THE MINISTRY OF LABOUR, WAR INVALIDS AND SOCIAL AFFAIRS | SOCIALIST REPUBLIC OF VIETNAM |
No.: 67/2008/QD-BLDTBXH | Hanoi, December 29, 2008 |
THE MINISTER OF LABOUR, WAR INVALIDS AND SOCIAL AFFAIRS
Pursuant to the Decree No.186/ 2007/ND-CP dated 26/12/2007 of the Government stipulating functions, duties, powers and organizational structure of the Ministry of Labor, War Invalids and Social Affairs;
Pursuant to the Decree No.06/CP dated January 20, 1995 of the Government detailing a number of Articles of the Labor Code on occupational safety, hygiene; the Decree No.110/2002/ND-CP of the Government on amending, supplementing number of Articles of the the Decree No.06/CP dated 20/01/1995 of the Government;
Pursuant to the Circular No.04/2008/TT-BLDTBXH dated February 27, the Ministry of Labor, War Invalids and Social Affairs guiding appraisal and registration procedures of machinery, equipment, materials with strict requirements on occupational safety;
At the proposal of Director of Occupational Safety,
DECIDES:
Article 1.Issuing together this Decision is “The Processes of safe technical testing for machinery, equipment, materials with strict requirements on occupational safety” as follows:
1. The Process of safe technical testing for pipelines of steam, hot water (QTKD 04-2008);
2. The Process of safe technical testing for the refrigeration system (QTKD 05-2008);
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4. The Process of safe technical testing for gas charge, processing system (QTKD 07-2008);
5. The Process of safe technical testing for gas cylinders (QTKD 08-2008);
6. The Process of safe technical testing for pressure vessels (QTKD 09-2008).
Article 2.This Decision take effects 15 days after its publication in the Official Gazette.
Annulling the Decision No.2013/2005/QD- BLDTBXH dated December 29, 2005 of the Minister of Labor, War Invalids and Social Affairs promulgating the Process of safety technical testing for machinery, equipment, materials with strict requirements on occupational safety.
Article 3.Director of Occupational Safety, Directors of Technical Safety Testing Units of Ministries, Branches and provinces, cities directly under the Central Government are responsible for the implementation of this Decision./.
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THE MINISTRY OF LABOUR, WAR INVALIDS AND SOCIAL AFFAIRS
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PRESSURE VESSELS - PROCESS OF SAFE TECHNICAL TESTING
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HANOI - 2008
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PREAMBLE
The Process of safe technical testing for pressure vesselscompiledby the Bureau for Safe Work, issued by the Ministry of Labor, War Invalids and Social Affairs according to the Decision No.67/2008/BLDTBXH dated December 29, 2008.
THE PROCESS OF SAFE TECHNICAL TESTING FOR PRESSURE VESSELS
This process specifies on the order, procedures of safe technical testing at the first, regular and irregular time for the pressure vessels to be of the list of types of machinery, equipment and materials with strict requirements on occupational safety issued by the Ministry of Labor - War Invalids and Social Affairs.
Based on this process, the testing agencies apply directly or develop specific, detail process for each shape, type of pressure vessels but not contrary to the provisions of this process.
2. The standards forced to apply
Including the national technical standards for safety as follows:
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+ TCVN 6154:1996: Pressure vesels - Safe technical requirements for design, structure, manufacture, method of testing.
+ TCVN 6155:1996: Pressure vesels - Safe technical requirements for installation, use, repair.
+ TCVN 6156:1966: Pressure vesels - Safe technical requirements for installation, use, repair, method of testing.
+ TCVN 6008:1995: Pressure equipment – Weld joint with technical requirements and checking methods.
+ TCVN 7472-2005: Pressure equipment – Joint weld.
To conduct a review, safe technical inspection according to the following steps:
- To prepare the testing: Item 3.1
- To check dossier: Item 3.2
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- To check inside: Item 3.4
- To check the capability to bear pressure: Item 3.5
- To check the tightness,onlyapply tothe vessels workingwithtoxic andflammable solvent-substance: Item 3.6
- To check the operation: Item 3.7
Note: Thefollowinginspectionsare conductedonlywhenthe inspection resultsof the previous stephas beensatisfactory.
Before conductingthe search: Thesafety measuresmust be taken, pressure vesselsmust be cleansed; theinspection door,door for person to creep into(if any) mustbe removed;whenhaving doubt on technical state of the parts bearing pressure of the vessel, it need to be removed a partor the whole of theinsulation layer to ensure totheexternal, internalexamination; the establishment must appointa person to witness the search.
3.1. Preparation of testing
3.1.1. To notifythe establishment of the plansandrequirementsbefore implementing the testing of vessels.
3.1.2. To define and agree on the safety measures with the establishment before implementing the testing. To prepare fully the instruments, facilities, checking equipment used forthe testing process.
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3.2.1. Based on thetesting regimeto inspect andreviewdossier of vessel.
3.2.1.1 Whentestingthe first time, it must considerthe following records:
a, Profile ofvessel (including the norms offabrication metal, welding metal,strengthcalculationsofpressureelements; drawing of structurewritten fully the main sizeand guidance of the operation, maintenance and repair…).
b, Factory profileof vessels (including certificatesoffabrication metal, weld metal,testing results of weld quality; minutes oftrial…).
c, Theminutes of thetesting ofmesurement unit; Theminutes of checking ground, anti-lightning,protection device(if any).
d, Profileof installation:only appliestothefixed vessel
3.2.1.2 Whentestingperiodically, it mustreviewthe following documents:
a, History, testing minutesandthe results ofprevioustesting.
b, Records on themanagement and use, operation and maintenance; minutes of inspection, testing(if any).
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a, In case ofrepair: repairdesign dossiers, minute of acceptance testing afterrepair with weldandreplacement of partsunder pressure.
b, In case of changing the location of installation: it needs to be considered to supplement the installation dossier.
c, If, after testing, equipment does notworkfrom12months or more, it shall be reviewed dossier as for periodicaltesting.
Note: Forthepressure vessels having clear origin, but the technicaldossieris incomplete, then it must be supplemented.
3.3. Outside and inside inspection
The outside and inside inspection is implemented according to the order of steps as follows:
3.3.1. When searching the indise and outside of the pressure vessels, the following lacks need to be paid attention to detect:
- The inside andoutsidecracked, sunken, bloated marks of thepressure vessel; gasleak traceattheweld, rivetconnection, pipestopper.
- Status of sediment, rust, corrosion of metal parts.
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- Technicalstatusof the insulation layer.
- To check the tightness of the connection details.
- Forthelocation that is unable to carry out the inside search when testing, the inspectionof technical conditionsmustcomply withthe technicaldocumentationof the manufacturers. It must be written clearly in the documents: theamount needs to be inspected,methodsandorder of inspection.
3.3.2. To check the location of installation of equipment: lighting system; floors, stairs, racks... anti-lightening, ground system (if any).
3.3.3. To check the number and working situation of the accessories.
3.3.4. For vessels that work with thetoxic, flammable substance, it musttake measures toremoveairprior tothe inspection; the persons who direct examine mustknow clearly theprocess ofcommon troubleshooting.
