AS/NZS 1200:2015
AS/NZS 1200:2015
Australian/New Zealand Standard™
Pressure equipment
AS/NZS 1200:2015
This Joint Australian/New Zealand Standard was prepared by Joint Technical
Committee ME-001, Pressure Equipment. It was approved on behalf of the Council
of Standards Australia on 5 November 2015 and on behalf of the Council of
Standards New Zealand on 6 November 2015.
This Standard was published on 3 December 2015.
The following are represented on Committee ME-001:
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 for the Certification of Inspection Personnel
Australian Institute of Energy
Australian Institute of Petroleum
Bureau of Steel Manufacturers of Australia
Department of Justice and Attorney General, Qld
Electricity Engineers Association, New Zealand
Energy Networks Association
Engineers Australia
Institution of Professional Engineers New Zealand
Materials Australia
National Association of Testing Authority Australia
New Zealand Heavy Engineering Research Association
New Zealand Manufacturers and Exporters Association
Welding Technology Institute of Australia
WorkCover New South Wales
WorkSafe Division, Department of Commerce, WA
WorkSafe New Zealand
WorkSafe Victoria
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cover.
This Standard was issued in draft form for comment as DR AS/NZS 1200:2014.
AS/NZS 1200:2015
Australian/New Zealand Standard™
Pressure equipment
Originated in Australia in part as AS CBI Int p2—1963, AS CBI Int p3—1963
and AS CBI Int p5—1967.
First joint edition AS/NZS 1200:1994.
Previous edition AS/NZS 1200:2000.
Seventh edition 2015.
COPYRIGHT
© Standards Australia Limited/Standards New Zealand
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, unless otherwise permitted under the Copyright Act 1968
(Australia) or the Copyright Act 1994 (New Zealand).
Jointly published by SAI Global Limited under licence from Standards Australia Limited,
GPO Box 476, Sydney, NSW 2001 and by Standards New Zealand, Private Bag 2439,
Wellington 6140.
ISBN 978 1 76035 340 7
AS/NZS 1200:2015
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PREFACE
This Standard was prepared by the Joint Standards Australia/Standards New Zealand
Committee ME-001, Pressure Equipment, to supersede AS/NZS 1200:2000, Pressure
equipment.
Changes to the 2000 edition include the following:
(a)
Continued recognition of the trend to self-regulation and the need for clear guidance
to industry.
(b)
Updated information for New Zealand regulatory matters, seismic, wind and snow
loading.
(c)
An informative Appendix I on the use of equivalents when referring to various
internationally available pressure equipment standards.
(d)
Revision to Appendix A where ‘LP Gas fuel vessels for automotive use’ are now
specifically mentioned as being covered by this Standard and where clarifications
have been added for some equipment not covered by this Standard (regarding gas
cylinders, miniature boilers and pressurized machines).
(e)
Removal of the process for requesting opinions, interpretations or rulings. Readers
will now need to make contact with Standards Australia as per information provided
inside the front cover of this Standard.
(f)
‘Safety requirements’ changed from informative to normative.
(g)
Updated Table 2.1, Standards for pressure equipment used in Australia and New
Zealand.
(h)
Detailed comparison between various equipment Standards available globally.
(i)
Replacement of Appendix G, ‘Organization of Australian, New Zealand and Other
Pressure Equipment Standards’ with a new Appendix ‘Australian Pressure Equipment
Practice’.
This edition retains the role of the Standard as a major reference document and also to
provide common requirements for pressure equipment that promote safety and uniformity
throughout Australia and New Zealand.
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.
Statements expressed in mandatory terms in notes to tables and figures are requirements of
this Standard.
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AS/NZS 1200:2015
CONTENTS
Page
SECTION 1 SCOPE AND GENERAL
1.1 SCOPE ......................................................................................................................... 4
1.2 OBJECTIVE ................................................................................................................ 4
1.3 APPLICATION ........................................................................................................... 4
1.4 DEFINITIONS............................................................................................................. 5
1.5 REFERENCED DOCUMENTS ................................................................................... 5
1.6 NEW DESIGNS, MATERIALS AND MANUFACTURING METHODS .................. 5
1.7 ROUNDING OF NUMERICAL VALUES .................................................................. 5
1.8 CONVERSION OF UNITS ......................................................................................... 5
1.9 TOLERANCES............................................................................................................ 5
1.10 CONCESSIONS .......................................................................................................... 5
1.11 NEW ZEALAND REQUIREMENTS .......................................................................... 6
SECTION 2 BASIC REQUIREMENTS AND COMPLIANCE STANDARDS
2.1 BASIC REQUIREMENTS .......................................................................................... 7
2.2 COMPLIANCE STANDARDS ................................................................................... 7
2.3 MIXING STANDARDS .............................................................................................. 8
APPENDICES
A
EQUIPMENT COVERED BY THIS STANDARD ................................................... 11
B
DEFINITIONS........................................................................................................... 13
C
LIST OF REFERENCED DOCUMENTS.................................................................. 18
D
MATERIALS FOR USE UNDER THIS STANDARD .............................................. 22
E
NOT ALLOCATED................................................................................................... 24
F
COMPARISON OF PRESSURE EQUIPMENT STANDARDS ................................ 25
G
AUSTRALIAN PRESSURE EQUIPMENT PRACTICE ........................................... 30
H
NEW ZEALAND REQUIREMENTS ........................................................................ 33
I
THE USE OF EQUIVALENT STANDARDS ........................................................... 34
J
SAFETY REQUIREMENTS ..................................................................................... 35
AS/NZS 1200:2015
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STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND
Australian/New Zealand Standard
Pressure equipment
S E C T I O N
1
S C O P E
A N D
G E N E R A L
1.1 SCOPE
This Standard is a ‘parent’ document for use by the pressure equipment industry in
Australia and New Zealand. It covers the design, materials, manufacture, examination,
testing, installation, conformity assessment, commissioning, operation, inspection,
maintenance, repair, alteration and disposal of pressure equipment (boilers, pressure vessels
and pressure piping), but excluding gas cylinders and other equipment as set out in
Appendix A.
This Standard specifies detailed requirements for various pressure equipment by direct
reference to a range of Australian, New Zealand and other Standards.
NOTES:
1 Appendix F provides a comparison of pressure equipment Standards.
2 Appendix G provides guidance on Australian pressure equipment practice.
1.2 OBJECTIVE
The purpose of this Standard is to provide requirements and guidance expressed in
specification form, suitable for use in contracts or other documentation, in order to—
(a)
achieve safe, economic and equitable supply and use of this equipment in Australia
and New Zealand;
(b)
provide various means to assist in complying with basic requirements (see
Clause 2.1); and
(c)
incorporate the experience and knowledge from Australia and New Zealand, and
world practice.
1.3 APPLICATION
This Standard applies to the pressure equipment specified in Appendix A.
Equipment with hazard level E to AS 4343 may be covered by one or more of the following
methods:
(a)
Standards referenced in this Standard.
(b)
Other applicable Standards.
(c)
Sound engineering practice that achieves a comparable level of safety.
Users of this Standard are reminded that it has no legal authority in its own right, but may
acquire legal standing when—
(i)
adopted by a government or other authority having jurisdiction;
(ii)
specified in a contract; or
(iii) a manufacturer, importer, supplier, purchaser/owner or user states that pressure
equipment is in accordance with this Standard or its referenced Standards.
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1.4 DEFINITIONS
For the purpose of this Standard and its referenced Standards, the definitions in Appendix B
apply. Reference should be made to the particular pressure equipment Standards for
definitions covering specific applications.
1.5 REFERENCED DOCUMENTS
The documents referred to in this Standard are listed in Appendix C.
Where reference is made to a Standard by its number only, the reference applies to the
current edition of that Standard, including amendments, unless otherwise agreed upon by
the parties concerned. Where reference is made to a Standard by number, year and
(where relevant) an amendment number, the reference applies to that specific document.
1.6 NEW DESIGNS, MATERIALS AND MANUFACTURING METHODS
The Standards listed herein do not prohibit the use of materials or methods of design or
manufacture that are not specifically referred to herein. Appendix D provides details on the
use of materials under this Standard.
1.7 ROUNDING OF NUMERICAL VALUES
Rounding of numerical values shall be in accordance with AS 2706 and to the same
significant number as in the applicable Standard.
1.8 CONVERSION OF UNITS
The international system of units is adopted in Australia and New Zealand. Conversion of
units shall be in accordance with AS ISO 1000 and to the same significant number as in the
applicable Standard.
1.9 TOLERANCES
Tolerances on numerical values shall be in accordance with the applicable Standard, and as
specified in drawings or other documents which satisfy Clause 1.10.
1.10 CONCESSIONS
Concessions or departures from required numerical values are permitted by this Standard
provided—
(a)
the parties concerned are in agreement;
(b)
the appropriate design verifying body, manufacture inspection body, or independent
in-service inspection body states in writing that the concession is acceptable and
gives details of the concession, the reasons justifying acceptance and any conditions
applicable;
(c)
the concession relates to a specific design under specified conditions or a particular
item of pressure equipment only and is not required as an on-going basis for
continued concessions on new designs or each item produced;
(d)
a review of all relevant factors and risk assessment is undertaken to ensure that the
concession will not result in equipment that is unsafe, unreliable or with inadequate
performance (see Note);
(e)
the documented concession is made available to the owner or user, any quality system
auditor and, where required, to the regulator; and
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(f)
6
the manufacturer’s data report, declaration of conformity or in-service inspection
report documents such concessions.
NOTE: Normally a departure by 1% of the required value can be readily accepted if all other
factors clearly comply and provide suitable compensation, e.g. 1% reduction in weld transverse
strength is acceptable where ductility or Charpy values are high, or a corrosion allowance is
provided.
1.11 NEW ZEALAND REQUIREMENTS
New Zealand regulatory matters and specific requirements are detailed in Appendix H.
New Zealand requirements for seismic loading for pressure equipment are detailed in
Appendix H.
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S E C T I O N 2
B A S I C R E Q U I R E M E N T S
C O M P L I A N C E S T A N D A R DS
AS/NZS 1200:2015
A N D
2.1 BASIC REQUIREMENTS
Pressure equipment covered by this Standard and used or intended for use in Australia or
New Zealand shall—
(a)
comply with the design, manufacture and use requirements specified in the Standards
listed in Table 2.1 or equivalents agreed by the parties concerned; and
NOTE: See Appendix I for information on equivalent Standards.
(b)
comply with the safety requirements given in Appendix J.
NOTE: Other requirements, including those of a legislative, regulatory and contractual nature,
may be relevant.
