As 3920 Presdure Equipment Conformity

AS 3920:2015

A S 3 9 2 0 : 2 0 1 5

Pressure equipment—Conformity assessment ) d e t n i r p n e h w d e e t n a r a u g t o n y c n e r r u c t n e m u c o D ( 5 1 0 2 l u J 9 2 n o Y R A R B I L Y T I S R E V I N U H S A N O M y b d e s s e c c A

This Australian Standard® was was prepared by Committee ME-001, Pressure Equipment. It was was approved on behalf of the Council of Standards Australia on 9 December 2014. This Standard was published on 16 16 February 2015.

The following are represented represented on Committee ME-001: • • • • • • • • • • • • • • • • •

) d e t n i r p n e h w d e e t n a r a u g t o n y c n e r r u c t n e m u c o D ( 5 1 0 2 l u J 9 2 n o Y R A R B I L Y T I S R E V I N U H S A N O M y b d e s s e c c A

• • •

Australasian Corrosion Association Association Australasian Institute of Engineer Engineer Surveyors Australasian Institute of Engineering Engineering Inspectors Australian Aluminium Council Council Australian Building Codes Board Board Australian Chamber of Commerce and Industry Australian Industry Group Australian Institute for the Certification Certification of Inspection Personnel Personnel Australian Institute of Energy Australian Institute of Petroleum 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 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 documents that reflect progress in science, 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 Standards may also be withdrawn.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 [email protected],, or write to Standards Australia, GPO Box 476, Sydney, NSW 2001. [email protected]

AS 3920:2015

Australian Standard Standard

®

Pressure equipment—Conformity assessment ) d e t n i r p n e h w d e e t n a r a u g t o n y c n e r r u c t n e m u c o D ( 5 1 0 2 l u J 9 2 n o Y R A R B I L Y T I S R E V I N U H S A N O M y b d e s s e c c A

Originated as AS 3920.1—1993. Revised and redesignated as AS 3920:2015.

COPYRIGHT

© Standards Australia Limited All rig hts are res erv ed. No par t o f t his wor k m ay be rep rod uce d o r c opi ed in any for m o r b y 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

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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, Assura Ass urance nce of produc pro ductt qual ity, ity, Part 1: Pre 1: Pressu ssure re equipm equ ipment ent manufa man ufactu cture re.. With this revision, the Standard will now be known as AS 3920, Pressu Pre ssure re equipm equ ipment ent — Conformity assessment . After consultation with stakeholders in both countries, Standards Australia and Standards New Zealan Zea land d decide dec ided d to develo dev elop p this thi s Standa Sta ndard rd as an Aust ralian ral ian Standa Sta ndard rd rather rat her than tha n 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. The changing laws and industry needs, including the increased prevalence of imported pressur pre ssuree equipm equ ipment ent,, have hav e now made mad e it essenti esse nti al to revise rev ise the Standa Sta ndard rd to addres add resss conformity assessment.


This Standard is expected to become a significant document used by industry in Australia to provid pro videe guidan gui dance ce in ensuri ens uring ng that tha t all pressur pre ssuree equipm equ ipment ent used use d in Austra Aus tralia lia , includ inc luding ing 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 Boi ler and Pressu Pre ssure re Vessel Ves selss Code C ode and 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, 4343—2005, Pre Pressu ssure re equipm equ ipment ent — Hazard Haz ard levels lev els..

(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, 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.

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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. 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.


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CONTENTS Page 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

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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 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

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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. 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 wit h commissioning and other in-service inspection, refer to AS/NZS 3788. NOTE: Fail ure to consider conformity assessment at the earl y 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. ) d e t n i r p n e h w d e e t n a r a u g t o n y c n e r r u c t n e m u c o D ( 5 1 0 2 l u J 9 2 n o Y R A R B I L Y T I S R E V I N U H S A N O M y b d e s s e c c A

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 informat ion on the main element s of the confo rmit y assessm ent 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—

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(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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WHS REGULATION REQUIREMENT

INDUSTRY NEED

CONFORMITY ASSESSMENT

S TAG E

METHOD

Tender/ Contract

MUTUAL REVIEW AND AG RE EME NT

DESIGN VERIFICATION • Calculation and/or • Type testing

Design


BY

• Supplier (des igner, manufacturer) & Purchaser (owner, user) • Contract • • • •

Design Verifier (See Table 2.1); Design Verification Certificate; Regulatory Registration (once only) Designer Quality System

• Manufacture Inspection Body: - independent of manufacturer, or - manufacturer Quality System or Inspection section • Declaration of Conformity (or MDR) and Marks

Manufacture

MANUFACTURE INSPECTION

Commissioning (before Use)

COMMISSIONING INSPECTION (includes installat ion) (Note)

• In-service Inspection Body; • Inspection Certificate; and • Regulatory Registration

IN-SERVICE INSPECTION (Note) • Periodic • Special • Risk based inspection (RBI)

• In-service Inspection Body; • Inspection Certificate; and • Registration renewal

Us e (and Disposal)

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 appl ication in Australia of pres sure equi pment desi gned comp lying with overseas design Standards, refer to AS/NZS 1200.