3.3.5. If the vessel has shell-and-tube, if having doubt on the technical state in the shell-and-tube zone, it must berequestedto remove each partor the whole shell-and-tube.
Note: If it is unable to conduct the inside searchdue to thestructuralcharacteristicsof the vessel, it is permitted to replacethe inside searchbyhydraulic test with the prescribed testing pressureandexamine the parts that are able to conduct.
3.5. Inspection of the capability to bear pressure (hydraulic test)
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3.5.1. If thevessel has the structure of many parts working at the level with differentpressures that may be separatedandhydraulictestfor each part
3.5.2. It must take measures torestrain theeffects ofthe course of hydraulic testtotheautomatic protectionequipment, testing and measurement equipment and make surethedevices not be destroyed during the course of testing. In case of unable to implement, it must be isolatedorremoved for separatetesting.
3.5.3. Solvent-substance andtemperature of testing solvent-substance, testing pressure, time to maintain pressure asprescribedin the item 3.11of TCVN6156:1996ifthe manufacturerhasdefinedhigher testing-pressure, it shall be in accordance with provisions of themanufacturer.
3.5.4. Where there is noconditions for hydraulictest due to the expansion on thenailbed, floor or difficulties in drainage; due to theinner base coatpreventingwater, it is permitted to replace by gas pressure testing (air orinert gas) and conduct the inspection of the tightnesswithsoapsolutionor byother means, inthe process of testing, it must apply thesafety measuresprescribed in 3.16TCVN 6156:1996.
3.5.5. Usingreagentsandconducting the slow increase ofpressuretoavoidsudden dilatation causing damages for the devices to maintain the testing pressurewithin5minutesandprohibit the use of hammer. Monitoring, detectingthephenomenon: deformation, cracks ...during thehydraulic test.
3.5.6. Decreasing pressure slowly back to the standard pressure, keeping it during the course of searching. Using hamber for checking at the location that has been doubt, then decreasing pressure back to (0); recovering the exist (if any) and rechecking the results that have been recovered.
3.5.7. Valuating the testing result: It must satisfy the results at least as prescribed in item 3.4.5 TCVN 6154:1996.
3.5.8. In case vessels are exempted from hydraulic test in accordance with provisions of TCVN on current safe technique, it must be written clearly in the testing minute and attached to the hydraulic acceptance test minutes of manufacturer, installation acceptance test minute (if any).
3.6. Inspection of tightness (closed test): It is applied only whenrequired by technology orthevesselsworking with toxic andflammable solvent- substance.
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3.6.2. Detecting the leaks; proposing themeasures for the establishment torecover, handle and re-check.
3.6.3. Valuating the testing result: vessels are considered as satisfactory at this testing when gas leak is not detected.
3.7. Operating inspection (operating test).
3.7.1. To check fully conditions enabling the vessels to operate normally.
3.7.2. Based on theprocess, coordinate with theestablishment sending vessel for using; consider thenormalworkingcondition of vesselsandaccessories; theworkofmeasuring, protective devices.
3.7.3. When the vessels work stably, the increase of pressure for checking and the adjustment of working pressure of the safe valve, the lead seal for the safe valve shall be implemented (except for the vessels containing the toxic, flamable solvent-substance).
The safe valve may be adjusted and sealed lead not at the same of the process of operation.
Adjustment value of the safe valve:
+ 0,05 MPa – When the working pressure allowed up to 0,3 MPa;
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+ 10% p - When the working pressure allowed more than 6 MPa.
4.1. Making the testing minute.
4.1.1. Making the testing minute as the form provided (issued attached herewith) when it is free from hydraulic test together with the minute referred to the item 3.5.8 of this process, recording fully contents of the minute. Stating clearly the standards applied during the course of testing.
4.1.2. Summarize the results of testing into vesselprofile(stating clearly full name of tester, date, month, year of testing).
4.2. Passing the testing minute
Participants to pass the minute oftestingrequiredhaving at leastthefollowing members:
+ Owner of the establishment or person who authorized by owner of the establishment.
+ Persons who are assigned toparticipate in andwitness thetesting.
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4.3. When the vessel gets the requirements as provided in Item 3, leader of the testing agency issues the testing result after the testing minute is publicized on site within 5 days.
4.4. When the vessel does not get the requirements as provided in Item 3, the steps 4.1 and 4.2 shall be implemented and leader of the testing agency only issues to the establishment the testing minute, stating clearly the reason that the vessel is not satisfactory.
5.1. Inside and outside search: 3 years per time.
5.2. Inside and outside search and hydraulic test: 6 years per time.
5.3. Operating inspection: 1 year per time.
5.4. For tank lorry and containers containing metal errosion solvent-substance (clo, sulfua, hidro…), its time limit of periodical search is not less than two years per time.
5.5. For tank lorry and containers containing propan-butan and commonly used solvent-substance, its time limit of periodical search is not less than four years per time.
5.6. If the manufacturer provides for a shorter time limit of search, then applying according to provisions of the manufaturer.
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5.8. The cases must be conducted the irregular search:
a, When using the types of vessels that are stopped using from 12 months or more.
b, When vessels are transformed or removed to a new installation location.
c, When repairing the bloated, sunken locations or the repair using the welding method at the major parts of vessel.
d, When doubting on vessel’s tecxhnical status.
The causes leading to irregular search must be stated clearly in the vessel profile.
THE MINISTRY OF LABOUR, WAR INVALIDS AND SOCIAL AFFAIRS
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GAS CYLINDERS – PROCESS OF SAFE TECHNICAL TESTING
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HANOI - 2008
PREAMBLE
The Process of safe technical testing for pressure vesselscompiledby the Bureau for Safe Work, issued by the Ministry of Labor, War Invalids and Social Affairs according to the Decision No.67/2008/BLDTBXH dated December 29, 2008
THE PROCESS OF SAFE TECHNICAL TESTING FOR GAS CYLINDERS
This process of testing specifies on the order, procedures of safe technical testing at the first, regular and irregular time for gas, liquefied gas, dissolved gas cylinders (hereinafter collectively called as cylinder) to be of the list of types of machinery, equipment and materials with strict requirements on occupational safety issued by the Ministry of Labour - War Invalids and Social Affairs.
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2. The standards forced to apply
Including the national technical standards for safety as follows:
+ TCVN 6156:1996: Pressure vessels - Safe technical requirements for installation, use, repair - method of testing.
+ TCVN 6292:1997: Gas cylinders - Gas cylinders made of welded steel which may be refilled... (< 75bar capacityfrom1to150liters containingcompressedgas, liquefied gasand dissolved gas at theambient air temperature)
+ TCVN 6294-1997: Gas cylinders. Gas cylinders made of welded carbon steel – Inspection and periodical test. (Not applying to the cylinder containing Axetylen and LPG)
+ TCVN 6295-1997: Gas cylinders. Gas cylinders without welding – Safety standardsandfeatures(capacityfrom0,5 liter to 150 liter, not limiting to pressure)
+ TCVN 6008-1995: Pressure equipment – Weld with technical requirement and method of inspection.
+ TCVN 7472-2005: Pressure equipment – joint weld.