2.2 COMPLIANCE STANDARDS
Compliance with the applicable Standards listed in Table 2.1 is deemed to satisfy
Clause 2.1, Items (a) and (b).
Where a Standard is used as the basis for a claim of pressure equipment compliance, that
Standard and all its referenced Standards shall be as referenced in their entirety, except as
provided by Clause 2.3.
NOTES:
1 Published application Standards should be viewed only as a starting point in the control of
risks. It should not be assumed that a design that meets the Standard is without risk. This is
because the Standard itself may not deal with all the matters relevant to hazard identification,
risk assessment and risk control for the pressure equipment in question. Appropriate
judgement needs to be exercised in such circumstances.
2 Designers, when designing pressure equipment to specifications in published application
Standard(s), such as those listed in Table 2.1, should determine whether the Standard(s) fully
deals with health, safety or environmental risks identified in the risk assessment process. This
should involve a systematic assessment of whether the application Standard(s) apply to the
whole pressure equipment or only certain parts of the plant and an assessment of the adequacy
of the Standard(s) in controlling a particular type of risk, having regard to the state of
knowledge.
3 If designing the pressure equipment in accordance with application Standard(s) listed in
Table 2.1, or any other published application Standard, does not eliminate the risk to health or
safety, the designer should reduce the risk so far as is reasonably practicable by altering the
design of the pressure equipment. If the design of pressure equipment using Standards such as
those listed in Table 2.1 does not adequately control the risks, then additional (identified)
controls may be used to reduce the risk to an acceptable level. If this is the case, then the
designer should specify the risk control measures that require implementation when the
pressure equipment is used.
4 Before using any pressure equipment Standard that originates from outside Australia and New
Zealand, the designer should carry out a comparative assessment to confirm that the proposed
Standard provides equivalent specifications in terms of loadings, materials, safety factors,
manufacturing quality and inspection, overpressure protection, and testing. All of the parties
concerned with the pressure equipment should agree to the use of the overseas Standard.
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2.3 MIXING STANDARDS
Pressure equipment shall comply with the full requirements of a nominated Standard,
except when the equipment or components of the equipment, comply with the more
appropriate requirements of other pressure equipment Standards, and provided—
(a)
such Standards are agreed alternatives or equivalents and are applicable to the
particular pressure equipment;
(b)
the relevant requirements of the Standards apply to the components concerned;
(c)
components at interfaces between different Standards comply with all relevant
Standards, as appropriate;
(d)
the design data, drawings and manufacturer’s data report clearly identify and record
departures from the Standard used for design;
(e)
the equipment marking includes the Standards used;
(f)
the overall equipment complies with Clause 2.1; and
(g)
the parties concerned, including the design verification and manufacture inspection
bodies, agree.
NOTES:
1 Typical examples are the use of pressure vessel or piping Standards for some parts of boilers,
the use of other Standards for materials, components, qualification and test methods, use of
piping Standards for some pressure vessels (e.g. piping strainers), and different
documentation or markings.
2 Some Standards already permit equivalent referenced Standards.
3 Appendix F provides a comparison of Australian and International PE Standards.
4 The parties concerned may agree to the use of equivalent Standards; see Appendix I for more
information.
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AS/NZS 1200:2015
TABLE 2.1
STANDARDS FOR PRESSURE EQUIPMENT USED IN AUSTRALIA
AND NEW ZEALAND (see Note 7)
1 General
AS/NZS 1200
Pressure equipment
AS 4942
Pressure equipment—Glossary of terms
AS 4343
Pressure equipment—Hazard levels
2 Design and manufacture
AUSTRALIAN AND JOINT AUSTRALIAN/
NEW ZEALAND STANDARDS (see Note 2)
OR INTERNATIONAL STANDARDS
(see Note 2)
AS 1228
Boilers
ASME BPV-I; BS 855; BS 1113; BS 2790;
EN 12952; EN 12953
AS 1210
Pressure vessels
ASME BPV-VIII (see Note 4); PD 5500;
BS 853; BS 5169; BS 3970; EN 13445;
GB 150; ISO 21029-1; ISO 20421-1
AMBSC Code
Miniature Boilers Parts 1–4
AS 2593
Boilers—Safety management and
supervisory systems (see Note 5)
ASME BPV-I (see Note 5)
AS 3857—1999
Heat exchanger—Tube plate design
TEMA; ASME BPV-VIII-1-UHX; EN 13445
AS 2971
Pressure vessels—Serially produced
EN 286-1 (air or nitrogen)
AS/NZS 3509
Pressure vessels—LP Gas auto vessels
ADG Code
Pressure vessels—Transport of dangerous
goods
NZS 5418; IMDG Code
AS 4041
Pressure piping
ASME B31.1; ASME B31.3; ASME B31.5
(see Note 6); BS 806; EN 13480
AS 2872
Atmospheric heating of vessels
AS 4458
PE Manufacture
ISO 14731 (see Note 1)
AS/NZS 3992
PE Welding and brazing qualification
ASME BPV-IX; EN 287; ISO 15607,
ISO 9606-1
AS 1796
Certification of welders and supervisors
AS 4037
PE Examination and testing
ASME BPV-V (see Note 1)
AS 3998
Certification of NDT personnel
ISO 9712
AS 3892
PE Installation
NZS 5351
AS 1548
Steel plates for PE
EN 10028 (see Note 1)
AS 2556
ERW steel air heater tubes
—
AS 1271
Safety valves and fittings for PE
—
AS 1358
Bursting discs
—
AS 1732
Fusible plugs
—
—
—
—
—
(continued)
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TABLE 2.1 (continued)
3 Conformity assessment
Conformity assessment of pressure equipment covered by this Standard shall be carried out where required or
where specified by the parties concerned.
NOTE: Below Standards may be used as guidance:
(a) AS 3920 for conformity assessment of pressure equipment in Australia, and the Health and Safety in
Employment (Pressure Equipment, Cranes and Passenger Ropeways) Regulations 1999 in New Zealand.
(b) AS/NZS ISO/IEC 17020 for inspection bodies.
(c) AS/NZS 4481 for pressure equipment inspector competencies.
(d) ASME BPV Code.
(e) EU-PED Pressure Equipment Directive.
(f) EU-PED for Simple Pressure vessels.
4 Use
AS 3873
PE Operation and maintenance
OR
NS for LPPHRW National Standard for Licencing Persons
or
Performing High Risk Work
NOHSC 1006
(see Note 3)
National Occupational Health and Safety
Certification Standard Certification for
users and Operators of Industrial Equipment
AS/NZS 3788
PE In-service inspection
AMBSC
Code for miniature boilers
—
NBIC
NOTES:
1
Where an international design Standard is applied and it provides PE manufacturing requirements and PE
examination/testing requirements within the design Standard itself, then those requirements are also applicable.
2
Other published national Standards may be used provided they satisfy the requirements of Clause 2.1.
3
NOHSC 1006 has been archived by Safe Work Australia and has been replaced by NS for LPPHRW; however,
NOHSC 1006 may still be referenced by authorities in some states.
4
For water tube boilers only in New Zealand, quality assurance, certification, marking and materials shall satisfy
the requirements of the New Zealand regulatory authority.
5
Accepted in New Zealand only as permitted within the scope of the New Zealand Approved Code of Practice
for the Design, Safe Operation, Maintenance and Servicing of Boilers.
6
In New Zealand, inspection and testing shall be to ASME B31.1.
7
For additional requirements applicable to New Zealand, refer Appendix H.
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APPENDIX A
EQUIPMENT COVERED BY THIS STANDARD
(Normative)
A1 PRESSURE EQUIPMENT COVERED
This Standard applies to all pressure equipment, with the exception of the equipment listed
in Paragraph A3.
A2 EXAMPLES
The following are examples of pressure equipment covered specifically by this Standard:
(a)
Boilers—watertube, firetube, shell, miscellaneous, electric, electrode, hot water,
locomotive, waste heat boilers, heat recovery steam generators, fired steam sterilizers
and fired pressure cookers.
(b)
Pressure vessels—air receivers, reactors, digesters, pressurized storage vessels,
process vessels, heat exchangers, jacketed pans, fired heaters, air-water vessels,
pressurized sterilizers, deaerators, autoclaves, pressurized transportable vessels (road
or rail tankers, ISO tank containers, but not gas cylinders), vessels for human
occupancy, LP Gas fuel vessels for automotive use.
(c)
Pressure piping—steam, high and low temperature liquid, gases and mixtures
(e.g. slurries and powders).
A3 EQUIPMENT
COVERED
OR
PLANT
UNDER
PRESSURE
NOT
SPECIFICALLY
The following is a list of equipment or plant that, whilst not covered by this Standard, may
be covered where required by other Standards, regulators or the parties concerned. The
inclusion of other equipment into this category is the subject of agreement between the
parties concerned.
1
Gas cylinders covered by the AS 2030 series up to a volume of 3000 L.
2
Equipment forming part of an aircraft, hovercraft or spacecraft.
3
Pressure equipment that forms a part of a sea-going ship or other marine or river craft
or offshore oil or gas rig.
4
Blast furnaces including cold blast main, hot stoves, hot blast main, bustle main and
tuyere stocks, blast furnace proper, uptakes and downcomer, dustcatcher, dirty and
semi-clean gas mains, gas scrubber and outlet main, charging material hopper and
integral equipment, and cooling system.
5
Pressure equipment that is the subject of research and development.
6
Pipelines, such as those covered by AS 2885, used for the transmission or distribution
of water, gas, oil or other fluid between two or more premises or in public places.
7
Sewerage, domestic water, roof and drainage piping.
8
Tyres, tubes, balloons and other inflatable equipment.
9
Pressure equipment that is an electrical or telecommunication cable or duct subject to
pressure.
10
Pressure equipment consisting of a liquid-filled coupling and used in power
transmission.
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11
Pressure equipment that is part of a tool or appliance to be held in the hand.
12
Air brake bleeding mechanisms for the removal of condensate from air brake bleeding
systems (excluding the air reservoir).
13
Air bags used for manufacturing and retreading tyres.
14
Low pressure gas holders, e.g. towns and natural gas holders (once known as
gasometers).
15
Hydraulic pressure vessels, including inert gas type ‘dampers’, shock absorbers, or
accumulators in which the product of pressure (MPa) and gas volume (L) does not
exceed 30 MPa.L (see Item 25 below for hydraulic actuated equipment).
16
Portable fire extinguishers covered by AS/NZS 1841 or equivalent Standard.
17
Steam cleaners in which steam is generated in the system and valves are not
incorporated between the inlet and outlet.
18
Aerosol containers covered by AS 2278.1 or equivalent Standard.
