Australian Standard. Pressure vessels. AS (Incorporating Amendment Nos. 1, 2 and 3) AS 1210

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1 AS (Incorporating Amendment Nos. 1, 2 and 3) AS 1210 Australian Standard Pressure vessels

2 This Australian Standard was prepared by Committee ME-001, Pressure Equipment. It was approved on behalf of the Council of Standards Australia on 31 January 1997 and published on 5 July The following interests are represented on Committee ME-001: A.C.T. WorkCover Australasian Corrosion Association Australasian Institute of Engineering Inspection Aluminium Development Council, Australia Australian Building Codes Board Australian Chamber of Commerce and Industry Australian Institute of Energy Australian Institute of Petroleum Australian Liquefied Petroleum Gas Association Boiler and Pressure Vessel Manufacturers Association of Australia Bureau of Steel Manufacturers of Australia Department for Industrial Affairs, S.A. Department of Labour, New Zealand Department of Training and Industrial Relations, Qld Electricity Corporation of New Zealand Electricity Supply Association of Australia Institute of Metals and Materials, Australasia Institution of Engineers, Australia Insurance Council of Australia Metal Trades Industry Association of Australia National Association of Testing Authorities, Australia New Zealand Engineering Federation New Zealand Heavy Engineering Research Association New Zealand Petrochemical Users Group New Zealand Timber Industry Federation Victorian WorkCover Authority Welding Technology Institute of Australia WorkCover N.S.W. Work Health Authority, N.T. Workplace Standards Authority, Tas. WorkSafe W.A. Keeping Standards up-to-date Standards are living documents which reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued. Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments which may have been published since the Standard was purchased. Detailed information about Standards can be found by visiting the Standards Australia web site at and looking up the relevant Standard in the on-line catalogue. Alternatively, the printed Catalogue provides information current at 1 January each year, and the monthly magazine, The Australian Standard, has a full listing of revisions and amendments published each month. We also welcome suggestions for improvement in our Standards, and especially encourage readers to notify us immediately of any apparent inaccuracies or ambiguities. Contact us via at mail@standards.com.au, or write to the Chief Executive, Standards Australia International Ltd, GPO Box 5420, Sydney, NSW This Standard was issued in draft form for comment as DR

3 AS (Incorporating Amendment Nos. 1, 2 and 3) Australian Standard Pressure vessels Originated in part as AS B and AS CB Previous edition Fifth edition Reissued incorporating Amendment Nos. 1 (February 1998), 2 (September 1998) and 3 (April 2002). COPYRIGHT Standards Australia International All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher. Published by Standards Australia International Ltd GPO Box 5420, Sydney, NSW 2001, Australia ISBN

4 AS PREFACE This Standard was prepared by the Joint Standards Australia/Standards New Zealand Committee ME/1 on Pressure Equipment to supersede AS , Unfired Pressure Vessels (known as the SAA Unfired Pressure Vessels Code). This Standard is a Primary Applicable Standard referenced in AS/NZS 1200 which is the main Standard for pressure equipment and outlines general requirements for water tube, fire tube, shell and miscellaneous boilers, pressure vessels, pressure piping and related matters. AS/NZS 1200 is referred to in the Worksafe Australia, National Standard for Plant. This Standard incorporates Amendment No. 1 (February 1998), Amendment No. 2 (September 1998) and Amendment No. 3 (April 2002). The changes arising from the Amendment are indicated in the text by a marginal bar and amendment number against the clause, note, table, figure, or part thereof affected. This Standard is the result of a consensus among representatives on the Joint Committee to produce it as an Australian Standard. Consensus means general agreement by all interested parties. Consensus includes an attempt to remove all objection and implies much more than the concept of a simple majority, but not necessarily unanimity. It is consistent with this meaning that a member may be included in the Committee list and yet not be in full agreement with all clauses of this Standard. Revisions and additions contained in the published Amendments 1 to 4 to the 1989 edition of this Standard, together with subsequent revisions and additions approved by the Committee, have been included in this edition. The main changes introduced subsequent to Amendment 4 include an extension to cover fired and unfired pressure vessels, non-metallic pressure vessels, extensive editorial modifications to align with current Standards Australia practice and a number of important technical changes, including the addition, revision and clarification of the scope, stress tables, minimum thickness, flat plates, inspection openings, transportable vessels, relief valve capacity and risk management. As part of the restructuring of various Standards covered by AS/NZS 1200 into core type Standards, most requirements for manufacture and heat treatment, welding and brazing qualification, examination and testing and installation have been deleted, and reference is made to specific Standards covering these matters. The removal of this data has left a number of appendices and clauses blank. The complete clause renumbering of the whole of the Standard has been avoided as clauses are referred to in many documents, such as quality assurance manuals, manufacturing specifications and computer calculations. Minor changes have been made in the welding procedure requirements, including relevant postweld heat treatment requirements, principally to align with world practice. It is not intended that qualified welding procedures will be invalidated by these changes nor that the changes will be applied retrospectively. References to riveted construction have been withdrawn as this type of construction is rarely used at the present time. For guidance, reference may be made to the now superseded AS CB1, Part 1: Boilers other than water tube boilers and locomotive boilers for railway purposes, reference copies of which are available at the Standards Australia Information Centres. A significant change by Amendment No. 2 to this 1997 edition is the reduction of the factor of safety used to determine the material design stress from 4 to 3.5. There are a number of justifications for such a change, including the improvement in the quality of materials, an improvement in the quality of welding and fabrication, improved inspection technology and better information on design, operation, maintenance and vessel failures. A2

