TSG特种设备安全技术规范TSG Safety Technical Specification for Special EquipmentTSG R7001-2004压力容器定期检验规则Pressure Vessels Periodical Inspection RegulationIssued by State General Bureau of Quality Supervision, Inspection and Quarantine of the People’s Republic of ChinaJune 23, 2004ContentsChapter 1 General (3)Chapter 2 Annual Examination (6)Chapter 3 Overall Inspection (14)Chapter 4 Pressure Resistance Test (25)Chapter 5 Evaluation of Class of safety Status (29)Chapter 6 Supplementary Provisions (36)Appendix I Additional Requirement for Periodical Inspection of Movable Pressure Vessels (38)Appendix II Requirement for Periodical Inspection of Medical Use Oxygen Cabin (48)Appendix III Requirement for Calibration of Safety V alves (63)Annex I Annual Examination Report on Pressure V essels (69)Annex II Overall Inspection Report on Pressure V essels (72)Annex III Report on Pressure Resistance Test (92)Annex IV Notice of Comments on Inspection of Special Equipment (1) (93)Pressure Vessels Periodical Inspection RegulationChapter 1 GeneralArticle 1 To guarantee the quality of periodical inspection of in-use pressure vessels and to secure safe running of pressure vessels as well as to avoid occurrence of any accident, this regulation is worked out in accordance with the Safety Supervision Regulation for Special Equipment and Safety Technical Supervision Regulation for Pressure Vessels (hereinafter referred to as RPV).Article 2 This regulation applies to annual examination and periodical inspection of pressure vessels within the scope of application of pressure vessels, annual examination and periodical inspection of in-use truck tanks (hereinafter referred to as truck tanks) and in-use tank containers (hereinafter referred to as tank containers) shall, apart from compliance with relevant requirements in the text of this regulation, also follow what specified in Appendix I of this regulation the Additional Requirement for Periodical Inspection of Movable Pressure Vessels.For annual examination and periodical inspection of in-use medical oxygen cabins (hereinafter referred to as oxygen cabins for medical use, abbreviated as MUOC), Appendix II of this regulation the Requirement for Periodical Inspection of Oxygen cabins for medical use shall apply.Article 3 Annual examination is the in-line examination during the running to secure the safety of pressure vessels within the inspection interval, which shall be done at least one a year. Annual examination of fixed pressure vessels may be done either by pressure vessel professional personnel of the user organization, or by certified pressure vessel inspection personnel of inspection organization (hereinafter referred to as inspection organization, abbreviated as IO) which is approved by the State General Bureau of Quality Supervision, Inspection and Quarantine (hereinafter referred to as SGBQI).Article 4 Periodical inspection of pressure vessels includes overall inspection and pressure resistance test.1. Overall inspection is the inspection at the halt of pressure vessels, which shall be done byIO. The inspection interval shall be:(1) For pressure vessels with safety status of Class 1 or Class 2, in general, it shall beonce 6 years;(2) For pressure vessels with safety status of Class 3, in general, it shall be once 3 ~ 6years;(3) For pressure vessels with safety status of Class 4, in general, it shall be determinedby IO.The evaluation of safety status of pressure vessels shall be done in accordance with Chapter 5 of this regulation.2. Pressure resistance test is the hydraulic test or air pressure test at pressure exceeding max.working pressure done after qualification of overall inspection of pressure vessels. In principle, within the period of two overall inspections, one pressure resistance test shall be done.In case the overall inspection, pressure resistance test and annual examination are done in same year, the sequence shall be overall inspection, pressure resistance test and annual examination, the items which have been overall inspected may not be examined in annual examination repeatedly.For pressure vessels for which overall inspection and pressure resistance test cannot be done or cannot be done in schedule, Article 138 of RPV shall apply.Article 5 First overall inspection shall be done to pressure vessels which have been put into operation for 3 years. The next overall inspection interval shall be determined by IO according to the results of this inspection based on relevant stipulations of Article 4 of this regulation.1. Overall inspection interval for pressure vessels of any of following cases shall beshortened appropriately:(1) The corrosion of medium to vessel material is not clear or the annual corrosion rateof medium to material is > 0.25mm, or the corrosion data determined by designer is not in conformity with actual condition;(2) The surface quality of material is bad or there is internal defects;(3) Application condition is severe or stress corrosion is found in application;(4) The application term exceeds 20 years and it is determined by inspectors or bytechnical verification that the normal inspection interval cannot secure the safe application;(5) The application is stopped for more than 2 years;(6) Medium is changed and there is possibility of worse corrosion;(7) Design drawing shows that pressure resistance test can not be made;(8) During the inspection, other factors affecting safety are doubtable;(9) Medium is LPG and there is stress corrosion, overall inspection shall be made everyyear or on necessary;(10) In case the process is used to make paper and no anti-corrosion