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- To prepare the testing: Item 3.1
- To check dossier: Item 3.2
- To check and handle preliminarily: Item 3.3
- To check outside, inside: Item 3.4
- To check the capability to bear pressure: Item 3.5
- To check the tightness (onlyapply tothe cylinders containingtoxic andflammable solvent-substance; other cylinders at request) Item 3.6
- Note: Thefollowinginspectionsare conductedonlywhenthe inspection resultsof the previous stephas beensatisfactory.
Before conductingthe search: it must prepare fully human resource, tools, equipment, facility equipped to protect person necessarily, gas cylinder must be sanitized; the establishment must appointa person to witness the search.
3.1 Preparation of testing
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+ Testing for the first time before putting the new cylinders into use: 5% of total cylinders.
+ Testing periodically or irregularly : 100% of total cylinders.
Note: Implementation of taking sample for testing at propability 5% of the cylinders must be ensured the representation for the groups of cylinder of the cylinder lot.
3.1.2 The cylinder testing may be implemented at the cylinder testing station or at the establishment requesting for testing:
+ When implementing testing at the station: to notifythe establishment of the testing plansandrequirementsbefore implementing the testing, coordinate with the establishment for taking sample (the first testing).
+ When implementing testing on site: as implemented at the station and raising the requirements for the establishment to arrage the location for testing, the location for handling odd gas ... to ensure safety and environmental protection.
3.2 Inspection of dossier
Based on the regime of testing, dossier for reviewing includes:
- The first testing: profile of factory, list of cylinder lot.
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- Irregular testing: The previous testing result, list of cylinders need to be tested, repair dossier.
3.3 Preliminary inspection and handling
3.3.1. To check thetechnical parameters stamped on the cylinder’s handleorneck; to compare with the technicaldatain the list of cylinders need to be tested; to remove the cylinders not belonging to the testing listand the cylinders with parametersmissed orblurred.
3.3.2. To conduct visual inspectionofthe exterior statusof each cylinder to remove theone which hasabnormal phenomenom so that it is notenough qualification fornormal work, such as bloated, sunken marks; broken handle, brokensupport; scratchedbydeepgrooves, pit, burning, peeled-offlabels...
3.3.3.It must conduct the handling of odd gas in the cylinders for periodical or irregular testing:
3.3.4. The cylinderscontaininginert, inflammable, non-toxicgas may be directly discharged.
3.3.5.The cylinders containing flammable, toxicgas must be handled inner odd gasby the way of discharging, exshausting air by specially used equipment, later, air may be withdrawed for use or with safe handling measures, notdirectly dischargedinto the environment.
3.3.6.After the inner odd gas has been handled all, valvein the cylinder’s top shall be taken by specializedtools andequipment.
3.3.7.To check the tightness of valves and the safety parts (if any); to remove unsatisfactory valves.
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3.4 Inside and outside inspection
The inside and outside inspection is implemented according to the following orders:
3.4.1. To check the status ofthe surface, welds,threadedneck, support, handle.
3.4.2. To checkthevolumformolded, moulded cylinders and for cylinders in accordance with provisions of themanufacturersand compared tothe volumeof factory.
3.4.3. Forweldedsteelcylinders (LPG...) thatthe manufacturerspecifies on inspection ofvolume, the provisions of themanufacturershall be applied.
3.4.3. To check the inside of cylinder by specialized flashing device to valuate status ofthe metal surface, the weld surface.
3.4.4. For cylinders having foam, the quality of foam shall be tested in accordance with guidance of the manufaturer.
3.4.5. To remove the cylinders that are unsatisfactory.
3.5 Inspection of the capability to bear pressure (hydraulic test)
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+ To refill fully reagents.
+ Testing pressure mustbe determinedin accordance with provisions of themanufacturercountersunk atthe appropriate positionon thecylinder.
+ The timeto maintain testing pressureis keptwithina period of long enough timetodetermine thecapability to bearpressure of the cylinder according tothe provision of manufacturer.
+ The increase and decrease of pressure must be implemented slowly so that it shall not make sudden expansion affecting the sustainability of the cylinders.
+ For cylinders containing foam or testing by liquid not allowed, then testing by compressed gas, inert gas shall be implemented; when testing by gas, it must comply with the minimum safety conditions according to provisions in 3.15, 3.16 TCVN 6156:1996.
+ The volume expansion testing of cylinder: applied to theform of regular orirregular testing of eachtype of cylinder, thepermanentexpansionof the cylinder is expressed by percentageoftotal expansion volume at the testing pressureandnot exceeding10%. Ifthis value is exceeded,the cylinder mustbe removed(provided in 11.2 TCVN 6294:1997).
3.5.2. For molded, moulded cylinders:
3.5.2.1.To implement as provided of the step 3.5.1. If the manufaturer provides for the standard of removing higher, it shall comply with the manaufacturer’s standard. Seperatly, it shall not be less than one minute for the time to maintain testing pressure in every case.
3.5.2.2.Basedonthe volumeincreaseor the volume decrease ofthe cylindersto reduce its working pressureorremove them in accordance with provisions in 4.10 TCVN6156:1996, ifthe manufacturer'sspecified standard is higher, such standard shall be applied.
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3.5.4. To insertcheckedvalves intothe cylinders withthe satisfactory testing results.
3.6 Inspection of tightness (tightness test)
3.6.1.To refill compressed gas or inert gas into the cylinder up to the pressure in accordance with provisions of the applicable standard or the manufaturer’s provisions.
3.6.2. To checktightness ofconnectors, valve joints...of the cylinder withsoap bubbleorin thededicated sealedtestingtank. Thecyliders that are leaked must be handled and retested.
3.6.3.When the testing cylinders are satisfactory, the discharge ofair, the drying of cylinders’ outside, degerating andaeration ofprotection shall be implemented (as required).
4.1. The testing cylinders are satisfactory withouttheexpressionreducingthe ability to workandduring thetrial test; they does not arise the unusual phenomenon.
4.1.1.The testing agency stamps its seal and date, month, year of following testing into the cylinder in compliance with size and location as provided (14.4b TCVN 6294:1997 or 4.2 TCVN 6156:1996).
4.1.2.On the cylinder being reduced working pressure, the new data on volum and working pressure must be stamped countersunk seal. The new data must be erased by stamping cross.
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4.1.4.To make testing minute: The testing minute is made in accordance with form (issued attached herewith). To record fully the testing result, comments and requirements for the using establishment. To state clearly the standards applied during the course of testing.
4.1.5.To grant the testing result, testing minute to the using establishment.
4.2.To coordinate with the establishment to handle the removed cylinders in the steps implemented in the Item 3 according to provisions of the applicable standard.
5.1.For the cylinders containing normal gas: to chect overall every 5 years.
5.2.For the cylinders containing toxic, metal errosion gas (Chlorine, hydrogensulphide, chlorideMetin, Photden, Anhydricsulfur dioxide, hydrogenchloride.....): to check safety overall every 2 years.
5.3. When the manufacturer provides for a testing cycle shorter than the above mentioned testing cycle, the testing cycle of manufaturer shall be applied.
