation are to be carried out by different organizations,
measures shall be taken to ensure compatibility between separate parts, components or
services.
Safe work practices shall be developed and implemented to control the entrance, presence
and exit of the personnel in all process areas involved with installation.
3.1.2 Instruction
Necessary drawings, documentation, site details, instructions and any other special
information, including information from equipment and the system suppliers, safety
information and instructions applicable to the supplied equipment and services shall be
provided.
All necessary safety information and instructions applicable to the supplied equipment and
services shall be obtained from the designer, manufacturer and installer.
3.2 INSTALLATION
3.2.1 General
The installation of the pressure equipment and associated plant shall be in accordance with
requirements in Clauses 2.1 and 2.2. Unless otherwise specified, this shall include
associated checks and inspections. The relevant organizations shall be advised of any
unique hazards that could be presented by the installation work, or if any hazards relating to
the pressure equipment are found during the installation work.
The information provided on-site should include the following:
(a)
Necessary information to enable the equipment to be installed so as to eliminate or
minimize risks.
(b)
All relevant emergency provisions and safe work practices operative at the site from
potential fire, explosion or toxic release hazards related to the installation of pressure
equipment.
3.2.2 Training and competency documentation
Personnel shall receive appropriate training in the current installing procedures. A record
shall be kept which contains the identity of the employee, date and details of the training,
the means to verify that the employee has understood the training and the competency level
attained.
NOTE: See Appendix D for a guide for competency of installers.
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AS 3892—2001
S E C T IO N
4
INS T A LLAT IO N
O F
B O I LE R S
4.1 HOUSING
4.1.1 Protection
Unless the boiler complies with the requirements of Clause 4.9 for outdoor installation, the
boiler shall be housed in a boiler house, room or other suitable enclosure that provides
adequate protection from weather and security from unauthorized access (see Clause 4.3.8).
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4.1.2 Floors
Floor surfaces and treads of stairs and ladders shall be of such material and construction as
to provide a firm footing when wet. Materials should be fire-resistant.
4.1.3 Drainage
The surface upon which the setting of a boiler is placed shall be properly drained. Drainage
from roofs, steam pipes and other sources shall be led away from supports and settings.
Settings shall be sloped and channelled to prevent water from remaining in contact with any
part of the boiler or boiler supports.
Adequate drains shall be provided for steam, water, and compressed air pipes and fittings.
Free-flow drains required for warming up steam pipes and any hazardous drains shall be
piped to a safe discharge point. Flashing mixtures (e.g. from the gauge glass or boiler
blowdown) shall not be discharged directly into floor drains or trenches.
Provision should be made for floor channels to be drained and carry all floor level pipes
without impeding access around the boiler. Pipes in floor channels should be arranged to
prevent external corrosion.
Provisions should be made to trap liquids and prevent their entry into public drains.
NOTE: The installation of a suitable drip-tray under the boiler will satisfy the drainage
requirement.
4.2 FOUNDATIONS AND SUPPORTS
4.2.1 General
Each boiler shall be provided with suitable foundations, appropriate fastenings and
supports. The foundations and structures shall be constructed to withstand any loads and
forces transmitted to them, including inherent loading in the structure; loading imposed
through expansion of the boiler, vessels or pipework; loading due to other equipment; or
forces due to wind, earthquake or other external forces, or as specified by the purchaser.
Foundations shall be sized in accordance with soil conditions and reinforced to carry all
loads and forces imposed without settling or distortion that would affect the safety or
serviceability of the installation.
Every supporting column or beam shall be protected from any furnace heat by suitable
refractory material or effective air spaces. Steel supports should not be heated to a
temperature of more than 300°C. Concrete should not be heated to a temperature of more
than 200°C.
Provision shall be made for free expansion of the boiler, where applicable.
All foundations shall be of material not substantially affected by water or oil.
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AS 3892—2001
4.2.2 Corrosion protection
Steel structures supporting boilers vessels shall be protected against corrosive agents,
including water from roofs, steam leaks, general drainage, weather or other sources.
Corrosion of supporting structures and columns shall be prevented during the life of the
installation.
4.3 LOCATION AND ACCESS
4.3.1 Building safety
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Each boiler should be located so as to minimize building damage or personal injury
resulting from any fire, explosion, escape of fuel, escape of combustion products or
deleterious process products.
NOTE: Additional requirements may apply to boilers installed in hazardous locations.
4.3.2 External damage
Each boiler with its auxiliaries and appurtenances should be located where they will be least
likely to be damaged from external causes and protected against mechanical damage.
4.3.3 Building structure
Unless the building structure has been designed to incorporate the boiler supports and
approved for the purpose by a qualified engineer, the boiler support structure shall be
separate from the building and all its members.
4.3.4 Safety and convenience
A boiler shall be located so that—
(a)
safe access for working is facilitated;
(b)
safe exits are available in the event of any emergency and so spaced as to allow rapid
evacuation of personnel from any location;
(c)
any passage of persons or goods along any passageway or through any exit is not
hindered;
(d)
traffic is not likely to cause damage to, or malfunction of, the boiler, vessel or its
components;
(e)
safe access for maintenance and servicing is available;
(f)
adequate clearance is provided to permit inspection and the removal of any
components that might require replacement; and
(g)
the possibility of undesirable interaction with other nearby processes is minimized,
e.g. certain solvents and refrigerants can interact with a flame to produce toxic or
corrosive vapours.
Service outlets, electric, water, steam and air-hose connections should be readily
identifiable and accessible, conveniently located, and adequate in number.
4.3.5 Access
Each boiler shall be provided with all platforms, walkways, stairways, and ladders
necessary for its safe operation and for the regular operational checks, inspection and
maintenance of controls and operational equipment. Such platforms, walkways, stairways
and ladders shall be fixed in position. They should comply with AS 1657.
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AS 3892—2001
Access to all operating and safety controls shall be limited to authorized personnel. This
may be achieved by using—
(a)
a control and safety system which is lockable; or
(b)
a lockable boiler housing which isolates the entire boiler, its controls and safety
systems.
Any boiler housing shall be large enough to provide clearances necessary for the safe
operation and maintenance of the boiler.
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For boilers, other than electric boilers, the size of any housing should be such as to provide
operating clearances around the boiler no less than—
(i)
2 m in front of the boiler; and
(ii)
1 m between the boiler and the side walls, the rear walls and the roof or ceiling, and
between adjacent boilers except where the boiler is designed so that access to the
relevant side or end is not required for operation, maintenance or safe egress.
Boilers having access openings, hand holes or cover plates, to permit inspection of the
interior, should be installed so that these openings are accessible, with consideration given
to emergency egress procedures.
4.3.6 Explosion relief protection
Where explosion relief devices are fitted, a boiler shall be located or protected or guarded,
so that when installed and operating, explosion reliefs, vents or closures, such as fire doors
or viewing ports, cannot cause injury from moving parts or ejected flames.
4.3.7 Clearance for explosion relief
The distance between the vent of an explosion relief and any nearby wall, roof, ceiling or
other solid construction shall be sufficient to ensure that the flow of products of an
explosion is not restricted, and shall be no less than the following:
(a)
V 

3
Clearance (from nearby wall or ceiling) is equal to 0.4
1/ 3
(in metres) with a
minimum of 0.4 m, where V is the volume of the space being vented, i.e. boiler
furnace up to the flue connection (see AS 1375), in cubic metres.
(b)
Clearance (from two walls at right angles or from one wall and a ceiling) is equal to
V 
0.6 
3
1/ 3
(in metres) with a minimum of 0.6 m.
NOTE: It should be recognized that if an explosion relief discharges into a contained space, that
space will be subjected to an increase of internal pressure.
4.3.8 Security
Each boiler shall be provided with sufficient protection to inhibit interference by
unauthorized personnel or the general public.
The security provision may be one of the following:
(a)
Location within a property that is surrounded by fencing or walls with lockable
entries.
(b)
The provision of a lockable plant room.
(c)
The provision of tamper-proofing for individual control elements or control panels.
(d)
Area procedures or notices that inhibit the entry of unauthorized persons. This
provision is acceptable for attended boilers only (see AS 2593).
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AS 3892—2001
4.4 SETTINGS
4.4.1 Levelling
Boilers shall be set in accordance with information provided.
4.4.2 Casings
Casings shall be installed in accordance with information provided.
4.4.3 Expansion provision
Expansion joints shall be correctly installed and provision for expansion shall be
incorporated.
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4.4.4 Load distribution
Settings of the suspended type shall be installed so that the load is properly distributed over
all points of suspension.
4.4.5 Gastightness
Gastight combustion chamber settings shall be used for pressurized furnaces. Pressure
testing of settings, where required, shall be carried out in accordance with information
provided by the design specifications, which shall include information on any safety relief
requirements.
NOTE: Gastight combustion chamber settings are recommended in all installations.
