EUROPEAN CONFEDERATION OF CONTROL, INSPECTION AND PREVENTION ORGANISATIONS

CONFÉDÉRATION EUROPÉENNE DES ORGANISMES DE CONTRÔLE, D'INSPECTION ET DE PRÉVENTION

EUROPÄISCHE VEREINIGUNG DER ÜBERWACHUNGS-, PRÜF- UND PRÄVENTIVORGANISATIONEN

______________________________________________________________________________________________

CEOC Recommendation

Periodicity of inspections of boilers and pressure vessels

R 47/CEOC/CP 83 Def

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R 47/CEOC/CP 83 Def 1

PERIODICITY OF INSPECTIONS OF BOILERS AND PRESSURE VESSELS

1. INTRODUCTION

1.1 General

1.1.1 Reasons for the study

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In the countries of all CEOC-members the periodical inspection of a given vessel, generally imposed
by national legislation, is carried out at intervals which vary enormously from one country to another
without apparent technical justification in all cases. It would therefore seem necessary to study this
periodicity from a purely technical point of view.

1.1.2 Aim of the study

----------------
- Within CEOC itself, the establishment of this recommendation constitutes first of all a very
valuable exchange of experience between the different participating members.
In another respect, it must constitute the advice that CEOC can give to the different delegates in
the national or international commissions in setting the CEOC position on this question.

- Outside CEOC, this recommendation could serve as a basis for discussion between a CEOC
member and its government concerning the evolution of legislation on pressure vessels and
particularly the periodicity of inspections.

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1.1.3 Definitions of terms

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- Periodicity :
Regular interval of time, in years or in months, which separates two consecutive inspections of
the same kind and on the same vessel.

- Internal inspection (I) :

Inspection inside and outside carried out whilst the vessel is out of service, cold and opened up
and including an inspection of all fittings and safety devices.

- Working inspection or external inspection (E) :

Inspection carried out whilst the vessel is in service, not necessarily in use but under pressure
including an inspection of all fittings and safety devices.

- Hydraulic overpressure (H) :

A test which involves maintaining the vessel under water pressure, for a certain length of time, at
a pressure greater than the maximum service pressure.

- Leak test (h) :

A test which involves maintaining the vessel under water pressure, for a certain length of time, at
a pressure no higher than the maximum service pressure. (If the leak test is carried out using a
gas, special precautions must be taken in accordance with CEOC Document R 31).

1.2 Existing periodicities

1.2.1 Comparison
----------
For the different categories of vessels or installations under review, that is to say :
- steam boilers,
- hot water boilers,
- pressure vessels containing
steam,
air,
gas,
- organic fluid heating systems,

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R 47/CEOC/CP 83 Def 3

a table was drawn up which gives, for the periodicities between 1 and 12 years, the number of
countries concerned, the average periodicity and the maximum periodicity.

It is quite clear that the very nature of this presentation calls for a summary leaving out of certain
details, particularly concerning gas pressure vessels.

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From Table 1 one can, by rounding off the figures, arrive at the following information for each
category of vessel as portrayed in Table 2 :

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It quite clear that the average periodicities contained in the table cannot logically be considered as
optimum periodicities. They can nevertheless serve as a basis for discussion as it would seem that no
country can in all cases truly justify from a technical viewpoint its own periodicities. This would
furthermore be very surprising taking into account the great differences that one sees for certain
categories of vessel. As an example, if one takes the case of an air receiver which would seem to
represent the most simple of pressure vessels, one sees from Table 1 that the periodicities vary from
1 to 8 years for internal inspections and that three countries do not carry out such inspections at all.

The same remark applies to the external inspections and particularly hydraulic retesting which is not
called for in 7 countries out of 13.

Therefore, must we conclude that certain inspections of short periodicity are unnecessary or that
certain countries are less conscientious ?

It is on this basis therefore that the discussions have been held and on which the present
recommendations have been developed.

1.2.2 Periodicities and statistics

----------------------------
It would seem that few or no statistics of accidents or incidents exist which provide useful indications
influencing the fixing of periodicity. In fact, these incidents or accidents are most often the result of
multiple causes, which makes it difficult to tabulate and analyse them for a same type of vessel.
These accidents or incidents are connected not only with the type of vessel but also and above all
with a certain number of elements constituting what one would call the vessel's environment :
material, method of construction, conception, maintenance, method of use. It would not therefore
seem possible to establish an optimum periodicity from any relationship (except in some particular
and rare cases) between the nature and frequency of certain defects or incidents on certain types of
vessel and the periodicity of inspections of these same vessels.

