AS 3920:2015
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AS 3920:2015
Pressure equipment—Conformity
assessment
This Australian Standard® was prepared by Committee ME-001, Pressure Equipment. It was
approved on behalf of the Council of Standards Australia on 9 December 2014.
This Standard was published on 16 February 2015.
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The following are represented on Committee ME-001:
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Australasian Corrosion Association
Australasian Institute of Engineer Surveyors
Australasian Institute of Engineering Inspectors
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
Energy Networks Association
Engineers Australia
Materials Australia
National Association of Testing Authorities Australia
Welding Technology Institute of Australia
WorkCover New South Wales
WorkSafe Victoria
WorkSafe Division, Department of Commerce, WA
This Standard was issued in draft form for comment as DR AS 3920.
Standards Australia wishes to acknowledge the participation of the expert individuals that
contributed to the development of this Standard through their representation on the
Committee and through the public comment period.
Keeping Standards up-to-date
Australian Standards® are living documents that reflect progress in science, technology and
systems. To maintain their currency, all Standards are periodically reviewed, and new editions
are published. Between editions, amendments may be issued.
Standards may also be withdrawn. It is important that readers assure themselves they are
using a current Standard, which should include any amendments that may have been
published since the Standard was published.
Detailed information about Australian Standards, drafts, amendments and new projects can
be found by visiting www.standards.org.au
Standards Australia welcomes suggestions for improvements, and encourages readers to
notify us immediately of any apparent inaccuracies or ambiguities. Contact us via email at
mail@standards.org.au, or write to Standards Australia, GPO Box 476, Sydney, NSW 2001.
AS 3920:2015
Australian Standard®
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Pressure equipment—Conformity
assessment
Originated as AS 3920.1—1993.
Revised and redesignated as AS 3920:2015.
COPYRIGHT
© Standards Australia Limited
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.
Published by SAI Global Limited under licence from Standards Australia Limited, GPO Box
476, Sydney, NSW 2001, Australia
ISBN 978 1 74342 984 6
AS 3920:2015
2
PREFACE
This Standard was prepared by the Australian members of Joint Standards Australia/
Standards New Zealand Committee ME-001, Pressure Equipment, to supersede
AS 3920.1—1993, Assurance of product quality, Part 1: Pressure equipment manufacture.
With this revision, the Standard will now be known as AS 3920, Pressure equipment—
Conformity assessment.
After consultation with stakeholders in both countries, Standards Australia and Standards
New Zealand decided to develop this Standard as an Australian Standard rather than an
Australia/New Zealand Standard.
When first issued, this Standard was a most advanced Standard which responded to the
increasing recognition of quality systems as alternatives to, or supplements for, inspection,
and the potential to reduce conformity assessment (CA) effort as the level of hazard is
reduced.
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The changing laws and industry needs, including the increased prevalence of imported
pressure equipment, have now made it essential to revise the Standard to address
conformity assessment.
This Standard is expected to become a significant document used by industry in Australia to
provide guidance in ensuring that all pressure equipment used in Australia, including
imported pressure equipment, is safe and conforms with an accepted Standard. Conformity
assessment requirements have been included to provide reasonable compatibility with
overseas pressure equipment practices, such as those required by the ASME Boiler and
Pressure Vessels Code and the EU-PED European Union—Pressure Equipment Directive.
The amount of conformity assessment follows the same basic principles as international
codes but an over-riding principle remains in applying more stringent requirements as the
consequences of pressure equipment failure (i.e. hazard level) increases.
Changes since the 1993 edition now include the following:
(a)
Removal of Appendix B, ‘Hazard levels of pressure equipment’ to a separate
Standard, AS 4343—2005, Pressure equipment—Hazard levels.
(b)
Incorporation of AS 3920.1—1993, Amendment 1:1995 and Amendment 2:1999.
(c)
Changes to align with the new work health and safety (WHS) laws recognizing the
need for prescriptive requirements for self-regulation by industry.
(d)
Requirements for whole of life conformity assessment, with reference to
AS/NZS 3788 for conformity assessment at the vital commissioning and in-service
stages.
(e)
Modification to Table 2.1 to improve flexibility and understanding of requirements,
to ensure Australian practices with design verification are clarified, and to provide
alignment and guidance on leading overseas practices in recognition of increased use
of overseas-designed pressure equipment in Australia.
(f)
Recognition and use of the latest international quality Standards,
e.g. AS/NZS ISO 9001 and AS/NZS ISO 3834 (the latter being appropriate for
welded manufacture), and specifying the requirements for the practices and
independence
of
inspection
and
design
verifying
bodies,
using
AS/NZS ISO/IEC 17020 in place of outdated requirements.
(g)
Normative Appendix F included on competent bodies and persons, design verification
and manufacture inspection.
(h)
Updating of terms, references and some details.
3
AS 3920:2015
The above changes are expected to improve safety and economy for all pressure equipment
from any source used in Australia at a reasonable cost appropriate to the hazard presented
by the equipment.
Statements expressed in mandatory terms in notes to tables and figures are deemed to be
requirements of this Standard.
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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.
AS 3920:2015
4
CONTENTS
Page
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SECTION 1 SCOPE AND GENERAL
1.1 SCOPE ......................................................................................................................... 6
1.2 OBJECTIVE ................................................................................................................ 6
1.3 APPLICATION ........................................................................................................... 7
1.4 REFERENCED DOCUMENTS ................................................................................... 8
1.5 DEFINITIONS............................................................................................................. 8
1.6 STATUS OF STANDARD ........................................................................................ 10
1.7 ABBREVIATIONS ................................................................................................... 11
SECTION 2 BASIC REQUIREMENTS
2.1 CONFORMITY ASSESSMENT ............................................................................... 12
2.2 ALTERATIONS ........................................................................................................ 14
2.3 TYPES OF INSPECTION AND VERIFICATION BODIES ..................................... 15
2.4 SUB-CONTRACTORS ............................................................................................. 15
2.5 DOCUMENT LANGUAGE ...................................................................................... 15
2.6 ASSESSMENT OF PRESSURE EQUIPMENT WITH LIMITED DATA ................. 15
2.7 DESIGN AND MANUFACTURE VALIDATION.................................................... 16
SECTION 3 QUALITY SYSTEMS—DESIGN AND MANUFACTURE
3.1 GENERAL ................................................................................................................. 17
3.2 QUALITY SYSTEM REQUIREMENTS .................................................................. 17
3.3 OPERATION OF QUALITY SYSTEM .................................................................... 18
3.4 QUALITY SYSTEM DOCUMENTATION .............................................................. 18
SECTION 4 DESIGN VERIFICATION
4.1 GENERAL ................................................................................................................. 19
4.2 PURPOSE .................................................................................................................. 19
4.3 BASIS OF DESIGN CONFORMITY ASSESSMENT .............................................. 19
4.4 STAGE OF DESIGN VERIFICATION ..................................................................... 19
4.5 INFORMATION FOR DESIGN VERIFICATION .................................................... 20
4.6 AMOUNT OF DESIGN VERIFICATION ................................................................ 20
4.7 DESIGN STANDARD AND SPECIFICATION ....................................................... 20
4.8 DESIGN VERIFYING BODIES AND DESIGN VERIFIERS .................................. 20
4.9 ELEMENTS AND METHOD OF DESIGN VERIFICATION .................................. 21
4.10 COMPUTER-AIDED DESIGN VERIFICATION ..................................................... 23
4.11 DESIGN VERIFICATION CERTIFICATE............................................................... 23
4.12 DESIGN REGISTRATION ....................................................................................... 23
4.13 DESIGN VERIFICATION WITH LIMITED DATA................................................. 23
4.14 DESIGN VERIFICATION TO CHANGED STANDARD ........................................ 24
4.15 CONFIDENTIALITY ................................................................................................ 24
SECTION 5 TYPE TESTING
5.1 GENERAL ................................................................................................................. 25
5.2 REQUEST FOR VERIFICATION OF TYPE TESTING ........................................... 25
5.3 WITNESS AND ASSESSMENT ............................................................................... 25
5.4 TYPE TESTING METHOD ...................................................................................... 26
5.5 TYPE TESTING CERTIFICATE .............................................................................. 26
5.6 MANUFACTURE INSPECTION .............................................................................. 26
5.7 ALTERATIONS ........................................................................................................ 26
5
AS 3920:2015
Page
SECTION 6 MANUFACTURE INSPECTION
6.1 GENERAL ................................................................................................................. 27
6.2 INFORMATION FOR MANUFACTURE INSPECTION ......................................... 27
6.3 AMOUNT OF MANUFACTURE INSPECTION ...................................................... 27
6.4 MANUFACTURING INSPECTION METHOD........................................................ 27
6.5 FACILITIES FOR INSPECTION .............................................................................. 27
6.6 MANUFACTURE INSPECTION BODY .................................................................. 28
6.7 INSPECTION REPORT ............................................................................................ 28
6.8 CONFIDENTIALITY ................................................................................................ 28
SECTION 7 CONFORMITY ASSESSMENT MARKING AND REPORTS
7.1 MARKING ................................................................................................................ 29
7.2 DESIGN VERIFICATION CERTIFICATE............................................................... 29
7.3 MANUFACTURER’S DECLARATION OF CONFORMITY .................................. 29
7.4 IN-SERVICE INSPECTION REPORT ...................................................................... 29
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SECTION 8 REGISTRATION ............................................................................................... 30
APPENDICES
A
REFERENCED DOCUMENTS ................................................................................. 31
B
DESIGN VERIFICATION PROCESS....................................................................... 33
C
DESIGN VERIFICATION CERTIFICATE............................................................... 35
D
MANUFACTURE INSPECTION .............................................................................. 36
E
DECLARATION OF CONFORMITY FOR THE DESIGN
AND MANUFACTURE OF PRESSURE EQUIPMENT .......................................... 38
F
REQUIREMENTS FOR CONFORMITY ASSESSMENT BODIES
AND PERSONNEL ................................................................................................... 39
G
CONCEPT OF CONFORMITY ASSESSMENT INFRASTRUCTURE.................... 42
AS 3920:2015
6
STANDARDS AUSTRALIA
Australian Standard
Pressure equipment—Conformity assessment
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 specifies the minimum requirements for the assessment for conformity of
boilers, pressure vessels and pressure piping, including pressure-retaining accessories, to a
nominated, recognized pressure equipment Standard or Code.