5.4.When shortening the testing cycle, the tester must state clearly the reason in the testing minute./.
THE MINISTRY OF LABOUR, WAR INVALIDS AND SOCIAL AFFAIRS
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GAS CHARGE PROCESSING SYSTEM - THE PROCESS OF SAFE TECHNICAL TESTING
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
HANOI - 2008
PREAMBLE
The Process of safe technical testing for pressure vesselscompiledby the Bureau for Safe Work, issued by the Ministry of Labor, War Invalids and Social Affairs according to the Decision No.67/2008/BLDTBXH dated December 29, 2008
THE PROCESS OF SAFE TECHNICAL TESTING FOR GAS CHARGE, PROCESSING SYSTEM
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This process specifies on the order, procedures of safe technical testing at the first, regular and irregular time for gas, liquefied gas, dissolved gas processing systems (or storage) (hereinafter collectively called as gas charge, processing systems) charging into vessels, cylinders to be of the list of types of machinery, equipment and materials with strict requirements on occupational safety issued by the Ministry of Labour - War Invalids and Social Affairs.
Based on this process, the testing agencies apply directly or develop specific, detail process for each shape, type of gas charge, processing systems but not contrary to the provisions of this process.
2. The standards forced to apply
Including the national technical standards for safety as follows:
+ TCVN 6153, 6154,6155 and 6156:1996: Pressure vessels - Safe technical requirements for design, structure, fabrication, installation, use, repair and method of testing.
+ TCVN 2622:1995: Fire protectionfor house andwork-Design requirements.
+ TCVN 4245:1996: Safe technical standards inproduction, use of oxygen, acetylene.
+ TCVN 6290:1997: Gas cylinders. Permanent gas cylinders – inspected at the time of charging gas.
+ TCVN 6713:2000: Gas cylinders - Safety operation.
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+ TCVN 6008:1995: pressure equipment – Welds: Technical requirements and method of testing.
To conduct a review, safe technical inspection according to the following steps:
- To prepare the testing: Item 3.1
- To check dossier: Item 3.2
- To check outside, inside: Item 3.3
- To check the sustainability, tightness: Item 3.4
- To check the operation:Item 3.5
- Note:
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+ Thefollowinginspectionsare conductedonlywhenthe inspection resultsof the previous stephas beensatisfactory.
3.1 Preparation of testing
3.1.1. To notifythe establishment of the plansandrequirementsbefore implementing the testing of gas charge, provessing system.
3.1.2. To define and agree on the safety measures with the establishment before implementing the testing. To prepare fully the instruments, personel protective facilities, checking equipment used forthe testing process.
3.1.3 To check the personel protective, rescue facilities forthe testing process.
3.2 Inspection of dossier
Based on thetesting regimeto inspect andreviewrecords of the gas charge, processingsystem
3.2.1 When implementing the first testing, it must consider the following dossiers:
a, Profileoffactory, profile of the gas charge, processingsystem; drawing ofworkingprincipleof the system, structure drawingofpressure equipmentin the system;and guidance ofoperation,maintenance; certificates ofquality inspection offabrication metal, weldmetal, welds.
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c, The process ofcheckingthe cylindersbeforefilling,the process offilling; records offire protection.
d, Testing card ofinstrument unit; anti-lighting, ground checking minute; checking minute of protection equipment(if any).
3.2.2 When implementing the regular testing, it must consider the following dossiers:
a, Profile, testing minute and output card of the previous testing.
b, Operationlogbook, monitoring book ofrepairandmaintenance; minute of inspection, examination(if any).
3.2.3 When implementing the irregular testing, it must consider the following dossiers:
To considerdossier as for considering regular testing and consider the supplementation of repair dossier, inspection minutefor repair quality, changes.
Note:When implementing the inspection, dossier ofthe gas charge, processingsystemmust be prepared fully andin accordance with provisions of Regulation,TCVNoncurrentsafety techniques. If it is not assured, the establishment must have the additionalremedies.
3.3 Internal and external inspection
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3.3.1. To check for determination of technical statusof the devicesin the gas charge, processingsystemin accordance with the current safe technical Regulation.
3.3.2. The inside, outside inspection of the pressure vessels in the gas charge, processingsystem must comply with “Pressure vessels– The process of safe technical testing”.
3.3.3. Before conducting the uncasing, inspectionof inside partsof thegas charge, processingsystem, it needs to determine firmly that the equipment is no longer the odd pressure andconcentration oftoxic andexplosivesubstances within the allowed scope.
3.3.4. To pay attention to check the cracked, sunken, floated, rusty marks, abnormal phenomenom on the parts, details of thegas charge, processingsystem.
3.3.5. To inspect and valuate the safety status ofthe accessories, testing measurement unit. Specially, pay attention to thetesting equipmentof filling level forliquefiedgas.
3.3.6. To check the pineline system, solvent-substance joint tube on the conditions of durability, layout, installation upon standard.
3.3.7. To checkthe tighten detailsworn,losen, jointsandinsulationparts.
3.3.8. To checkvalves, control valvesonthe number, category and the installation locationupon standardas well.
3.3.9. To checkthe number ofsafety valvesandothersafety protection structuresofthe system must be ensured upontherequirements of thestandard.
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3.3.11. To checkthecooling systemforthe filled cylinder(if any). To check the filling systemandthe details of tightening, keeping cylindersduring the course of filling; to check the inspection systemand to determine the amount of gas filled.
3.4 Inspection of durability, tightness
3.4.1.The pressure testing durability, tightness; testing solvent-substance; time to maintain the pressure testing durability, tightness for the gas charge, processing system must be complied in accordance with provisions of the manufacturer.
3.4.2.For the acetylene charge, processing system, the oxygen charge, processing system: pressure testing durability, tightness; testing solvent-substance; time to maintain the pressure testing durability, tightness is implemented upon item 7 of TCVN 4245:1996.
3.4.3.It must have the measures to control the impact of the over-pressure protection equipment and ensure such equipment not to be destroyed during the course of testing. In case unable to implement, it must be isolated or assembled for seperate testing.
3.4.4. The increase, decrease of pressure during the course of testing must be conducted slowly, ensuring not to cause expansion suddenly affecting the equipment in the system.
3.4.5.To recover the impact of the over-pressure protection equipment; to increase thepressurebackto checktheimpactand working pressure ofthesafety valve.
3.4.6. Valuating testing result: The systemis considered as satisfactoryofthis testing step when theequipment, pipeline in thesystem has not got the phenomenom ofdeformation, cracking orleakage of testing solvent-substance during the course of testing.
3.4.7. In case the gas charge, processing system is exempted from hydraulic test according to provisions of TCVN on current safety technique, it must state clearly the reason in the testing minute and attatch the testing minutes of factory of the technical council of manufacturer.
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It must test the capability of operation of the gas charge, processing system according to the following orders:
3.5.1. Basedon the process of requesting the establishment putting the gas charge, processing system into use.
3.5.1. To check operation of the gas charge, processing system to ensure the design parameters.
3.5.2. To check the impact value of automatic equipment; safety valve of the degree of compression on the compressor; safety valves of the gas admittance are adjusted with the opening pressure according to provisions of the manufacturer. Safety valves of admittance must be sealed.