What is more, the absence of defects or incidents is no absolute proof that one can increase the
periodicity of inspections or even stop them altogether ; it is perhaps just because these inspections
are carried out at this periodicity that we experience few or no defects.

© by CEOC 1983
R 47/CEOC/CP 83 Def 7

Under these conditions, the use of statistics of accidents or incidents, themselves very difficult to
establish, does not appear to be the ideal criterion on which to base the periodicity of inspections.

1.3 General guidelines and tendencies

If one wishes to arrive at a reasonable periodicity for inspections, that is to say, a periodicity which,
without compromising safety, does not penalise the rate of use of the vessel, it would seem
necessary to take into account the following points :

1.3.1 Construction
------------
The vessel must have been designed, built and controlled according to the requirements of a
recognised code. It should be stamped on a plate showing design details and identification number
which should be checked by the Inspector at each periodic inspection.

1.3.2 Initial Inspection

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The vessel, its fittings and safety devices must undergo an external inspection (E) before being taken
into use for the first time. In some cases an internal inspection (I) will be carried out at the discretion of
the Inspection Authority, e.g. after any significant alteration to the installation.

1.3.3 Hydraulic overpressure test and leak test

-----------------------------------------
Overpressure tests (H) are carried out at pressure exceeding the maximum service pressure with the
object of proving the mechanical strength and integrity of the vessel and as a final check of the design
and quality of the vessel on completion of manufacture.

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Although most countries continue to prescribe overpressure testing for new vessels, after major
repairs or important alterations ; this routine testing on a recurring basis has largely been replaced by
non-destructive testing unless access for adequate visual inspection and non-destructive testing is
not possible.

In the countries of several CEOC-Members routine overpressure testing or leak testing is still
prescribe in their national regulations as an effective means of ensuring the continuing integrity of the
vessel.

We arrive therefore at the following tendencies :

1.3.3.1 Overpressure testing should be carried out in accordance with the requirements of national
regulations. Where no specific regulation applies, it should be replaced by external and internal
non-destructive testing. If the construction or geometry of the vessel precludes internal access,
overpressure testing must be reconsidered.

1.3.3.2 If leakage is suspected, a leak test (h) should be carried out at a pressure which does not exceed the
maximum permissible working pressure.

1.3.3.3 Overpressure testing is a requirement for new vessels or after major repair to parts under pressure
or important changes such as an increase in working pressure and is complimentary to non-
destructive testing.

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1.3.4 Cycle of periodicities

----------------------

It would seem technically desirable to carry out inspections following a variable cycle throughout the
life of the vessel and which one could define as follows :

At the start of the life of a vessel, the inspections should be carried out following a periodicity
relatively short in order to assure in the first place that all is in good order as far as the vessel is
concerned and in the second place that all is correctly in place in its environment : personnel
involved in the operation and maintenance, conditions of use, etc.

Subsequently, and during the normal life of the vessel, the periodicity could be extended but with the
possibility of being returned to a shorter frequency by the inspector or the inspecting organisation if he
has detected something abnormal which could affect its safety.

Towards the end of the life of the vessel, the periodicity of inspections could be shortened, either in
the normal course by the inspector as described above, or by a pre-established method if one wished
to anticipate creep damage for example.

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2. RECOMMENDATION FOR MAXIMUM PERIODICITY OF INSPECTIONS

FOR DIFFERENT CATEGORIES OF VESSEL

2.1 Steam boilers

2.1.1 Commissioning
-------------
Before commissioning, the boiler must undergo a complete internal and external inspection. As soon
as possible after first raising steam, a working inspection (E) is to be carried out on the boiler and its
auxiliary equipment.

2.1.2 First periodic inspection

-------------------------
The first periodic inspection of the boiler "in service" (I) (as distinct from the initial inspection of a
"new" boiler) shall be carried out within a period specified by the inspecting organisation but within the
twelve months which follow the first raising of pressure and shall be immediately followed by a
working inspection (E).

2.1.3 Subsequent periodicity

----------------------

2.1.3.1 For internal inspections (I)

a) 2 years
for normal boilers (i.e. shell and water tube boilers with drums and/or headers) if the first report
does not include any unfavourable remarks.

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b) The inspector or the inspecting organisation will have the power to reduce the periodicity if he is
not satisfied and if he thinks that the boiler cannot continue to be used in safety during the whole
of the following two years. The reasons for dissatisfaction could in particular be based on any one
of the following points :
- qualification and training of operators,
- maintenance of the boiler and its control equipment,
- feedwater treatment,
- operating conditions,
- constructional characteristics.