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This Standard details specific requirements for conformity assessment of design and
manufacture; however, it can equally be used more generally over the whole life cycle of
pressure equipment, including repairs. For conformity assessment associated with
commissioning and other in-service inspection, refer to AS/NZS 3788.
NOTE: Failure to consider conformity assessment at the early stages of the life cycle of pressure
equipment can add significantly to the time and costs of the project. In the worst case
inappropriate conformity assessment may force the rejection of prior work.
Optional methods for conformity assessment (CA) are provided through various
combinations of—
(a)
design and manufacture quality systems; and
(b)
design verification, type testing and manufacture inspection.
The selection of the appropriate method of conformity assessment depends on the hazard
levels determined by AS 4343.
NOTE: Figure 1.1 provides information on the main elements of the conformity assessment
process covered by this Standard.
Additional requirements may be specified provided these are not lower than the level of
conformity in this Standard and are negotiated by the relevant parties, e.g. purchaser,
designer, manufacturer, repairer, design verifying body, manufacture inspection body and
accreditation or certification bodies.
1.2 OBJECTIVE
The objective of this Standard is to—
(a)
specify clear, safe, minimum requirements for conformity assessment of pressure
equipment;
(b)
assist all parties involved in the provision and use of safe pressure equipment;
(c)
provide alternative conformity assessment methods that are appropriate to the hazard
level of the equipment and acceptable to the parties concerned; and
(d)
help ensure that the pressure equipment conforms to relevant requirements during its
lifetime.
© Standards Australia
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7
AS 3920:2015
W H S R EG U L AT I O N
R EQ UIR EMEN T
IN D UST RY N EED
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C O N FO R MI T Y AS S ES S M EN T
S TAG E
METHOD
BY
Te n d e r/
C o ntr a c t
M U T UA L R E V IE W A N D
AG R EEMEN T
• S u p p l i e r (d e s i g n e r, m a n u f a c tu r e r)
& Pu r c h a s e r (ow n e r, u s e r)
• C o ntr a c t
Design
D ES IG N V ER IFI CAT I O N
• Ca l c u l ati o n a n d /o r
• Ty p e te s ti n g
• D e s i g n Ve r i f i e r (S e e Ta b l e 2.1);
• D e s i g n Ve r i f i c ati o n C e r ti f i c ate;
• R e g u l a to r y R e g i s t r a ti o n (o n c e o n l y)
• D e s i g n e r Q u a li t y S ys te m
M a n u f a c tu r e
M A N U FACT U R E IN S PECT I O N
• M a n u fa c tu r e In s p e c ti o n B o d y:
- i n d e p e n d e nt of m a n u fa c tu r e r, o r
- m a n u fa c tu r e r Q u a li t y S ys te m o r
I n s p e c ti o n s e c ti o n
• D e c l a r ati o n of C o nfo r m i t y (o r MD R)
a n d M a r ks
Commissioning
( b efo r e U s e)
C O M M I S S I O N I N G I N S PECT I O N
( i n c l u d e s i n s t a ll ati o n) ( N ote)
• I n - s e r vi c e In s p e c ti o n B o d y;
• In s p e c ti o n C e r ti f i c ate; a n d
• R e g ul ato r y R e g i s tr ati o n
Use
(a n d D i s p o s a l )
I N - S ERV I C E I N S PECT I O N ( N o te)
• Pe r i o di c
• Special
• R i s k b a s e d i n s p e c ti o n ( R BI )
• I n - s e r vi c e In s p e c ti o n B o d y;
• I n s p e c ti o n C e r ti f i c a te; a n d
• R e g i s tr ati o n r e n ewa l
NOTE: Details are given in AS/NZS 3788.
FIGURE 1.1 PRESSURE EQUIPMENT CONFORMITY ASSESSMENT—
MAIN ELEMENTS
1.3 APPLICATION
This Standard is written for use by those involved with the supply, procurement, use and
associated aspects of pressure equipment, including repairs, i.e. purchasers, importers,
suppliers, manufacturers, repairers, designers, material and component suppliers, test
laboratories, design verifying bodies, owners, users, inspection bodies and regulators.
This Standard specifically applies to—
(a)
pressure equipment and pressure-retaining accessories of the type covered in
AS/NZS 1200;
(b)
pressure equipment for use in Australia and provided from any source or provided
using any pressure equipment Standard. It is strongly recommended for use with
exported equipment; and
NOTE: For application in Australia of pressure equipment designed complying with overseas
design Standards, refer to AS/NZS 1200.
(c)
design verification and manufacture inspection of alterations, modifications and
repairs.
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© Standards Australia
AS 3920:2015
8
Unless specified by the parties concerned, this Standard does not specifically apply to—
(i)
installation of boilers, pressure vessels and pressure piping covered by AS 3892;
(ii)
operation, servicing and maintenance of boilers, pressure vessels and piping covered
by AS 3873;
(iii) in-service inspection of pressure equipment covered by AS/NZS 3788, except where
such inspections identify a need for a fitness for service assessment, an alteration,
modification or repair as indicated in Item (c) above; or
(iv)
miniature boilers complying with the AMBSC Code.
It may be applied to similar equipment where agreed by parties concerned.
1.4 REFERENCED DOCUMENTS
The documents referred to in this Standard are listed in Appendix A.
1.5 DEFINITIONS
For the purposes of this Standard, the definitions in AS 4942 and those below apply.
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1.5.1 Alteration
A change to pressure equipment where the change may impair health or safety, but does not
include safe routine maintenance, repair or replacement where the equipment is returned to
a state that matches the original design.
1.5.2 Accreditation body
A body that conducts and administers an accreditation system and grants accreditation.
1.5.3 Audit
A full or partial formal review performed by an accredited or approved auditing
organization in which compliance or non-compliance with all the system elements
prescribed in the quality management Standard is ascertained.
1.5.4 Certification body
A body accredited or approved for the purpose of certifying quality systems, design
verifying bodies, manufacture inspection bodies, in-service inspection bodies or personnel.
1.5.5 Certified
Certified by a certification body.
1.5.6 Competent person
A person who has acquired, through education, training, qualification or experience or a
combination of these, the knowledge and skill enabling that person to perform the task
required.
1.5.7 Conformity
Fulfilment of a requirement.
NOTE: The term ‘conformance’ is synonymous. Compare with ‘compliance’, which is taken to
mean ‘to act in accordance with’.
1.5.8 Conformity assessment (CA)
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.
© Standards Australia
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9
AS 3920:2015
1.5.9 Declaration of conformity
A certificate issued by the manufacturer or the manufacturer’s authorized representative in
which the manufacturer declares that the pressure equipment being supplied complies with
specified requirements.
1.5.10 Design review
Activity to determine the suitability, adequacy and effectiveness of the design.
NOTE: This is normally completed prior to approval of a design.
1.5.11 Design validation
Confirmation through the provision of objective evidence that the specified requirements
have been fulfilled.
1.5.12 Design verification
Documented comprehensive examination and review of a design to evaluate its
conformance with specified requirements, and identify any perceived deficiencies.
1.5.13 Design verifier
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A suitably experienced and qualified person in the employ or control of a ‘design verifying
body’.
1.5.14 Design verifying body
A body corporate, firm or person responsible for design verification.
1.5.15 Designer
A body corporate, firm or person responsible for the design of the pressure equipment.
1.5.16 Equivalent
Having the same, better or acceptable outcome.
NOTE: An acceptable outcome is agreed to be equivalent by the parties concerned.
1.5.17 Inspection
Examination of a product design, product, process or installation and determination of its
conformity with specific requirements, or on the basis of professional judgement, with
general requirements.
NOTE: Inspection of a process may include inspection of persons, facilities, technology and
methodology.
1.5.18 Manufacturer
A body corporate, firm or person responsible for the manufacture of pressure equipment.
1.5.19 Manufacture inspection body
A body corporate, firm, or person responsible for the inspection of the manufacture of
pressure equipment.
1.5.20 Manufacturer’s data report (MDR)
A one or two page report giving main pressure equipment data with declaration of
conformity by the manufacturer and inspection body. The MDR and added related
documents become a manufacture dossier or package.
1.5.21 Nationally recognized
A document or organization that is recognized in its country of origin.
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© Standards Australia
AS 3920:2015
10
1.5.22 Owner or user inspection body
An inspection body that inspects pressure equipment and forms a separate and identifiable
part of the owner or user organization involved in the design, manufacture, supply,
installation, use or maintenance of the owner organization’s pressure equipment. For
example, Type B inspection body to AS/NZS ISO/IEC 17020.
1.5.23 Parties concerned
The purchaser, designer, manufacturer, design verifying and manufacture inspection bodies,
supplier, importer, installer, owner, user and other persons, as appropriate.
NOTE: It is expected that the minimum number of parties will be the purchaser and manufacturer;
others may be the importer, supplier, manufacture inspector and the user.
1.5.24 Pressure equipment (PE)
Boilers, pressure vessels and pressure piping.
1.5.25 Purchaser (owner or user)
The person or body for whom the pressure equipment is manufactured and who purchased it
for use.
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NOTE: This term is intended to be equivalent to the ‘person conducting a business or undertaking
activities involving management or control of an item of plant’.
1.5.26 Regulator
An authority which is legally charged with the enforcement of the requirements of
legislation relating to the pressure equipment in the jurisdiction in which the equipment is
to be used.
1.5.27 Quality system
Organizational structure, procedures, processes and resources needed to implement quality
management.
1.5.28 Type testing
A design and manufacture evaluation procedure on representative samples of prototype and
production units to verify the design and manufacture of pressure equipment built to a
Standard that permits product acceptance by testing, e.g. AS 2030, AS 2971, AS/NZS 3509.
1.6 STATUS OF STANDARD
This Standard is a voluntary industry Standard prepared by Standards Australia and
nominated industry representatives to provide minimum conformity assessment criteria
necessary to comply with safety requirements in AS/NZS 1200. For Australia, this Standard
is equivalent (see Clause 1.5.16) to essential conformity assessment requirements contained
in the following:
(a)
ISO 16528-1, Boilers and pressure vessels, Part 1: Performance requirements.
(b)
EU-PED, European Union—Pressure equipment directive.
(c)
ASME Boiler and Pressure Vessel Code.