(c)

design verification and manufacture inspection of alterations, modifications and repairs.

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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. 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 managem ent Standard is a scertained. 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 syno nymous. Compare with ‘compliance ’, which is take n 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: Typi cal exam ples of confo rmit y assessment activities are samp ling, testing and inspection, evaluation, verification and assurance of conformity (supplier’s declaration, certification), registration, accreditation and approval, as well as other combinations. ©

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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 compl eted pr ior to a pproval 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

A suitably experienced and qualified person in the employ or control of a ‘design verifying body’. 1.5.14 Design verifying body ) d e t n i r p n e h w d e e t n a r a u g t o n y c n e r r u c t n e m u c o D ( 5 1 0 2 l u J 9 2 n o Y R A R B I L Y T I S R E V I N U H S A N O M y b d e s s e c c A

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 acceptab le outcome is agreed to be equivalent b y the p arti es conce rned.

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 inspect ion of persons, faci lit ies, 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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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 expe cted that the mini mum number of parties will be the purchaser and manuf actu rer; others may be the i mporter, 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. NOTE: This term is int ended to be equiv alent to the ‘person condu cting a business or under taki ng 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 equipm ent 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: Confo rmance with t he document s i n Items (a), (b) or (c) above does not nece ssarily 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 Boi ler and Pres sur e Ves sel Cod e does not specify suitable requirements for design verification, commissioning or in-service inspection.

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1.7 ABBREVIATIONS

The following abbreviations are used in this Standard: AINDT

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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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

Each item of new, altered or repaired pressure equipment shall be subjected to conformity assessment which—


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(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 avail able nat ionally, int ernationally 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.

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TABLE 2.1 DESIGN AND MANUFACTURE CONFORMITY ASSESSMENT (see Notes 1–5) Design Hazard level to AS 4343

Manufacture

Designer QS

Design verifying body

Hazard level to AS 4343

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 cert ifi ed (see Note 10)

OR

OR


Certified—Type A

Certified

Certified—Type B

C

C

Not certified (see Note 10)

Certified—Type B

Certified to AS/NZS ISO 9001 or AS/NZS ISO 3834.2


OR ) d e t n i r p n e h w d e e t n a r a u g t o n y c n e r r u c t n e m u c o D ( 5 1 0 2 l u J 9 2 n o Y R A R B I L Y T I S R E V I N U H S A N O M y b d e s s e c c A

OR


Certified—Type A

Certified


D

E

Certified—Type B



Certified—Type B

Not cert ified (see Note 10)




D

OR Not cert ifi ed (see Note 10)


E

NOT ES: 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 o r C, des ign 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. 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 equipme nt.

(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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2.3 TYPES OF INSPECTION AND VERIFICATION BODIES

Types A and B inspection bodies for design verification or Types A and B inspection bodies for manufact uring 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) wit h ownershi p 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 desi gner 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. © Standards

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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

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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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 U R 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

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—

(d)

(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: (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-A NZ accr edit s cert ification bodies in Australia and New Zeal and. NATA accr edits 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 cert ification and accreditat ion to the above may appl y when internation al mutual recognition or trade agreements exist.

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— ) d e t n i r p n e h w d e e t n a r a u g t o n y c n e r r u c t n e m u c o D ( 5 1 0 2 l u J 9 2 n o Y R A R B I L Y T I S R E V I N U H S A N O M y b d e s s e c c A

(a)

procedures for design verification and personnel compet ence;

(b)

procedures for material and component purchase, identification and traceability;

(c)

procedures for forming, welding and personn el 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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S E C T I O N

4

D E S I G N

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. 4.2 PURPOSE

Design verification is to provide suitable and sufficient checking of the design drawings and other nominated documents to— ) d e t n i r p n e h w d e e t n a r a u g t o n y c n e r r u c t n e m u c o D ( 5 1 0 2 l u J 9 2 n o Y R A R B I L Y T I S R E V I N U H S A N O M y b d e s s e c c A

(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. NOTE: Veri fication of FEA base d desi gns is a difficult proce ss and flex ibility is requ ired. 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 pres sure equipmen t suppor ts do not requ ire another full and complex calcula tion 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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(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—

(h)

(i)

have quality system certification and Type A or Type B independence from the production of the original desi gn in accordance with Table 2.1;

(ii)

comply with Clause 3.2.1(b);

(iii)

comply with Appendix F; and

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. 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: ) d e t n i r p n e h w d e e t n a r a u g t o n y c n e r r u c t n e m u c o D ( 5 1 0 2 l u J 9 2 n o Y R A R B I L Y T I S R E V I N U H S A N O M y b d e s s e c c A

NOTE: The sequence may diff er 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 supp orts 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-destr uctive 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 i n acceptable level s of stress and strain, acc eptable 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 rel ief 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, s ee 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;

(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

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

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 uncha nged original type test ing would be acce ptable to another design verifying body.