4.5 LIGHTING
4.5.1 General
Permanent lighting shall be installed in accordance with AS 1680 (series), and shall provide
a level of illumination which ensures that portable lights will not be required in the normal
operation of the boiler or its auxiliaries. An independent and reliable source of emergency
illumination shall be provided in the boiler house, e.g. portable torches. Provision should be
made for extra lighting, where necessary, for maintenance purposes.
4.5.2 Lighting for controls and access
The gauges and operating controls of each boiler shall be clearly visible from the operating
position and adequately illuminated for ease of reading.
All obstructions in passageways, overhead or otherwise, should be clearly marked with
light-coloured paint, striped tape or reflectors.
4.6 VENTILATION
The ventilation provisions of the installation area shall be capable of providing adequate
fresh air for the safety and comfort of personnel and for the requirements of the boiler.
The climate within any zone requiring the presence of personnel should not cause excessive
discomfort.
NOTE: Comfort condition requirements cannot be specified because of such variables as personal
sensitivity variations, ability to acclimatize, and the like. Length of exposure is a major factor,
i.e. a workstation that is manned for considerable periods would require better climatic control
than an area that is entered only momentarily for an observation or an adjustment.
Where the ventilation and combustion supply requirements are combined, two permanent
openings with a minimum free air inlet area of 675 mm2 /kW output should be provided.
Each opening shall be designed so that it cannot be closed or restricted below the minimum
requirements.
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AS 3892—2001
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The following requirements shall apply:
(a)
Where the boiler house ventilation system provides combustion air, by either natural
or mechanical means, the air pressure in the boiler house or boiler room (measured
adjacent to the combustion air intake) shall not differ from the external barometric
pressure by more than 10 Pa suction.
(b)
Natural or mechanical ventilation shall ensure that the general air temperature in the
boiler house or boiler room does not exceed 31°C or the external ambient temperature
plus 10°C, whichever is the higher.
(c)
Where fans or blowers are used to supply fresh air or for the specific case where part
of the operating enclosure is pressurized and provided with air locks, appropriate
interlocks or warning devices shall be provided to ensure safe conditions in the event
of air supply failure.
4.7 NOISE CONTROL
In all areas, the noise level due to the operation of the boiler and the auxiliaries shall
comply with AS/NZS 2107 and other relevant requirements.
4.8 CONTROL ROOMS
Where a control room is used for the control of the boiler and auxiliaries, it shall—
(a)
meet the applicable requirements of Clauses 4.1, 4.3, 4.5, 4.6, 4.7, 4.16 and 4.18;
(b)
contain gauges, instruments, alarms and controls that will enable personnel to safely
operate the boiler; and
NOTE: It is recommended that, within the control room, pressurized gauges should be kept to
a minimum.
(c)
comply with the requirements of any other relevant body or agency.
4.9 PROVISION FOR OUTDOOR INSTALLATION
4.9.1 General
Outdoor installations shall—
(a)
be in accordance with Clauses 4.1 to 4.8, except that requirements specifically related
to a boiler house do not apply;
(b)
comply with this Clause (4.9); and
(c)
be designed to withstand the forces of wind and earthquakes in areas where they may
occur, as specified in local building codes.
4.9.2 Drainage
Outdoor installations should be erected on foundations or pads with surfaces sloped to shed
rainwater and high enough above ground level to keep surface water from metal parts.
Unless special surface protection is provided, equipment shall be protected with a
weatherproof casing to prevent rainwater from coming in contact with the pressure parts,
refractories and insulation. Any roof provided should be sloped. Casing flanges, platforms,
walkways and backstays should be provided with methods to facilitate drainage of water.
4.9.3 Insulation
Exposed insulation should be sealed to prevent water ingress and be protected either by a
light-gauge metal cover or by a weatherproof coating. Direct contact between incompatible
materials should be avoided.
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AS 3892—2001
4.9.4 Shelters
Control rooms in accordance with Clause 4.8 or shelters should be provided for personnel
involved with attended boilers. Where shelters are not provided, controls and instruments
should be individually protected from effects of the elements, e.g. by means of light gauge
metal covers.
4.9.5 Provision against freezing
All steam and water lines outside the boiler setting, such as lines to control pressure gauges,
drains from gauge glasses and water columns, and blowdown lines, shall be completely
drainable and shall be protected against freezing (where applicable). Compressed air
systems and equipment for control units and other services shall receive special attention.
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4.9.6
Fan protection
Forced-draft fans, primary air fans and all other fans with air intake from the atmosphere
should be provided with rain shields for their inlets.
4.9.7 Partial outdoor installation
Where an outdoor boiler is installed with its operating zone indoors, the structure shall be
provided with adequate flashing to permit expansion. Each boiler so installed shall have an
access door through the partition wall separating the outdoor from the indoor portion of the
installation.
4.10 FEEDWATER TREATMENT AND SUPPLY PLANT
4.10.1 Feed water supply plant
Unless otherwise agreed by the parties concerned, each boiler plant installation shall be
provided with a dedicated feedwater and condensate recovery storage facility capable of
holding 15 minutes of equivalent evaporation of all boilers when working at their maximum
continuous rating. The feedwater system shall provide sufficient head pressure to all the
boiler feedwater pump suction inlets at a minimum operating temperature of 90°C in the
case of atmospheric vented feedwater systems or 105°C in the case of pressurized deaerator
systems.
4.10.2 Feedwater treatment
Each boiler installation shall be provided with suitably treated water to meet the
requirements of AS 3873, BS 2486 and the specifications provided by a competent water
treatment organization or person.
The characteristics of the treated water shall be periodically monitored, documented and
reviewed accordingly.
4.11 BLOWDOWN SYSTEMS
4.11.1 General
Blowdown facilities shall be provided which are capable of removing precipitates formed
by the water treatment and maintaining the concentration of suspended and dissolved solids
below the maximum recommended by the boiler manufacturer. For unattended and limited
attendance boilers, the additional blowdown system requirements of AS 2593 shall apply.
4.11.2 Common mains
Each boiler shall have a separate blowdown main, except that the blowdown pipes from two
or more boilers may be led to a common main, provided that the points of entry to the
common main are limited to two per boiler. At the point of entry to the common main, each
branch shall be provided with a non-return valve (fitted with a means of securing it fully
closed). No superheater drain shall be connected to any boiler blowdown line.
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AS 3892—2001
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4.11.3 Piping location
Blowdown pipes shall be so located that all exposed portions within the building and within
any pipe tunnel opening directly into the boiler room can be inspected. Blowdown lines and
connections should not be exposed to excessive heat, freezing or corrosive conditions.
Blowdown lines and connections shall discharge to a safe place.
Blowdown valves and cocks shall be in such locations that they are accessible and, if
located in a floor channel, an extension shall be applied to the valve stems so that they can
be operated from the floor or some convenient and safe location.
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The blowdown line should be self-draining and should be so installed as to provide a visible
means of detecting leakage. Any low points or pockets in the line shall be provided with
drain valves.
4.11.4 Piping supports
Blowdown pipes are subject to severe forces and vibration; consequently, they shall be
firmly supported and braced to resist reactive forces to permit expansion of the boiler and
pipes without imposing excessive stresses on the boiler or connections, and to avoid
excessive vibration.
4.11.5 Blowdown tank
Where fitted, each blowdown tank shall be installed to ensure safety of personnel and
adequate access for cleaning and inspection. Discharge shall comply with the temperature
and pollution requirements of the local drainage, and other, bodies or agencies.
NOTE: Appendix E provides guidelines on the design of blowdown tanks.
4.12 BOILER FLUE GAS EXHAUST SYSTEMS
4.12.1 General
Each boiler shall be fitted with a flue and every flue shall be connected to a separate
chimney except as permitted by Clause 4.12.3.3. The flues and chimneys shall comply with
Clauses 4.12.2 to 4.12.5 and with the requirements of the boiler, or the body or agency
having jurisdiction over atmospheric discharges.
NOTES:
1
This Clause (4.12) has been composed with only the needs of this Standard in mind, i.e. the
efficiency, effectiveness and safety of the boiler(s), and the safety and health of personnel. No
attempt has been made to cater for or rationalize the requirements of the various clean air
agencies or similar bodies, which should be consulted separately for applicable requirements.
Such agencies usually specify both the height and diameter of the chimney, for the purpose of
achieving their own objectives of optimizing disposal and dispersal of effluent products. It
should not be assumed that such requirements automatically cope with the thermodynamic
aspects of design, and the possible effects on combustion should always be checked.
2
The terms ‘chimney’ and ‘flue’ have been used throughout Clause 4.12 as an editorial
convenience. These terms are most commonly used in the industrial boiler industry. The
chimney (sometimes referred to as a smoke stack or flue) is regarded as the vertical final part
of the exhaust system. Flues (or ducts) are regarded as the initial part of the system leading to
the chimney.