NOTE: Conformance with the documents in Items (a), (b) or (c) above does not necessarily imply
that there is conformance with AS 3920. For example, ISO 16528-1 only provides essential safety
requirements and is not a Standard that is suitable for design and manufacture. Also the ASME
Boiler and Pressure Vessel Code does not specify suitable requirements for design verification,
commissioning or in-service inspection.
© Standards Australia
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AS 3920:2015
1.7 ABBREVIATIONS
The following abbreviations are used in this Standard:
Australian Institute for Non-Destructive Testing
ASME
American Society of Mechanical Engineers
EU-PED
European Union—Pressure Equipment Directive
FEA
Finite Element Analysis
IIW
International Institute of Welding
JAS-ANZ
Joint Accreditation System of Australian and New Zealand
MDR
Manufacturer’s Data Report
NATA
National Association of Testing Authorities
NDT
Non-Destructive Testing
PWHT
Post Weld Heat Treatment
WTIA
Welding Technology Institute of Australia
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AINDT
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© Standards Australia
AS 3920:2015
12
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
2.1 CONFORMITY ASSESSMENT
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Each item of new, altered or repaired pressure equipment shall be subjected to conformity
assessment which—
(a)
applies to pressure retaining and associated parts of pressure equipment, as defined in
Clause 1.5.24 and covered in AS/NZS 1200 (also see Note 1 of Table 2.1); or
(b)
applies to pressure equipment to Australian Standards (AS 1210, AS 1228, AS 2971,
AS 4041, and AS/NZS 3509) or to any other available nationally, internationally
recognized pressure equipment Standard; or
(c)
applies to the pressure and vacuum retaining parts of the equipment specified in the
design, including supports, welded attachments and where applicable, pressure relief
capacity [see Clause 4.9 Item (m)] but excluding attached valves, fittings, controls
and ancillary equipment, unless otherwise agreed by the parties concerned;
(d)
increases in degree as the hazard level increases;
(e)
demonstrates that the design, materials, manufacture, repair, alterations, testing and
documentation conform to applicable Standards and specified additional purchaser
requirements;
(f)
uses a combination of—
(i)
quality system certification or accreditation (see Section 3);
(ii)
design verification (see Section 4);
(iii) type testing (see Section 5); and
(iv)
manufacture inspection (see Section 6);
(g)
is performed by competent persons; and
(h)
is in accordance with Table 2.1 and this Standard.
© Standards Australia
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AS 3920:2015
TABLE 2.1
DESIGN AND MANUFACTURE CONFORMITY ASSESSMENT (see Notes 1–5)
Design
Hazard
level to
AS 4343
Manufacture
Hazard
level to
AS 4343
Designer QS
Design verifying
body
Manufacturer QS
Manufacture
inspection body
(see Note 6
and Clause 3.2)
(see Notes 8 and 9
and Clause 3.2)
(see Note 7
and Clause 3.2)
(see Clause 3.2)
A
Certified
Certified—Type A
A
Certified to
AS/NZS ISO 9001 and
AS/NZS ISO 3834.2
Certified—Type A
B
Certified
Certified—Type B
B
Certified to
AS/NZS ISO 9001 or
AS/NZS ISO 3834.2
Not certified
(see Note 10)
OR
Not certified
(see Note 10)
Certified—Type A
Certified
Certified—Type B
C
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OR
C
Not certified
(see Note 10)
Certified—Type B
Certified to
AS/NZS ISO 9001 or
AS/NZS ISO 3834.2
Not certified
(see Note 10)
OR
OR
Not certified
(see Note 10)
Certified—Type A
Certified
Not certified
(see Note 10)
D
E
Certified—Type B
Not certified
(see Note 10)
Not certified
(see Note 10)
Certified—Type B
Not certified
(see Note 10)
Not certified
(see Note 10)
Not certified
(see Note 10)
Not certified
(see Note 10)
D
OR
Not certified
(see Note 10)
Not certified
(see Note 10)
E
NOTES:
1
This table applies specifically to boilers and pressure vessels. It only applies to pressure piping and
pressure-retaining accessories when specified in a regulation, or when specified by the purchaser.
2
If pressure safety devices are provided by the purchasers, then they do not require checking by a design
verifying body or manufacture inspection body. Where the pressure equipment manufacturer designs,
manufactures and supplies a pressure safety system, the manufacturer shall supply all design and
manufacture details to allow the design verifier to verify the safety devices unless specifically excluded
by both the manufacturer and the purchaser. The design verifier shall state on the verification certificate
if safety devices are included in the verification.
3
QS = quality system for pressure equipment.
4
Higher conformity assessment methods may be used in place of lower methods (highest level is Hazard
Level A).
5
Types A and B inspection bodies are described in Clause 2.3.
6
For ASME-stamped pressure equipment with hazard levels A to D, the designer shall operate under the
manufacturer’s ASME certified quality system.
7
For ASME-stamped pressure equipment with hazard levels A to D, the manufacturer shall be certified by
ASME for the ASME Section or Division appropriate for the pressure equipment.
8
Design verifying bodies and design verifiers shall comply with the requirements of Clause 4.8.
9
For transportable pressure equipment as defined in AS 1210 with Hazard level A, B or C, design
verification shall be carried out by a Type A inspection body.
10 Where ‘not certified’ is specified in this Table, refer to Clause 3.2.3.
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2.2 ALTERATIONS
2.2.1 Alterations requiring design verification
Where an alteration is made to pressure equipment before or after pressure equipment
completion, alterations of the type listed below shall be treated as a new design and, where
required by Table 2.1 for the relevant hazard level, the altered design shall be verified in
accordance with Section 4.
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Alterations requiring design verification include, but are not limited, to the following:
(a)
An increase in the design pressure (internal or external) or an increase in design
temperature sufficient to affect component strength regardless of whether or not a
physical change was made to the pressure equipment.
(b)
A decrease in the minimum operating temperature such that other material type or
additional mechanical tests are required.
(c)
The addition of new nozzles, openings or attachments in a boiler or pressure vessel,
which require new design calculations, e.g. where the nozzles or openings are larger
in diameter than openings already in the equipment, or are located in positions which
require redesign.
(d)
A change in the dimensions or contour of pressure equipment which affects stress
calculations.
(e)
A change of more than 2% in any heating surface area of a boiler.
(f)
The addition of a pressurized or vacuum jacket to pressure equipment which affects
stress calculations.
(g)
Replacement of a pressure retaining part in a pressure vessel or boiler with a material
of lower nominal tensile strength or a different nominal composition from that used in
the original design.
(h)
A change in materials or manufacturing methods, such as forming, welding
consumables and heat treatment including re-heat treatment, which could reduce the
safety and serviceability of the equipment.
(i)
A change in pressure equipment Standard or to a specification which may reduce the
safety, performance or serviceability of the equipment.
(j)
A change that would impair internal access for inspection or maintenance.
(k)
Other alterations that may harm the health and safety of personnel or pressure
equipment performance.
2.2.2 Alterations not requiring design verification
When an alteration does not require design verification (see Clause 2.2.1), the alteration
shall conform with the original pressure equipment, design and manufacturing Standard and
be suitably communicated and documented by the designer, manufacturer and purchaser as
appropriate.
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AS 3920:2015
2.3 TYPES OF INSPECTION AND VERIFICATION BODIES
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Types A and B inspection bodies for design verification or Types A and B inspection bodies
for manufacturing inspection activities are specified in AS/NZS ISO/IEC 17020, which
recognizes that the credibility of inspection findings depends on the independence of
inspectors and other factors. It identifies three independent types, A, B and C, and the
structural and operational parameters that support proper inspections:
(a)
Type A is a ‘third party’ body, independent of manufacturer (first party) and
purchaser (second party) with ownership and management formally separated from an
interest in the items inspected. A Type A design verification body shall not be the
same body as that of the designer irrespective of the designer body having a quality
system that permits design work and verification work.
(b)
Type B is an inspection body which is a part of an organization having an interest in
the item inspected, possibly as purchaser, owner, user or manufacturer but has
internal structural safeguards promoting confidence in its inspections and maintaining
the independence of the inspector or verifier from the original design or manufacture
process. A Type B design verification body can be part of the designer body provided
that its quality system has that provision and the design verifier has had no input into
the design.
(c)
Type C is an inspection body providing first party inspections, second party
inspections, or both, which forms an identifiable but not necessarily a separate part of
an organization involved in the design, manufacture, supply, installation, use or
maintenance of the items it inspects and which supplies inspection services to its
parent organization or to other parties, or to both.
2.4 SUB-CONTRACTORS
Where a sub-contractor is used to support design verification or manufacture inspection the
design verifying body or manufacture inspection body, as appropriate, shall ensure that the
sub-contractor complies with the applicable requirements of this Standard. The information
provided to the sub-contractor shall be sufficient to ensure that the sub-contractor can
comply with the requirements of the contract and the applicable Standards.
2.5 DOCUMENT LANGUAGE
For pressure equipment to be made in or used in Australia, essential documents required by
this Standard for conformity assessment shall be in the English language.
2.6 ASSESSMENT OF PRESSURE EQUIPMENT WITH LIMITED DATA
Where pressure equipment with Hazard level A, B, C or D is imported, supplied or installed
without sufficient evidence of conformity assessment to a recognized pressure equipment
Standard and this Standard, the pressure equipment shall, where appropriate—
(a)
be thoroughly inspected by a competent person;
(b)
have material suitability confirmed by one of the following:
(i)
Remove and test a sample of the material for chemical composition and
mechanical properties to confirm compliance with a recognized material(s) of
construction Standard to allow design strengths to be determined per the
selected design and manufacturing code.
OR
(ii)
Assessment of the material composition and mechanical properties by
competent persons using non-destructive metallurgical/mechanical testing
methods as agreed by the parties concerned.
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(c)
have sufficient calculations undertaken by a competent person(s) other than the
verifier, examinations and tests to give sufficient evidence that the pressure
equipment as far as reasonably practicable conforms to an acceptable Australian
Standard or equivalent;
(d)
have tests which include, as necessary—
(i)
destructive tests on samples of serially produced or multiple-duplicate pressure
equipment (in accordance with Section 5); or
(ii)
sample non-destructive tests such as radiography, ultrasonic examination,
magnetic particle examination, penetrant examination, positive material
identification (PMI), hardness, replica, and/or pressure tests.