measures are taken,overall inspection shall be made at least once a year for steam balls;(11) Spherical tanks (made of material of lower limit of standard tensile strength σb≥540Mpa, open tank inspection shall be made to them after putting into operation for one year.);(12) E quipment of glass lining.2. Overall inspection interval for pressure vessels with safety status of Class 1 or Class 2 ofany of following cases shall be shortened appropriately:(1) Inspection interval for those of good non-metal lining can be prolonged to 9 years;(2) In case the corrosion rate of medium to material is < 0.1mm (actually measured data)and there is reliable corrosion resistance metal lining（composite steel plate）or hot-sprayed metal coat (aluminum powder or stainless steel) and it is confirmed after1 ~2 overall inspections that the corrosion is light or the lining is good, theinspection interval can be prolonged to 12 years;(3) For reactors filled with catalyst and large pressure vessels packed with fillingmaterial, the inspection interval shall be determined by user organization, designer and IO after discussion in accordance with design drawings and actual application conditions, which shall be reported to the quality technical supervision department where the Application Register Card was applied and obtained (hereinafter referred to as Certificate Issuing Organ, abbreviated as CIO) for record.Article 6 The accumulated application time for pressure vessels under monitoring with safety status of Class 4 shall not exceed 3 years. During the app lication period under monitoring, defects shall be treated to raise the class of safety status , otherwise they shall not be used further.Article 7 Pressure resistance test shall be made after overall inspection to pressure vessels of any of following cases is made and qualified:1. Pressure elements are replaced by the way of welding;2. The depth of remedy welding for pressure element is > 1/2 wall thickness;3. Application condition is changed and the original design parameters are exceeded andafter strength verification, it is qualified;4. Those needing lining replacement (pressure resistance test shall be done before liningreplacement);5. Application is resumed after 2 years’ stoppage;6. It is replanted from external organization or from same organization;7. The user organization or IO has doubt about the safety status of the pressure vessel.Article 8 IO and inspectors engaging in periodical inspection of pressure vessels shall makeinspection strictly in accordance with the scope of inspection approved. IO and inspectors shall accept supervision of local quality technical supervision department and shall be responsible for the correctness of the results of periodical inspection of pressure vessels.Prior to the inspection, IO shall work out inspection scheme, which shall be checked and approved by technical responsible person authorized by IO. For inspection scheme for pressure vessels of special requirements, IO shall solicit opinion of user organization and original designer. In case of any discrepancy, the opinion of IO shall apply. Inspectors shall make inspection strictly in accordance with the approved inspection scheme.Article 9 User organization shall apply for periodical inspection of pressure vessels 30 days in advance the expiration date of inspection validity, meanwhile the application form for pressure vessels inspection shall be submitted to IO and CIO. IO shall fulfill inspection in accordance with inspection plan.Article 10 User organization shall closely cooperate with IO and well do the technical treatment after halt as well as safety checks before inspection in accordance with this regulation. Inspection shall not start until it is confirmed that it meets requirements for inspection. They shall also provide cooperation at inspection site.Chapter 2 Annual ExaminationArticle 11Annual examination of pressure vessels includes examination of safety management of pressure vessels by user organization, examination of pressure vessels themselves and their running status as well as examination of safety accessories of pressure vessels.The way of examination shall be mainly the macro examination, if necessary, thickness measuring, examination of wall temperature and measurement of content of corrosive medium as well as test of vacuum shall be made.Article 12 Prior to annual examination, user organization shall make following preparation ready:1. Cleaning of outer surface and environment of pressure vessels;2. Site lighting, protection for high position climbing and removal of local insulation shallbe done to meet the need of site examination;3. Technical files, running records as well as records of harmful impurities used for pressurevessels shall be ready;4. Regulations for safety management of pressure vessels as well as regulations for safetyoperation and certificates of operators shall be ready;5. During examination, management personnel and relevant personnel for pressure vesselsof user organization shall be present to assist examination and provide other informationexaminers needed.Article 13Before examination, examiners shall have an overall understanding of use condition and management condition of pressure vessels to be examined and seriously review technical files and management information of pressure vessels and relevant records shall be made.The examination of safety management conditions of pressure vessels shall include followings:1. Regulations for safety management and regulations for safety operation of pressurevessels, whether records are complete and