4.12.2 Flue temperatures
The casing or outer shells of flues, grit arresters, fans or chimneys that are accessible during
normal work operations and which are at temperatures that could prove injurious to
personnel shall be insulated so that the external temperature does not exceed 70°C or be
shielded to prevent inadvertent human contact.
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AS 3892—2001
4.12.3 Chimney and flue design and construction
4.12.3.1 General
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Chimneys and flues shall be designed and constructed to withstand—
(a)
wind forces as specified in AS 1170.2;
(b)
earthquake forces as specified in AS 1170.4; and
(c)
the operating temperatures, pressure and corrosive conditions of the installation.
NOTE: Where an exposed chimney is less than 10 m high, or less than 450 mm in diameter, the
structural design can be relatively simple, requiring only adequate provisions for supports, guys
and stays, and corrosion. However, if a larger structure is required, expert advice should be
sought. BS 4076 is typical of established design Standards in this field. However, any such
Standard needs to be used in conjunction with certain basic Australian requirements, e.g.
AS 1170.2, AS 3990, AS 1170.4, and relevant regulations.
Care should be taken to avoid any stress in the boiler structure or chimney due to movement
of the chimney or boiler. All chimneys and flues shall be constructed to permit proper
inspection and maintenance.
4.12.3.2 Performance
The exhaust system design shall ensure that the free flow of flue gas is not hindered by
sharp turns or restrictions of cross-sectional area of the flue. For solid fuel firing, the use of
lateral flues should be minimized as grit deposition may occur at low loads.
Due regard should be given to the acid dewpoint of the flue gas and to the selected boiler
exit flue gas temperature. Care should be taken to minimize the effects of corrosion on the
flue and any nearby structural components.
4.12.3.3 Common flues
Individual flues from two or more boilers may be connected to a single chimney. In this
case the following requirements apply:
(a)
For gas-fired boilers or oil-fired boilers, or both, the flue gas temperature from any
boiler at entry to the common chimney shall be no less than 100°C below the
auto-ignition temperature of the gas or oil vapour, or any ignitable mixture that may
be generated, whichever is the lowest (see AG 601 or AS 5601).
(b)
For a gas-fired or oil-fired boiler and a solid-fuel-fired boiler or other appliance—
(c)
(i)
the requirements of Item (a) shall apply with respect to the gas or oil vapour
and the solid fuel suspension mixture; and
(ii)
the solid-fuel-fired boiler shall be equipped with an effective dust removal
device.
For two or more solid-fuel-fired boilers, the requirements of Item (b) shall apply. The
requirement of Item (b)(ii) may be waived if—
(i)
the fuel is substantially dust-free; and
(ii)
the boilers do not have any gas-fired or oil-fired equipment.
Boilers connected to the compartments of a divided chimney shall be deemed to be
connected to separate chimneys.
In all cases, where two or more boilers are interconnected, means shall be provided for
effectively isolating each boiler for maintenance purposes. Such isolation shall prevent the
flow of gas to and from the isolated boiler.
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AS 3892—2001
4.12.3.4 Chimneys
Chimneys and flues that terminate outside a building shall discharge away from doors,
windows or other possible air intakes so as to preclude the re-entry of vapours, hot air,
exhaust products, and the like, into the building. The discharge point shall not impede the
free discharge of gases; and shall be located clear of any building or other construction that
may impede free discharge.
Care shall be exercised to prevent any exhaust gases that may contain volatile flammable
materials, particularly those being discharged during purging, from being directed towards
any objects or zones where ignition may take place.
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Steel chimneys shall comply with BS 4076, except as noted in Clause 4.12.3.1.
The chimney design, height and efflux velocity of the flue gas shall comply with the
requirements of the body or agency having jurisdiction over atmospheric discharge.
However, the efflux velocity for solid-fuel-fired boilers at maximum combustion rate
should be no less than 8 m/s. Chimneys shall not be fitted with any form of cap or
obstruction that will prevent the free exit of flue gas. Any outlet cones shall have an
included angle of no more than 30 degrees.
Where required, the chimney design should include galleries and gas-sampling equipment.
Special lighting may be required, depending on the height and location of the chimney.
Where applicable, chimneys shall be connected to earth by means of an earth strap
complying with AS 1768.
4.12.3.5 Cross-sectional area
The cross-sectional area of a chimney or flue should be sized to suit the boiler and firing
requirements.
4.12.3.6 Existing chimneys or flues
An existing chimney or flue may be used provided that the net pressure achieved ensures
compliance with the requirements of Clauses 4.12.3.4 and 4.12.3.5 and is deemed safe.
4.12.4 Connection flues
4.12.4.1
Arrangement of flues
Flues shall be arranged as follows:
(a)
Gas-fired and oil-fired boilers
Flues for gas-fired and oil-fired boilers shall be designed and constructed so that no
vapour lock or dead space exists between the boiler outlet and the chimney flow.
(b)
Solid-fuel-fired boilers
Flues for solid-fuel-fired boilers having gas-fired or oil-fired ignition burners shall
comply with Clauses 4.12.3.2 and 4.12.3.3.
NOTE: Fans and grit arresters or similar components are not regarded as part of the flue.
4.12.4.2 Cross-sectional area of flues
The cross-sectional area of a flue should be such as will ensure that, at normal operating
conditions, any grit that may be carried from the boiler is transported in the gas stream to
the grit arrester.
4.12.4.3 Construction
Construction shall be of adequate strength and rigidity, sufficiently braced and supported,
and adequately protected from mechanical damage, to meet the normal conditions of
operation.
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AS 3892—2001
4.12.4.4 Joints
Where leakage from, or air induction into, a flue is unacceptable, e.g. where a flue is
carrying volatile or toxic materials, the joint shall be sealed in a manner and with materials
suitable to the conditions of the application.
NOTE: Where condensation may occur in a vertical or sloped flue, the direction of the lap of the
joint and the sealing should be arranged so that leakage is prevented.
4.12.4.5 Cleaning
Flues used to convey materials in suspension that may settle or form deposits shall be
designed and constructed to facilitate cleaning.
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4.12.4.6 Drainage provisions
The design of any exhaust system shall be such that any vapours that condense in it do not
drip back into an area where they could create a hazard. Adequate means shall be provided
to drain any condensate away from the exhaust system; in such an instance, a sealing device
may be required.
4.12.5 Chimney support
4.12.5.1 Direct-mounted chimneys
Chimneys mounted directly on the boiler outlet shall be subject to the following
requirements:
(a)
The boiler structure shall be designed and constructed to provide for additional load
and dynamic effects, or a load-bearing structure shall be provided.
(b)
The chimney shall be adequately guyed or otherwise laterally supported, or be
designed as a self-supporting chimney.
4.12.5.2 Self-supporting chimneys
A chimney that is self-supporting and not directly mounted on the boiler shall be mounted
on a structure or concrete footing suitable for the load.
4.12.5.3 Guys, stays and supports
A chimney shall be provided with adequate guys or stays, where necessary, to ensure
stability and to minimize stresses due to wind-induced oscillations. Any supports, brackets
or fastenings shall not be combustible, and shall be sufficiently durable to ensure that
clearances from building constructions are maintained.
4.12.6 Dampers and interlocks
Flue dampers that affect the volume of fresh air admitted to the boiler and the volume of
vapours or gases exhausted from the boiler shall be designed or interlocked with the heat
input system so as to ensure that unsafe accumulations of volatiles cannot occur, and
heating cannot be initiated or allowed to continue unless the dampers are in a safe operating
position.
The leak rate through the damper should be minimized.
4.13 SOLID FUEL AND ASH STORAGE,
COLLECTION EQUIPMENT
AND
HANDLING
AND
DUST
4.13.1 General
Each solid-fuel-fired boiler should be provided with solid fuel, ash storage, handling and
dust collection equipment complying with the requirements and recommendations of
Clauses 4.13.2 to 4.13.6, the relevant boiler Standard(s) and the following:
(a)
All equipment should be accessible for inspection, maintenance and repair.
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© Standards Australia
AS 3892—2001
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(b)
Equipment should be designed and installed to provide a safe and clean environment
for operation.
(c)
Those parts of equipment that are subject to serious abrasion should be fabricated
using wear-resistant material.
(d)
Where there is a risk of dust nuisance from indoor storage and handling equipment,
the relevant parts of such equipment should be enclosed to minimize dust discharge.
4.13.2 Location of storage structures
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Storage structures (silos, bunkers, bins and hoppers) should be located—
(a)
in or adjacent to boiler rooms;
(b)
to avoid interference with operation and maintenance; and
(c)
to avoid heat sources, e.g. uninsulated steam pipes, chimneys and flues.
4.13.3 Solid-fuel storage bunkers
4.13.3.1 Design
Storage facilities, e.g. bunkers and hoppers, should be of substantially closed construction
with all joints sealed.