(e)
be suitably marked; and
(f)
be covered by an equivalent MDR signed by a competent person, and a design verifier
as required in Table 2.1 and acceptable to the purchaser.
2.7 DESIGN AND MANUFACTURE VALIDATION
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For hazard levels A and B, it is recommended that the design and manufacture be validated
as far as practicable to the satisfaction of the parties involved by successful—
(a)
passing of the hydrostatic test;
(b)
transport, installation and site inspection;
(c)
site testing if required;
(d)
commissioning and start-up; and
(e)
completion of a guarantee service period.
Such validation does not necessarily ensure performance against time-dependent failure
modes (material degradation or damage mechanism), i.e. resistance to fatigue, creep,
corrosion or collision, or other rare random but credible events.
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S E C T I O N
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AS 3920:2015
Q U A L I T Y S Y S T E M S — D E S I G N
A N D M A N U F A C T UR E
3.1 GENERAL
This Section applies to quality systems for the design and manufacture of pressure
equipment. Sections 4 and 6 provide additional requirements for design verifying bodies
and manufacture inspection bodies.
3.2 QUALITY SYSTEM REQUIREMENTS
3.2.1 Certified quality system
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Where a certified quality system for design, design verification, manufacture, or
manufacture inspection is required in Table 2.1, certification or accreditation shall be to the
following Standards as appropriate:
(a)
For design—AS/NZS ISO 9001.
(b)
For design verification—AS/NZS ISO 9001 or AS/NZS ISO/IEC 17020 or complying
with, but not certified to, one of these Standards but using a design verifier
(individual) listed by an alternative nationally recognized body/organization that is
acceptable to the purchaser.
(c)
For manufacture—
(i)
AS/NZS ISO 9001; or
(ii)
AS/NZS ISO 3834.2; or
(iii) systems for manufacture considered ‘equivalent’ by the parties concerned. For
example:
(d)
(A)
ASME Quality Control System with Authorized or National Board
Inspectors and ASME Certification (e.g. ‘U’ stamp).
(B)
EU-PED with Notified Bodies and ‘CE’ mark.
For manufacture inspection—AS/NZS ISO/IEC 17020 or a system for manufacture
inspection considered ‘equivalent’ by the parties concerned. For example:
(i)
ASME Quality Control System with Authorized or National Board Inspectors.
(ii)
EU-PED with Notified Bodies and ‘CE’ mark.
The above requirements shall also apply to the design and manufacture aspects of type
testing (Section 5).
3.2.2 Certification and accreditation
Certification and accreditation of the above quality systems shall—
(a)
for design, be carried out by an accredited certification body or by an alternative
nationally recognized body/organization that is acceptable to the purchaser;
(b)
for design verification, be carried out by accredited certification bodies acceptable to
the purchaser;
(c)
for manufacture, be carried out by accredited certification body or by the
International Institute of Welding (IIW), or an equivalent recognized national
organization for the codes of manufacture that the manufacturer is competent in; and
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for manufacture inspection, be carried out by accredited inspection body or be carried
out by an equivalent recognized organization.
NOTE: JAS-ANZ accredits certification bodies in Australia and New Zealand. NATA accredits
facilities to perform specific types of testing, inspection, calibration and other related activities.
Certification and accreditation programs shall be conducted in accordance with the rules of
the certifying body; however, certification programs shall include at least the following
features:
(i)
Full audits initially and at 3 to 5 year intervals, with interim partial audits
approximately once per year.
(ii)
Audits carried out by an auditing team that includes at least one person having at least
five years’ experience in the design, manufacture, maintenance or inspection of
pressure equipment as appropriate.
(iii) Assessment of the quality systems and their direct application in practice to the
design or manufacture, and representative personnel involved.
NOTE: Equivalent certification and accreditation to the above may apply when international
mutual recognition or trade agreements exist.
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3.2.3 Non-certified quality system
Where a certified quality system is not required by Table 2.1 documents shall be prepared
for the critical operations affecting quality. These shall include—
(a)
procedures for design verification and personnel competence;
(b)
procedures for material and component purchase, identification and traceability;
(c)
procedures for forming, welding and personnel qualification;
(d)
inspection and test plans (ITPs); and
(e)
a declaration of conformity or manufacturer’s data report (MDR) for the pressure
equipment.
3.3 OPERATION OF QUALITY SYSTEM
Bodies operating a quality system required by Table 2.1 shall include at least the following:
(a)
Operation in accordance with the quality system and the rules of the certifying body.
(b)
Designs verified and manufacture inspected to comply with Sections 4 and 6
respectively.
(c)
Provision of a design verification certificate.
(d)
Provision of a declaration of conformity or MDR for the pressure equipment.
(e)
Provision of reports and keep records in accordance with Section 7.
(f)
Provision of evidence that certification or accreditation of the quality system is
current and applicable to the pressure equipment.
3.4 QUALITY SYSTEM DOCUMENTATION
Quality system documentation, (e.g. quality manual, documented procedures, work
instructions and standardized forms and quality records required in the quality system) shall
relate to, and identify applicable requirements of the pressure equipment Standard or
Standards used.
Manufacturers shall plan and provide evidence of inspection and tests utilizing an
inspection test plan (ITP). A manufacturer’s quality system shall state in the inspection
procedures the names or titles of those personnel with authority to review an ITP. An ITP
shall be established prior to the start of manufacture or repair.
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D E S I G N
AS 3920:2015
V E R I F I C A T I O N
4.1 GENERAL
Design of new and altered pressure equipment for use in Australia, or claiming to be in
accordance with this Standard, shall be verified as required by Table 2.1 and this Section 4.
The purpose of the design verification is to identify any omissions and inadequacy of the
design and data submitted. Any identified omissions or inadequacies shall be provided to
the body or person submitting the design.
Unless otherwise specified by the design verifier more than one item of equipment may be
manufactured to a verified design.
The design verification requirements of this Standard are optional for pressure piping if
piping is designed in accordance with AS 4041, ASME B31.1, ASME B31.3 or any other
recognized International Standard.
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4.2 PURPOSE
Design verification is to provide suitable and sufficient checking of the design drawings
and other nominated documents to—
(a)
identify any significant errors or omissions;
(b)
confirm that the design conforms with good engineering principles; and
(c)
give a high degree of confidence that the design of pressure equipment is safe and
complies with the design Standard, applicable laws and the stated purchaser
requirements.
4.3 BASIS OF DESIGN CONFORMITY ASSESSMENT
The overall risk largely depends on suitable design of the particular pressure equipment.
This in turn depends primarily on the designer. As almost all failures are due to human
deficiency, it is necessary to have design checks and independent design verification.
To limit overall risk to an acceptable very low level and to align with good global practice
the amount, level and competence of design verification is to increase as the hazard level
increases.
4.4 STAGE OF DESIGN VERIFICATION
The design shall be verified before commencement of manufacture, except where the
manufacturer—
(a)
accepts the risk of possible future rejection or rework or extra inspection and test;
(b)
ensures that all tests and inspections are carried out in accordance with the relevant
Standard and purchaser specification; and
(c)
makes all necessary documentation, including drawings, available to the manufacture
inspection body as well as the design verifier.
The design shall be verified before being placed in service.
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4.5 INFORMATION FOR DESIGN VERIFICATION
The request for design verification shall contain the following:
(a)
Fully identified drawings showing the basic design conditions, hazard level, design
Standard, class of construction, contents, operating conditions of the pressure
equipment, essential dimensions, material specifications of component parts, weld
details, location and purpose of connections and openings, supports, non-destructive
testing (NDT), post weld heat treatment (PWHT), test position and test pressure,
corrosion allowance and other details considered essential for proper verification,
e.g. site conditions (seismic, wind, snow, flood and the like), lifting facilities, and
transport and installation requirements, e.g. the applicable items of AS 1210.
(b)
Information on design inputs and design service conditions, where possible, or by
specific request of the design verifier, a copy of the design calculations.
(c)
A report adequately explaining any finite element analysis (FEA) or similar analysis
and showing the model, basic assumptions, results and conclusions.
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NOTE: Verification of FEA based designs is a difficult process and flexibility is required.
The provision of a report may not in itself be sufficient, and the design verifier may need to
reproduce the work completely or undertake an audit of the FEA at the designer’s office.
(d)
Parts of the purchase or design specification essential for design verification.
(e)
Any other data necessary to assist verification of the design.
4.6 AMOUNT OF DESIGN VERIFICATION
The amount of verification—
(a)
shall be sufficient to satisfy, as far as reasonably practicable, the design verifier and
purchaser that the design and drawings represent a safe design and conform to the
Standard used in the design, and will be suitable for manufacture and designed use;
(b)
shall depend on the verifier’s competence and experience and knowledge relative to
the design, design standard, the designer and previously accepted or proven designs;
NOTE: Most pressure equipment supports do not require another full and complex calculation
or finite element analysis by the design verification.
(c)
shall increase as the complexity of the design and pressure equipment hazard level
increases; and
(d)
shall cover the elements and methods in Clause 4.9.
Design of elements of the pressure equipment other than mentioned above shall be suitably
assessed to the satisfaction of the designer, manufacturer and purchaser.
4.7 DESIGN STANDARD AND SPECIFICATION
The design verification shall be made for conformance of the design with the nominated
Standard and purchaser or design specification.
4.8 DESIGN VERIFYING BODIES AND DESIGN VERIFIERS
A design verifying body shall—
(a)
operate under a documented system in accordance with Table 2.1;
(b)
use competent design verifiers who are covered by their certification;
(c)
comply with the certifying authorities rules or restrictions, which can be on the types
of pressure equipment;
(d)
be a legal entity;
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AS 3920:2015
(e)
have adequate provision, e.g. insurance or reserves to cover liabilities arising from its
operations;
(f)
verify whether the design complies with the requirements of the applicable pressure
equipment Standard as specified by the purchaser or designer;
(g)
conform with this Standard including—
(i)
have quality system certification and Type A or Type B independence from the
production of the original design in accordance with Table 2.1;
(ii)
comply with Clause 3.2.1(b);
(iii) comply with Appendix F; and
(h)
for finite element analysis (FEA) and similar computer analyses, be competent and
experienced in the proper use of FEA or equivalent for pressure equipment and satisfy
FEA requirements equivalent to AS 1210.