5 3 AS This Standard follows in principle other codes forming part of AS/NZS 1200 in giving guidance to designers, manufacturers, inspection bodies, purchasers and users in the form of minimum engineering requirements which are necessary for the safe design, manufacture and testing of pressure vessels. In special instances additional requirements may be necessary for adequate performance or safety. The requirements in this Standard have been formulated to afford reasonably certain protection of life and property and to indicate where a margin for deterioration in service may be needed so as to give a reasonably long, safe period of usefulness. The Standard takes into consideration advancements in design and materials, and the evidence of experience. The Standard contains basic data necessary for design, including material specification, design parameters, requirements for fabrication, testing and inspection. These requirements are specified in terms of principles to the fullest practicable extent, supplemented where necessary by further detail to obtain uniform interpretation of principle and guidance on best methods. In other areas the Standard indicates where caution is necessary but a direct prohibition would be unwise at the present level of knowledge. The Standard incorporates the class system of vessels based on different classes of construction, and gives basic principles to indicate where such classes should or are to be used. Three main classes are adopted using the present level of stress (safety factor of 4 approximately). Additional classes of vessel, i.e. Class 1 H and 2 H, may be produced in accordance with AS 1210 Supplement 1, which permits the use of design stresses higher than those contained herein. The specific design requirements of the Standard are based on a simplified engineering approach and are intended to be the standard methods of design. However, in special instances, particularly where guidance is not provided in this Standard, other methods may be used provided that the validity of the design is satisfactorily established and agreed. No rules for manufacture can be written in sufficient detail to ensure good workmanship in manufacture. Each vessel manufacturer is responsible for taking every necessary step to make sure that the quality of manufacture is such as will ensure compliance with good engineering practice and design. The user will also need to consider many factors beyond those covered by this Standard in the final specification of a vessel and is cautioned that the Standard is not a complete design handbook and that there is a need for competent engineering judgement. The Standard continues to be written largely for Australian conditions and to cater for recent moves in various States and Territories to objective or performance regulations rather than the earlier prescriptive ones. These moves also have lead to privatization of inspection functions such as design verification, manufacture and in-service inspection, and agreement by designers, manufacturers, purchasers and others involved. Thus the Standard uses competent inspection bodies as in European Union practice in place of the previous regulatory authority; and is written as far as practical for clear interpretation and use in contracts to assist all parties and facilitate safety and trade. It provides flexibility to use alternative methods, materials, Standards and the like where equivalent safety and performance is achieved and any departures from the Standard are clearly identified in all documentation and are agreed. Acknowledgment is gratefully made to the American Society of Mechanical Engineers for permission to reproduce certain extracts from the ASME Boiler and Pressure Vessel Code. In addition, acknowledgment is made of the considerable assistance provided by British and other national Standards. This Standard makes use of the draft ISO Standard for pressure vessels and the current American and British Standards for pressure vessels as well as other selected leading Standards including the developing European Standards and the experience and

6 AS development in Australia. This has been done to take advantage of world experience and align with these major Standards to optimize safety and standardization and facilitate trade. Similarly compliance with the appropriate class of this Standard will satisfy the technical requirements for equivalent vessels to the above international Standards. However compliance with regulatory and quality assurance requirements of the country of use will need to be satisfied. For comparison of this Standard with the above Standards see AS/NZS 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 Appendices. A normative appendix is an integral part of this Standard and an informative appendix is only for information and guidance.