The design shall be such as will prevent the leakage of fuel or combustible dust in the
vicinity of the boiler.
4.13.3.2 Shape
The slope of surfaces and valley angles in the storage structure shall be such as to ensure
the free flow of the fuel used.
4.13.3.3 Construction material
Storage structures should be constructed of materials compatible with the corrosion,
abrasion and handling characteristics of the fuel.
4.13.3.4 Internal access
All storage bunkers should have an access opening at the top with hinged cover and safety
rail; in such an instance, an internal access ladder may be required.
4.13.3.5 Fuel outlets
All gravity flow outlets should be designed to minimize bridging or other unplanned
interruption to flow. Control gates should, in general, be of the swinging type with either
double or single jaws. Gates should be of adequate design and manufactured using suitable
materials.
Where it is likely that the fuel to be stored will not flow freely from any outlet (i.e. bridge),
some means of agitation should be fitted to the bunker.
4.13.3.6 Fire prevention
Where fuel is to be stored, firefighting equipment shall be installed to satisfy local
ordinances.
4.13.4 Fuel handling
4.13.4.1 Feed
Fuel handling from the storage bunker to the combustion equipment shall be by gravity,
pneumatic or by some other suitable means. Where appropriate, the fuel chute for a
gravity-fed system should be designed to minimize the segregation of fines and maintain a
uniform distribution across the fuel feeder.
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AS 3892—2001
4.13.4.2 Burn-back protection
With unattended or limited attendance boiler installations, burn-back protection shall be
incorporated into the system for feeding fuel as required by AS 2593.
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This shall be achieved by one of the following methods:
(a)
The fuel-feeding system shall be provided with two independent inlets of steam,
water or other fire-extinguishing fluid-spray systems, independent of the boiler
management system, fitted in the fuel feeder or chute, to extinguish any fire caused
by a burn-back of the fuel. The sprays shall be automatically controlled by
thermostats to operate upon temperature rise in the fuel feeder, chute or hopper.
(b)
The fuel supply chute or duct shall have an air break between the fuel storage bunker
and the combustion equipment hopper that will prevent a burn-back into the fuel
storage bunker.
(c)
Other approved methods.
4.13.5 Handling of ash
Any handling and storage of ash shall be designed, constructed and installed so as to—
(a)
minimize any dust escaping into the environment;
(b)
prevent any temperature hazard from injuring personnel; and
(c)
guard and protect any personnel in accordance with AS 1755.
4.13.6 Grit or dust collectors
Means shall be provided to remove dust from the products of combustion and ensure
compliance with the requirements of the body or agency having jurisdiction over
atmospheric discharge.
4.14 GAS AND OIL EQUIPMENT
For guidance, see AS 5601 (AG 601). For gas and fuel oil installations, see Clause 2.1(c).
4.15 ASSOCIATED PROTECTIVE AND EMERGENCY SYSTEMS
The following protective and emergency equipment, where appropriate, shall be installed
prior to commissioning and operation:
(a)
Fire prevention, detection and fighting equipment.
(b)
First aid equipment.
(c)
Personnel protective equipment.
(d)
Other equipment as required in applicable regulations and ordinances.
The equipment shall be located to maximize safety.
Suitable instruction and guidance information shall be provided to facilitate proper use of
the equipment and the development of emergency procedures.
Such equipment and instructions may be provided by the equipment manufacturer, the
installer or the purchaser.
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AS 3892—2001
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4.16 ELECTRICAL INSTALLATION
All wiring shall comply with the requirements of AS/NZS 3000 and the relevant boiler
Standard.
In places where flammable gas or liquid may accumulate in sufficient quantity to form a
flammable or explosive mixture, electrical equipment shall be suitable for use in hazardous
locations in accordance with the relevant classification in AS/NZS 3000 and shall be
suitable for use in explosive atmospheres in accordance with one of the techniques detailed
in AS/NZS 3000.
4.17 ERECTION
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Erection of the boiler shall be carried out so that the boiler is not damaged in any way, and
that the procedure is safe.
4.18 COMMUNICATION FACILITY
Effective communication shall be provided to ensure that the boiler and associated
equipment can be commissioned and operated safely and efficiently. This facility shall
permit rapid contact between boiler personnel, (emergency) maintenance personnel and
emergency response organizations, i.e. fire, police and ambulance.
4.19 FINAL CONDITION AND HOUSEKEEPING
The boiler and associated auxiliaries and housing shall be cleaned, adjusted or repaired, as
necessary, after installation to facilitate safe and efficient commissioning and operation.
4.20 PRECOMMISSIONING INSPECTION
4.20.1 General
The installation shall be prepared and inspected in accordance with specified requirements
in Clause 3.1 and this Clause (4.20). The recommendations of Clauses 2.1(a) and (b) also
apply.
4.20.2 General boiler inspection
Prior to commissioning, an inspection shall ensure that the boiler and any ancillary pressure
equipment—
(a)
have been manufactured and installed to the appropriate Standard and the boiler has
been appropriately marked;
(b)
are internally inspected and hydrostatically tested to the appropriate Standard, such as
AS 1228 and Clause 4.20.4 of this Standard, where the pressure equipment has been
assembled on site;
(c)
have the appropriate documentation;
(d)
meet the requirements of any relevant body or agency; and
(e)
have the required pressure safety devices fitted, adjusted where appropriate and in
working order.
4.20.3 Installation inspection
The installation, and each component of the installation, shall be inspected for possible
damage or incorrect installation prior to commissioning. Any problems shall be reported
and subsequently rectified.
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AS 3892—2001
4.20.4 Water side preparation
For the hydrostatic test required following the completion of any site erection of pressure
parts, care should be taken to ensure that the water used is of the feedwater quality
recommended for the pressure equipment and that the temperature is not less than the
minimum recommended temperature for hydrostatic testing in the applicable Standard. Care
should be taken if water is to be left in non-drainable areas for an extended period, or if the
locality is likely to be subject to temperatures that may cause the water to freeze.
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Prior to commissioning, each boiler or hot water system shall be—
(a)
flushed with water treated for cleaning;
(b)
drained; and
(c)
flushed with clean water.
Each boiler should be immediately filled with water treated for the initial commissioning
process, which may include an alkali boil-out or an acid clean, or both.
NOTE: If not immediately filled with water, consideration should be given to the need for
appropriate waterside preservation measures.
Special attention shall be given to the water used with equipment manufactured from
austenitic stainless steel.
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AS 3892—2001
S E C T ION
5
INS T A L LAT IO N
VES S E LS
O F
P R E S S UR E
5.1 SITING
5.1.1 General
Pressure vessels may be installed outdoors or in a suitable enclosure or room. Outdoor
installations should be sited at a safe distance from roadways, passageways, or other
general areas of thoroughfare of the general public or site personnel.
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5.1.2 Drainage
The floors of buildings accommodating vessels that contain liquid (including liquefied gas,
see Note) shall be constructed to be impervious to the liquid and, wherever practicable,
shall be graded to prevent any accumulation of liquid.
The surface upon which the support of a vessel containing liquid (including liquefied gas,
see Note) is placed shall be properly drained. Drainage from roofs, steam pipes and other
sources shall be led away from supports. Supports shall be sloped and channelled to prevent
water remaining in contact with any part of the vessel.
NOTE: For specific requirements for particular liquefied gases, see the relevant application
Standard.
Outdoor installations should be erected on foundations or pads with surfaces sloped to shed
rainwater and high enough above ground level to keep surface water from metal parts.
5.2 FOUNDATIONS AND SUPPORTS
5.2.1 General
Each vessel shall be provided with suitable foundations or structural supports, or both, in
accordance with the relevant pressure vessel Standard. The foundations and structures shall
be constructed so as to withstand any loads and force transmitted to them, including
inherent loading on the structure; loading imposed by the expansion of the vessel,
associated boiler or pipework; loading due to other equipment; and forces due to wind,
earthquakes or other specified external forces, or as specified by the purchaser.
Foundations shall be sized in accordance with soil conditions, and reinforced so as to carry
all loads and forces imposed without settling or distortion that would affect the safety or
serviceability of the installation.
5.2.2 Corrosion protection
Steel structures supporting pressure vessels shall be protected against corrosive agents,
including water from roofs, steam leaks, general drainage, weather or other sources.
Corrosion of supporting structures and columns shall be prevented during the life of the
installation.
5.3 LOCATION AND ACCESS
5.3.1 Vessel supports
Vessel supports shall be arranged so as to provide adequate facility for the inspection of
every part of the vessel.
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AS 3892—2001
5.3.2 Safety and convenience
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A pressure vessel shall be located so that —
(a)
safe access for working operators is facilitated;
(b)
safe access for cleaning, inspection and maintenance is available;
(c)
safe exits are available in the event of any emergency and spaced so as to allow rapid
evacuation of personnel from any location;
(d)
any passage of persons or goods along any passageway or through any exit is not
hindered;
(e)
traffic is not likely to cause damage to, or malfunction of, the vessel or its
components;
(f)
adequate clearance is provided to permit inspection and the removal of any
components that might require replacement; and
(g)
the possibility of undesirable interaction with other nearby processes is minimized,
e.g. certain solvents and refrigerants can interact with a flame to produce toxic or
corrosive vapours.