3.5.3. Valuation of testing results: The system is considered as achieving results while ensuring the working parameters in accordance with provisions of the manufacturer.
4.1. Making testing minute.
4.1.1. Making testing minute upon the provided form (issued attached herewith) attached the minute of hydraulic test reffered to in 3.4.9 of this process (as the hydraulic test is exempted), stating fully the contents of the minute. Stating clearly the standards applied during the course of testing.
4.1.2. Stating briefly the result of testing into the profile of the system (stating clearly name of tester, date, month, year of testing).
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Participants to pass the minute oftestingrequiredhaving at leastthefollowing members:
+ Owner of the establishment or person who authorized by owner of the establishment.
+ Persons who are assigned toparticipate in andwitness thetesting
When the minute is passed, the tester, attandants to witness, owner of the establishment together sign; the owner of the establishment seals onto the minute.
4.3. When the gas charge, processing system gets the requirements as provided in Item 3, leader of the testing agency issues the testing result and the testing minute to the establishment.
4.4. When the system does not get the requirements as provided in Item 3, the steps 4.1 and 4.2 shall be implemented and leader of the testing agency only issues to the establishment the testing minute, stating clearly the reason that the gas charge, processing system is not satisfactory.
5.1. For type of metal non-corrosive gas charge, processing system:
5.1.1. To implement all testing steps (except for durability test): 3 years/time.
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5.2. For type of metal corrosive gas charge, processing system: the cycle of testing is according to provisions as item 5.1 but reducing 1/3.
5.3. For type of toxic, metal corrosive gas charge, processing system (Chlorine, hydrogen sulphide...): To implement all testing steps: 2 years/time.
5.4. When manufacturer stipulates the cycle of testing shorter than the provisions of the above mentioned cycle of testing, the manufacturer’s provisions shall be applied.
5.5. When shortening the cycle of testing, tester must state clearly the reason in the testing minute.
5.6. The cases must be conducted irregular testing:
- After being repaired, the system was welded the parts of bearing pressure.
- The location of installation has been changed.
- The system han been terminated its operation from 12 months or more.
Note: When replacing the pipes (made in the form of quick assembly), pressure vessels in the system that the parts have been tested for factory not exceeding 12 months are not required to try durability for the whole system.
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PIPELINES OF STEAM, HOT WATER - THE PROCESS OF SAFE TECHNICAL TESTING
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
HANOI - 2008
PREAMBLE
The Process of safe technical testing for pressure vesselscompiledby the Bureau for Safe Work, issued by the Ministry of Labor, War Invalids and Social Affairs according to the Decision No.67/2008/BLDTBXH dated December 29, 2008
THE PROCESS OF SAFE TECHNICAL TESTING FOR PIPELINES OF STEAM, HOT WATER
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
This process specifies on the order, procedures of safe technical testing at the first, regular and irregular time for the pipelines systems of steam, hot water (hereinafter collectively called as pipeline systems) to be of the list of types of machinery, equipment and materials with strict requirements on occupational safety issued by the Ministry of Labour - War Invalids and Social Affairs.
Based on this process, the testing agencies apply directly or develop specific, detail process for each shape of pipeline systems but not contrary to the provisions of this process
2. The standards forced to apply
Including the national technical standards for safety as follows:
+ TCVN 6158:1996: Pipelines of steam and hot water – Technical requirement.
+ TCVN 6159:1996: Pipelines of steam and hot water – Method of testing.
+ TCVN 6008:1995: Pressure equipment – Welds, technical requirement and method of testing.
+ TCVN 4395:1986 Non-destructive testing - Testing of welds by Ronghen and gamma rays.
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- To prepare the testing: Item 3.1
- To check dossier: Item 3.2
- To check outside: Item 3.3
- To check the capability to bear pressure: Item 3.4
- Note: Thefollowinginspectionsare conductedonlywhenthe inspection resultsof the previous stephas beensatisfactory
3.1 Preparation of testing
3.1.1. To notifythe establishment of the plansandrequirementsbefore implementing the testing of pipeline system.
3.1.2. To define and agree on the safety measures with the establishment before implementing the testing. To prepare fully the instruments, personel protective facilities, tools, equipment used forthe testing process.
3.1.3 To check the personel protective, rescue facilities forthe testing process
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Based on thetesting regimeto inspect andreviewrecords of the pipelinesystem:
3.2.1 When implementing the first testing, it must consider the following dossiers:
a, Dossier of installation: installation design , pipeline location layout (location of welds, racks; parts clearing expansion, condensate drain), the overall system acceptance test minute.
b, The certificates of quality inspection of fabrication metal, weld metal, inspection minute of welds quality.
3.2.2 When implementing the regular testing, it must consider the following dossiers:
a, Testing minute and the previous testing result.
b, Book of monitoring repair and maintenance, the proposals stated in the minutes of inspection and testing related to the technical condition of the pipelines (if any).
3.2.3 When implementing the irregular testing, it must consider the following dossiers:
As item 3.2.2 and supplement dossiers relating to repair or changes compared with the pipeline location layout in the initial installation dosier.
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3.3 Outside inspection
Before the outside inspection is implemented, it needs to take the measures to ensure safety to tester.
To perform the inspection with eyes and use the necessary tools such as magnifying glass, test hammer, measure (solid measure, measuring tape, caliper square, pan me ...) and dedicated lights.
+ Before the outside inspection is implemented, slag, splashed metal marks, rust and other dirty of the surface of the welds on the width not less than 20 mm and the base metal parts located close to the welds must be cleaned (in both sides of the weld).
+ To check outside on the entire length of pipe and length of welds in accordance with the technical requirements of pipeline fabrication and process of weld technology; to check metal surfaces and the degree of corrosion.
+ To check the parts of the pipeline; to determine the degree of deformation and the stiffness of the suspension parts, pipe racks; the curvature of the pipe, pipe bending angle.
+ To check paint colors and signs as prescribed.
+ To check the tighness of the joint details.
+ To check the operational status of the parts and details of expansion; the discharge point, valve of draining off standing water on the pipeline, the location and condition of safety for discharge hole.
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
3.4 Inspection of the capability to bear pressure (hydraulic test)
It must conduct hydraulic test to consider the capability to bear pressure of the pipeline system according to the following orders:
The hydraulic is implemented after the installation has been completed.
3.4.1. Determination of the testing pressure: testing pressure equal to 1.5 times of maximum working pressure of such pipeline.
Allowing hydraulic test for the entire pipeline or each pipeline segment.
3.4.2. To perform hydraulic test for pipeline when ambient temperature is more than 0o C. When testing hydraulic, the pipeline has working pressure more than or equal to 10 MPa, ambient air temperature shall not be less than 100C.
3.4.3. To be allowed to test by air pressure only when there is not condition to test by hydraulic or due to the volume of water is too great affecting the pipeline suspensions, cracks.
3.4.3. In case of testing with air pressure, the testing pressure and testing period is similar to hydraulic test. Absolutely, not to hammer onto the welds when testing the pipeline by air pressure at any pressure.