7 5 AS CONTENTS Page SECTION 1 SCOPE AND GENERAL REQUIREMENTS 1.1 SCOPE OBJECTIVE AND PERFORMANCE CRITERIA APPLICATION INTERPRETATION OF STANDARD NEW DESIGNS, MATERIALS AND MANUFACTURING METHODS CLASSES OF VESSEL CONSTRUCTION APPLICATION OF VESSEL CLASSES AND TYPES DEFINITIONS UNITS NOTATION INFORMATION TO BE SUPPLIED BY THE PURCHASER AND MANUFACTURER DESIGNATION REFERENCED DOCUMENTS SECTION 2 MATERIALS 2.1 MATERIAL SPECIFICATIONS STANDARD COMPONENTS AND INTEGRALLY CLAD METALS ALTERNATIVE MATERIAL AND COMPONENT SPECIFICATIONS MATERIAL IDENTIFICATION LIMITS OF APPLICATION OF MATERIALS AND COMPONENTS MATERIAL FOR LOW TEMPERATURE SERVICE MATERIAL FOR HIGH TEMPERATURE SERVICE NON-DESTRUCTIVE TESTING OF MATERIALS SECTION 3 DESIGN 3.1 GENERAL DESIGN DESIGN CONDITIONS DESIGN STRENGTHS THICKNESS OF VESSEL WALL WELDED AND BRAZED JOINTS LIGAMENT EFFICIENCY CYLINDRICAL AND SPHERICAL SHELLS SUBJECT TO INTERNAL PRESSURE AND COMBINED LOADINGS THICK-WALLED CYLINDRICAL AND SPHERICAL SHELLS SUBJECT TO INTERNAL PRESSURE CYLINDRICAL AND SPHERICAL SHELLS SUBJECT TO EXTERNAL PRESSURE CONICAL ENDS AND REDUCERS SUBJECT TO INTERNAL PRESSURE CONICAL ENDS AND REDUCERS SUBJECT TO EXTERNAL PRESSURE DISHED ENDS SUBJECT TO INTERNAL PRESSURE...121

8 AS Page 3.13 DISHED ENDS SUBJECT TO EXTERNAL PRESSURE DISHED ENDS BOLTED SPHERICAL TYPE UNSTAYED FLAT ENDS AND COVERS STAYED FLAT ENDS AND SURFACES FLAT TUBEPLATES OPENINGS AND REINFORCEMENTS CONNECTIONS AND BRANCHES INSPECTION OPENINGS BOLTED FLANGED CONNECTIONS PIPES AND TUBES JACKETED VESSELS VESSEL SUPPORTS ATTACHED STRUCTURES AND EQUIPMENT TRANSPORTABLE VESSELS QUICK-ACTUATING CLOSURES METALLIC EXPANSION JOINTS PRESSURE VESSELS FOR HUMAN OCCUPANCY BURIED AND MOUNDED STORAGE VESSELS VESSELS OF NON-CIRCULAR CROSS-SECTION FIRED PRESSURE VESSELS A VESSELS WITH INCREASED DESIGN STRENGTH AT LOW TEMPERATURE PLATE HEAT EXCHANGERS SECTION 4 MANUFACTURE 4.1 GENERAL WELDED CONSTRUCTION CLAD AND LINED CONSTRUCTION NOT ALLOCATED BRAZED CONSTRUCTION FORGED CONSTRUCTION CAST CONSTRUCTION SECTION 5 TESTING AND QUALIFICATION 5.1 GENERAL WELDING AND BRAZING QUALIFICATION AND PRODUCTION TEST PLATES NON-DESTRUCTIVE EXAMINATION TO 5.9 NOT ALLOCATED 5.10 HYDROSTATIC TESTS PNEUMATIC TESTS PROOF HYDROSTATIC TESTS LEAK TEST TO 5.16 NOT ALLOCATED 5.17 SPECIAL EXAMINATIONS AND TESTS SECTION 6 ASSURANCE OF PRODUCT QUALITY...273