5.3.3 Buried, mounded or underground equipment
For buried, mounded or underground pressure vessels, refer to AS/NZS 1596 and
AS/NZS 3788.
5.3.4 Outdoor installations
Vessels subject to external corrosion shall be located so that there is sufficient access to all
parts of the exterior to permit proper inspection, unless adequate protection against
corrosion is provided, or unless the vessel is of such a size and is so connected that it can
readily be removed from its permanent location for inspection.
5.3.5 Access
Each pressure vessel shall be provided with all platforms, walkways, stairways, and ladders
necessary for its safe operation and for the regular operational checks, inspection and
maintenance of controls and operational equipment. Such platforms, walkways, stairways
and ladders shall be fixed in position and should comply with AS 1657.
Floor surfaces and treads of stairs and ladders shall be of such material and construction as
to provide a firm footing when wet.
5.4 LIGHTING
The illumination level at the vessel shall be sufficient to allow safe operation of the vessel
and access to the vessel under normal conditions.
5.5 VENTILATION
Vessels shall have adequate ventilation around them, particularly where vessels are located
indoors. The ventilation requirements shall take into account the density of gas or liquid
that could escape from the vessel. Special requirements for lethal materials should be
agreed upon with the appropriate authority.
5.6 NOISE CONTROL
In all areas, the noise level due to the operation of the pressure vessel and the auxiliaries
shall comply with AS/NZS 2107 and any other relevant requirements.
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AS 3892—2001
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5.7 ELECTRICAL INSTALLATION
All wiring shall comply with the requirements of AS/NZS 3000.
In places where flammable gas or liquid may accumulate in sufficient quantity to form a
flammable or explosive mixture, electrical equipment shall be suitable for use in hazardous
locations in accordance with the relevant classification in AS/NZS 3000 and shall be
suitable for use in explosive atmospheres in accordance with one of the techniques detailed
in AS/NZS 3000.
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Where a vessel contains flammable gases or liquids of 680 L capacity or greater, the vessel
shall be earthed electrically in accordance with AS/NZS 1020. Where the vessel contains
flammable gases or liquids and is of 9100 L capacity or greater, the vessel should be
protected against lightning in accordance with AS 1768.
5.8 ERECTION
Erection of the vessel shall be carried out so that the vessel is not damaged and the erection
procedure is safe.
5.9 CORROSION PROTECTION
The vessel shall be treated externally, or otherwise protected, to ensure that it will not be
subject to excessive corrosion.
5.10 INSULATION
Where the vessel is required to be insulated, this shall be carried out in accordance with the
requirements of Clause 3.1. The recommendations of Clauses 2.1(a) and (b) also apply. For
vessels containing cryogenic liquids, the insulation shall comply with AS 1894. The
insulation shall be non-corrosive to the parts of the vessel with which it is in contact and
should be fire-retardant. The insulation should be of a type that will not seriously hamper
the locating of leaks. Insulation should be provided that is readily removable for access to
inspection openings, to supports and other positions where it is necessary to carry out
frequent inspections.
For outdoor installations, exposed insulation shall be sealed to prevent water ingress and be
protected either by a light gauge metal cover or by a weatherproof coating, or by other
external protection to prevent ingress and accumulation of rain or water from any other
source.
5.11 PRECOMMISSIONING INSPECTION
5.11.1 General
The installation shall be prepared and inspected in accordance with specified requirements
in Clause 3.1 and this Clause (5.11). The recommendations of Clause 2.1(a) also apply.
5.11.2 General pressure vessel inspection
Prior to commissioning, an inspection shall ensure that the pressure vessel and any ancillary
pressure equipment—
(a)
have been manufactured and installed to the appropriate Standard and the vessel has
been appropriately marked;
(b)
are internally inspected and hydrostatically tested to the appropriate Standard, such as
AS 1210, and Clause 5.11.4 of this Standard, where the pressure equipment has been
assembled on site;
(c)
have the appropriate documentation;
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AS 3892—2001
(d)
meet the requirements of any relevant body or agency; and
(e)
have the required pressure safety devices fitted, adjusted, where appropriate, and in
working order.
5.11.3 Installation inspection
The installation, and each component of the installation, shall be inspected for possible
damage or incorrect installation prior to commissioning. Any problems shall be reported
and subsequently rectified.
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5.11.4 Hydrostatic testing
For the hydrostatic test required following the completion of any site erection of pressure
parts, care should be taken to ensure the water or other suitable liquid used is of the quality
recommended for the pressure equipment and that the temperature is not less than the
minimum recommended temperature in the applicable Standard during the hydrostatic test.
Care should be taken if water is to be left in non-drainable areas for an extended period or if
the locality is likely to be subject to temperatures that may cause the water to freeze.
Prior to commissioning, each vessel shall be treated in accordance with the specified
requirements. Treatment may include one, or a combination of the following:
(a)
Flushed with water that is treated for cleaning, then drained.
(b)
Flushed with clean water, then drained.
(c)
Other appropriate surface treatment.
Special attention shall be given to the water used with equipment manufactured from
austenitic stainless steel.
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AS 3892—2001
S E C T ION
6
INS T A L LAT IO N
P IP ING
O F
P R E S S UR E
6.1 GENERAL
Assembly of piping components shall be carried out either on-site or off-site so that
ultimately the installed piping complies with AS 4041 and this Section for the installation.
6.2 PIPING
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6.2.1 Protection
Piping and components shall be protected against damage or corrosion before and during
installation. Any protective coating should be inspected regularly, and renewed and
replaced when necessary.
6.2.2 Assembly
During the initial stages of the pipe installation, all flexible components, such as support
springs and expansion bellows shall be protected from overloading.
Piping shall be installed with drainage slopes as specified in the design in the direction of
flow of the condensate, to prevent condensate collecting in pockets. Where the slope does
not prevent the accumulation of fluids and this accumulation could be detrimental to the
operation, a drain shall be fitted. Piping shall be supported as specified in the design and
the span lengths shall ensure that the pipe will not sag below the elevation of the support at
the lower end of the span. The pipeline should be erected on permanently installed pipe
supports, where possible.
Where any fouling in existing structures occurs, changes to the existing structure should not
be undertaken unless specified in the design documents, or appropriate approval is
obtained.
Distortion of the pipe work is not normally an acceptable method of overcoming
misalignment. This may induce detrimental loading onto equipment and undesirable strain
into components such as bellows, flange joints, etc.
6.2.3 Cut-ins
On many piping installations the starting or termination of the system involves cutting into
an existing line. Where the pipe has operated at a temperature exceeding 100°C above
ambient temperature, the existing line should be firmly fixed with temporary restraints or
anchors before attempting to cut into or break a pipeline. Restraints and anchors should
remain in position until the completion of the new section of pipe work. Anchors should
control rotational, as well as linear displacements. Any necessary cold springing shall
comply with Clause 6.2.4.
6.2.4 Cold-spring
Piping to be cold-pulled should hang freely when the gap is measured, i.e. there should be
no out-of-balance spring effort or any intermediate restraints other than those necessary to
counteract any horizontal components of out-of-vertical supports. Piping should hang freely
when alignment marks and end checks are made. Pipes shall not be heated when the gap is
being closed. The joint made last should be in a location where moments are small.
Alignment shall be strictly maintained after the pipes have been pulled together.
Where the effects of thermal expansion in service are to be counteracted by cold-pull during
the erection of the pipe assembly, the cold-pull shall be maintained during all stages of the
welding operation including, any postweld heat treatment.
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AS 3892—2001
Before applying cold-pull to a joint, all other joints in the pipe assembly shall be welded,
subjected to any postweld treatment, and inspected.
6.2.5 Stress-free connections
At connections to rotating machinery or vessels, it may be necessary to demonstrate that
unintentional loads are not being applied to the machine or vessel nozzles. All permanent
restraints and guides should be in place, and any temporary restraints removed from the
new pipework unless otherwise specified.
Some configurations may require additional forces for stability. In such cases, the effort
required should be nominated and measured, where required.
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6.2.6 Site-run pipework
Line sizes with DN50 and smaller are normally run at site. Design drawings, schedules
and/or line lists should indicate the material, size, wall thickness, bend radius, flange rating,
fitting class and similar data.
All necessary piping design aspects shall be considered when determining the pipe layout
and types of support. Connections to larger lines are vulnerable to any thermal expansion
movements of the larger line. The first support at least on the small pipe should allow the
branch point to expand freely with the main. Where appreciable vertical movement is
involved, spring supports may be required to limit piping stress. In this case, the design
criteria should comply with AS 4041.