3.4.4. The increase and decrease of pressure during the course of testing must be proceeded slowly so as not to cause sudden expansion affecting the durability of the pipeline.
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
3.4.6. During the durability test, it can proceed to calibrate and seal safety valve. safety valve can be calibrated and sealed not at the same time with the durability testing process.
Opening pressure of safety valve depends on the technology process, not exceeding 1.1 times of permitted working pressure of the pipeline in any case.
3.4.7. The result of testing the pipeline by hydraulic or compressed air is considered as satisfactory when:
- During the course of testing, the pressure is not reduced more than 3% compared with prescribed testing pressure.
- The pipeline is not deformed, leaked in the joints or welds.
4.1. Making the testing minute according to the prescribed form with full contents of the minute (issued attached herewith). Stating clearly the standards applied during the course of testing.
4.2. Recording brieftly the testing result into the profile of the pipeline (stating clearly name of tester, date, month, year of testing).
4.3. Passing the testing minute
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
+ Owner of the establishment or person who authorized by owner of the establishment.
+ Persons who are assigned toparticipate in andwitness thetesting.
When the minute is passed, the tester, attandants to witness, owner of the establishment together sign; the owner of the establishment seals onto the minute
4.4. When the pipeline system gets the requirements as provided in Item 3, leader of the testing agency issues the testing result after the testing minute is passed on site within 5 days.
4.5. When the pipeline system does not get the requirements as provided in Item 3, the steps 4.1 and 4.2 shall be implemented and leader of the testing agency only issues to the establishment the testing minute, stating clearly the reason that the pipeline system is not satisfactory
5.1. To implement all the testing steps (except for hydraulic test): 3 years/time.
5.2. To implement all the testing steps: 6 years/time.
5.3. When shortening the cycle of testing, tester must state clearly the reason in the testing minute.
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
THE MINISTRY OF LABOUR, WAR INVALIDS AND SOCIAL AFFAIRS
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THE REFRIGERATION SYSTEM - THE PROCESS OF SAFE TECHNICAL TESTING
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
HANOI - 2008
PREAMBLE
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
THE PROCESS OF SAFE TECHNICAL TESTING FOR THE REFRIGERATION SYSTEM
This process specifies on the order, procedures of safe technical testing at the first, regular and irregular time for the refrigeration systems stipulated according to the list of types of machinery, equipment and materials with strict requirements on occupational safety issued by the Ministry of Labour - War Invalids and Social Affairs.
Based on this process, the testing agencies apply directly or develop specific, detail process for each shap, type of refrigeration systems but not contrary to the provisions of this process.
2. The standards forced to apply
Including the national technical standards for safety as follows
+ TCVN 6153, 6154, 6155 and 6156:1996: Pressure vessel – Safe technical requirements for design, structure, fabrication, installation, use, repair and method of testing.
+ TCVN 6104: 1996: Refrigeration systems used for chilling and warming – Safety requirements
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
+ TCVN 7472-2005: Pressure equipment – Joint weld.
To conduct a review, safe technical inspection according to the following steps:
- To prepare the testing: Item 3.1
- To check dossier: Item 3.2
- To check outside, inside: Item 3.3
- To check the capability to bear pressure: Item 3.4
- To check tighness: item 3.5
- To check operation: item 3.6
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
3.1 Preparation of testing
3.1.1. To notifythe establishment of the plansandrequirementsbefore implementing the testing of refrigeration system.
3.1.2. To define the safety measures before implementing the testing. To arrange tester for participation in testing, prepare fully the instruments, facilities, equipment used forthe testing process and facilities equiped for personal protection.
3.2 Inspection of dossier
3.2.1. Based on thetesting regimeto inspect andreviewrecords of the system.
3.2.1.1 When implementing the first testing, it must consider the following dossiers:
a, Dossier of factory, profile of the refrigeration system; schematic drawing of working principle of the system, structure drawing of parts bearing pressure of the system, the certificates of weld materials, fabrication materials quality inspection, welding material.
b, Profile of installation and installation acceptance minute.
c, The minutes of the weld inspection, measurement unit testing paper; minute of checking ground, anti-lightning, protective equipment.
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
a, Profile, testing minute and the previous testing result.
b, Operation log books, books of monitoring repair and maintenance; minutes of inspection, testing (if any).
3.2.1.3 When implementing the irregular testing, it must consider the following dossiers:
a, In case of repair: repair design dossier, after-repair acceptance test minute with welding equipment bearing pressure.
b, In case of changing the installation location: need to consider the supplementation of installation dossier.
c, In case equipment does not work from 12 months or more, dossier shall be considered as regular testing.
Note:When implementing the inspection, dossier ofthe refrigerationsystemmust be prepared fully andin accordance with provisions of Regulation,TCVNoncurrentsafety national techniques. If it is not assured, the establishments must have the additionalremedies
3.3 Inside, outside inspection
3.3.1. Inside, outside inspection of the pressure vessels of the refrigeration system complies with “Pressure vessels – The Process of safe technical testing”.
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3.3.3.Prior to the inspection of the inside parts of the system, it needs to withdraw gas to ensure the equipment which is no longer excess pressure and concentrations of explosive, hazardous substances is within allowed level.
3.3.4.Inspection to detect the cracked, sunken, floated, rusty, errosive marks on the parts, details of the system.
3.3.5. To check the working status of the accessories, measurement units, the number of safety valves and the safety protection structures of the system must ensure the requirements of the standard.
3.3.6.To check technical status of the pipeline system in the system.
3.3.7.To checkthe tighten detailsworn,losen, jointsandinsulationparts destroyed.
3.3.8. To checkvalves, control valvesonthe number, category and the installation locationupon standardas well.
3.3.9.Where the refrigeration system layouts other protection structures such as lead tack, bursting disk, its integrity need to be determined, when these structures have been replaced, its working parameters need to be checked and must conform to provisions of the standards.
3.3.10. To checkthe working status of the cooling systems.
3.3.11. Where the refrigeration system using toxic or explosive solvent-substance, it needs to check the ventilation system for the compressor roomandthe exitofthe safety valveto ensureupon regulations of the applicable standards.
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
It must conduct hydtaulic test to considerthe capability to bear pressure of the system according to following orders:
- Preparation of testing: to isolate compressor, to interupt suction head air pressure gauge, to open valves (except for discharge valves), connect with devices to provide testing pressure.
- To raise system pressure slowly up to the durability testing pressure for the low-pressure side, perform the isolation, then raise to durability testing pressure for high-voltage side.
- To maintain testing pressurewithin 5 minutes, then reduce slowly to the tight testing pressure.
3.4.1.Determination of testing pressure: Testing pressure is under provisions in item 3.1.1.1 and 3.1.1.2 of TCVN 6104 -1996.
3.4.2. It must take measures to controll the effects of overvoltage protection devices and ensure these devices not to be ruined during the testing process. In case of unable to implement, it must be isolated or dismantled for separate tests.
3.4.3. Determination of testing solvent-substance is under provisions of manufacturers and applicable standards.
3.4.4.If there is not test condition with water, other liquids, then may use compressed air, inert gas to test with the conditions that the durability of the device was tested by calculation; to implement fully the safety regulations for the testing method by air.