See AS/NZS 4481 and SAA/SNZ MP 76 for guidance.
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4.9 ELEMENTS AND METHOD OF DESIGN VERIFICATION
The following elements and methods shall be used to verify the mechanical design and
drawings of hazard levels A to D pressure equipment with the specified design Standard
and any agreed additional requirements of the purchaser:
NOTE: The sequence may differ from that shown.
(a)
Design dossier Verify by visual examination that the documents provided are
sufficient and adequate for design verification, and are signed by the designer.
(b)
Design input Verify by visual examination that design input equals calculations and
drawing, i.e. Standard and Class, design pressure, diameter, minimum temperature,
maximum temperature, volume, contents type and mass, hazard level, material,
corrosion allowance, nozzles, flanges, bolting, supports, attachments, access, design
loads (piping, seismic, wind, etc.), life (hours, years, cycles), post weld heat treatment
(PWHT), non-destructive testing (NDT), test pressure and position, and the principal
dimensions essential for design.
(c)
Material Verify by visual examination that material is permitted in the design
Standard or is an acceptable equivalent, and properties used agree with the design
Standard, and are suitable for manufacture and the design service temperatures and
conditions and for allowable stresses and strains.
(d)
Thickness and adequacy of parts Verify by calculation, visual examination,
experience, and/or tests that the following conform to the nominated design Standard:
(i)
Pressure and vacuum retaining parts including shells(s), ends, jackets, nozzles,
manways, openings, flanges, gaskets, bolts, stays, covers, reinforcing plates,
etc. up to the first point of connection to attached piping and other pressure
equipment.
(ii)
Non-pressure parts such as supports and attachments where applicable loads
applied to the pressure envelope are significant.
(iii) Design values and all necessary load cases.
(e)
Welded joints Verify by visual examination and/or calculation that drawing details
of size, type, location and shape are specified and conform to the nominated or
equivalent Standard.
(f)
Manufacture and welding requirements Verify by visual examination for a reference
to a suitable Standard.
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(g)
Post weld heat treatment (PWHT) Verify by visual examination that PWHT is
specified and appropriate when required by the design and Standard.
(h)
Non-destructive testing (NDT) Verify by visual examination that NDT is adequately
referenced and is as required.
(i)
Pressure test Verify by visual examination and/or calculation.
(j)
Type testing Use successful suitable test results, as appropriate, to verify that the
above Items (e) to (i) result in acceptable levels of stress and strain, acceptable
resistance to high and low temperatures, acceptable fatigue or impact performance,
and provide sufficient performance against other degradation mechanisms such as
corrosion or erosion.
(k)
Fracture mechanics Verify the suitability of designs or modifications incorporating
fracture mechanics analysis as provided for in AS/NZS 1200, AS 4458 and
AS/NZS 3788 or to verify special features that require such analysis.
(l)
Designs using finite element analysis (FEA) For FEA and similar computer analyses,
verify that—
(i)
the FEA described in the report from the designer [see Clause 4.6(c)] is
consistent with Clause 4.10;
(ii)
the analysis complies with AS 1210 or equivalent;
(iii) reported high stresses, strains or intensities are satisfactory;
(iv)
by at least one calculation, the thickness of a main pressure part is adequate and
confirms the FEA output;
(v)
if required by the purchaser, a repeat full or partial equivalent FEA confirms
the design output; and
(vi)
if requested by the verifier and approved by the purchaser, verification may be
undertaken by an audit process at the designer’s office.
(m)
Pressure relief devices Verify by visual examination specifications and capacity of
these devices where such components are required by the designer or purchaser to be
verified.
(n)
Other elements Verify, on the above basis, other elements of the mechanical design
which are essential for proper design verification as specified by the designer or
determined by the design verifier.
At least one calculation of the thickness of the main cylindrical shell, end and nozzle of
each pressure equipment section under different pressure shall have been made.
See Clause 4.10 for computer-aided design verification.
The above verification shall be based on experience, by recalculation by spreadsheet, hand
or computer, by direct check of supplied calculations, or by comparison with proven
designs, type test results.
In the event of non-conformance or doubt, the verifier shall discuss these with the designer
giving reasons, and if practical, aid in resolving the issue. If this is not practicable, a check
with a competent pressure equipment design specialist is recommended before final
determination.
NOTE: For guidance, see Appendix B.
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AS 3920:2015
4.10 COMPUTER-AIDED DESIGN VERIFICATION
Design verification using computers shall be in accordance with Clause 4.9 and the
following:
(a)
Software shall be—
(i)
suitably identified with origin, title and version;
(ii)
suitable for the applicable calculations and type and scope of the assessment;
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(iii) kept up-to-date and preferably in metric units (for calculations, loads, material
properties, etc.);
(iv)
supported by an up-to-date application manual;
(v)
suitably secure to prevent unauthorized access; and
(vi)
supported with data files, which are suitably backed up.
(b)
Commercial vendor-supplied software shall have been verified and approved by
recognized organizations and shall be supplied with a test file to check its use.
(c)
Software validation is required by actual use and direct comparison of results of at
least three cases of varying complexity with other acceptable design methods, design
formulae, design analyses, results of tests (e.g. strain, deflection, stress or pressure)
or comparison with other proven software.
(d)
Combination—the combination of computer hardware/software/verifier and
application must have been proven successful by adequate documented checks and
comparison with known results or hand calculations or equivalent means.
(e)
FEA—see Clause 4.9(l).
(f)
Re-verification of the combination of computer hardware/software/verifier and
application shall be performed when moving software between computers or
installing the software on a different computer, and regularly where user-entered data
can impact formulas and calculation processes.
4.11 DESIGN VERIFICATION CERTIFICATE
Where the design satisfies requirements, the design verifier shall—
(a)
issue and retain a copy of the certificate complying with Appendix C, or equivalent;
and
(b)
record the method and basis of verification used and retain sufficient documents to
justify the verification certificate.
4.12 DESIGN REGISTRATION
Designs of boilers and pressure vessels of hazard levels A to D for use in Australia may
need to be registered with an Australian regulator and such registration may require a copy
of the design verification certificate.
Any allocated design registration number shall be retained in a readily accessible position
in the vicinity of the pressure equipment in use, and shall be added to the pressure
equipment name plates (refer to AS 1210).
4.13 DESIGN VERIFICATION WITH LIMITED DATA
See Clause 2.6.
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4.14 DESIGN VERIFICATION TO CHANGED STANDARD
Where a verified design is to be used for pressure equipment required to comply with a
revised or an amended Standard, it is recommended that a gap analysis be completed and if
necessary the design calculations be suitably amended. The drawing shall be suitably
amended.
Where the amendments to the design are considered to be alterations (see Clause 2.2), the
designs shall be re-verified.
4.15 CONFIDENTIALITY
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The design verifying body and design verifier shall ensure that the details of the design in
their possession are disclosed only to those authorized by the designer or owner of the
design or as required by the regulator.
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S E C T I O N
5
T Y P E
AS 3920:2015
T E S T I N G
5.1 GENERAL
Type testing may be used for serially produced unfired pressure vessels (sometimes known
as ‘multiple duplicates’) or other pressure equipment as an alternative or supplement for
conformity assessment of designs and manufacture.
NOTE: It is expected that any unchanged original type testing would be acceptable to another
design verifying body.
5.2 REQUEST FOR VERIFICATION OF TYPE TESTING
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A request by the designer, manufacturer, or others for verification type testing shall—
(a)
be lodged with a design verifying body or manufacture inspection body complying
with Clauses 4.8 and 6.6 respectively;
(b)
place at the disposal of the design verifying body a representative example of the
pressure equipment;
(c)
include—
(i)
name and address of the manufacturer;
(ii)
location of production and testing facilities;
(iii) technical documentation; and
(d)
provide—
(i)
general description of the ‘type’;
(ii)
conceptual design
sub-assemblies;
and
manufacturing
drawings
of
components
and
(iii) description of manufacture and test procedures;
(iv)
any design calculations;
(v)
results of any tests and examinations carried out;
(vi)
the type tests required; and
(vii) applicable Standards used, and any additional information required by the
design verifying body.
5.3 WITNESS AND ASSESSMENT
The design verifying body and/or manufacture inspection body shall—
(a)
witness the type tests and examinations;
(b)
establish that the tests and any supporting conformity assessment will adequately
support the design and manufacture and are commensurate with the manufacturer’s
quality system and the hazard level of the pressure equipment;
(c)
assess results and issue a type testing certificate and/or report, as appropriate;
(d)
retain the relevant design, manufacture and testing documentation of the type testing;
and
(e)
ensure the type test samples are suitably identified and retained for future reference,
e.g. 10 years or as long as the pressure equipment continues to be manufactured.
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5.4 TYPE TESTING METHOD
The method of testing shall conform to the particular Standard and be acceptable to the
designer, design verifying body, manufacturer and manufacturing inspection body as
appropriate.
5.5 TYPE TESTING CERTIFICATE
Where the design, materials, manufacture, marking and the manufacturer’s declaration of
conformity meet the requirements of AS 2971, or equivalent, and this Standard, the design
verifying body shall issue a design verification certificate to the manufacturer referring to
the type testing certificate or report.
The design verification certificate shall remain valid for the duration of the manufacturing
life of the pressure equipment.
5.6 MANUFACTURE INSPECTION
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Manufacture inspection shall be in accordance with Section 6 and AS 2971 or equivalent.
Pressure equipment with hazard levels A, B or C shall be subject to an annual audit to
ensure the original type and its manufacturing methods and quality are continuing to be
complied with.
5.7 ALTERATIONS
Alterations to the design, materials or manufacturing methods, which are of a type in
accordance with Clause 2.2.1 shall require re-examination, testing and new design
verification certificate (see also Clause 4.14).
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6
M A N U F A C T U R E
AS 3920:2015
I N S P E C T I ON
6.1 GENERAL
The pressure equipment shall be subjected to manufacture inspection as required by
Table 2.1. The purpose of this inspection is to identify any omissions and inadequacies in
the manufacture, and the manufacture inspection body shall provide such information on
any identified omissions or inadequacies identified to the manufacturer.
6.2 INFORMATION FOR MANUFACTURE INSPECTION
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Documentation provided to the manufacture inspection body shall include the following:
(a)
A copy of all relevant manufacture drawings including the latest amendments.