2.1.3.2 Working inspections (E) : annual

Whenever there has been an internal inspection (I), the working inspection (E) must be carried out
as quickly as possible and in all cases not more than two months after return of the vessel to
service under pressure.

There must be at least one inspection (E) each calendar year.

2.1.3.3 Hydraulic overpressure testing (H) or Leak test (h)

Hydraulic overpressure testing (H) or leak test (h) should only be carried out on certain types of
boiler where due to the type of construction visual inspection is impracticable and where NDT
cannot be fully applied. These tests should be complementary to the internal inspection (I) on a
periodic basis. Periodicity in such cases : 4 years.

Hydraulic overpressure testing should always be carried out following major repairs or after
important changes or before important changes in operating conditions such as an increase in
working pressure.

2.2 Hot water boilers

Comments for this type of boiler are similar to these for steam boilers but with the following
periodicities :

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(I) (E)

a) with operating temperatures over 120°C 3 years 1 year

b) with operating temperatures between 90°C and 120°C 00 1 year

c) with operating temperatures under 90°C oo oo

Power of inspectors and inspecting organisations to reduce periodicity is similar to that given for
steam boilers with particular reference to dangers associated with high temperatures. Similarly with
regard to the lower temperature boilers, the inspector can call for inspections (I) and (E).

However, inspection requirements for hot water boilers depend not only on operating temperature but
on volume of water contained in the system and on the layout of the system in relation to occupied
premises.

For such reasons, boilers operating below 120°C should be subject to internal inspection (I) at 3-
yearly intervals where large volumes of water are contained and especially where the boiler or system
is accommodated inside or adjacent to occupied premises.

Hydraulic overpressure testing (H) or Leak test (h) :

Where the nature of the construction of the boiler prevents access for adequate inspection, hydraulic
overpressure testing (H) should be carried out every 6 years .

2.3 Pressure vessels

2.3.1 Steam pressure vessels

----------------------

2.3.1.1 General
Steam pressure vessels create particular problems varying widely according to their usage, size,
whether or not they contain great quantities of water, the environment in which they have to work,
etc.

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It would seem desirable therefore to classify the vessels in different categories according to pressure
and volume.

where :
P x V : Product of the pressure in bars by volume in litres,
Po : Pressure in bars at and below which inspection is not required,
Vo : Volume in litres at and below which inspection is not required.

In addition, considering that the more dangerous a vessel is the more frequently should it be
inspected, it would seem necessary to examine a certain number of factors which might influence the
necessity to lengthen or shorten the periodicities of inspection of the vessel. These are as follows :
- stored energy form hot water,
- pressure variations,
- corrosion,
- construction,
- high strength materials,
- working temperature if higher than 450°C,
- severe service conditions (excepting pressure and temperature variations),
- temperature variations.

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R 47/CEOC/CP 83 Def 14

Under these conditions different classes of periodicity (A, B and C) can be defined according to the
number of points to be taken into account assuming the allocation of one point to each of the above
factors :

O and 1 point: Periodicity class A

2 and 3 points: Periodicity class B
4 points and above: Periodicity class C

2.3.1.2 Internal inspection (I)

Taking the above remarks into consideration, the following periodicities (in years) emerge for
periodicity classes A, B and C for the three categories of vessels as in table 3 :

Table 3

Periodicity in years

A B C

CATEGORY I 6 4 2

CATEGORY II 00 6 3

CATEGORY III 00 00 00

Note :

For vessels with multiple compartments containing steam and hot water, the product PV is obtained
by the addition of the individual compartments P1 x V1 + P2 x V2 + ... If one of the compartments
contains neither steam or hot water, special regulations may apply.

Inspection frequencies would be as follows :

- an initial inspection at the commissioning of the vessel, when its classification for periodicity would
be determined with the possibility of regrading at any time using the points system ;

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- the first internal inspection (I) : class C to apply, i.e. to be carried out after either two or three years.

- from thereon the periodicity of inspections would be confirmed and the normal cycle of inspections
as defined by the above table would be adopted.

2.3.1.3 External inspections (E)

Required annually.

2.3.1.4 Hydraulic overpressure testing (H) or Leak test (h)

In cases where the construction or geometry of the vessel precludes adequate access for internal
visual inspection, examination by NDT methods should be applied as far as practicable and, if
necessary, supplemented by hydraulic overpressure test (H) or leak test (h).