19
Storage tanks or equipment designed for the storage of liquids at or near atmospheric
pressure (i.e. pressure at the top of the tank does not exceed 1.4 kPa above or
0.06 kPa below atmospheric pressure) or covered by AS 1692, ANSI/API Std 650 or
equivalent Standard.
20
Large low pressure gas storage tanks such as tanks complying with ANSI/API
Std 620 or equivalent Standard (i.e. with pressure at the top of the tank not exceeding
207 kPa above nor 10 kPa below atmospheric pressure) and excluded by Figures 1.3.1
and 1.3.2 of AS 1210.
21
Domestic-type hot water supply heaters and tanks complying with AS/NZS 4692.1,
AS 3500.4.1, AS/NZS 60335.2.21, AS/NZS 60335.2.35 or equivalent Standard.
22
Sterilizers covered by AS 1410, AS 2182, AS 2192, AS 2487 or equivalent Standard.
NOTE: Where AS 1210 is referenced in the above Standards, it is intended that AS/NZS 1200
is also applicable.
23
Domestic-type pressure cookers covered by BS 1746 or equivalent Standard, i.e. with
pressure not exceeding 110 kPa and volume not exceeding 60 L.
24
Miniature model boilers used as toys or by model clubs and with water capacity not
exceeding one litre.
25
Pressurized machines, e.g. steam and gas turbines, compressors, pumps, internal
combustion engines, steam engines, hydraulically actuated equipment (e.g. hydraulic
cylinders, rams, and shock absorbers with piston), and similar machines; except in
rare cases where the designer considers the pressure-retaining parts are primarily
determined by stresses comparable with AS 1210 and not by control of strain to
maintain close fit to ensure performance (e.g. the external envelope of hermetic or
sealed air or refrigerant compressors are covered by this Standard).
NOTE: For New Zealand, see Appendix H.
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APPENDIX B
DEFINITIONS
(Normative)
B1 GENERAL
The definitions of the more important terms relating to pressure equipment, actions and
personnel mentioned in this Standard and other Australian and New Zealand pressure
equipment Standards are listed in Paragraph B2.
NOTES:
1 These definitions are aimed to align, where possible, with the Australian Work Health and
Safety Act and Regulations and the New Zealand Health and Safety in Employment (Pressure
Equipment, Cranes and Passenger Ropeways) Regulations. These documents or state/territory
regulations should be referred to for the actual definitions that apply in the respective
jurisdiction.
2 For the definition of terms not listed in this Appendix, refer to AS 4942.
B2 DEFINITIONS
For the purpose of this Standard, the definitions below apply.
B2.1 Alter
To change the design of, add to or take away from the pressure equipment where the change
may reduce health or safety but does not include routine maintenance, repairs or
replacements.
B2.2 Boiler
A vessel or an arrangement of vessels and interconnecting parts, wherein steam or other
vapour is generated, or water or other liquid is heated at a pressure above that of the
atmosphere, and at a temperature at or above the normal atmospheric boiling temperature of
the liquid, by the application of fire, the products of combustion, electrical power, or
similar high temperature means. It also includes superheaters, reheaters, economizers,
boiler piping, supports, mountings, valves, gauges, fittings, controls, the boiler setting and
directly associated equipment. It excludes fired heaters.
NOTES:
1 The New Zealand, definition of hot water boiler (see Paragraph B2.11) approximates the
above but applies only to the generation of steam heated by a directly applied combustion
process or by heated gases.
2 See also ‘fired heater’, which may be more appropriate for some equipment in which steam or
other vapour is generated.
B2.3 Commissioning
Performing the necessary adjustments, tests and inspections to ensure pressure equipment is
in full working order to specified requirements before the pressure equipment is used.
Commissioning includes re-commissioning.
B2.4 Competent person
A person who has acquired through education, 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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B2.5 Conformity assessment
Any activity concerned with determining directly or indirectly that relevant requirements
are fulfilled.
NOTE: Typical examples of conformity assessment activities are sampling, testing and
inspection, evaluation, verification and assurance of conformity (supplier’s declaration,
certification), registration, accreditation and approval, as well as other combinations.
B2.6 Designer
A body corporate, firm or person responsible for the design of the pressure equipment.
A person who designs pressure equipment.
B2.7 Equivalent
Having the same, better or acceptable outcome.
B2.8 Fired heater
A pressure vessel in which a liquid is heated below its atmospheric boiling temperature or a
process fluid is heated in tubes above or below its atmospheric boiling temperature by the
application of fire, the products of combustion or electric power, or similar high
temperature means.
NOTE: For New Zealand, refer to the Health and Safety in Employment (Pressure Equipment,
Cranes and Passenger Ropeways) Regulations 1999 [PECPR Regulations].
B2.9 Gas cylinder
A particular rigid pressure vessel not exceeding 3000 L water capacity and without
openings or integral attachments on the shell other than at the ends, designed for the storage
and transport of gas under pressure and which is covered by AS 2030 series.
NOTE: Gas cylinders are a special type of transportable pressure vessel built using serial
production to various Australian and overseas gas cylinder standards, They are used for a wide
range of gases and services and are subject to periodic testing at approved gas cylinder test
stations.
B2.10 Hazard
Any source of potential damage, harm or adverse health effects on someone or something
under certain conditions at work.
B2.11 Hot water boiler (New Zealand)
Similar to ‘boiler’ except that water is heated and steam is not generated.
NOTE: For New Zealand, refer to the Health and Safety in Employment (Pressure Equipment,
Cranes and Passenger Ropeways) Regulations 1999 [PECPR Regulations].
B2.12 Inspection
Activities such as examining, measuring, testing, gauging, calculating, checking, verifying
one or more characteristics of a product design, material, manufacture, service, process,
plant or reports and determination of their conformity with specific requirements or on the
basis of professional judgement with general requirements.
B2.13 Installer
A body corporate, firm or person who installs pressure equipment.
B2.14 LP gas fuel vessel for automotive use
A pressure vessel that is used to store and supply LP Gas as fuel to power a vehicle in
which it is contained.
NOTE: LP Gas automotive fuel vessels are not gas cylinders but they are a special type of
transportable pressure vessel, which can be designed and manufactured in accordance with
Australian and overseas pressure vessel standards; e.g. AS/NZS 3509, AS 1210, ASME
BPVC VIII, and equivalent Standards.
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B2.15 Maintain
To keep pressure equipment in a safe and satisfactory condition; includes replacement and
repair.
B2.16 Manufacturer
A body corporate, firm or person who manufactures pressure equipment.
NOTE: The manufacturer may include the designer.
B2.17 May
Indicates that a statement is optional.
B2.18 Nationally recognized
A document or organization that is recognized in its country of origin.
B2.19 Operate
To use or operate pressure equipment and includes operational supervision and surveillance.
B2.20 Owner
A body corporate, firm or person who has right of title to, or management of, or control
over the pressure equipment and includes a person exercising such management or control
as an agent of the owner. (See also definition of ‘purchaser’.)
NOTE: In the NZ regulations the term ‘controller’ is used and in Australia the term ‘Person
Conducting a Business or Undertaking’ (PCBU) is used.
B2.21 Parties concerned
The purchaser, designer, importer, manufacturer, design verifying and inspection bodies,
supplier, installer, owner, user and other persons, as appropriate. Where regulatory matters
are involved, this may include the regulator.
B2.22 Practicable
Having regard to taking into account and weighing up all relevant matters including—
(a)
the likelihood of the hazard or the risk occurring;
(b)
the degree of harm that might result from the hazard or risk; and
(c)
what the person concerned knows, or ought reasonably to know, about—
(i)
the hazard or risk; and
(ii)
ways of eliminating or minimizing the risk; and
(d)
the availability and suitability of ways to eliminate or minimize the risk; and
(e)
after assessing the extent of the risk and the available ways of eliminating or
minimizing the risk, the cost associated with available ways of eliminating or
minimizing the risk, including whether the cost is grossly disproportionate to the risk.
B2.23 Pressures
Gauge pressures are relative to atmospheric pressure, unless otherwise identified.
B2.24 Pressure equipment
Boilers, pressure vessels and pressure piping.
NOTE: New Zealand regulations also include certain fired heaters, hot water boilers, gas and
steam turbines, steam engines, pumps and compressors. See Appendix H.
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B2.25 Pressure piping
An assembly of pipes, pipe fittings, valves and pipe accessories subject to internal or
external pressure and used to contain or convey fluid or to transmit fluid pressure. It
includes distribution headers, bolting, gaskets, pipe supports and pressure retaining
accessories. It does not include any vessel that falls within the definition of a boiler or
pressure vessel in this Standard, nor any pipeline covered by any other Standard.
B2.26 Pressure vessel
A vessel subject to internal or external pressure. It includes interconnected parts and
components, valves, gauges and other fittings up to the first point of connection to
connecting piping. It also includes fired heaters and gas cylinders, but excludes any vessel
that falls within the definition of a boiler or pressure piping in this Standard.
B2.27 Purchaser
A body corporate, firm or person who buys the pressure equipment from the manufacturer
or supplier.
NOTE: The purchaser may include the owner or user.
B2.28 Regulator
Any federal, state or territory regulator in Australia or regulator in New Zealand, with the
jurisdiction for pressure equipment safety and includes an officer of that authority with
responsibility delegated by that authority.
B2.29 Repair
To restore pressure equipment to an operating condition, but does not include routine
maintenance or replacement. (See also definition of ‘alter’).
B2.30 Risk
The chance or probability that a person will be harmed or experience an adverse health
effect if exposed to a hazard. It may also apply to situations with property, equipment loss
or adverse environmental effect.
NOTE: Attention is also drawn to the definition of ‘risk’, ‘event’, ‘consequences’ and
‘likelihood’ in AS/NZS ISO 31000.
B2.31 Risk assessment
The process of evaluating the probability and consequences of injury or illness, or damage
to property or environment, arising from exposure to identified hazards associated with
pressure equipment.
B2.32 Safety requirements
Those requirements considered necessary to ensure the risks with pressure equipment
arising from rupture, leakage or other means of failure are controlled to acceptably low
levels to provide suitable safety during the equipment’s life.
NOTE: Other requirements may be necessary to ensure safety for particular applications or other
risks.
B2.33 Serially produced pressure vessels
Pressure vessels not exceeding 500 L of identical design produced in significantly sized
batches where quality control and sampling inspection ensures that the manufactured
vessels conform with the design. For example, as in AS 2971 or ASME BPVC-VIII
‘Multiple Duplicates’.