true, look over desk exercises (or accounting books) of pressure vessels to be sure they are in conformity with actual condition;2. Examine file documents of drawings, application register cards, product qualitycertificates, instructions, supervision and inspection certificates, annual inspection reports in history, documents of reconstruction to be sure whether they are complete and meet requirements.3. Whether operators of pressure vessels are working in posts with certificate;4. Are issues referred in last inspection and examination reports solved?Article 14 For examination of pressure vessels themselves and their running condition, in general, insulation may not be removed unless required by examiners.Article 15 Examination of pressure vessels themselves and their running condition shall include followings:1. Whether the nameplate, color of painting, marks as well as painted application cardnumber meet relevant regulation?2. Whether there are crack, overheat, deformation, leakage or damage in the body,connecting places (valves, piping) and welding joints of pressure vessels;3. Whether there are damage, abnormal, frosting or dewing in outside surface;4. Whether there are damage, peeling off, damping or cold leakage of insulation;5. Whether there are liquid leakage or air leakage from leakage inspection holes or signalholes and whether leakage inspection holes are unimpeded;6. Whether there are abnormal vibration or abnormal sound or mutual friction betweenpressure vessels and adjoining piping or elements;7. Whether there is damage to supports or supporting seats, whether there are settlement,inclination, crack in foundation, whether fastening bolts are complete and in good order;8. Whether draining facilities (traps, drainage) are good;9. Whether there are over pressure, over temperature or over quantity during running;10. Whether earthing for tanks needing earthing meet requirements;11. The implementation of measures for those pressure vessels with safety status class ofClass 4 under monitoring and whether there is any abnormal situation;12. Whether safety-interlocking devices for pressure vessels of quick-open door meetsrequirements.Article 16 Inspection of safety accessories includes examination and calibration of pressure gauges, level gauges, temperature measuring instruments, disrupture disk devices and safety valves (for calibration requirements of safety valves, see Appendix III).1. Pressure gauges(1) Annual examination of pressure gauges shall at least include followings:(a) Type selection of pressure gauges;(b) Rules for periodical inspection and maintenance of pressure gauges, validity ofverification and the seal;(c) Appearance, class of precision, scale range and diameter of panel of pressuregauges;(d) The position, marks for opening as well as interlocking devices of T plugs andneedle valves installed between pressure vessels and pressure gauges;(e) Whether readings of pressure gauges in same system are same.(2) During annual examination, for any of following cases found, user organization shallbe asked to rectify them within limited time and effective measures shall be taken to secure the safe during the rectification period. In case they are not corrected beyond the time, the use of that pressure vessels shall be stopped temporarily:(a) Wrong selection of type;(b) Panel cover glass is broken or scale of graduation in panel is not clear;(c) Lead seal is damaged or it is beyond validity of verification;(d) There is leakage in the spring tube in instrument or the indicating hand ofpressure gauge is loose;(e) Indicating hand is tortured or broken or outer housing is seriously corroded;(f) Marks for opening of T plug or needle valves are not clear or the locking deviceis damaged.2. Level gauges(1) Annual examination of level gauges shall at least include followings:(a) Rules for periodical inspection and maintenance of level gauges;(b) Appearance and accessories of level gauges;(c) Selection of type of level gauges outdoor used in cold areas or fully filled withmedium with temperature below 0℃;(d) Protection device from leakage of level gauges used in pressure vessels forliquefied gases with flammable medium of toxicity degree of extreme and highhazard.(2) During examination, for any of following cases found, user organization shall beasked to rectify them within limited time and effective measures shall be taken to secure the safe during the rectification period. In case they are not corrected beyond the time, the use of that pressure vessels shall be stopped temporarily:(a) Inspection and maintenance period is beyond the specified period;(b) There is crack or break in glass plate (tube);(c) V alve elements are dead;(d) There is false level;(e) Indication of level gauge is not clear;(f) Wrong selection of type;(g) Protection device from leakage is damaged.3. Temperature measuring instruments(1) Annual examination of temperature measuring instruments shall at least includefollowings:(a) Rules for periodical verification, inspection and maintenance of temperaturemeasuring instruments;(b) The meeting of the scale range of temperature measuring instruments to therange of temperature to measure;(c) Appearance of temperature measuring instruments and their secondaryinstruments.