Hydraulic overpressure testing should always be carried out following major repairs or before any
important changes such as an increase in working pressure.

2.3.2 Air vessels

2.3.2.1 General
-------
In a similar manner to the above, the inspection requirements for the different types of vessel can be
arrived at by simultaneous application of the following three conditions :
P > 1
V > 1
P x V > 1 000

which can be expressed by the diagram after :

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P x V : product of the pressure in bars by volume in litres,

Po : pressure in bars at and below which inspection is not required,
Vo : volume in litres at and below which inspection is not required.

2.3.2.2 Internal inspection (I)

The periodicity for the internal inspections under normal conditions is fixed at 6 years.

As before, the vessel must be subjected to an initial inspection (I) and (E) on being put into service
for the first time.

2.3.2.3 Working inspection (E)

Working inspections (E) should be carried out every 2 years.

At the time of the first working inspection (E), that is, after two years' service, particular attention
must be given to problems of corrosion by means of non-destructive testing in order to confirm or to
modify the periodicity of the internal inspections defined above.

2.3.2.4 Hydraulic overpressure testing (H) or Leak test (h)

In cases where the construction or geometry of the vessel precludes adequate access for internal
visual inspection, examination by NDT methods should be applied as far as practicable and, if
necessary, supplemented by hydraulic overpressure test or leak test (h).

Hydraulic overpressure testing should always be carried out following major repairs or before any
important changes such as an increase in working pressure.

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2.3.3 Gas vessels

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2.3.3.1 General
In a similar manner to the steam vessels it would seem desirable to classify the gas vessels in three
categories based on PV (bars x liters) with a points loading system according to degree of hazard.

Three categories according to PV :

III : PV ≤ 1 000
II : 1 000 < PV ≤ 200 000
I: PV > 200 000

as shown in the following diagram :

P x V : product of the pressure in bars by volume in litres,

Po : pressure in bars at and below which inspection is not required,
Vo : Volume in litres at and below which inspection is not required.

Points to allocated according to hazard as follows.

Hazard Number of points

Cyclic stresses 1
Stress corrosion 1
Toxicity 1
Flammability 1
2 2
370 N/mm ≤ Re < 470 N/mm 1
2
Re ≥ 470 N/mm 2
Corrosion 1
Thickness 30 mm ≤ e < 60 mm 1
Thickness e ≥ 60 mm 2

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Vessels would then be graded by degree of hazard into four classes A, B, C and D according to the
total number of points allocated - tabulated as follows :

Points allocated Class

0-1 A
2-3 B
4-5 C
>5 D

2.3.3.2 Internal inspection (I)

Taking the above remarks into consideration, the following periodicities (in years) emerge for the
three categories divided into their four classes as shown in table 4 :

Table 4

2.3.3.3 External inspections (E)

Periodicities for external inspections (E) were fixed by line E-E positioned as shown :

- above line E-E : 2 years

- below line E-E : 1 year.

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With regard to vessels in category III, classes A and B :

Class A : periodicity oo
Class B : - periodicity where contents are toxic or flammable : 2 years,
- otherwise : oo.

2.3.3.4 Hydraulic overpressure testing (H) or Leak test (h)

In cases where the construction or geometry of the vessel precludes adequate access for internal
visual inspection, examination by NDT methods should be applied as far as practicable and, if
necessary, supplemented by hydraulic overpressure test (H) or leak test (h).

Hydraulic overpressure testing should always be carried out following major repairs of before any
important changes such as increase in working pressure.

2.4 Organic fluid system

Any proposals on this subject should bear in mind the existing CEOC Recommendation R
18/CEOC/77 Def "Recommendation on the use of organic fluids for heating purposes".

It was agreed that the nature of construction of these systems invariably prevents internal inspection
as commonly understood.

Inspection practices therefore concentrate on external inspections, visual, NDT techniques, leak
testing, thickness measurement, manifestations of swelling or other deformation, verification of safety
devices, sampling and analysis of organic fluid, etc.

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R 47/CEOC/CP 83 Def 20

Periodic inspections therefore should consist of a thorough examination as far as practicable with the
system cold and out of service to cover the following aspects :

- visual inspection,
- NDT,
- thickness measurements,
- examination for swelling, deformation, etc.,
- sampling and analysis of fluid.

Recommended periodicity : 3 years.

These three-yearly inspections should be supplemented by annual working inspections during which
the following should be attended to :

- searching for leaks,

- verification of safety devices,
- quality of operating methods and control.

oOo

© by CEOC 1983