NOTE: It is intended that serially produced pressure vessels of AS 4343, Hazard Levels A, B
or C, are registered and periodically inspected in accordance with the WHS Regulations and
either AS/NZS 3788 or as for gas cylinders.
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B2.34 Shall
Indicates that a statement is mandatory.
B2.35 Should
Indicates a recommendation.
NOTE: For this Standard and its associated Standards, it indicates an action that when performed
is generally considered to be good practice. ‘Should’ is used to provide flexibility and is not
mandatory or normative unless agreed.
B2.36 Supplier
A body corporate, firm or a person who supplies pressure equipment by way of sale, lease,
exchange or hire, whether as a principal or agent for another.
B2.37 User
A body corporate, firm or person who uses and has operational control of pressure
equipment.
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APPENDIX C
LIST OF REFERENCED DOCUMENTS
(Normative)
AS
1210
Pressure vessels
1228
Pressure equipment—Boilers
1271
Safety valves, other valves, liquid level gauges, and other fittings for boilers
and unfired pressure vessels
1358
Bursting discs and bursting disc devices—application, selection and
installation
1410
Sterilizers—Steam—Pre-vacuum
1548
Fine grained, weldable steel plates for pressure equipment
1692
Tanks for flammable and combustible liquids
1732
Fusible plugs for boilers
1796
Certification of welders and welding supervisors
1940
The storage and handling of flammable and combustible liquids
2030
Gas cylinders (series)
2182
Sterilizers—Steam—Benchtop
2192
Sterilizers—Steam—Downward displacement
2278
2278.1
Aerosol containers
Part 1: Metal aerosol dispensers of capacity 50 mL to 1000 mL inclusive
2487
Dry heat sterilizers
2556
Electric resistance welded steel air heater tubes
2593
Boilers—Safety management and supervision systems
2706
Numerical values—Rounding and interpretation of limiting values
2872
Atmospheric heating of vessels containing fluids—Estimation of maximum
temperature
2885
Pipelines—Gas and liquid petroleum (series)
2971
Serially produced pressure vessels
3500
3500.4.1
National plumbing and drainage
Part 4.1:
Hot water supply systems—Performance requirements
3857
Heat exchangers—Tubeplates—Method of design
3873
Pressure equipment—Operation and maintenance
3892
Pressure equipment—Installation
3920
Pressure equipment—Conformity assessment
3998
Non-destructive testing—Qualification and certification of personnel
4037
Pressure equipment—Examination and testing
4041
Pressure piping
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AS
4343
Pressure equipment—Hazard levels
4458
Pressure equipment—Manufacture
4942
Pressure equipment—Glossary of terms
Z30
Interconversion of inch and metric dimensions
AS ISO
1000
The international system of units (SI) and its application
AS/NZS
1841
Portable fire extinguishers (series)
3509
LP Gas fuel vessels for automotive use
3788
Pressure equipment—In-service inspection
3992
Pressure equipment—Welding and brazing qualification
4481
Pressure equipment—Competencies of inspectors
4692
4692.1
Electric water heaters
Part 1: Energy consumption, performance and general requirements
60335
60335.2.21
60335.2.35
Household and similar electrical appliances—Safety
Part 2.21: Particular requirements for storage water heaters
Part 2.35: Particular requirements for instantaneous water heaters
AS/NZS ISO
3834
Quality requirements for fusion welding of metallic materials
3834.2
Part 2: Comprehensive quality requirements
31000
Risk management—Principles and guidelines
AS/NZS ISO/IEC
17020
Conformity assessment—Requirements for the operation of various types of
bodies performing inspection
NZS
1170.5
Structural design actions—Earthquake actions—New Zealand
4219
Seismic performance of engineering systems in buildings
5351
Code of practice for the installation, operation and maintenance of building
service and small industrial boilers
5418
Transportation containers for hazardous substances (series)
ISO
9606
9606-1
Qualification testing of welders—Fusion welding
Part 1: Steels
9712
Non-destructive testing—Qualification and certification of NDT personnel
14731
Welding coordination—Tasks and responsibilities
15607
Specification and qualification of welding procedures for metallic
materials—General rules
16528
Boilers and pressure vessels (Parts 1 and 2)
20421
20421-1
Cryogenic vessels—Large transportable vacuum-insulated vessels
Part 1: Design, fabrication, inspection and testing
21029
Cryogenic vessels—Transportable vacuum insulated vessels of not more
than 1 000 litres volume
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ANSI/API
STD 620
Design and construction of large, welded, low-pressure storage tanks
STD 650
Welded steel tanks for oil storage
ASME
B31.1
B31.3
B31.5
Power piping
Process piping
Refrigeration piping and heat transfer components
BPV-I
Boilers and pressure vessel code
Section I: Rules for construction of power boilers
BPV-V
Boilers and pressure vessel code
Section V: Nondestructive examination
BPV-VIII-1
Boilers and pressure vessel code
Section VIII: Rules for construction of pressure vessels. Division 1
BPV-VIII-2
Boilers and pressure vessel code
Section VIII: Rules
for
construction
Division 2: Alternative rules
BPV-IX
NB
NBIC
BS
806
of
pressure
vessels.
Boiler and pressure vessel code
Section IX: Qualification standard for welding and brazing procedures,
welders, brazers, and welding and brazing operators
National Board Inspection Code
Specification for design and construction of ferrous piping installations for
and in connection with land boilers
853
Specification for vessels for use in heating systems (series)
855
Specification for welded steel boilers for central heating and indirect hot
water supply (rated output 44 kW to 3 MW)
1113
Specification for design and manufacture of water-tube steam generating
plant (including superheaters, reheaters, and steel tube economizers)
1746
Specification for domestic pressure cookers
2790
Specification for design and manufacture of shell boilers of welded
construction
3970
Sterilizing and disinfecting equipment for medical products (series)
5169
Specification for fusion welded steel air receivers
PD
5500
Specification for unfired fusion welded pressure vessels
EN
286
286.1
Simple unfired pressure vessels designed to contain air or nitrogen
Part 1: Pressure vessels for general purposes
287
Approval testing of welders for fusion welding (series)
12952
Water-tube boilers and auxiliary installations
12953
Shell boilers
13445
Unfired Pressure vessels
13480
Metallic industrial piping
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ADG
Australian Code for the Transport of Dangerous Goods by Road and Rail (ADG Code)
IMDG
International Maritime Dangerous Goods Code (IMDG Code)
SAC
Standardization Administration of the People’ Republic of China
GB 150
Pressure vessels
Safe Work Australia
NOHSC 1006 National Occupational Health and Safety Standard for Users and Operators
of Industrial Equipment
TEMA
TEMA Code
Tubular Exchanger Manufacturers Association (TEMA) Standards
Code for the Design of Shell/Tube Exchanger Tubesheets
Australian Miniature Boiler Safety Committee
AMBSC Code Part 1: Copper Boilers
Part 2: Steel Boilers
Part 3: Sub-Miniature Boilers
Part 4: Duplex Steel Boilers
NS for LPPHRW—National Standard for Licencing Persons Performing High Risk Work
New Zealand Health and Safety in Employment (Pressure Equipment, Cranes and
Passenger Ropeways) Regulations
New Zealand Approved Code of Practice for the Design, Safe Operation, Maintenance and
Servicing of Boilers
New Zealand Approved Code of Practice for Pressure Equipment (Excluding Boilers)
Institute of Professional Engineers NZ Practice Note 19—Seismic Resistance of Pressure
Equipment
EU-PED European Union—Pressure Equipment Directive
Work Health and Safety Act and Regulations (various States and territories)
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APPENDIX D
MATERIALS FOR USE UNDER THIS STANDARD
(Normative)
D1 POLICY FOR MATERIALS
D1.1 General
This Appendix specifies acceptable material specifications for use in application Standards.
D1.2 Permitted material Standards
Pressure equipment produced to relevant Standards developed by Committee ME-001 or
accepted for use in Australia and New Zealand, may use material complying with AS,
AS/NZS, ISO, EN, BS, ASME, ASTM or API material Standards that apply specifically to
pressure equipment, or with other approved material Standards (see Paragraph D1.3).
Any departure from listed material in the pressure equipment Standard shall be documented.
Such materials may affect strict compliance with that Standard.
Australian/New Zealand Standards for pressure equipment will only refer to, and provide
design and manufacture data for, Australian/New Zealand material Standards. Suitable ISO,
EN, BS, ASME, ASTM or API material Standards may also be included where there is no
suitable Australian/New Zealand Standard or the Standard is commonly used for pressure
equipment in Australia and New Zealand.
D1.3 Alternative national Standards
A material other than those specified in Paragraph D1.2 may be used provided—
(a)
it is covered by a national Standard that applies to the same type of pressure
equipment in the country of the material’s origin; OR provides equivalent
requirements for composition, method of manufacture, properties, method and amount
of testing and examination, imperfections, marking, documentation and quality
assurance;
(b)
evidence for either option in Item (a) is made available in English; and
(c)
the Standard and its application are acceptable to the parties concerned.
D2 NEW MATERIAL
D2.1 Amendment or Supplement
To allow the development and use of a new material (not covered by existing national
Standards) within the scope of Australian and New Zealand Standards, the parties
concerned shall consider the following issues in determining the acceptability of the
material:
(a)
The material is commercially available and can be purchased within the specified
range of chemical composition, mechanical properties and other requirements
outlined in the material specification.
(b)
There will be a reasonable demand for the material by industry or that there exists an
urgency for acceptance.
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AS/NZS 1200:2015
(c)
The acceptance of the material clearly describes it in specification format, including
such items as the process of manufacture, conditions for delivery, heat treatment,
chemical composition range, minimum mechanical properties, tests (methods and
requirements), workmanship, finish, marking, inspection and rejection, and
documentation.
(d)
The limits of an intended application in terms of service conditions, pressure,
temperature, contents and thickness ranges are clearly stated.
D2.2 Mechanical properties
The parties concerned shall have adequate data to enable design strength to be determined.
The data shall include, as appropriate, values of the tensile strength, yield strength, impact
toughness, elongation and creep rupture strength of the metal and of welded joints over the
range of temperatures at which the material is to be used. Any heat treatment that is
required to produce the mechanical properties shall be fully described. Adequate data on the
notch toughness in the proposed range of service temperatures shall be submitted. Service
experience in the temperature range contemplated shall be considered.
Statistical data shall give the range of chemical and mechanical properties and the number
of heats or batches, or both, tested.
If the material is to be used in equipment to operate under conditions where buckling may
occur (e.g. external pressure), stress-strain curves (tension or compression) shall be
furnished for the range of design temperatures desired.
Where appropriate, information on machinability should also be considered.