(b)
A copy of the design verification certificate.
(c)
A copy of the design registration if it was required (refer to Clause 4.12).
(d)
All other documentation agreed to in the manufacturing contract.
Other documentation, such as welding procedure and welder qualifications, material
certification, examination reports, etc. shall be made available when necessary for viewing
by manufacture inspection personnel in the manufacturer’s works.
6.3 AMOUNT OF MANUFACTURE INSPECTION
The amount of manufacture inspection—
(a)
shall be sufficient to satisfy the manufacture inspection body that the manufactured
pressure equipment is in accordance with the stated Standards and purchaser specified
requirements;
(b)
shall depend on the knowledge, skill and experience of the manufacture inspection
body, on previously accepted or proven manufacture, and particularly on the
manufacturer’s present and past performance, reputation, reliability of personnel and
effectiveness of the quality control system; and
(c)
shall involve the applicable type of inspections listed in Appendix D for some part of
the manufacture. It is not necessary to closely inspect every material certificate,
surface, joint set-up, or witness all welding and welder qualification tests, welds
being performed, or review all test results, or witness all heat treatment, other tests or
hydro-tests of multiple duplicate or serially-produced production or multiple
produced equipment fabricated by the same materials, processes and procedures
within a one-year period. Collectively the amount shall be sufficient to satisfy (a)
above, include 100% visual examination of accessible parts during witnessing of
pressure tests, and be carried out at least once per year.
6.4 MANUFACTURING INSPECTION METHOD
Inspection methods shall be in accordance with Appendix D or equivalent.
6.5 FACILITIES FOR INSPECTION
Facilities for inspection shall be provided as follows:
(a)
Access The manufacture inspection personnel shall be given free access, within
reason, to those parts of the manufacturer’s or supplier’s works engaged in the
manufacture of the equipment, and to the site of field-erected equipment, and shall be
permitted to inspect the manufacture at any reasonable stage.
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(b)
Preparation for inspection The material components and pressure equipment shall
be in suitable condition and accessible at the time selected for inspection.
(c)
Notice A reasonable notice period shall be provided for the manufacture inspector
prior to any stage of inspection specified in this Standard.
6.6 MANUFACTURE INSPECTION BODY
The manufacture inspection body shall—
(a)
operate under a documented system in accordance with Table 2.1;
(b)
be a legal entity;
(c)
have adequate provision (e.g. insurance or reserves) to cover liabilities arising from
its operations;
(d)
verify whether the equipment has been manufactured, tested and inspected to and
conforms with the requirements of the applicable pressure equipment Standard and
the verified design; and
(e)
comply with this Standard.
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Where Table 2.1 requires the manufacture inspection body to be certified, the manufacture
inspection body shall—
(i)
hold certification covering inspection to AS/NZS 9001 or AS/NZS ISO 3834.2, and
comply with AS/NZS ISO/IEC 17020; and
(ii)
for pressure equipment with hazard level C, the manufacture inspection body shall
comply with (i) or use inspectors certified and complying with ISO/IEC 17020,
(see Table G1 for more information).
For the use of type testing to verify manufacture, refer to Section 5.
6.7 INSPECTION REPORT
After the manufacture has been inspected and verified as conforming with this Standard and
the requirements of the Standard nominated on the design verification certificate, the
manufacture inspection body shall issue an appropriate statement indicating that the
manufacture meets the requirements of both Standards. This may be achieved by signing the
manufacturer’s declaration of conformity in Appendix E or the manufacturer’s data report.
6.8 CONFIDENTIALITY
The manufacture inspection body shall ensure that the details of the pressure equipment are
disclosed only to those authorized by the manufacturer or as required by the regulator.
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AS 3920:2015
S E C T I O N 7
C O N F O R M I T Y A S S E S S M E N T
M A R K I N G A N D R E P O R T S
7.1 MARKING
To identify that conformity assessment has been completed, boilers and pressure vessels
shall be conspicuously and permanently marked with—
(a)
the manufacturer’s identification mark; and
(b)
the manufacture inspection body’s identification mark and/or the manufacturer’s
quality system certification identification, indicating compliance with Table 2.1 of
this Standard.
For all pressure equipment the marking on the equipment in conformity with the relevant
Standard is regarded as a statement that the equipment conforms to the Standard. Similarly,
a certificate or mark of a manufacture inspection body is regarded as a statement of
conformity with the relevant Standard.
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7.2 DESIGN VERIFICATION CERTIFICATE
The design verifying body shall issue a design verification certificate as per Appendix C
and, if necessary, a type testing certificate to the manufacturer or designer.
7.3 MANUFACTURER’S DECLARATION OF CONFORMITY
A declaration of conformity (also known as Certificate of Conformity) or manufacturer’s
data report (MDR) shall—
(a)
be issued by the manufacturer to the purchaser for boilers and pressure vessels with
hazard levels A to D;
(b)
conform to Appendix E or AS 4458;
(c)
be signed by the manufacturer and the manufacture inspection body (or equivalent) as
complying with the applicable pressure equipment Standard;
(d)
be retained by the manufacturer for at least seven years; and
(e)
be retained by the owner for the life of the equipment, and be made available as
necessary for in-service inspection and be transferred to any subsequent owner.
7.4 IN-SERVICE INSPECTION REPORT
Conformity assessment marking and inspection reports for commissioning and other
in-service inspection are addressed in AS/NZS 3788.
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S E C T I O N
8
R E G I S T R AT I O N
Under legislation in Australia, boilers and pressure vessels identified in AS 4343 with
hazard levels A, B, C and D may require registration of design and some also require
registration of the equipment item prior to use. Refer to the applicable regulator for
requirements.
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In addition to the above regulatory requirements, imported pressure equipment may also be
subject to random inspection by customs regulators for freedom from prohibited materials,
e.g. asbestos products, radioactive or bug-infested material.
© Standards Australia
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AS 3920:2015
APPENDIX A
REFERENCED DOCUMENTS
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(Normative)
AS
1210
Pressure vessels
1228
Pressure equipment—Boilers
1796
Certification of welders and welding supervisors
2030
Gas cylinders (series)
2337
2337.1
Gas cylinder test stations
Part 1: General requirements, inspection and tests—Gas cylinders
2971
Serially produced pressure vessels
3873
Pressure equipment—Operation and maintenance
3892
Pressure equipment—Installation
3998
Non-destructive testing—Qualification and certification of personnel
4037
Pressure equipment—Examination and testing
4041
Pressure piping
4343
Pressure equipment—Hazard levels
4458
Pressure equipment—Manufacture
4942
Pressure equipment—Glossary of terms
AS ISO/IEC
17025
General requirements for the competence of testing and calibration
laboratories
AS/NZS
1200
Pressure equipment
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
AS/NZS ISO
3834
Quality requirements for fusion welding of metallic materials
3834.2
Part 2: Comprehensive quality requirements
3834.3
Part 3: Standard quality requirements
9001
Quality management systems—Requirements
AS/NZS ISO/IEC
17020
Conformity assessment—Requirements for the operation of various types of
bodies performing inspection
17021
Conformity assessment—Requirements for bodies providing audit and
certification of management systems
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AS/NZS ISO/IEC
17024
Conformity assessment—General
certification of persons
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17065
requirements
Conformity assessment—Requirements
processes and services
for
for
bodies
bodies
operating
certifying
products
SAA/SNZ
MP 76
Pressure equipment—Inspection bodies and personnel
ISO
9712
Non-destructive testing—Qualification and certification of NDT personnel
16528
16528-1
Boilers and pressure vessels
Part 1: Performance requirements
ISO/IEC
Guide 65
General requirements for bodies operating product certification systems
AMBSC
Code
Australian Miniature Boiler Safety Committee
Part 1: Copper boilers
Part 2: Steel boilers
Part 3: Sub-miniature boilers
Part 4: Duplex steel boilers
EU-PED
European Union—Pressure equipment directive
ASME
BPV
Boiler and Pressure Vessel Code
BPV-IX: Section IX Boiler and Pressure Vessel Code, Qualification Standard
for Welding and Brazing Procedure, Welders, Brazers and Welding
Brazing operators
B31.1
Power Piping
B31.3
Process Piping Code
© Standards Australia
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AS 3920:2015
APPENDIX B
DESIGN VERIFICATION PROCESS
(Informative)
B1 GENERAL
The following examples in Table B1 aim to provide consensus guidance for all parties to—
(a)
facilitate harmonized, effective, efficient and economic verification;
(b)
overcome current problems and widely different opinions;
(c)
improve productivity; and
(d)
give flexibility to suit different hazard levels, types of PE, verification methods and
purchaser needs.
TABLE B1
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EXAMPLE FOR SIMPLE PRESSURE VESSEL (Note 1)
Elements for verification
AS 1210
reference
Verification
(by visual review, check, calculation
or comparison to ensure conformance
of the design with the Standard used for design)
1
Verification contract
Clear and agreed including scope, Standard and
extras
2
Designer
Clearly identified—Competent person
3
Design drawings
(suitable numbers)
Provided, signed, dated, identified, sufficiently
clear with critical data in English
4
Design specifications and
calculations
As for 3 (not always supplied)
5
Design features:
(a)
Design input data
(b)
Main vessel details
6
Material (specification and grade)
7
Shell thickness:
Appendix E As for 3 and include vessel contents. May be on
drawing. Those assumed in the design, be
identified in design specifications or equivalent,
e.g. P, T, Test P, class, PWHT, dimensions, hazard
level, hydro-test position, life (cycles, etc.)
Section 2
Be listed in AS 1210 or accepted equivalent and
suitable for P, T, welding, corrosion, etc.