9 7 AS Page SECTION 7 MARKING 7.1 MARKING REQUIRED METHODS OF MARKING LOCATION OF MARKING SIZE AND TYPE OF MARKING MULTI-CHAMBER VESSELS WITNESSING OF MARKING SECTION 8 PROTECTIVE DEVICES AND OTHER FITTINGS 8.1 GENERAL REQUIREMENTS VESSELS REQUIRING PRESSURE-RELIEF DEVICES TYPES OF PRESSURE-RELIEF DEVICES PRESSURE-RELIEF VALVES BURSTING DISCS AND OTHER NON-RECLOSING PRESSURE-RELIEF DEVICES REQUIRED DISCHARGE CAPACITY OF PRESSURE-RELIEF DEVICES PRESSURE SETTING OF PRESSURE-RELIEF DEVICES INSTALLATION OF PRESSURE-RELIEF DEVICES DISCHARGE FROM PRESSURE-RELIEF DEVICES VACUUM-RELIEF DEVICES FUSIBLE PLUGS PROTECTION AGAINST EXCESSIVE TEMPERATURE PRESSURE GAUGES LIQUID LEVEL INDICATORS ISOLATION FITTINGS DRAINAGE VENTS PROTECTION OF VALVES AND FITTINGS SECTION 9 PROVISIONS FOR DISPATCH 9.1 CLEANING PROTECTION ASSOCIATED FITTINGS AND COMPONENTS SECTION 10 NON-METALLIC VESSELS 10.1 SCOPE GENERAL REQUIREMENTS APPENDICES A BASIS OF DESIGN TENSILE STRENGTH B FINITE ELEMENT ANALYSIS C RISK MANAGEMENT D RECOMMENDED CORROSION PREVENTION PRACTICE E INFORMATION TO BE SUPPLIED BY THE PURCHASER TO THE DESIGNER/MANUFACTURER F INFORMATION TO BE SUPPLIED BY THE DESIGNER/MANUFACTURER...310

10 AS Page G TO J NOT ALLOCATED K LOW TEMPERATURE VESSELS L TO Q NOT ALLOCATED R LIST OF REFERENCED DOCUMENTS S FIRE PROTECTION OF PRESSURE VESSELS INDEX...330

11 9 AS STANDARDS AUSTRALIA Australian Standard Pressure vessels A3 SECTION 1 SCOPE AND GENERAL REQUIREMENTS 1.1 SCOPE This Standard sets out minimum requirements for the materials, design, manufacture, testing, inspection, certification and despatch of fired and unfired pressure vessels constructed in ferrous or non-ferrous metals by welding, brazing, casting, forging, or cladding and lining and includes the application of non-integral fittings required for safe and proper functioning of pressure vessels. This Standard also specifies requirements for non-metallic vessels and metallic vessels with non-metallic linings. For detailed requirements for metallic materials, manufacture and testing, reference should be made to the relevant material Standards, and to AS 4458, AS/NZS 3992 and AS The requirements of this Standard have been formulated on the basis that the required examinations and inspection during manufacture are performed and that appropriate reasonable care is taken of the vessels during subsequent stages in the life of vessels including appropriate inspection for deterioration. 1.2 OBJECTIVE AND PERFORMANCE CRITERIA Objective of the Standard This Standard aims to specify clear, uniform, safe requirements which (a) cover the materials, design, manufacture, testing, inspection, certification and despatch of pressure vessels; and (b) facilitate the supply of pressure vessels which meet the purchaser s requirements Performance requirements To meet the above objective, pressure vessels supplied to this Standard are to satisfy the following performance criteria when produced and used in accordance with the contract, the designed service conditions and sound practice (a) provide reasonably certain protection of all persons involved in various stages of the vessel s life and of adjacent property and environment; (b) provide appropriate economy, performance, reliability, operability, inspectability and maintainability over a reasonably long life; and (c) control risks to at least satisfy applicable safety, health and environment laws. The remainder of this Standard gives prescriptive requirements which satisfy the above criteria in the matters covered. 1.3 APPLICATION This Standard is intended to apply to pressure vessels (a) with design pressures above the curves in Figures and but not exceeding 21 MPa for welded, forged, brazed or cast metallic vessels or non-metallic vessels unless otherwise agreed by the parties concerned; and (b) with operating temperatures within the temperature limits for various materials and components as stated in the appropriate Section of this Standard. Standards Australia

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