D2.3 Weldability
If the material is to be welded, the enquirer shall submit complete data on the weldability of
the material. Data shall include details of results of procedure and welder qualification tests
made in accordance with the requirements of AS/NZS 3992 or other equivalent Standard.
Welding tests shall be made over the full range of thickness in which the material is to be
used. Pertinent information such as heat treatment required, susceptibility to air hardening,
and the amount of experience in welding the material shall be supplied.
D2.4 Physical changes
Information on any significant physical changes that may occur with the material during
manufacture or service shall be available. It is important to know the structural stability and
the degree of retention of properties with exposure at operating temperature. The influence
of manufacture practices, such as forming, welding and thermal treatments on the
mechanical properties, ductility and microstructure of the material, is important,
particularly where degradation in properties may be encountered. In some materials certain
process conditions (such as heat treatment, cooling rates mechanical working and/or
combinations thereof) are known to cause significant changes in mechanical properties.
These conditions may occur during manufacture or in the service life of the material. It is
important to draw attention to those conditions that are prohibited in service or in the
manufacture of parts or equipment from the material. Data on susceptibility to other forms
of degradation, e.g. creep, corrosion or erosion, shall be available.
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APPENDIX E
NOT ALLOCATED
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APPENDIX F
COMPARISON OF PRESSURE EQUIPMENT STANDARDS
(Informative)
F1 INTRODUCTION
This Appendix gives a comparison of the main elements of some nationally recognized
Standards for metallic pressure equipment used in Australian industry. Some of these are
shown in Table F1. Nuclear and aerospace equipment are excluded.
F2 PURPOSE
This Appendix seeks to provide all parties with information and guidance on the main
differences between these Standards so that better decisions may be made on the provision
and use of pressure equipment. This is to help Australian industry improve safety,
performance and economy.
F3 RECOGNIZED STANDARDS
The Standards listed in this Appendix are pressure equipment Standards that are well
recognized, accepted, used in their country of origin, and which have been extensively used
or critically examined and accepted in Australia.
F4 COMPARISON OF AUSTRALIAN AND OVERSEAS PRESSURE EQUIPMENT
STANDARDS
A comparison between the main elements of the main features of some Australian,
International and overseas pressure equipment Standards is presented in Table F1. These
elements are those that will have most effect on the purchase cost of any pressure vessel.
The details in Table F1 mainly relate to pressure vessels of welded manufacture using
carbon, carbon-manganese or low alloy steel materials.
None of the listed Standards are the same. Safety factors vary significantly but many
requirements are the same or very similar.
F5 BOILER STANDARDS
The Australian boiler Standard is AS 1228 and those mainly used globally are ASME
BPVC-I, EN 12952 and EN 12953. All have a similar basis:
(a)
ASME is most commonly used globally, is more comprehensive and more frequently
updated. It has safety factors similar to AS 1228 and EN 12952 except the safety
factor on specified design tensile strength at design temperature (R mT) is 3.5.
(b)
AS 1228 has a safety factor on specified design tensile strength at design temperature
(R mT) of 2.7.
(c)
EN 12952 is not well known in Australia but has the same safety factors as AS 1228.
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F6 PRESSURE PIPING STANDARDS
The Australian pressure piping Standard is AS 4041 and those mainly used globally are the
ASME B31 series (B31.1 and B31.3) and EN 13480. All have similar basis and contents:
(a)
ASME is more commonly used globally, is more comprehensive and more frequently
updated. It has a safety factor a little higher than AS 4041 and EN 13480. For ASME
B31.1 Power Piping, the safety factor on specified design tensile strength at design
temperature (R mT) is 4.0. For ASME B31.3 Process Piping, the safety factor on
specified design tensile strength at design temperature (R mT) is 3.0.
(b)
AS 4041 is used extensively in Australia, covers all materials and applications, and
has a safety factor on specified design tensile strength at design temperature (R mT) of
2.35, which aligns with pressure vessels.
F7 RELATED PRESSURE EQUIPMENT STANDARDS
All Standards listed in this Appendix make use of referenced Standards for materials,
components, etc. Australian pressure equipment Standards provide for materials and
components from all countries.
F8 OBSERVATIONS/RECOMMENDATIONS
All Standards listed in this Appendix are reasonable, comparable, have a sound basis, and
have been proven by experience. Frequently, they result in identical pressure equipment but
in other cases there could be significant differences in details.
It is often the case that pressure equipment manufactured overseas and intended for use in
Australia is more costly when applying Australian Standards; however, using overseas
standards requires greater care and more attention to conformity assessment.
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TABLE F1
COMPARISON OF MAIN ELEMENTS OF PRESSURE VESSEL STANDARDS
Origin
Australia
ISO
USA
European Union
UK
China
AS 1210
ISO 20421-1
ASME BPVC-VIII
EN 13445
PD 5500
GB 150
Pressure vessels
Cryogenic vessels
Pressure vessels
Unfired pressure
vessels
Unfired pressure
vessels
Steel pressure vessels
2015 (704 + 763 + 343)
2014 (1137)
2012 (1023)
2011 (342)
1 Standard (Note 1)
2 Title
3 Date
(and No. of pages)
4 Application
5 Class, division or
testing group
2010 (418) + AS 4458—1997 (100)
Static, transportable, fired, unfired. All except nuclear and
aircraft
IH
2H
1S
2S
1
2A
2B
3
No limit
7 Max. temperature
(°C)
No limit
400°C
8 Maximum thickness
(mm)
No limit
30
9 Materials (metallic)
All
Stainless steel
10 Design strength
safety factor
SF = R m /f
2.35
2.5
11 Thickness under
tolerance
Yes
Yes
As
required
Nil
No limit
No limit
32
32
20
Similar to AS 1210
—
Div 1
Div 2
Div 3
—
20
No limit
>70
No limit
30
No limit
Steel and
aluminium
3.5
Y
Cryogenic vessels,
static and
transportable
50°C
All
Y
(170)
2.4
Y
As required
Y
Yes
Nil
All
3.5
All except nuclear, All except nuclear,
aircraft and fired
aircraft and fired
1, 2
3
Yes
As required
Cat 1 Cat 2 Cat 3
Part 1, 2, 3 and 4
No limit
35 MPa
No limit
No limit
No
limit
No limit
No
limit
Steel
2.4
4
2.4
Static, non-fatigue
service. Transportable
and nuclear vessel are
excluded
No 300°C
limit
40
13
Steel and aluminium
2.35
5.0
Yes
Yes
As required
As required
900°C
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6 Maximum pressure
(MPa)
12 Corrosion allowance
c (mm)
2004
No limit
Steel
2.7
Yes
≥1 mm carbon steel
or low alloy steel
vessel for air, water,
steam
AS/NZS 1200:2015
(continued)
Origin
13 Joint efficiency or
factor, η
Australia
1.0
1.0
1.0
14 Manufacture—
General
15 Thickness above
which Post Weld
Heat Treatment
(PWHT) is required
(mm) (Note 2)
1.0
0.85
0.8
0.70
1.0
USA
1.0
0.85
0.7
European Union
1.0
1.0
Well covered in AS 4458
32
No PWHT
100
100
100
20
100
100
17 Weld production test Yes
plate
Yes
32; 50
1.0
0.85 0.70
Yes
China
1.0
0.9 or 1.0 0.8 or 0.85
for full
for spot
NDT
NDT
35
Depending on
material type,
thickness of weld
joint and design
requirements
e.g. >32 mm for
carbon steel
All similar
Not required
No HT
32; 40
100
100
20
UK
100
100
10
10
0
0
0
0
100
100
Yes
Yes
Yes
No
Yes
100
100
10
10
0
0
100 100
100 100
Only for low temperature
100
100
10
5
Spot
0
100
20
0
0
Yes, for some
Only if ordered
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16 RT or UT %:
– Longitudinal weld
– Circumferential
weld
1.0
ISO
AS/NZS 1200:2015
TABLE F1 (continued)
Yes for—
(a) containing
extremely or
highly toxic
medium;
(b) R m ≥540 MPa;
(c) low temperature
service;
(d) heat treatment
required to
improve or restore
the mechanical
properties; or
(e) required by
design drawings.
(continued)
TABLE F1 (continued)
Origin
18 Hydrostatic test
pressure, minimum
Australia
1.25P f 20 /f r
19 Conformity
assessment
20 Example PV
thickness (mm)
(Note 3)
1.5P
ISO
1.43P f 20 /f r
AS 3920—Design verification (DV) specified
5.91
N/A
(Note 4)
9.8
11.4
21.1
European Union
UK
China
1.25P f 20 /f r
1.25P f 20 /f r
1.25P f 20 /f r × t/(t-c)
1.25P f 20 /f r
Not specified.
ASME Quality system and
Technical Standard authorized inspector.
only.
No DV specified
No DV specified
EU-PED, and
notified bodies.
DV specified
1.3P
19.7
USA
1.3P f 20 /f r
9.8
11.4 19.7
7.0
(η = 1.0)
7
8.1
9.6
Inspecting authority. Safety licence for
designer and
No DV specified
manufacturer.
Supervisory
inspection during
construction by
inspecting authority.
No DV specified
6.9
6.9
13.7
7.80
9.0
(η = 1.0) (η = 0.85)
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LEGEND:
SF = minimum safety factor on specified minimum tensile strength R m for ferritic steels
R m = specified tensile strength
f
= design strength
c
= corrosion allowance
P
= design pressure
N/A = not applicable
NOTES:
1
Most standards provide for some variation to the listed features under specific conditions.
2
Figures shown are for carbon steel and other materials will differ. In some Standards, minimum thickness for PWHT is increased when certain specific conditions apply.
3
This example is the shell thickness calculation for a horizontal dry air receiver with design pressure = 2 MPa; design temperature = 50°C, internal diameter = 1000 mm. Material is
carbon steel with R m = 400 MPa. Corrosion allowance is 1 mm unless otherwise noted.
4
Thickness figures for Class 1S or 2S thickness would be misleading because thickness is not dependent on R m and SF but is determined by cold stretching increasing R e and by
partly taking into account actual R e and R m.
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AS/NZS 1200:2015
30
APPENDIX G
AUSTRALIAN PRESSURE EQUIPMENT PRACTICE
(Informative)
G1 GENERAL
Table G1 is for guidance on Australian practice for pressure equipment of all hazard levels.
Design, manufacture, conformity assessment of pressure equipment to be used overseas
should be in accordance with the requirements of the overseas user/purchaser and the laws
of the country of use and ISO 16528.