(2) During examination, for any of following cases found, user organization shall beasked to rectify them within limited time and effective measures shall be taken to secure the safety during the rectification period. In case they are not corrected beyond the time, the use of that pressure vessels shall be stopped temporarily:(a) Inspection and maintenance period is beyond the specified period;(b) Instruments and their protection devices are broken;(c) Wrong selection of scale range of instruments.4.Disrupture disk devices(1) Annual examination of disrupture disk devices shall at least include followings:(a) Examine the disrupture disk devices to be sure whether they are beyond theapplication period specified in product instructions;(b) Examine the installation direction of the disrupture disk devices to be surewhether they are correct and check the blast pressure and temperature in nameplate to be sure whether they meet running requirements;(c) For the case in which the disrupture disk is used to release pressure separately(Figure 1), examine the globe valve between the disrupture disk and the vessel to be sure whether it is at full open status and whether the lead seal is good;(d) For the case the disrupture disk is used with safety valve in series and if thedisrupture disk is installed at the inlet side of the safety valve (Figure 2), examine the pressure indication of the pressure gauge installed between the disrupture disk and the safety valve, and open the globe valve to check whether there is air vent;Figure 1 Disrupture disk is used separately1 – Disrupture disk；2 – Globe valveFigure 2 Disrupture disk and safety valve are used in series (Disrupture disk is installed at inlet side of the safety valve)1 – Disrupture disk；2 – Globe valve；3 – Pressure gauge；4 – Safety valve(e) In case the disrupture disk is used with safety valve in series and if the disrupturedisk is installed at the outlet side of the safety valve (Figure 3), examine the pressure indication of the pressure gauge installed between the disrupture disk and the safety valve, if there is pressure indication, open the globe valve to check whether the trap and air vent is good;(f) For the case the disrupture disk is used with safety valve in parallel (Figure 4),examine the globe valve installed between the disrupture disk and the safety valve to be sure whether it is at full open status and whether the lead seal is in good order.Figure 3 Disrupture disk and safety valveare used in series(Disrupture disk is installed at outlet side ofthe safety valve)1 – Disrupture disk ；2 – Globe valve ；3 – Pressure gauge ；4 – Safety valveFigure 4 Disrupture disk and safety valve are used in parallel 1 – Disrupture disk ；2 – Globe valve ； 3 – Safety valve(2) During annual examination, for any of following cases found, user organization shallbe asked to replace the disrupture disk device and effective measures shall be taken to secure the safety during the replacing period. In case they are not replaced beyond the time, the use of that pressure vessel shall be stopped temporarily:(a) Application term of disrupture disk is beyond the specified period;(b) Wrong installation direction of the disrupture disk;(c) Rated blast pressure and temperature of the disrupture disk do not meet runningrequirements;(d) During application, when pressure exceeds rated blast pressure, it does not blast; (e) In case the disrupture disk is installed at the inlet side of the safety valve to beused with the safety valve in series, there is pressure indication in the pressuregauge installed between the disrupture disk and the safety valve or air leakswhen the globe valve is open.(f) Disrupture disk device leaks.(3) For annual examination of pressure vessels for which the disrupture disk device isseparately used as pressure release device or the disrupture disk is used with safety valve in parallel, in case the globe valve installed between the disrupture disk and the vessel is found to be not at full open status or the lead seal is damaged, user organization shall be asked to rectify them within limited time and effective measures shall be taken to secure the safety during the rectification period. In case they are not corrected beyond the time, the use of that pressure vessels shallbestopped temporarily5. Safety valves(1) Annual examination of safety valves shall at least include followings:(a) Whether the selection of type of safety valves is correct;(b) Whether the calibration validity of safety valve is expired;(c) For lever type safety valves, check the device which prevents the hammer fromfree movement and the lever from out-positioning of the lever to be sure they arein good order; for still weight type safety valves, check the device whichprevents the weight from flying off to be sure it is in good order.(d) In case globe valves are installed between safety valves and draining ports,check the globe valve to be sure they are at full open status and lead seal is ingood order.(e) Whether safety valves leak;(2) During annual examination, for any of following cases found, user organization shallbe asked to rectify them within limited time and effective measures shall be taken to secure the safety during the rectification period. In case they are not corrected beyond the time, the use of that pressure vessel shall be stopped temporarily:(a) Wrong selection of type;(b) Calibration and inspection validity is expired;(c) Lead seal is damaged;(d) Safety valves leak.Article 17 In general, safety valves shall be inspected and calibrated at least once a year. For safety valves of spring direct load type, the inspection and calibration interval may be prolonged appropriately subject to approval of technical responsible person of user organization and meeting what specified in this article.1. The inspection and calibration interval of the safety valves of spring direct load type,which meet all following conditions, may be prolonged to 3 years;(1) Manufacturer of safety valves has obtained manufacture license issued by the statequality inspection department;(2) Manufacturer of safety valves may provide certificate to proof that all springs havebeen strong pressure treated or strong pressure treated with heat in accordance with the standard the Safety Valves of Spring Direct Load Type GB / T 12243 – 1989, in addition, 10% (not less than 2 pieces) springs of same specification and same heat treatment furnace shall be measured at specified load for their deformation or rigidity and the error of the deformation or rigidity shall not be > 15%.