Spacing recommendations of supports for steel pipe are shown in AS 4041.
Closer spacing may be required where valves, vertical runs, or other loads are applied. A
support should be positioned close to each bend to avoid sagging at the corner.
The open end of any vent or drain shall be restrained to prevent sudden lateral movement
when discharging. Valves should preferably be mounted in horizontal runs of pipe. Where
mounted in vertical runs, an additional drain is usually required in the upper section.
Consideration shall be given to any potential thermal expansion in the site-run line.
6.3 JOINTS
6.3.1 Welded joints
Welded joints shall comply with AS 4458.
6.3.2 Flanged joints
Before bolting up, flanged faces shall be aligned within 1 mm in 200 mm measured across
any diameter. Bolt holes shall be aligned such that bolts are readily inserted without
distorting the pipe, with a maximum of 2 mm offset.
Any damage to the gasket seating surface that may prevent gasket sealing shall be repaired,
or the flange shall be replaced. No more than one gasket should be used in assembling a
flanged joint.
A tightened bolt shall have complete threading through the nut or threaded attachment.
Temperature-resistant lubricants should be applied to threads of bolting intended to operate
at high temperature. Any compound or lubricant used on threads shall be suitable for the
service conditions and not react unfavourably with either the service fluid or the piping
material.
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AS 3892—2001
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Bolting torque, tensioning and sequence shall be appropriate to the bolt, flange and gasket.
The contact faces of the flanges of bolted and gasketed flanged joints shall bear uniformly
on the gasket, and the gasket shall be compressed in accordance with the design principles
appropriate to the type used. During assembly of flanged joints in which one flange has
mechanical properties which differ widely from the other flange, the bolts shall be tightened
to an appropriate predetermined load.
6.3.3 Other jointing methods
Other methods of jointing pipes shall be carried out in accordance with the component
manufacturer’s instructions.
6.4 SUPPORTS
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6.4.1 Pipe supports
Pipe supports that are attached to the structure by welding shall be welded by competent
personnel. The potential need for adjustment of position should be considered before
welding is carried out.
Care should be exercised when substituting nominated components with an available
commercial alternative. Spring units shall have an equivalent spring rate to meet the design
criteria.
Temporary supports needed for the erection of the pipes should be attached to the structure
so that existing steelwork is not overloaded.
The repositioning of a support from the location shown on the design drawings should not
be carried out without appropriate instruction. This is of particular importance when the
support is located adjacent to a rotating machinery or pressure vessel nozzle.
6.4.2 Protection of support threads
Exposed threads of supports should be greased or painted immediately after installation
except where corrosion-resistant materials are used. Pipe surfaces at supports should be
protected as specified in the engineering design.
6.4.3 Hangers
Locknuts shall be fitted to one end of all threaded rod segments, i.e. at turnbuckles,
clevises, joint to spring hanger, etc.
The depth of thread engagement shall be visible. Rods and bolts shall protrude through nuts
by at least one full thread. Enclosed female threaded components shall have a tell-tale hole
to allow the minimum engagement to be verified.
Where double hangers are used, the location of the pipe shown on the design drawings shall
be maintained. Any need for repositioning should be referred to the design engineer,
particularly if spring units are involved in the construction.
6.4.4 Sliding supports
The support foot for sliding supports should be fully supported at all times. Sufficient
overlap should be allowed to cater for all expected pipe movements during plant operation.
Any temporary stops used for erection stability shall be removed before the application of
any pre-set or plant start-up.
Slide bearings are a special variation of the sliding support manufactured from materials
that ensure a very low friction force. The slide bearings shall be installed in accordance
with manufacturer’s instructions. Sliding faces should be parallel to each other.
Roller supports that are used in place of sliding supports shall be installed in their correct
orientation of the roller as shown on the design drawings.
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AS 3892—2001
6.4.5 Support units
Supports with variable springs, constant effort units, counterweight units or hydraulic units
designed to carry the weight of the pipe should be installed ‘gagged’ to prevent movement
downwards and ensure the pipe stays erected at the correct level.
Support units gags should not be removed until all in line equipment, insulation and
cladding are installed. See AS 4041 for commissioning requirements.
Spring units shall remain gagged until after hydrostatic testing.
6.4.6 Snubbers
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Snubbers are a special form of restraint that control vibration and seismic loads but allow
the pipe to move freely under thermal expansion and wind loads.
Snubber units shall be selected according to the specific load capacity and travel range.
They should be purchased locked at the installation length to prevent travel in either
direction. They should not be connected to the pipe system until any pre-set has been
applied, unless directed otherwise by the design documentation.
Units shall be unlocked before any thermal load is applied. Sufficient travel shall be
available to meet expected pipe expansion.
For hydraulic units, the oil reservoir should be mounted in accordance with the
manufacturer’s instructions.
6.5 IN-LINE EQUIPMENT
6.5.1 Valves
Gear operators and hand wheels and/or actuators should be positioned such that they are
readily accessible for operation.
Valves shall be installed for the correct flow direction.
6.5.2 Expansion units (including bellows)
Expansion units should be supplied fitted with suitable gags to ensure that the bellows
cannot be distorted unintentionally. Gagging devices should remain in place until the line is
ready for use, or deflection of the bellows is necessary to close preset gaps. Preset gaps
should be closed in accordance with Clause 6.2.4. All pipe guides and permanent restraints
shall be installed before de-gagging takes place.
Expansion bellows are normally supplied with internal liners. In this case, the bellows shall
be installed for the correct flow direction. Hinged bellows shall be installed with the hinges
at the correct orientation, as shown on the design drawings.
6.5.3 Spectacle plates
Spectacle plates should be installed such that they can be rotated from the open to the
closed position without obstruction. A trial rotation should be carried out before setting the
joint as required. Spades and spacer rings should be fitted with handles to facilitate
insertion and removal. Where the weight exceeds 20 kg, lifting lugs or other suitable
handling means shall be provided.
6.5.4 Flow measuring devices
Orifice plates for flow measurement shall be installed for the correct flow direction. They
should be installed in accordance with the manufacturer’s recommendations.
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6.5.5 Strainers
Many installations have either temporary or permanent strainers to protect downstream
equipment. Strainers should be installed before any fluid is permitted in the line. Temporary
strainers shall be removed after commissioning, prior to plant operation.
6.6 TESTING
Hydrostatic testing, when applied, shall be carried out in accordance with AS 4041.
Pressure retaining attachments shall be completed or blanked off prior to testing. Blanks
shall be standard pipe fittings of the required rating or as otherwise specified.
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Where the test fluid adds significant weight to the pipe system, additional temporary
supports may be required. The line shall be fitted with suitable vent and drain connections
for testing.
6.7 CLEANING OF PIPEWORK
Internal cleaning of piping should be carried out where necessary. When the piping is
commissioned the internal surface shall be free of detrimental materials. Supports shall be
designed for any additional loads that may be applied during cleaning.
6.8 THERMAL INSULATION AND PROTECTION
Where piping is thermally insulated, the materials used shall not cause corrosion of the pipe
and not char or burn at the maximum temperature at which the material may be normally
operated. Asbestos shall not be used. For piping which is to be operated intermittently
and/or operated at temperatures between 65°C and 120°C, consideration should be given to
the use of expanded mesh materials rather than those which can retain moisture thus
increasing the possibility of corrosion.
Where required, insulation of piping including supports shall be of the specified fire
performance.
Where flanged or threaded joints are lagged, provision shall be made for the detection of
leaks, and inspection and repair of these joints.
Guidance on thermal insulation is given in BS 5970.
Guidance on the insulation of thermally insulated underground piping is given in BS 7572.
6.9 IDENTIFICATION
Contents of piping should be suitably identified, e.g. in accordance with AS 1345, or other
agreed means.
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S E C T ION
A S S O C IA T E D
AS 3892—2001
7
INS T A L LAT IO N O F
S E R V IC E S , F IT T IN G S A N D
P IP ING
7.1 CONNECTION TO SERVICES
Any connection of a boiler, pressure vessel or auxiliary to services, e.g. fuel, water, air,
electricity and drains, shall be made in accordance with the requirements of the relevant
Standards.
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7.2 FITTINGS AND PIPING
All piping, including pipes, valves, gauges, safety devices and other fittings connected to
boilers, vessels and their auxiliaries, shall be designed and installed in accordance with the
relevant Standard, so as not to exceed the allowable loadings on the boiler, vessel or
auxiliary connections.
7.3 LOCATION OF FITTINGS AND PIPING
Pressure-relief devices, other safety devices, and important vessel fittings and piping shall
be located and installed so that they —
(a)
are readily accessible for operation, inspection, maintenance and removal;
(b)
provide adequate clearances; and
(c)
permit adequate access to other equipment, e.g. boiler feedwater regulating valves,
and arranged to enable them to be satisfactorily operated from the firing floor or other
convenient platform.