3.4.5. To check the working pressure of the safety valves mounted on the trial part of the system. To reduce testing pressure back to the working pressure and being maintained during the testing process.
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
3.4.6.Valuation of testing result: Testing result must meet minimum requirements as provisions on hydraulic test in “Pressure vessels – The process of safe technical testing”.
3.4.7.Where the system is free from hydraulic test in accordance with provision of TCVN on current safety technique, it must state clearly the reasons in the testing minute and attach the minutes of the hydraulic test of the technical council of the fabrication and installation establishment into the testing minute.
3.4.8.In the special cases: When the presure bearing equipment of refrigeration system (the time limit of testing has not come yet) is replaced and such replacement equipment has been tested the capability to bear pressure, so when it is installed into the system, durability test for the entire system shall be permited free however the system must be conducted tight test.
3.5 Inspection of tightness (tightness test)
3.5.1.The tightness test is implemented after the system is mantled completely (due to the first installation or request to separate the system for hydraulic test when conducting regular test). It can test the tightness in accordance with each block of the system and retest at the connections.
3.5.2. The tightness testing pressure equal to working pressure of the system.
3.5.3.To maintain testing pressure within 24 hours. In the first 6 hours, testing pressure is not more than 10% and not reducing later.
3.5.4.Time for tightness test is according to provisions of applicable standards or of the manufacturer.
3.5.5.To conduct the test with soapy water. The possibility of leakage on the pipeline is less likely to occur so should check the welds, flanges, front valve connections. If the above mentioned test was implemented without detecting blowed, opened traces however, the pressure is still reduced, then inspection on pipeline can be implemented.
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
Only after the test was implemented completely without detecting leakage, the insulation covering for the pipeline and equipment shall be implemented.
Note: The pressure in the system depends on the ambient temperature, means dependent on time in day, so it is needed to check in a certain time in day.
3.5.6.Valuation of testing result: The tightness testing step is considers satisfactory when there is no leakage phenomenom and pressure in the system is not reduced.
3.6 Operating inspection (operating test)
It must test the capability of operation of the refrigeration system according to the following orders:
Before the operating test is implemented, the evacuation of vacuum and charging refrigerant to the system needs to be implemented.
To check entire system to ensure the operation.
3.6.1.Based on the process, coordinating with the establishment to put the system into use.
3.6.2.To check safety valves working pressure on the entire refrigeration system.
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
3.6.4. To check the impact parameter of protection, automation equipment (except for safety valve).
3.6.5.When the system works well, stably; correction and lead seal for safety valves shall be implemented. The dischage pressure of the safety valve is implemented as specified in Table 3TCVN 6104:1996.
3.6.6.Valuation of testing result
4.1.Making testing minutes.
4.1.1. Making testing minutes under provided form (issued attached herewith). When the hydraulic test is free, the minute of hydraulic test exemption reffered to in 3.4.7 of this process shall be attached, stating fully the contents of the minute. Stating clearly the standards applied during the course of testing.
4.1.2. Recording brieftly the testing result into the profile of the system (stating clearly name of tester, date, month, year of testing).
4.2. Passing the testing minute
Participants to pass the minute oftestingrequiredhaving at leastthefollowing members:
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
+ Persons who are assigned toparticipate in andwitness thetesting.
When the minute is passed, the tester, attandants to witness, owner of the establishment together sign; the owner of the establishment seals onto the minute.
4.3. When the system gets the requirements as provided in Item 3, leader of the testing agency issues the testing result after the testing minute is publicized on site within 5 days.
4.4. When the e system does not get the requirements as provided in Item 3, the steps 4.1 and 4.2 shall be implemented and leader of the testing agency only issues to the establishment the testing minute, stating clearly the reason that the tested system is not satisfactory.
5.1.For refrigeration systems using cooling agents of metal non-corrosion:
5.1.1. To implement all the testing steps (except for hydraulic test): 3 years/time.
5.1.2. To implement all the testing steps: 6 years/time
5.2. For refrigeration systems using cooling agents of metal corrosion:the cycle of testing is under the provisions in 5.1 but being reduced 1/3 of time.
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
5.4. When shortening the cycle of testing, tester must state clearly the reason in the testing minute./.
THE MINISTRY OF LABOUR, WAR INVALIDS AND SOCIAL AFFAIRS
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
BOILERS - THE PROCESS OF SAFE TECHNICAL TESTING
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
HANOI – 2008
PREAMBLE
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
THE PROCESS OF SAFE TECHNICAL TESTING FOR THE BOILERS
This process specifies on the order, procedures of safe technical testing at the first, regular and irregular time for the boilers to the list of types of machinery, equipment and materials with strict requirements on occupational safety issued by the Ministry of Labour - War Invalids and Social Affairs.
Based on this process, the testing agencies apply directly or develop specific, detail process for each shap, type of boiler but not contrary to the provisions of this process.
2. The standards forced to apply
Including the national technical standards for safety as follows
+ TCVN 7704: Boilers - Safe technical requirements for design, structure, fabrication, installation, use, repair.
+ TCVN 6008-1995: Pressure equipment– Welds: Technical requirements and method of testing.
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Mọi chi tiết xin liên hệ: ĐT:(028) 3930 3279DĐ:0906 22 99 66
To conduct safe technical inspection according to the following steps:
- To prepare the testing: Item 3.1
- To check dossier: Item 3.2
- To check outside, inside: Item 3.3
- To check the capability to bear pressure: Item 3.4
- To check operation: item 3.5
- Note: Thefollowinginspectionsare conductedonlywhenthe inspection resultsof the previous stephas beensatisfactory
Before conductingthe search: Thesafety measuresmust be taken, boilermust be cleansed; theinspection door,door for person to creep into(if any) mustbe removed;whenhaving doubt on technical state of the parts bearing pressure of the vessel, it need to be removed a partor the whole of theinsulation layer to ensure totheexternal, internalexamination; the establishment must appointa person to witness the search.
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3.1.1. To notifythe establishment of the plansandrequirementsbefore implementing the testing of boilers.
3.1.2. To define and agree the safety measures with the establishment before implementing the testing. To arrange tester for participation in testing, prepare fully the instruments, facilities, equipment used forthe testing process and facilities equiped for personal protection
3.2 Inspection of dossier
3.2.1. Based on thetesting regimeto inspect andreviewrecords of the boilers
3.2.1.1 When implementing the first testing, it must consider the following dossiers:
a, Profile of the boilers, (includes: criteria on fabrication metal, welding metal, durability calculation of parts bearing pressure, structure drawing stated fully the major size and guidance of the operation and maintenance, repair; regime of supplying water...).
b, Factory profileof boilers (including certificatesoffabrication metal, welding metal,testing results of welding quality; minutes of factory trial...)
c, The place to locate boiler: space to locate boilers, regulations on safe distance, stairs and operations floor, lighting systems, fuel storage, fuel supply and discharge, anti-lightning system, the communication system, exits arrangement, toilets.
d, Installation minute includes the main items as follows:
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- Characteristics of the additional materials when installed.