5.2 REQUEST FOR VERIFICATION OF TYPE TESTING

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 represe ntative example of the pressure equipment;

(c)

include—

(d)

(i)

name and address of the manufacturer;

(ii)

location of production and testing facilities;

(iii)

technical documentation; and

provide— (i)

general description of the ‘type’;

(ii)

conceptual design sub-assemblies;

(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

and

manufacturing

drawings

of

components

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

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 ) d e t n i r p n e h w d e e t n a r a u g t o n y c n e r r u c t n e m u c o D ( 5 1 0 2 l u J 9 2 n o Y R A R B I L Y T I S R E V I N U H S A N O M y b d e s s e c c A

Alterations to the design, materials or manufacturing methods, which are of a type in accordance wit h Clause 2.2.1 shall require re-exami nation, testi ng and new design verification certificate (see also Clause 4.14).

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S E C T I O N

6

M A N U F A C T U R E

I N S P E C T I O N

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

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. ) d e t n i r p n e h w d e e t n a r a u g t o n y c n e r r u c t n e m u c o D ( 5 1 0 2 l u J 9 2 n o Y R A R B I L Y T I S R E V I N U H S A N O M y b d e s s e c c A

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 mat erials, 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 man ufacture at any reasonable stage.


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(b)

Preparati on 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 thi s 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.

Where Table 2.1 requires the manufacture inspection body to be certified, the manufacture inspection body shall— ) d e t n i r p n e h w d e e t n a r a u g t o n y c n e r r u c t n e m u c o D ( 5 1 0 2 l u J 9 2 n o Y R A R B I L Y T I S R E V I N U H S A N O M y b d e s s e c c A

(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 w ith 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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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, indicati ng compliance with T able 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. 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. ) d e t n i r p n e h w d e e t n a r a u g t o n y c n e r r u c t n e m u c o D ( 5 1 0 2 l u J 9 2 n o Y R A R B I L Y T I S R E V I N U H S A N O M y b d e s s e c c A

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 A T I O N

Under legislation in Australia, boi lers 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. 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.


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APPENDIX A

REFERENCED DOCUMENTS (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—Examinatio n 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 laboratories

for

the

competence

of

testing

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

and

calibration

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 17065


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

©

requirements

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

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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 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

Section 2

Be listed in AS 1210 or accepted equivalent and suitable for P, T, welding, corrosion, etc.

Cl 3.3.1

In accordance with Appendix A of AS 1210 for design temperature

Cl 3.5.1.7

Suitable for weld, location, class, material and

(a)

Design strength ‘f’

(b)

Weld joint efficiency ‘ η ‘

(c)

Corrosion allowance ‘c’

(d)

t min

Cl 3.4.3

8

End thickness

Cl 3.8–3.12

9

Nozzles, branches and compensation

10

Openings (access)

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.)

Cl 3.4

t

Suitable for intended service Complies with drawing Similar to 7 but minimum thickness after forming and shape be identified

Cl 3.18–3.19 Similar to 7 but weld types and sizes to comply with Standard and where in doubt re-determined Cl 3.20

Adequate access for maintenance and inspection ( continued )


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TABLE B1 (continued )

Elements for verification


AS 1210 reference

Cl 3.21 and 3.27

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)

12

Supports and attachments

13

Fatigue analysis

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

18

Safety devices (e.g. SV), drains, vents, etc. (Note 2)

Section 8

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)

Cl 3.24 and 3.25

For quick actuating doors, interlock design and operation be clear and complying 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

Appendix M Where required by AS 1210, e.g. Class 1H or 2H where lifetime cycles > 1 000 full pressure range

Review design for these operations including lifting, maintenance, inspection and cleaning Size, type, location, Standard (capacity and nozzle size) where appropriate 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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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. ............................................................................................................................................


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: ...................................... ...................................... .....


Date: .......................... ...

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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

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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D2.4 During welding

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

2

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.

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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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:

................................... ..........

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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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 asse ssment infr astr ucture with in Austr alia.

F2 ASSESSMENT BODIES AND PERSONNEL REQUIREMENTS

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. (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 ) d e t n i r p n e h w d e e t n a r a u g t o n y c n e r r u c t n e m u c o D ( 5 1 0 2 l u J 9 2 n o Y R A R B I L Y T I S R E V I N U H S A N O M y b d e s s e c c A

(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. NOT E: Eng ineers Aus tralia or oth er nat ion ally /in tern ationally reco gni zed bod y may pro vid e 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

(e)

(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

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) NOT E: Int erna tio nal Ins tit ute of Weldin g ( IIW), Weldin g Technol ogy Ins tit ute of Aus tralia (WT IA) or other nationally/internationally recognized body may provide certificate. ( continued )

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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 NOT E: Aus tra lian Institute for Certificat ion of Ins pectio n Pers onn el (AICIP), Nation al Board BPVI (in USA), American Petroleum Institute (API) or other nationally/internationally recognized organization may provide in-service inspection certificates.

(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

NOT ES: 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.


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APPENDIX G

CONCEPT OF CONFORMITY ASSESSMENT INFRASTRUCTURE (Informative) 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.


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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

NOT ES:


©

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


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