7.4 PROTECTION OF FITTINGS AGAINST INTERFERENCE
Where a pressure or other adjustment is external to a safety device, the adjustment shall be
locked or sealed, or both.
Such devices and fittings shall be installed and protected so that they cannot be readily
rendered inoperative or be tampered with, and so that the entrance of dirt, water, wildlife
and other potential obstructions to the valve outlet will be at a minimum. Devices shall be
protected or located to prevent freezing and from making them inoperative.
7.5 PROTECTION AGAINST DAMAGE
All safety valves, safety devices, fittings, and piping on vessels shall be arranged, where
possible, to afford maximum protection against accidental damage.
7.6 DRAINAGE PIPING
Where a drain valve is required to discharge noxious or flammable material, piping shall be
attached to the valve and shall lead such discharge to a safe location. The discharge shall be
made in such a manner so as to prevent danger to persons or damage to equipment and so
that the discharge is visible. Some liquids may require special drainage arrangements (see
the relevant application Standard, e.g. AS 1894, for cryogenic fluids).
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7.7 SAFETY DEVICE DISCHARGE PIPING
7.7.1 Waste discharge
Direct discharge of fluid from the safety device shall not be permitted unless it can be
shown that the discharge does not interfere with an emergency or regular operating routine,
or create a hazard to personnel, cause material damage to property or the environment, or
present a noise problem.
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In other circumstances, a discharge pipe and, where required, a waste pipe shall be fitted to
the safety device to conduct the escaping steam or other hazardous fluid to a safe outlet
location.
An individual discharge pipe should be provided for each safety device except that, where it
can be shown that it does not interfere with the operation of any device or create a hazard to
personnel, the waste from more than one device may be connected to a common discharge
pipe.
7.7.2 Expansion joints
Where the layout of a discharge pipe is such as to impose excessive stress on the safety
device or restrict the expansion or movement of the device, a waste pipe shall be fitted
between the device outlet and the discharge pipe. A suitable expansion joint or equivalent
arrangement shall be provided at the junction of the waste and discharge pipes.
7.7.3 Discharge and waste pipe sizes
The waste pipe and the discharge pipe, where individual discharge pipes are provided for
each safety device, shall have cross-sectional areas no less than the areas of the outlet
connection of the devices.
Where more than one safety device discharges into a common discharge pipe, the
cross-sectional area of the discharge pipe shall be sufficient to avoid interference with
correct operation of any of the safety devices due to excessive back pressure.
7.7.4 Pipe support
Waste pipes shall be as short and direct as practicable and shall be supported to prevent
undue vibration and to resist the reaction at bends due to the valve blowing-off.
Discharge piping and expansion joints shall be suitably and adequately supported,
independent of the safety valve or waste pipes, so that no excessive external loading will be
imposed on the safety valve body.
7.7.5 Discharge restriction
No shut-off valve, cock or obstruction of any kind shall be fitted on the discharge side of
the safety device except as permitted in the relevant application Standard. This does not
preclude the use of a muffler in accordance with Clause 7.7.7.
7.7.6 Drainage of discharge piping
An unrestricted means of drainage shall be provided from the lowest part of each enclosed
safety valve chest, from each waste pipe, and from each discharge pipe and expansion joint.
Each valve unit shall be independent of other drains and runs with a continuous fall to a
place where the discharge is visible and does not create a hazard to personnel.
7.7.7 Mufflers
Adequate muffling of the discharge should be provided to reduce noise to an acceptable
level. Where a muffler is used on a safety valve or safety valve discharge pipe, it shall have
sufficient flow area to prevent back pressure from interfering with the proper operation and
discharge capacity of the valve. The muffler plates or other devices shall be constructed to
avoid the possibility of any restriction of the steam or gas passages due to deposit or
dislodgment.
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AS 3892—2001
7.7.8 Discharge pipe for economizer safety valves
The area of the discharge pipe from an economizer safety valve shall be at least twice the
area of the valve seat.
Where the discharge from several economizer safety valves is connected to a common
discharge pipe, the diameter of the pipe shall be such as to prevent the accumulation of
pressure due to the formation of steam under the particular conditions of temperature and
pressure that is applicable.
7.8 ISOLATION OF INTERCONNECTED PRESSURE EQUIPMENT
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Where two or more boilers or pressure vessels are interconnected, special piping
arrangements shall comply with the requirements in the relevant boiler or pressure vessel
Standard.
7.9 OUTDOOR INSTALLATION
For the outdoor installation of boilers, the relevant requirements of Clause 4.9.5 shall apply.
The recommendations of Clause 4.9.4 also apply.
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AS 3892—2001
APPENDIX A
LIST OF REFERENCED DOCUMENTS
(Normative)
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AS
1170
1170.2
1170.4
Minimum design loads on structures (known as the SAA Loading Code)
Part 2: Wind loads
Part 4: Earthquake loads
1210
Pressure vessels
1228
Pressure equipment — Boilers
1345
Identification of the contents of piping, conduits and ducts
1375
Industrial fuel-fired appliances (known as SAA Industrial Fuel-fired
Appliances Code)
1657
Fixed platforms, walkways, stairways and ladders—Design, construction
and installation
1674
1674.1
1674.2
Safety in welding and allied processes
Part 1: Fire precautions
Part 2: Electrical
1680
1680.1
1680.2.0
1680.2.1
Interior lighting
Part 1:
General principles and recommendations
Part 2.0: Recommendations for specific tasks and interiors
Part 2.1: Circulation spaces and other general areas
1755
Conveyors—Safety requirements
1768
Lightning protection
1894
The storage and handling of non-flammable cryogenic and refrigerated
fluids
1940
The storage and handling of flammable and combustible liquids
2022
Anhydrous ammonia—Storage and handling (known as the SAA
Anhydrous Ammonia Code)
AS/NZS
2107
Acoustics— Recommended design sound levels and reverberation times for
building interiors
2593
Boilers — Unattended and limited attendance
2865
Safe working in a confined space
3814 (AG 501) Industrial and commercial gas-fired appliances
3873
Pressure equipment — Operation and maintenance
3920
3920.1
Assurance of product quality
Part 1: Pressure equipment manufacture
3961
Liquefied natural gas—Storage and handling
3990
Mechanical equipment — Steelwork
© Standards Australia
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39
AS
4041
Pressure piping
4343
Pressure equipment — Hazard levels
4458
Pressure equipment — Manufacture
AS 3892—2001
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5601 (AG 601) Gas installations
HB 90.3
The Construction Industry—Guide to ISO 9001:2000
AS/NZS
1020
The control of undesirable static electricity
1200
Pressure equipment
1596
Storage and handling of LP Gas
3000
Electrical installation (known as the Australian/New Zealand Wiring
Rules)
3788
Pressure equipment — In-service inspection
4360
Risk management
AS/NZS ISO
9001
Quality management systems —Requirements
BS
2486
Recommendations for treatment of water for steam boilers and water
heaters
4076
Specification for steel chimneys
5970
Code of practice for thermal insulation of pipework and equipment (in the
temperature range −100°C to +870°C) superseded in part (calculation
method only) by BS EN ISO 12241:1998
7572
Code of practice for thermally insulated underground piping systems
AG (Industrial Standard)
501
Industrial and commercial gas-fired appliances Code
601
Gas installation Code
NOHSC
1014
Control of Major Hazard Facilities National Standard
2016
National Code of Practice
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© Standards Australia
40
AS 3892—2001
APPENDIX B
GUIDE FOR A METHODOLOGY OF INCIDENT INVESTIGATION
(Informative)
B1 GENERAL
This Appendix provides a guide to a method of incident investigation during the installation
of pressure equipment.
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B2 METHOD
The method of incident investigation is as follows:
(a)
Investigate any incident which resulted in, or could have resulted in, an unsafe
condition arising during installation or where personnel are injured, e.g. catastrophic
release of a hazardous chemicals from a pressure vessel.
(b)
Initiate the incident investigation as promptly as possible but not later than 48 hours
following the incident.
(c)
Establish an incident investigation team consisting of at least one person
knowledgeable in the installation of pressure equipment and the process involved, and
other personnel with appropriate knowledge and experience.
(d)
Prepare a report at the conclusion of the investigation. The report should include the
following:
(i)
Date of incident.
(ii)
Identification of damaged plant.
(iii) Date investigation began.
(iv)
A description of the incident.
(v)
The factors that contributed to the incident.
(vi)
Any recommendations resulting from the investigation.
(e)
Establish a documented system to promptly address and resolve the incident report
findings and recommendations, and implement any necessary corrective actions.
(f)
Review the report with all affected personnel whose job tasks are relevant to the
incident findings.
(g)
Notify the relevant authorities of the incident, where applicable.