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TABLE G1
AUSTRALIAN PRESSURE EQUIPMENT (PE) PRACTICE
Element
1 Overall need
Practice
— Appropriate state/territory/federal work health and safety (WHS)
laws for hazardous plant and with federal trade, competition,
contract, civil, criminal and other applicable laws
— Meet purchaser’s requirements and specifications
2 Supply of PE
— Manufactured within or outside Australia
— Company registration according to Australian laws
3 Design and manufacture
— Capable of designing and manufacturing to the specified Standard
and contract; may subcontract work
— May or may not have certified quality system (e.g. to ISO 9001,
AS/NZS ISO 3834.2, or equivalent)
— Responsible for suitable PE risk assessment
— Be acceptable to the purchaser
4 Designer and manufacturer
(a) Acceptable Standards or Codes
— Table 2.1—in full; or to a mix of such Standards as per Clause 2.3
— Agreed by supplier and purchaser and where required by the
Regulator
— Australian Standards are preferred for manufacture and use in
Australia. Designs for specific applications can be done in less
time and with lower cost, retains more know-how and skills, and
ensures capability for future repairs and modification
(b) If Australian funding/resources are
needed for the project
— Project details (Government requirements may apply)
(c) Materials, components, manufacture — Australian Standards or equivalent ISO, regional or national PE
and testing
Standards
— Acceptable to parties concerned
— UT and RT complying with nationally recognized testing body
(e.g. National Association of Testing Authorities, Australia) or
equivalent
(d) Reports and marking
— Manufacturer data report (MDR) or conformity declaration
(to purchaser)
— Drawings and calculations to purchaser if contracted—not to
Regulator unless specified
— As for Element 4(a), plus design registration number plus
conformity assessment marks
(e) Operating and maintenance
instructions
— As necessary to purchaser (owner and user)
— MDR available to enable owner to meet WHS requirements
(continued)
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TABLE G1 (continued)
Element
Practice
5 Conformity assessment
(a) Design verification (DV) with
signed certificate/declaration to
satisfy Regulator, performed by a
person—
(i)
with competence;
(ii)
with no input to design; and
— For pressure equipment with AS 4343 Hazard levels A, B, C
and D
— Done by DV Body. AS 3920 and AS/NZS ISO/IEC 17020
provides guidance
— DV Body normally nominated by the manufacturer
(iii) not engaged/employed by the
designer unless design body
has a certified quality
management system,
e.g. ISO 9001.
(b) Design registration
(registration number issued)
— For boilers and pressure vessels with AS 4343, Hazard level A, B,
C, and D—based on DV certificate or declaration
— By Australian or state/territory Acts and Regulations in location
where PE is to be used
(c) Manufacture inspection (MI)
(signed certificate or MDR)
— For PE with AS 4343 Hazard Levels A, B and C
— Done by an MI Body. See AS 3920 and AS/NZS ISO/IEC 17020
6 Use
(a) Commissioning inspection
— Done by a competent inspection body—usually an in-service
inspection body/inspector similar to an MI body in Element 5(c)
(b) Operation and maintenance
— Safety management system—Safe equipment; trained, instructed,
supervised personnel and risk management
— Boiler attendants need a High Risk Work Licence, where required
by WHS Regulations
(c) In-service inspection
— AS/NZS 3788 by competent inspector, similar to Element 6(a)
(d) Registration of equipment
— For PE with AS 4343 Hazard Levels A, B and C
— Based on reports from Elements 6(a) and 6(c)
— By Australian State/Territory Act and Regulations in location
where PE is to be used
7 For PE with AS 4343 Hazard Level E
— Apply all above elements as for Hazard Level D, or exercise good
engineering practice to ensure safety and minimize risk
— DV, MI and design registration are not required
NOTE: Item 1 to Item 6 apply to pressure equipment with Hazard Levels A to D.
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APPENDIX H
NEW ZEALAND REQUIREMENTS
(Normative)
H1 GENERAL
In New Zealand, the authority requires pressure equipment to comply with the Health and
Safety in Employment (Pressure Equipment, Cranes, and Passenger Ropeways) Regulations
1999 [PECPR Regulations] before being operated. It is expected, but not mandatory, that
pressure equipment will also comply with the following, as appropriate:
(a)
Approved Code of Practice for Pressure Equipment (Excluding Boilers).
(b)
Approved Code of Practice for the Design, Safe Operation, Maintenance and
Servicing of Boilers.
For New Zealand, pressurized machines (see Note at Paragraph B2.24) are included in the
coverage of the PECPR Regulations as pressure equipment; however, in some instances
with reduced compliance requirements.
For equipment to be used in New Zealand, the user should consult the New Zealand
regulator prior to placing reliance on any standard that is not referenced in the appropriate
New Zealand Code of Practice.
NOTE: See Notes to Table 2.1 and Appendix B as appropriate.
H2 SPECIFIC REQUIREMENTS
H2.1 Design verification
In general, pressure equipment is subject to design verification by an inspection body
recognized for that function under the PECPR Regulations.
H2.2 Fabrication inspection
In general, pressure equipment is subject to fabrication inspection by an inspection body
recognized for that function under the PECPR Regulations.
H2.3 Certificate of inspection
In general, pressure equipment shall have a current certificate of inspection issued by an
inspection body recognized for that function under the PECPR Regulations.
H3 SEISMIC LOADINGS
Seismic design requirements for New Zealand shall be determined, as appropriate, from
NZS 1170.5 with guidance from Institute of Professional Engineers NZ Practice Note 19.
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APPENDIX I
THE USE OF EQUIVALENT STANDARDS
(Informative)
I1 GENERAL
This Appendix provides guidance for the purchaser and manufacturer when agreed to the
use of equivalent Standards. For this Standard, it is intended that the equivalent Standard is
acceptable to the parties concerned and recorded.
I2 BASIS FOR USE
For pressure equipment for use in Australia, the basis of determining an equivalent
Standard should be as follows:
(a)
The safety and other required outcomes should be consistent with those being
achieved with the nominated Australian, New Zealand, or Joint Australian/
New Zealand Standards, and should meet the essential safety outcome as specified in
Appendix J.
Users of pressure equipment should also investigate the safety outcome requirements
of Australian or New Zealand Law.
(b)
Safety and performance requirements should align with nationally recognized
Standards (e.g. for pressure vessels ISO 21029, ASME BPVC-I, II or III, BSI
PD 5500, EN 286.1, EN 13445, GB 150, etc.).
NOTES:
1 Table 2.1 lists the Standards for pressure equipment used in Australia and New Zealand.
2 Appendix F provides a comparison of pressure equipment Standards.
(c)
The equivalent Standard should be documented with its limitations and where
necessary, the basis for selection.
NOTES:
1 Objectives for the use of equivalent Standards may be to—
(a)
improve safety, efficiency, availability and cost;
(b)
provide flexibility to allow improvement, innovation and also permit variations to
suit ‘non-standard’ conditions or circumstances;
(c)
utilize practices normally adopted for many years that have shown consistently to
provide acceptable safety and performance outcomes; or
(d)
align with the principles adopted in new Australian work health and safety laws.
2 Equivalent Standards apply to pressure equipment and to different specific elements of
pressure equipment, e.g. design stresses, design safety factors, materials, radiographic
testing, ultrasonic testing, other test methods, competencies of testing personnel,
tolerances, weld faults, and documentation. In many cases, Australian Standards identify
acceptable equivalent Standards or alternatives, e.g. AS/NZS 3992 accepts ASME
BPVC-IX, AS 4041 accepts ASME B31.1 or ASME B31.3.
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APPENDIX J
SAFETY REQUIREMENTS
(Normative)
J1 GENERAL
This Appendix specifies in performance terms the safety requirements necessary for the
safe design, manufacture and use of pressure equipment.
This Appendix deals with specific requirements related to the equipment itself, but other
safety requirements may be needed to satisfy applicable laws and regulations.
NOTE: For this Appendix, reference has been made to EU-PED but modifications have been
made to suit Australian and New Zealand circumstances.
J2 GENERAL REQUIREMENTS
J2.1 Design and manufacture
Pressure equipment shall be designed, manufactured, installed with all required ancillaries
and commissioned in such a way as to ensure its safety when put into service, in accordance
with the designer’s/manufacturer’s instructions.
In choosing the most appropriate solutions, the principles set out below shall apply:
(a)
Eliminate or minimize hazards and associated risks as far as reasonably practicable.
NOTE: Main hazards are the potential for—
(a) equipment rupture leading to effects of blast and projectiles on people, plant and the
environment; and
(b) loss of containment leading to suffocation, infection, poisoning, fire, explosion or burns.
(b)
Apply appropriate protection measures (i.e. safeguards) against hazards that cannot be
eliminated.
(c)
Where appropriate, inform users of residual hazards and special measures necessary
to minimize risks at the time of installation, commissioning and use.
Where the potential for misuse is known, the pressure equipment shall be designed to
prevent danger from such misuse. If that is not possible, adequate warning should be given
to ensure the pressure equipment is not misused in such a way.
J2.2 Use
Pressure equipment shall be commissioned, operated, maintained, inspected, cleaned and
otherwise generally used in such a way as to control risk and ensure safety.
J3 DESIGN
J3.1 General
The pressure equipment shall be properly designed taking all relevant factors into account
in order to ensure that the equipment will be safe throughout its intended life.
The design shall incorporate appropriate safety coefficients using comprehensive methods
that are known to incorporate adequate safety margins against all relevant failure modes in
a consistent manner. Such safety coefficients and margins shall be equivalent with those
applied by the standards listed in Table 2.1 or as per Paragraph J7.
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J3.2 Design for adequate strength and deflection control
J3.2.1 General
The pressure equipment shall be designed for loadings appropriate to its intended hydrotest,
transport, installation, use and other operating conditions, in particular, the following
factors shall be taken into account:
(a)
Internal/external pressure.
(b)
Ambient and operational temperatures (thermal loads, strains and degradation).
(c)
Static pressure and mass of contents in operating and test conditions.
(d)
Traffic, wind, earthquake, snow, earth, water and other loads.
(e)
Reaction forces and moments that result from the supports, attachments, piping, and
the like.
(f)
Corrosion, wear, fatigue and other forms of degradation.
(g)
Decomposition of unstable fluids.
(h)
Fire.
Various loadings that can occur at the same time shall be considered, taking into account
the probability of their simultaneous occurrence.
J3.2.2 Basis
Design for adequate strength and deflection control shall be based on—
(a)
as a general rule, a calculation method as described in Paragraph J3.2.3, and
supplemented if necessary by an experimental design method, as described in
Paragraph J3.2.4; or
(b)
an experimental design method without calculation, as described in Paragraph J3.2.4.