(a)
Design strength ‘f’
Cl 3.3.1
In accordance with Appendix A of AS 1210 for
design temperature
(b)
Weld joint efficiency ‘ η ‘
Cl 3.5.1.7
Suitable for weld, location, class, material and t
(c)
Corrosion allowance ‘c’
Cl 3.4
Suitable for intended service
(d)
t min
Cl 3.4.3
Complies with drawing
8
End thickness
Cl 3.8–3.12 Similar to 7 but minimum thickness after forming
and shape be identified
9
Nozzles, branches and
compensation
Cl 3.18–3.19 Similar to 7 but weld types and sizes to comply
with Standard and where in doubt re-determined
10
Openings (access)
Cl 3.20
Adequate access for maintenance and inspection
(continued)
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© Standards Australia
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TABLE B1 (continued)
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Elements for verification
AS 1210
reference
Verification
(by visual review, check, calculation
or comparison to ensure conformance
of the design with the Standard used for design)
11
Connections (covers, flanges,
bolting, gaskets, quick actuating
doors)
Cl 3.21
and 3.27
For quick actuating doors, interlock design and
operation be clear and complying
12
Supports and attachments
Cl 3.24
and
3.25
Check by calculation unless experience allows a
check by visual examination. If experience is used
as the basis, then ensure that environmental and
external design loads are the same or lower and
document the basis of such acceptance. Check by
calculation for transportable vessels or where
transportable criteria are used
13
Fatigue analysis
Appendix M Where required by AS 1210, e.g. Class 1H or 2H
where lifetime cycles > 1 000 full pressure range
14
Manufacture
Section 4
Check capable of manufacture. All to AS 4458
15
Welding
Section 3
and Cl 4.2
Suitability weld type, size and location, PWHT
(for thickness or service). All to AS/NZS 4458
16
Testing and qualification
Section 5
Ensure design is suitable for NDT and hydrotest
position. All to AS 4037
17
Design for transport, installation,
operation (Note 2)
Cl 3.26
Review design for these operations including
lifting, maintenance, inspection and cleaning
18
Safety devices (e.g. SV), drains,
vents, etc. (Note 2)
Section 8
Size, type, location, Standard (capacity and nozzle
size) where appropriate
19
Instructions (Note 2)
20
Risk management (Note 2)
21
Declaration of design compliance
Drawing signed by designer or equivalent
22
Type testing—Drawing, test results,
manufacturer’s details and
sample(s) (Note 2)
Justify design and manufacture. May require
manufacture inspector to assess and accept
manufacture process for consistent product
23
Design verification certification
Issue to client with stamped drawings; retain
copies (see Appendix C)
Review for transport, installation, commissioning,
and inspection, operation and maintenance
(Note 3)
Appendix C Supplied as evidence of compliance
NOTES:
1
Shown for AS 1210 but minor changes may be needed for ASME, EN, ISO or other Standards. Only
required for hazard levels A, B, C and D to AS 4343.
2
Only required when applicable or specially agreed. Similarly with insulation and surface treatment.
3
Commissioning inspection has been included very briefly in this Standard to add checks on the design
and its verification and on manufacture inspection and detect errors particularly from unknown overseas
suppliers.
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AS 3920:2015
APPENDIX C
DESIGN VERIFICATION CERTIFICATE
(Normative)
DESIGN VERIFYING BODY (Name ABN, address, phone, fax, email and logo)
............................................................................................................................................
............................................................................................................................................
CERTIFICATE No.: ..............................................................................................................
FOR:
................................................................................................................................
DESIGNED BY: ...................................................................................................................
(Name)
I, .........................................................................................................................................
am a design verifier for the above Design Verifying Body.
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............................................................................................................................................
I have verified the design described below and as presented in the documents listed in
accordance with AS 3920 and the pressure equipment Standard:
PE Description:
.......................................................................................................
AS 4343 hazard level:
.......................................................................................................
Design pressure:
............................................. Design temperature: .......................
Test pressure:
............................................. Corrosion allowance: ......................
Fluid description:
.......................................................................................................
Drawings (numbers):
.......................................................................................................
Calculations (document numbers): ......................................................................................
............................................................................................................................................
Other relevant documents: ................................................................................................
............................................................................................................................................
I certify that the design meets the requirements of the following:
Standards:
............................................................................................................................................
Additional purchaser’s requirements as specified in (documents numbers):
............................................................................................................................................
subject to the following conditions:
............................................................................................................................................
Signature: .................................................................................
www.standards.org.au
Date: .............................
© Standards Australia
AS 3920:2015
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APPENDIX D
MANUFACTURE INSPECTION
(Normative)
D1 GENERAL
Where manufacture inspection is required for pressure equipment by Table 2.1, the
inspection shall include, as applicable and necessary, examinations, test checks,
measurements, related documents or verifications as set out in this Appendix.
D2 VERIFICATION PROCEDURES
D2.1 Preliminary
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The preliminary procedures shall include the following:
(a)
Assurance that the manufacturer has acceptable inspection and test techniques and
procedures that are being adhered to, documented and completed as required.
(b)
Verification that the manufacturer has an appropriate and valid quality system,
including where necessary an inspection and test plan.
(c)
Verification that design drawings are available and have been verified, where
required by Table 2.1, at least prior to completion of the manufacturer’s data report.
D2.2 Material
Verification of materials shall include the following:
(a)
Verification that materials used in manufacture comply with the design documents
and are covered by the required mill test reports or material certification, which
correlates with the material used, and have been checked for compliance with the
material specification, where required by the relevant pressure equipment Standard.
(b)
Verification that forgings and castings have been examined at such stages and
frequency as to ensure that they comply with the relevant material specifications and
pressure equipment Standard.
D2.3 Preparation for welding
Verification of welding preparation shall include the following:
(a)
Verification that the weld preparation, shape, fit-up and cleanliness of parts comply
with the design documents and the relevant pressure equipment Standard
(see Note 1).
(b)
Verification that the welding and brazing procedures used are qualified in accordance
with suitable Standards, e.g. AS/NZS 3992, ASME IX (see Note 2).
(c)
Verification that the welders and brazers engaged in manufacturing are certificated or
qualified in accordance with AS/NZS 3992 (see Note 2). Where there is a specific
reason to question the welder’s ability to make the required welds, the manufacture
inspector may require requalification as a requirement for the welder to continue
welding the pressure equipment (see Note 2).
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AS 3920:2015
D2.4 During welding
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Verification of welding procedures shall include the following:
(a)
Verification that the specified welding and brazing procedures are being used.
(b)
Verification that required heat treatment has been properly performed.
(c)
Verification that the required production test welds are carried out and the results are
acceptable (see Note 2).
(d)
Verification that material, weld and other imperfections repaired by welding have
been acceptably repaired.
(e)
Verification that the required non-destructive examinations and other tests have been
performed as per the relevant manufacturing Standard, and the results are acceptable
to that Standard and/or the relevant acceptance Standard, e.g. AS 4037.
(f)
Visually inspecting the pressure equipment internally and externally to ensure that
material marks have been properly transferred and that thicknesses, surfaces and
shapes are acceptable.
(g)
Witnessing hydrostatic or pneumatic tests for compliance with the relevant pressure
equipment Standard.
(h)
Performing internal and external dimensional checks to ensure compliance with
tolerances specified in the relevant pressure equipment Standard and design
documents.
D2.5 Completion
Verification of the completion processes shall include the following:
(a)
Verification that equipment stamping and nameplate markings comply with the
relevant pressure equipment Standard.
(b)
Reviewing and signing the completed MDR and inspection and test plan on
completion of manufacture.
(c)
Visually inspecting the type and installation of protective fittings, where fitted, for
compliance with the relevant pressure equipment Standard.
(d)
Any other aspects which are essential for verification in accordance with this
Standard.
NOTES:
1 Verification in accordance with Item (a) in Paragraph D2.3 is deemed to have been performed
where one of the following applies:
(a)
The equipment is subjected to full or spot radiographic or ultrasonic examination and is
acceptable in accordance with Item (e) in Paragraph D2.4.
(b)
Selected representative joints sufficient to satisfy the manufacture inspector are
visually inspected and are acceptable.
(c)
The manufacturer’s certified quality system specifically identifies the inspection as a
manufacturer’s inspection which is listed on the inspection and test plan and is
recorded by the manufacturer on completion of the inspection.
2 Verification in accordance with Items (b) and (c), of Paragraph D2.3 and Item (c) of
Paragraph D2.4 and (k) are deemed to have been performed where—
(a)
the manufacture inspector witnesses the making of the test plates and reviews and
accepts the test results; or
(b)
satisfactory documentary evidence exists to show that the procedure, welder, brazer or
production tests, as appropriate, have previously been accepted by another manufacture
inspector to this Standard.
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© Standards Australia
AS 3920:2015
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APPENDIX E
DECLARATION OF CONFORMITY FOR THE DESIGN AND MANUFACTURE
OF PRESSURE EQUIPMENT
(Normative)
Purchase Order No.:
Purchaser:
...........................................................
.......................................................................
Equipment Serial No: ...........................................................
Manufacturer: .......................................................................
Manufacture Inspection Body:
.............................................
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Pressure Equipment Standard: .............................................
I, the undersigned, certify that the above pressure equipment conforms with the stated
Pressure Equipment Standard.
Special Notes:
............................................................................................................................................
............................................................................................................................................
............................................................................................................................................
Title and responsibility:
.....................................................................................................
Signature:
.....................................................................................................
Date: (Day-Month-Year): ........................................................
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AS 3920:2015
APPENDIX F
REQUIREMENTS FOR CONFORMITY ASSESSMENT BODIES
AND PERSONNEL
(Normative)
F1 GENERAL
This Appendix applies to bodies and personnel who are required to perform various tasks in
accordance with this Standard to ensure that pressure equipment conforms with stated
requirements and is able to perform satisfactorily and safely in credible service.
NOTE: Appendix G shows the conformity assessment infrastructure within Australia.
F2 ASSESSMENT BODIES AND PERSONNEL REQUIREMENTS
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Assessment bodies and/or personnel shall meet the requirements of Table F1.
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TABLE F1
EVIDENCE OF COMPETENCY (see Note 1)
(a)
Inspection body (for pressure equipment design verification, manufacture inspection or in-service
inspection)
(i)
Has satisfactory knowledge and experience in the particular type of inspection and pressure equipment
(ii)
Complies with AS/NZS ISO/IEC 17020 or equivalent, and is accredited where required by Table 2.1 or
certified by a nationally recognized organization, or
(A)
For design verification, has a verifier as in (c) below or as in Clause 3.2
(B)
For manufacture, modification and repair inspection, has inspectors as in (e) below
(C)
For in-service inspection, has an inspector as in (f) below
See Notes 2 and 4.