(3) Material of internals of safety valves shall corrosion resistance to the medium;(4) Safety valves have never been opened during application;(5) No notable rust in pressure vessels and body of safety valve;(6) Medium of non-sticky and toxicity degree of intermediate or below is filled inpressure vessels.2. In case the user organization has established and executed perfect rules for use,management and maintenance of equipment and all of following conditions are met, it may also be prolonged to 3 years:(1) During 2 continuous running examinations, no problem listed in (2) of 5 in Article16 is found to any safety valve;(2) User organization has set up safety valve inspection and calibration station whichmeets requirements in Appendix III to make inspection and calibration of safety valves himself;(3) User organization has set up reliable pressure control and regulating device or overpressure alarming device.3. For safety valves of spring direct load type which meet requirements specified in (1), (3),(4) and (5) of 1 in this article as well as 2 of this article, the inspection and calibrationinterval may be prolonged to 5 years subject to they meet all following conditions:(1) Manufacturer of safety valves may provide certificate to proof that all springs havebeen strong pressure treated or strong pressure treated with heat in accordance with the standard the Safety Valves of Spring Direct Load Type GB / T 12243 – 1989, in addition, 20% (not less than 4 pieces) springs of same specification and same heat treatment furnace shall be measured at specified load for their deformation or rigidity and the error of the deformation or rigidity shall not be > 10%;(2) Medium of toxicity degree of low or below is filled in pressure vessels and workingtemperature is not > 200℃.4. For all safety valves of which inspection and calibration interval are prolonged, userorganization shall report the condition for prolonged inspection and calibration in written to CIO.Article 18In case site calibration and pressure adjustment (in-line calibration) of safety valves is necessary, technical personnel in charge of safety of pressure vessels of user organization as well as trained and qualified personnel for safety valves shall be present. Lead seal shall be made to calibrated and qualified safety valves. The precision of pressure gauges for adjustment and calibration use shall not be lower than Class 1. Reliable protection measures shall be provided to the adjustment and calibration of safety valves.Article 19 On completion of annual examination, examiners shall issue examination reportbased on the actual examination conditions to make following conclusion:1. Allowable running: It means no defect or light defect which will not affect the safety isfound;2. Running under monitoring: It means the defect of general nature is found, safe runningcan be secured after taking measures by user organization. In the conclusion, the problems to solve and the time limit to complete for the running under monitoring shall be noted;3. Stop running temporarily: It only refers to the case that the problems of safety accessorieshave not been solved beyond the time limit specified. When problems are solved and confirmed, the running can be resumed.4. Stop running: It refers to the case that serious defects are found and the safe running ofpressure vessels can not be secured, the running shall be stopped or further inspection shall be made by pressure vessel certified inspectors from IO.In general, annual examination shall not evaluate the class of safety status of pressure vessels. However in case serious problems are found, it shall be evaluated by certified pressure vessel inspectors from IO in accordance with what specified in Chapter 5 of this regulation and the class of safety status of pressure vessels may be lowered appropriately.Chapter 3 Overall InspectionArticle 20 Prior to the inspection, following documents shall be reviewed:1. Qualification of designer, design and installation instructions, design drawings as well asstrength calculations and so on;2. Qualification of manufacturer, date of manufacture, product certificate, qualitycertificate (for low temperature (heat isolated) pressure vessels, criteria of vacuum of sealed openings, inspection results of leakage rate of vacuum jacket as well as static evaporation rate and so on shall also be included) and as-built drawings;3. Qualification of organization for site assembling of large pressure vessels, date ofinstallation as well as documents of completion and acceptance;4. Certificate of supervision and inspection of manufacture and installation, supervisionand inspection reports on safety performance of imported pressure vessels;5. Application register card;6. Annual examination reports in running interval;7. Overall inspection reports in history;8. Records of running, records of start-up and shut down, records of changes of operationconditions and abnormal conditions occurred in running;。