J3.2.3 Calculation method
The method is as follows:
(a)
Pressure containment and other loading aspects The allowable stresses for pressure
equipment shall be limited having regard to failure modes under operating conditions.
To this end, suitable safety factors shall be applied to compensate for any uncertainty
arising out of manufacture, actual operational conditions, stresses, calculation models
and the properties and behaviour of the material.
The calculation methods shall provide sufficient safety margins consistent, where
applicable, with the requirements of Paragraph J7.
The requirements set out above may be met by applying one of the following
methods, as appropriate, if necessary as a supplement to or in combination with
another method:
(i)
Design by formula.
(ii)
Design by analysis.
(iii) Design by fracture mechanics.
(b)
Resistance to pressure and other loads Appropriate design calculations shall be used
to establish the safety of the pressure equipment concerned.
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In particular the following shall apply:
(i)
The calculation pressure shall not be less than the design pressure and shall take
into account static head and dynamic fluid pressures and the decomposition of
unstable fluids. Where a vessel is separated into individual pressure-containing
chambers, the partition wall shall be designed on the basis of the highest
possible chamber pressure relative to the lowest pressure possible in the
adjoining chamber.
(ii)
The design temperatures shall allow for appropriate safety margins.
(iii) The design shall take appropriate account of all possible combinations of
temperature and pressure that might arise under operating conditions for the
equipment.
(iv)
The maximum stresses and peak stress concentrations shall be kept within safe
limits.
(v)
The calculation for pressure containment shall utilize the values appropriate to
the properties of the material, based on documented data, together with
appropriate safety factors. Material characteristics to be considered, where
applicable, shall include the following:
(vi)
(A)
Yield strength, 0.2% or 1.0% proof strength as appropriate at design
temperature.
(B)
Tensile strength.
(C)
Time dependent strength, i.e. creep strength.
(D)
Fatigue data.
(E)
Young’s modulus (modulus of elasticity).
(F)
Appropriate amount of plastic strain (e.g. percentage of elongation and
reduction of area).
(G)
Impact strength.
(H)
Fracture toughness.
(I)
Other properties important with particular materials.
Appropriate joint factors shall be applied to the material properties depending,
for example, on the type and extent of non-destructive testing, the materials
joined and the operating conditions envisaged.
(vii) The design shall take appropriate account of all reasonably foreseeable
degradation mechanisms, e.g. corrosion, creep, fatigue, commensurate with the
intended use of the equipment. Attention shall be drawn, in the instructions
referred to in Paragraph J4.4, to particular features of the design that are
relevant to the life of the equipment.
(viii) The design shall take into account collision and fire with transportable
equipment.
(c)
Stability Where the calculated thickness does not allow for adequate structural
stability, the necessary measures shall be taken to remedy the situation taking into
account the risks from transport, handling and operation.
J3.2.4 Experimental design
The design of the equipment may be validated, as a whole or in part, by an appropriate test
programme carried out on a sample or samples representative of the equipment or the
category of equipment.
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The test programme shall be clearly defined prior to testing. Where design verification is a
requirement, the test programme shall be acceptable to the design verifier.
This programme shall define test conditions and criteria for acceptance and rejection. The
actual values of the essential dimensions and characteristics of the materials that constitute
the equipment tested shall be measured before the test.
Where appropriate, during tests, the critical zones of the pressure equipment shall be
capable of being observed using instrumentation capable of registering strains and stresses
with sufficient precision.
The test programme shall include the following:
(a)
A pressure strength test, the purpose of which is to check that, if a pressure with a
defined safety margin in relation to the design pressure is applied, the equipment does
not deform beyond agreed thresholds, or exhibit significant leaks. The test pressure
shall be determined on the basis of the differences between the values of the
geometrical and material characteristics measured under test conditions and the
values used for design purposes. Design values shall take into account the differences
between the test and design temperatures.
(b)
Where the risk of creep or fatigue exists, appropriate tests determined on the basis of
the service conditions laid down for the equipment, e.g. hold time at specified
temperatures, number of cycles at specified stress-levels and the like.
(c)
Where necessary, additional tests concerning other factors referred to in
Paragraph J3.2.1 such as corrosion, external damage and the like.
J3.3 Design for safe handling and operation
The design method of operation specified for pressure equipment shall be such as to
preclude any risk in operation of the equipment. Particular attention shall be paid, where
appropriate, to the following:
(a)
Closures and openings.
(b)
Dangerous discharge of pressure relief devices.
(c)
Devices to prevent physical access while pressure or a vacuum exists.
(d)
Surface temperature taking into consideration the intended use.
(e)
Decomposition of unstable fluids.
In particular, pressure equipment fitted with an access door shall be equipped with an
automatic or manual device enabling the user to easily ascertain that the opening will not
present any hazard. Furthermore, where the opening can be operated quickly, the pressure
equipment shall be fitted with a device to prevent it being opened whenever the pressure or
temperature of the fluid presents a hazard.
J3.4 Means of examination
Pressure equipment shall be designed and manufactured so that all necessary examinations
during manufacture and in-service can be safely carried out.
The means of determining the internal condition of the equipment shall be available, where
this is necessary to ensure the safety of the equipment, such as access openings, allowing
physical access to the inside of the pressure equipment so that appropriate examinations can
be carried out safely and ergonomically.
Other means of ensuring safety of the pressure equipment may be applied—
(a)
where it is too small for physical internal access;
(b)
where opening the pressure equipment would adversely affect the inside; or
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where the substance contained has been shown not to be harmful to the material from
which the pressure equipment is made and no other internal degradation mechanisms
are identified.
J3.5 Means of isolation, draining and venting
Adequate means shall be provided for the isolation, draining and venting of pressure
equipment, where necessary to—
(a)
avoid harmful effects such as water hammer, vacuum collapse, corrosion and
uncontrolled chemical reactions (all stages of operation and testing, particularly
pressure testing shall be considered); and
(b)
permit cleaning, inspection and maintenance in a safe manner.
J3.6 Corrosion or other chemical attack
Where necessary, adequate allowance or protection against corrosion or other chemical
attack shall be provided, taking due account of the intended use.
J3.7 Wear
Where severe conditions of erosion or abrasion may arise, adequate measures shall be taken
to—
(a)
minimize that effect by appropriate design, e.g. additional material thickness, or by
the use of wear plates, liners or cladding materials;
(b)
permit replacement of affected parts as appropriate; and
(c)
draw attention, in the operating instructions referred to in Paragraph J4.4, to measures
necessary for continued safe use.
J3.8 Provisions for filling and discharge
Where appropriate, the pressure equipment shall be so designed and provided with
accessories, or provision made for their fitting, as to ensure safe filling and discharge in
particular with respect to hazards such as the following:
(a)
On filling—
(i)
overfilling or over-pressurization, having regard, in particular, to the filling
ratio and to vapour pressure at the reference temperature; and
(ii)
instability of the pressure equipment.
(b)
On discharge—the uncontrolled release of the pressurized fluid.
(c)
On filling or discharge—unsafe connection and disconnection.
J3.9 Protection against exceeding allowable limits
Where, under reasonably foreseeable conditions, the allowable limits, e.g. pressure,
temperature or mass flow, could be exceeded, the pressure equipment shall be fitted with, or
provision made for the fitting of, suitable protective devices, unless the equipment is
intended to be protected by other protective devices.
The suitable device or combination of such devices shall be determined on the basis of the
particular characteristics of the equipment or assembly.
Suitable protective devices and combinations comprise the following:
(a)
Safety accessories that are devices designed to protect pressure equipment against the
allowable limits being exceeded. These include—
(i)
devices for direct pressure limitation including safety valves, bursting discs,
buckling rods, controlled safety pressure relieving systems; and
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limiting devices that activate means of correction or provide shut-down or
lockout, including pressure, temperature and liquid level switches and safety
related measurement and regulation devices.
Where appropriate, adequate monitoring devices, such as indicators and alarms,
which enable adequate action to be taken either automatically or manually to keep the
pressure equipment within the allowable limit.
J3.10 Safety accessories
J3.10.1 General
Safety accessories shall—
(a)
be so designed, manufactured and installed as to be reliable and suitable for their
intended duty and take into account the maintenance and testing requirements of the
devices, where applicable;
(b)
be independent of other functions, unless their safety function cannot be affected by
such other functions; and
(c)
comply with appropriate design principles in order to obtain suitable and reliable
protection. These principles include, in particular, fail-safe modes, redundancy,
diversity and self-diagnosis.
J3.10.2 Pressure limiting devices
The devices shall be designed so that the pressure will not permanently exceed the design
pressure; however, a short-duration pressure surge in accordance with Paragraph J7 is
allowable where appropriate (which shall not exceed 10% of the design pressure or other
suitable limit).
J3.10.3 Temperature limiting and monitoring devices
These devices shall be operated within temperature limits and response times necessary to
ensure safe operation.
J3.11 External fire
Where necessary and having particular regard to its intended use, pressure equipment shall
be so designed and, where appropriate, fitted with suitable accessories, or provision made
for their fitting to meet damage-limitation requirements in the event of external fire.
J4 MANUFACTURE
J4.1 Manufacturing procedures
J4.1.1 General
The pressure equipment shall be manufactured in accordance with the provisions set out at
the design stage by applying the appropriate techniques and procedures, especially with a
view to the aspects set out in this Paragraph (J4.1).
J4.1.2 Preparation of the component parts
Preparation of the component parts, e.g. cutting, forming and chamfering, shall be done in
such a manner as to avoid imperfections or changes in the mechanical characteristics
detrimental to the safety of the pressure equipment.
J4.1.3 Permanent joining
The permanent joints and adjacent zones shall be free of any surface or internal
imperfection detrimental to the safety of the equipment.
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The properties of permanent joints shall meet the minimum properties specified for the
materials to be joined unless other relevant property values or variations are specifically
taken into account in establishing the design.
Permanent joining of components that contribute to the pressure resistance of the equipment
and components that are directly attached to them shall be carried out by suitably qualified
personnel and joining procedures.
J4.1.4 Non-destructive tests
Non-destructive tests of permanent joints shall be carried out, where specified in the design,
by suitably qualified personnel.
J4.1.5 Heat treatment
Where there is a risk that the manufacturing process may change the material properties to
an extent that would unacceptably lower the safety of the pressure equipment, suitable heat
treatment shall be applied at the appropriate stage of manufacture.
J4.1.6 Traceability
Procedures shall be established and maintained for identifying the material making up the
components of the equipment that contribute to pressure resistance by suitable means from
receipt through production, up to the final test of the manufactured pressure equipment.