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(b) Designer (organization or individual for new PE design, modification, or rerating)
(i)
Has satisfactory knowledge and experience in the design of the particular type of pressure equipment
or equivalent
(ii)
Where required by Table 2.1, has a design quality system certified or accredited by a nationally
recognized approval organization, e.g. to AS/NZS ISO 9001, EU Pressure Equipment Directive
(or equivalent), which is directed to pressure equipment and the relevant construction Standard
(iii) Has suitably qualified personnel for design review
(c)
Design verifier (individual person for verification of new pressure equipment design, modification or
rerating)
(i)
Has satisfactory knowledge, training and experience in design or verification of design of the
particular or similar pressure equipment
(ii)
Where required by Table 2.1, or as in Clause 3.2 holds an appropriate qualification or certificate as a
design verifier from a nationally or internationally recognized body or association. See Notes 3 and 4.
NOTE: Engineers Australia or other nationally/internationally recognized body may provide such
certificate.
(d)
Manufacturer or repair organization
(i)
Has satisfactory knowledge and experience in the particular or similar type of work, pressure
equipment, Standard, materials, size and thickness, proven by suitable evidence and satisfied clients or
others
(ii)
Has equipment and facilities needed to manufacture or repair the pressure equipment
(iii) Has a reputation for delivery of pressure equipment or repair service with the right quality, on time, at
a fair price, acceptable to the pressure equipment purchaser
(iv) Has a suitable management system, documented for essential elements, covering quality
(v)
Where required by Table 2.1, has a manufacturer’s quality system certified or accredited by a
nationally recognized organization to AS/NZS ISO 9001, AS/NZS ISO 3834, EU Pressure Equipment
Directive, ASME BPV Code or equivalent
(vi) Has suitably qualified personnel for quality control and examination equivalent to manufacture,
e.g. (e) below
(e)
Manufacture, modification, or repair inspector (individual person for conformity assessment)
(i)
Has satisfactory knowledge, training and experience in inspection of the particular pressure equipment
manufacture or repair, and the processes used including special processes, such as welding
(ii)
Where required by Table 2.1, holds an appropriate qualification or a certificate as a manufacture or
welding inspector from nationally or internationally recognized body or association (see Table G1 for
more information)
NOTE: International Institute of Welding (IIW), Welding Technology Institute of Australia (WTIA) or
other nationally/internationally recognized body may provide certificate.
(continued)
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AS 3920:2015
TABLE F1 (continued)
(f)
Inspector (i.e. in-service inspector)
(i)
Has satisfactory knowledge, training and experience in the particular type of inspection and pressure
equipment
(ii)
Has competency in the areas and elements in AS/NZS 3788
(iii) Has a certificate as an in-service inspector
(iv) While AS/NZS ISO/IEC 17020 does not apply directly to personnel, it does include requirements for
the expertise, training and qualifications of inspectors employed by an inspection body, and for their
training and development system. These requirements are considered as part of the accreditation of
inspection bodies by national bodies (see Item (a)(ii) above), and thus may provide suitable evidence
for the competence of inspectors and approved signatories
(v)
Typically persons performing fitness for service assessment and risk based inspection (RBI) analysis
will have formal engineering qualifications
NOTE: Australian Institute for Certification of Inspection Personnel (AICIP), National Board BPVI
(in USA), American Petroleum Institute (API) or other nationally/internationally recognized
organization may provide in-service inspection certificates.
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(g)
Test body and personnel
(i)
Have satisfactory knowledge, training and experience in the particular test method
(ii)
For radiographic testing (or examination) and Ultrasonic testing (or examination), a test body
registered by a nationally or internationally recognized accreditation organization, e.g. NATA or
equivalent, with personnel having a certificate to AS 3998 or ISO 9712 issued by Australian Institute
for Non-Destructive Testing (AINDT), or equivalent
(iii) For other NDT or destructive tests, certificated or accredited similar to [Item (g)(ii)] above
(h)
All personnel
(i)
Are adjudged competent by their employer for the work undertaken
(ii)
Are physically and mentally able to perform the required work
(iii) Only undertaken work for which they consider themselves competent
(iv) Where required, have permission and certificate for work in confined space or hazardous location
(v)
Have suitable insurance cover, either individually or through their employer
NOTES:
1
A body or person may perform the functions of a number of bodies or persons, provided they are competent
in the functions undertaken. A body may be a single person.
2
For guidance on competency of inspection bodies and personnel see AS/NZS 4481 and SA/SNZ MP76.
3
A design verifier shall—
(a)
have a degree or equivalent in an appropriate engineering discipline plus at least three years relevant
experience in the design or design review of pressure equipment; or
(b)
hold a certificate or equivalent in an appropriate engineering discipline plus at least four years relevant
experience in the design or design review of pressure equipment; or
(c)
have other qualifications or experience acceptable to a certifying body or the purchaser; and
(d)
comply with the requirements equivalent to the requirements for the acceptance of inspection bodies in
AS/NZS ISO/IEC 17020; and
(e)
have no involvement in the particular design other than verification.
4
Certification of a manufacture inspection or design verifying body shall include the review and acceptance of
all personnel employed in addition to the Quality System in place.
5
Registration of bodies and personnel:
(a)
In Australia there is no central register providing evidence of competency of those concerned with
conformity assessment for PE.
(b)
However, bodies providing accreditation or certification have their own registration systems.
www.standards.org.au
© Standards Australia
AS 3920:2015
42
APPENDIX G
CONCEPT OF CONFORMITY ASSESSMENT INFRASTRUCTURE
(Informative)
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Figure G1 and Table G1 show the concept of conformity assessment infrastructure within
Australia. It is an example only and identifies a range of bodies and their functions and the
instruments or Standards that govern their operations.
© Standards Australia
www.standards.org.au
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www.standards.org.au
B y AU S T R A L I A N
G OV E R N M E N T S
People
BY I N D U S T RY a n d PU B L I C
Authorize
Accreditation
Bodies
AC C R E D I TAT I O N B O D I ES
To A S I S O/ I EC
170 25
Accept
J O I N T AC C R ED I TAT I O N SYS T EM
AU S T R A L I A & N E W Z E A L A N D (JA S - A N Z )
Accredit
OT H E R I N D U S T RY &
PU B L I C B O D I ES
A c c e pt a n d
Recognise
Accredit
To A S / N Z S
I S O/ I EC 170 20
( N o te)
To
AS/NZS ISO/IEC 17065
or ISO/IEC Guide 65
To
AS/NZS ISO/IEC 17021
To A S / N Z S I S O/ I EC
170 24
PR O D U C T
C E R T I FI CAT I O N
B O D I ES
Q UA L I T Y SYS T EM
C E R T I FI CAT I O N
B O D I ES
PE R S O N N E L
C E R T I FI CAT I O N
B O D I ES
C e r t i f y to p r o d u c t
M a r k S y s te m
& A S 23 37.1
C e r t i f y to
AS 3998 &
I S O 9712
C e r t i f y to A S 3 9 20,
A S / N Z S 4 4 81 & s p e c i f i c
requirements
C e r t i f y to
AS 3998 &
I S O 9712
C e r t i f y to
A S/N Z S I S O 3 8 3 4 &
Industr y Standard
C E R T I FI E D
G A S CY L I N D ER
T ES T S TAT I O N S
B O D I ES
Designer
Manufacturer
User In-ser vice
Inspection
Bodies
C E R T I FI CAT E D
I N S PEC TO R S
D e s i g n Ve r i f i e r
Manufacturer
I n s p e c to r
I S I n s p e c to r
C E R T I FI E D
T ES T I N G
PE R S O N N E L
N DT
Pe r s o n n e l
C E R T I FI E D
Manufacturer
Engineer
Ve r i f i e r
I n s p e c to r
Per form
te s t s f o r Te s t i n g
Authority or User
Per form
va r i o u s t a s k s
for industr y
Q UA L I T Y SYS T EM
& PE R S O N N E L
C ER T I FI CAT I O N B O D I ES
43
Action
Bodies
Fu n c t i o n
AC C R E D I T E D
T ES T I N G
AU T H O R I T I ES
O R B O D I ES
I N S PEC T I O N B O D I ES
D e s i g n Ve r i f i f i c a t i o n
Manufacturer Inspection
In-ser vice Inspection
Bodies
O ve r 10 0 f o r
pressure
equipment
Ty p e A ( 3 r d Pa r t y )
Ty p e s B & C (1 s t & 2 n d Pa r t y )
Te s t
to s p e c i f i c
Standards
Inspect
to s p e c i f i c
Standards
(a l s o i n c l u d e s s o m e ve r i f i c a t i o n
& I n s p e c t i o n B o d i e s)
Assess & Audit
to s p e c i f i c
Standards
Per form
to s p e c i f i c
Standards
Per form
inspections for
Inspection
Body or User
End User
Designer
Manufacturer
User
R e g u l a to r
NOTE: Industry also recognizes or accepts equivalent systems, bodies and personnel—accredited, certified or not, including interstate and overseas bodies and personnel.
FIGURE G1 AUSTRALIAN SYSTEM OF PRESSURE EQUIPMENT CONFORMITY ASSESSMENT BODIES AND PERSONNEL
AS 3920:2015
© Standards Australia
I s s u e r e s u l t s a n d r e c o m m e n d a t i o n s a s r e p o r t s o r c e r t i f i c a t e s to
AS 3920:2015
44
TABLE G1
QUALIFICATION AND EXPERIENCE FOR MANUFACTURE INSPECTORS
Qualifications
(see Note 1)
Manufacture inspection
training course duration
(minimum)
hours
General engineering
experience
(minimum years)
(see Note 2)
Degree or diploma in
engineering or science
(3 year course minimum)
0
2
Certificate in engineering
(for relevant discipline)
120
1
Welding supervisor
certificate to AS 1796
0
3
Welding inspector
certificate (see Note 4)
0
3
120
4
Trade qualification
(see Note 3)
Pressure equipment
experience (minimum)
(see Note 2)
1 year minimum,
including 100 hours
practical experience
under the supervision of
a manufacturer inspector
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NOTES:
1
Other equivalent Australian or overseas qualifications are considered acceptable but have not been
listed.
2
General engineering experience is satisfactory experience in the design, manufacture, maintenance or
inspection of similar fabricated equipment. General experience and pressure equipment experience may
be concurrent. At least 50% of the nominated time is to be spent in manufacture, maintenance or
inspection.
3
Relevant to inspection of pressure equipment manufacture.
4
Welding Technology Institute of Australia (WTIA) provides such certificate.
© Standards Australia
www.standards.org.au
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