- Data on the welding such as welding technology, welding codes, the name of the welders and result of welds test.
- The testing minutes of each parts of boiler (if any).
- Documents on the system inspection by the way of ball or by other methods to ensure the through system (if any).
- Documents on the spectral inspection for boiler components, superheater works with a larger temperature 450o C
- Documents certifying the quality of boilers after they are transported to the place of installation.
3.2.1.2 When implementing the regular testing, it must consider the following dossiers
a, Profile, testing minute and previous testing results.
b, Operation log books, book of monitoring maintenance and repair; testing, inspection minute (if any).
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a, For boilers meeting breakdown or overhaul: with replacement, welding ... the pressure bearing parts of boilers shall be made a record of repair and boilers which stop operating from 12 months or more, change the installation location must be conducted irregular testing.
b, Dossier of inspection includes:
- Design for repair and after-repair acceptance test minute or installation acceptance test minutes.
- The other related records must be checked as in step of regular testing.(3.2.1.2)
Note: For boilers with clear origin but technical dossier which is insufficient, then they must be made additional dossier.
3.3 Outside, inside inspection
Tools for inspection: magnifying glass, testing hammer, mesurement unit, specialized lighting ... enough to determine the type and size of defect.
For the boiler equipment with height of 2m or more, the work (scaffolding) must be set up to consider all parts of the boiler.
3.3.1. Upon examination of the boiler’s outside and inside, it needs to note for finding out the following shortcomings:
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- Status of sediment, rust, metal errosion of parts.
- Technical status of the accessories, measurement units and safety.
- Technical status of the insulation layer.
- To check the tighness of the connection details.
- For the location that is unable to inspect inside when testing, the inspection of technical conditions must comply with the technical documentation of the manufacturers. it must be clearly stated in the dossier: the volume needs to be inspected, methods and inspection order.
3.3.2. To check equipment of water supply on quantity and the current technical status.
3.3.3. To check the requirements of water supply regime – boiler water and the status of water treating equipment.
3.3.4. Upon detection of defects reducing the durability of pressure bearing rod (to be thin, the joints worn ...), the working parameters of boilers need to be reduced. The reduction of parameters must be based on the strength calculation by the design data.
3.3.5. Where meeting difficulty in determining the cause of the defects discovered, the establishment using the boiler is responsible for conducting the necessary testing. Boiler must be stoped working when the metallicity testing results of water, air bags, or other essential parts of the boiler are:
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- Tensile durability is lower than 3,2MPa;
- The ratio betweenconventional limit of stretching strain (when the residual deformation is 0.2 % ) with tensile durability is more than 0,75.
- Relative elongation is lower than 16%.
- Impact toughness on the sample with sharp heads smaller than 0,25 N/c
When made from alloy steel upon provisions in the technical materials of the factory:
3.4 Inspection of the capability to bear pressure (hydraulic test)
It must conduct hydraulic test to consider the capability to bear pressure of the boilers according to the following orders:
order of regular or irregular hydraulic test for boiler equipment after being installed is stipulated in 10.3.1;10.3.3; 10.3.4; 10.3.5 of TCVN 7704:2007.
3.4.1. Determination of testing pressure:
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Design pressure,MPa
Hydraulic testing pressure,MPa
p ≤ 0,5
2 p but not less than 0,2 MPa
p ≥ 0,5
1,5 p but not less than 1 MPa
Hydraulic testing pressure of boilers when testing regularly or irregularly depends on the permitted standard working pressure according to the following table:
Standard working pressure of boilers,MPa
Hydraulic testing pressure,MPa
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1,5 but not less than 0,2MPa
> 0,5
1,25 but not less than + 0,3 MPa
Note:
means pressure of steam from the boiler for the boiler only producing saturated steam;
means pressure of steam from superheater for the boiler only producing superheat steam.
3.4.2. Determination of time for hydraulic test: time to maintain hydraulic testing pressure after the installation is 20 minutes; boilers are made upon the type of intergral (fast installation) and the boilers for regular and irregular testing is 5 minutes.
3.4.3. To fill fully water into the boiler (temperature below 50oC and not lower than ambient temperature of over 5oC), the increasing of pressure in accordance with provisions on speed and time to avoid the sudden expansion.
3.4.4. To prohibit the hamber during the time that boiler bears testing pressure.
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3.4.6. Upon testing, if detecting cracks on the surface or the connections, rivet connections not tighten thanking to signs of water, steam leakage; salt ... the using establishment must find the cause and have measures to handle thoroughly.
3.4.7. When doubting on the technical status of pressure bearing parts of boilers, the boiler user needs to remove part or the entire insulation layer, remove number of fire tubes or cut a portion of water tube for checking.
3.4.8. Boilers made upon the type of intergral (fast installation), if when being transported to the place of installation, they are not damaged parts of bearing pressure and time of factory of less than 12 months are free from hydraulic test. It must be stated clearly reasons in the testing minute and attatched the hydraulic testing minutes of factory of the technical council of manufacturer and the installation testing minutes of the installation unit and using establishment.
3.5 Operating inspection (operating test)
It must test the capability of operation of the boilers according to the following orders:
3.5.1. To check the conditions for the normal operation of the boilers.
3.5.2. Based on the operating process, the establishment is required to conduct the process of burning and increasing pressure of boilers.
3.5.3. In the process of increasing pressure to working pressure of the boiler, the working status of the boiler, protection, measurement unit, supplementary equipment need to be closely monitored. If finding out an unusual phenomenom, requesting the establishment to stop boiler’s working according to procedures, conducting inspection, making specific conclusions and remedies.
3.5.4. When increasing up to the working pressure, if there is any unusual phenomenom, then continuing to increase to check and adjust working pressure of the safety valves, making the lead seal for checked safety valves.
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3.5.6. Valuation of testing result: boiler operates normally, gains the standard technical parameters.
4.1. Making testing minute.
4.1.1. Making testing minutes under provided form with full contents of minute (issued attached herewith). When the hydraulic test is free, the minutes reffered to in 3.4.8 of this process shall be attached. Stating clearly the standards applied during the course of testing
4.1.2. Recording brieftly the testing result into the profile of boiler (stating clearly name of tester, date, month, year of testing).
4.2. Passing the testing minute
Participants to pass the minute oftestingrequiredhaving at leastthefollowing members:
+ Owner of the establishment or person who authorized by owner of the establishment.
+ Persons who are assigned toparticipate in andwitness thetesting.
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4.3. When the boiler gets the requirements as provided in Item 3, leader of the testing agency issues the testing result after the testing minute is publicized on site within 5 days.
4.4. When the boiler does not get the requirements as provided in Item 3, the steps 4.1 and 4.2 shall be implemented and leader of the testing agency only issues to the establishment the testing minute, stating clearly the reason that the tested boiler is not satisfactory.
5.1. Outside, inside inspection: 02 years per time
5.2. Outside, inside inspection, hydraulic test: 06 years per time
5.3. Inspection of boiler’s operation: 01 year per time
5.4. When shortening the cycle of testing, tester must state clearly the reason in the testing minute.
5.5. The cases must be tested irregularly: according to provisions in 11.2.5 TCVN 7704:2007