J4.1.7 Repair
Where unacceptable imperfections or material damage occurs, repairs shall be made with
suitable qualified procedures and personnel, and the equipment shall be re-inspected.
J4.2 Final assessment
J4.2.1 General
Pressure equipment shall be subjected to final assessment as described in Paragraph J4.2.
J4.2.2 Final inspection
Pressure equipment shall undergo a final examination by the manufacturer and appropriate
final inspection.
The inspection shall assess visually and by examination of the accompanying documents,
compliance with the requirements of the design. Tests carried out during manufacture shall
be taken into account. The final inspection shall be carried out internally and externally on
every part of the equipment, and where appropriate in the course of manufacture (e.g. where
examination during the final inspection is no longer possible).
J4.2.3 Proof test
Final assessment of pressure equipment shall include a test for strength and pressure
containment, which will normally take the form of a hydrostatic pressure test at a suitable
pressure. See Paragraph J7.
Where the hydrostatic pressure test is harmful or impractical, other equivalent tests may be
carried out. For tests other than the hydrostatic pressure test additional measures, such as
non-destructive tests or other methods of equivalent validity, shall be applied before those
tests are carried out.
J4.3 Marking and labelling
The following information shall be provided where required:
(a)
For all pressure equipment—
(i)
the identification of the manufacturer;
(ii)
the year of manufacture;
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(iii) the design registration number (Australia only);
(iv)
essential maximum and minimum allowable limits; and
(v)
other marking required by the Standard to which the equipment conforms,
including the required conformity assessment mark.
(b)
Depending on the type of pressure equipment, further information necessary for safe
installation, operation and use and, where applicable, maintenance and periodic
inspection.
(c)
Where necessary, warnings fixed to the pressure equipment drawing attention to
misuse that experience has shown might occur.
The required information shall be given on the pressure equipment or on a data plate firmly
attached to it, with the following exceptions:
(i)
Where applicable, appropriate documentation may be used to avoid repetitive
marking of individual parts such as piping components, intended for the same
assembly.
(ii)
Where the pressure equipment is too small, e.g. accessories, the information referred
to in Item (b) may be given on a label attached to that pressure equipment.
(iii) Labelling or other adequate means may be used for the mass to be filled and the
warnings referred to in Item (c) provided it remains legible for the appropriate period
of time.
J4.4 Operating instructions
When pressure equipment is made available on the market, it shall be accompanied, as far
as relevant, with instructions for the user, containing all the safety information relating to
the following:
(a)
Mounting, including assembling, of different pieces of pressure equipment.
(b)
Putting into service.
(c)
Use.
(d)
Maintenance including checks by the user.
Instructions shall cover information affixed to the pressure equipment in accordance with
Paragraph J4.3, with the exception of serial identification, and shall be accompanied, where
appropriate, by the technical documents, drawings and diagrams necessary for the full
understanding of these instructions.
If appropriate, these instructions shall also refer to hazards arising from misuse in
accordance with Paragraph J2 and particular features of the design in accordance with
Paragraph J3.2.3.
J5 MATERIALS
J5.1 General
Materials used for the manufacture of equipment shall be suitable for their application for
the duration of their scheduled lifetime unless replacement is foreseen.
Welding consumables and other joining materials need fulfil only the relevant parts of
Paragraphs J5.2, J5.3 and J5.4 in an appropriate way, both individually and in a joined
structure.
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J5.2 Materials for pressurized parts
Materials for pressurized parts shall comply with the following:
(a)
Have appropriate properties for all operating conditions and test conditions, and they
shall be sufficiently ductile and tough. Due care should be taken in selecting materials
to prevent brittle-type fracture. Where brittle material has to be used, appropriate
measures shall be taken.
(b)
Be sufficiently chemically resistant to the fluid contained in the pressure equipment
and its equivalent. The chemical and physical properties of the pressure equipment
necessary for operational safety shall not be significantly affected within the
scheduled lifetime of the equipment.
(c)
Not be significantly affected by ageing.
(d)
Be suitable for the intended processing procedures.
(e)
Be selected in order to avoid significant undesirable effects when the various
materials are put together.
J5.3 Documentation
The manufacturer shall define the values necessary for the design calculations referred to in
Paragraph J3.2.3 and the essential characteristics of the materials and their treatment
referred to in Paragraph J5.2.
The manufacturer’s documentation shall provide evidence of compliance with the materials
specifications by one of the following forms—
(a)
by using materials that comply with appropriate national Standards;
(b)
by using materials complying with requirements of Appendix D; or
(c)
by a particular material appraisal.
J5.4 Compliance
The equipment manufacturer shall take appropriate measures to ensure that the material
used complies with the required specification. In particular, documentation prepared by the
materials manufacturer affirming compliance with a specification shall be obtained for all
materials.
J6 SAFETY REQUIREMENTS FOR SPECIAL APPLICATIONS
J6.1 Fired or otherwise heated pressure equipment with a risk of overheating
In addition to the applicable parts of Paragraphs J1 to J5, this Paragraph (J6.1) applies to
pressure equipment including—
(a)
steam and hot-water generators such as fired steam and hot-water boilers,
superheaters and reheaters, waste-heat boilers, waste incineration boilers, electrode or
immersion-type electrically heated boilers, pressure cookers, together with their
accessories and where applicable their systems for treatment of feedwater and for fuel
supply; and
(b)
process-heating equipment and equipment other than in Item (a), such as heaters for
chemical and other similar processes and heaters for hot water and pressurized
foodprocessing equipment.
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This pressure equipment shall be designed and manufactured so as to avoid or minimize
risks of a significant loss of containment from overheating. In particular, where appropriate,
the following shall be ensured:
(i)
Appropriate means of protection shall be provided to restrict operating parameters
such as heat input, heat take-off and, where applicable, fluid level so as to avoid risk
of local and general overheating.
(ii)
Sampling points shall be provided where required to allow evaluation of the
properties of the fluid so as to avoid risks related to deposits and corrosion.
(iii) Adequate provisions shall be made to eliminate risks of damage from deposits.
(iv)
Means of safe removal of residual heat after shutdown shall be provided.
(v)
Steps shall be taken to avoid dangerous accumulation of ignitable mixtures of
combustible substances and air, or flame blowback.
J6.2 Additional safety requirements for piping
In addition to the applicable parts of Paragraphs J1 to J5, this Paragraph (J6.2) applies to
pressure piping.
Design, manufacture and installation of pressure piping shall ensure the following:
(a)
The risk of overstressing from inadmissible free movement or excessive forces being
produced, e.g. on flanges, connections, bellows or hoses, shall be adequately
controlled by means such as support, constraint, anchoring, alignment and pretension.
(b)
Where there is a possibility of condensation occurring inside pipes for gaseous fluids,
means shall be provided for drainage and removal of deposits from low areas to avoid
damage from water hammer or corrosion.
(c)
Due consideration shall be given to the potential damage from turbulence and
formation of vortices; the relevant parts of Paragraph J3.7 are applicable.
(d)
Due consideration shall be given to the risk of fatigue due to vibrations in pipes or
components.
(e)
Where lethal or very harmful fluids (see AS 4343) are contained in the piping,
appropriate means shall be provided to isolate ‘take-off’ pipes, the size of which
represents a significant risk.
(f)
The risk of inadvertent discharge shall be minimized; the take-off point shall be
clearly marked on the permanent upstream side, indicating the fluid contained.
(g)
The position and route of underground piping shall be recorded in the technical
documentation to facilitate safe maintenance, inspection or repair.
J7 SPECIFIC QUANTITATIVE REQUIREMENTS FOR CERTAIN PRESSURE
EQUIPMENT
J7.1 Provisions
The following provisions supplement the above section and apply as a general rule.
However, where they are not applied, including in cases where materials are not specifically
referred to and no recognized standards are applied, the manufacturer shall demonstrate that
appropriate measures have been taken to achieve an equivalent overall level of safety.
The provisions laid down in this Paragraph J7 supplement the safety requirements of
Paragraphs J1 to J6 for the pressure equipment to which they apply.
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AS/NZS 1200:2015
J7.2 Allowable stresses
The permissible general membrane stress for predominantly static loads and for
temperatures outside the range in which creep is significant shall not exceed the smaller of
the following values:
— Ferritic steel including normalized and normalized rolled = Ret/1.5 or Rm/2.4.
(not-fine grained or specially heat-treated)
— Austenitic steel A5 > 30%
= Ret/1.5.
A5 > 35%
= Ret/1.2 or Rmt/3.
— Cast steel (non-alloy or low alloy)
= Ret/1.9 or Rm/3.
Aluminium
= Ret/1.5.
Aluminium alloys (not precipitation hardening)
= Re/1.5 or Rm/2.4.
J7.3 Joint coefficients
For welded joints the joint coefficient (efficiency or factor) shall not exceed the following:
= 1.0 if destructive and NDTs show no significant defects.
= 0.85 if NDT is random.
= 0.7 if only VT is used.
If necessary, the type of stress and the mechanical and technological properties of the joint
shall also be taken into account.
J7.4 Pressure limiting device
The pressure surge referred to in Paragraph J3.10.2 shall not exceed 10% of max allowable
pressure.
J7.5 Hydrostatic test
The hydrostatic test pressure shall be no less than either of the following:
(a)
1.25 × maximum allowable pressure with temperature correction for allowable stress;
or
(b)
1.43 × maximum allowable pressure.
J7.6 Material characteristics (for steel only)
Unless other values are required in accordance with other criteria—
A5 = 14% minimum
Charpy V = 27 Joules minimum at temperature.
J8 USE
J8.1 General
At all times during various operations over its life, pressure equipment shall be used by
each person involved with the equipment in a manner that minimizes the risk of harm to the
health and safety of all persons, property and the environment (i.e. ensures safety).
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J8.2 Equipment operations
The following operations or stages shall be addressed in the overall control of pressure
equipment:
(a)
Initial management necessary to ensure the integrity and compliance of the
equipment, e.g. procurement, planning, development and site approval, location
(e.g. clearances, access and egress), installation and required safeguard (e.g. grading,
deluge or screening system against fire).
(b)
Operations such as to commission, (including recommission), operate (including
preliminary checks, start-up, monitoring, supervision, checks, shutdown and
isolation), maintain (including routine replacement and repair, inspection and test),
cleaning, repair, modify (i.e. a change), alter (a change that may affect safety),
decommission, dismantle, relocate, store, dispose of and recycle.
(c)
Emergency operations.
J8.3 Safety management system
An appropriate system shall be available and used to safely manage and perform the
operations listed in Paragraph J8.2.
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NOTES
AS/NZS 1200:2015
AS/NZS 1200:2015
48
NOTES
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