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AS 3892—2001
APPENDIX C
GUIDE FOR MANAGEMENT SYSTEMS FOR THE INSTALLATION OF
PRESSURE EQUIPMENT
(Informative)
C1 GENERAL
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This Appendix is intended to guide purchasers of pressure equipment on the basic
information that should be covered in a management system to ensure that the equipment
installed conforms to the organization’s requirements. The management system should be
implemented, maintained and improved as required.
C2 DOCUMENTED MANAGEMENT SYSTEMS
The following recommendations apply in accordance with AS 3920.1:
(a)
For pressure equipment designated Hazard Level ‘A’, implement a management
system for installation work.
(b)
For pressure equipment designated Hazard Level ‘B’, implement a management
system for installation work, if a risk assessment based on size, complexity,
configuration, location and operating conditions determines its necessity.
(c)
For pressure equipment designated Hazard Levels C, D and E, see Item C2(b).
C3 INSTALLATION PROCEDURES
The following procedures should be undertaken for the installation of pressure equipment:
(a)
Defining and documenting policy to be observed during installation.
(b)
Establishing and documenting the inter-relationship between purchaser’s personnel
and the installation organizations.
(c)
Documentation to Paragraph C13.
(d)
Retention of copies of all pressure equipment documentation in a relevant file for the
life of the pressure equipment.
C4 MANAGEMENT SYSTEM
The management system should cover the following:
(a)
Identification of processes needed to ensure that the installation of pressure
equipment conforms to specific requirements;
(b)
The processes needed to conform with the requirements and guidance provided in
HB 90.3, AS/NZS ISO 9001 and AS 3920.1 relevant to the particular equipment and
operations.
(c)
Determining the sequence and interaction of the process.
(d)
The criteria and methods to ensure the effective operation and control of these
processes.
(e)
Documentation necessary to support the operation and control of processes for
installing of pressure equipment including methods to ensure that the pressure
equipment and associated services continue to meet the specified requirements. Such
documentation includes the following:
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AS 3892—2001
(i)
Details of the organizational structure for the installation of pressure
equipment.
(ii)
Details of the personnel involved in the supervision of pressure equipment
safety.
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(iii) Details of extent of the particular plant concerned; in particular, the complexity
of the pressure equipment especially the construction factors that may affect the
safety of the completed installation.
(f)
Documented evidence that the requirements of this Standard, and any other relevant
requirements, are understood and being complied with.
(g)
Methods to monitor, measure and analyse these processes and implement any
necessary actions for improvement.
C5 DESIGN CHANGES OR ALTERATIONS
Procedures for design changes or alternations should be established and maintained to
ensure that any changes made to the pressure equipment during installation comply with
AS/NZS 1200 and receive necessary verification and acceptance.
C6 DOCUMENT AND DATA CONTROL
A suitable document control system to record and store all procedures should be established
including essential data, documented reports, agreements, reviews, amendments and the
like. Documentation should be stored, with the pressure equipment records.
The authority to change procedures or any other type of controlled record should be clearly
identified.
C7 PURCHASING
Purchasing details of the pressure equipment item, service being purchased, items replaced
or to be worked should be specified.
Each purchase order for pressure equipment components or services should include
information which informs the supplier of the technical and other requirements relevant for
the equipment including the right to conduct verification audits/third party inspections at
their premises, or other assurance or inspection activities.
C8 PURCHASER SUPPLIED COMPONENTS
Any components supplied by the purchaser and incorporated into the pressure equipment
system should be subjected to the same degree of management system control as items
supplied by the manufacturer of the pressure equipment, or otherwise agreed upon between
the parties.
C9 PRODUCT IDENTIFICATION AND TRACEABILITY
C9.1 General
For this Standard, the product is the pressure equipment, components and the associated
servicing activities.
C9.2 Identification
Each item of pressure equipment should be clearly identified in accordance with
AS/NZS 1200 requirements and, where desired, with a unique equipment number and
function description.
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AS 3892—2001
C9.3 Traceability
Adequate records pertaining to pressure equipment to enable traceability of all pressureretaining components to the full extent outlined in the relevant Standards should be
maintained. The data should be retained with the vessel records (see Paragraph C6).
C10 PROCEDURES DURING INSTALLATION
Where required by Paragraph C3 procedures should be established to cover the installation
and inspection of the pressure equipment.
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C11 INSPECTION AND TESTING
For each replacement or modification of the pressure equipment, inspections of the
equipment should be carried out to ensure compliance with the relevant equipment Standard
and the results recorded.
C12 NONCONFORMANCE
Any identified nonconformance of the pressure equipment should be treated as follows:
(a)
Appropriately tagged as ‘not complying’.
(b)
Subjected to applicable assessment processes which will detail the extent and severity
of the non-compliance.
After the completion of Items C12 (a) and (b), the pressure equipment should be either —
(i)
repaired or reworked to bring the item into compliance; or
(ii)
put into service without repair or rework after assessment. Such assessment should be
recorded.
When nonconformance is identified the system should ensure that appropriate procedures
are established and documented to record that corrective action has been performed.
C13 DOCUMENTATION
The following documents should be obtained and where applicable made available:
(a)
All approvals and registrations, where required.
(b)
Manufacturer’s data report for each boiler and pressure vessel installed.
(c)
The installer’s statement or certificate of compliance and completion.
(d)
Status report on the readiness of equipment for use or, if any problems, for future use.
(e)
Drawings and instructions required for operation and maintenance.
(f)
Information for emergency operating procedures and, where specified, data required
for planning for emergencies.
(g)
Other relevant records, certificates and any subsequent amendments thereto, relevant
to the installation and installed equipment.
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AS 3892—2001
APPENDIX D
GUIDE FOR ASSESSING THE COMPETENCY OF INSTALLERS
(Informative)
D1 GENERAL
This Appendix provides a general guide for assessing the competency of installers.
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D2 COMPETENCIES OF INSTALLERS
Prior to the commencement of the installation, the organization should demonstrate that it is
capable of carrying out the installation competently by providing evidence of appropriate
procedures and experienced personnel. The procedures should be in accordance with the
purchaser’s specifications, the equipment manufacturer’s instructions and recommendations
and this Standard.
The installer should have employed or subcontracted personnel assignable to the project
who are competent and suitably experienced in the functional areas involved, and should
meet any other relevant requirements.
Where required for a specific type or class of pressure equipment system, the installation
personnel should have appropriate certificates of competency.
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AS 3892—2001
APPENDIX E
GUIDE FOR THE DESIGN OF BOILER BLOWDOWN TANKS
(Informative)
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The following is a list of design aspects of blowdown tanks:
(a)
The temperature of the water leaving the tank should not exceed 71 °C.
(b)
The pressure in the tank during blowdown periods and consequently the pressure of
the water leaving the tank should not exceed 35 kPa.
(c)
The tank capacity depends upon the amount of water to be blown out of the boiler at
any one time. This can be related to the volume of water discharged to lower the
water level in the gauge glass. The size of the tank should be at least three times the
volume of the water discharged into it from the boiler, i.e. if 283 L of water are
discharged from the boiler, the tank will have a capacity of approximately 849 L.
(d)
The water outlet connection should be positioned so that the tank will remain onethird to one-half full after each blowdown. The outlet connection should have a water
seal incorporated in its design. The vertical leg of the water seal inside the tank
should extend to within 150 mm of the bottom of the tank, and the top end of the
vertical leg should have about a 19 mm hole drilled into it to act as a syphon breaker.
No valve or other obstruction should be fitted to the outlet pipe.
(e)
A vent pipe should be fitted to the top of the tank and should be extended so that the
vapour discharged will not constitute a hazard. No valves or other obstructions should
be placed in the vent pipe.
(f)
The inlet line from the boiler to the tank should be connected between the level of
water in the tank and the top of the tank.
(g)
The ratio of inlet line to water outlet to vent can only be accurately assessed by
calculation for each individual job. An approximate ratio might be 1:2:3. The
connections to the tank should be designed so that freezing will not close the inlet,
outlet or vent.
(h)
The tank should be designed and constructed as a pressure vessel having a working
pressure of 350 kPa and should have the following fittings (see Figure E1):
(i)
Inspection openings as required for pressure vessels.
(ii)
A drain cock or valve at the lowest point of the tank about 25 mm NB pipe size.
(iii) A cold water supply line of about 19 mm NB pipe size.
If, during the operation of the blowdown tank, the pressure in the tank is found to be more
than 35 kPa, additional vent area should be provided. Should the temperature of the outlet
water exceed 71°C, cooling water should be mixed with the discharge from the tank to
lower the temperature below 71°C.
It may also be found that after blowing down, the level of retained water in the tank is
below that required, in which case the water should be brought to the proper level by the
addition of cold water from the cold water supply line.
A maximum temperature (as required by the local authority) should apply to water
discharged into a sewerage or drainage system.
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AS 3892—2001
© Standards Australia
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FIGURE E1 TYPICAL BLOWDOWN TANK
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