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AS/NZS 1200:2015
Pressure equipment
AS/NZS 1200:2015
This Joint Australian/New Zealand Standard was prepared by Joint Technical
Committee ME-001, Pressure Equipment. It was approved on behalf of the Council
of Standards Australia on 5 November 2015 and on behalf of the Council of
Standards New Zealand on 6 November 2015.
This Standard was published on 3 December 2015.
This Standard was issued in draft form for comment as DR AS/NZS 1200:2014.
AS/NZS 1200:2015
Pressure equipment
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© Standards Australia Limited/Standards New Zealand
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, unless otherwise permitted under the Copyright Act 1968
(Australia) or the Copyright Act 1994 (New Zealand).
Jointly published by SAI Global Limited under licence from Standards Australia Limited,
GPO Box 476, Sydney, NSW 2001 and by Standards New Zealand, Private Bag 2439,
Wellington 6140.
PREFACE
This Standard was prepared by the Joint Standards Australia/Standards New Zealand
Committee ME-001, Pressure Equipment, to supersede AS/NZS 1200:2000, Pressure
equipment.
Changes to the 2000 edition include the following:
(a) Continued recognition of the trend to self-regulation and the need for clear guidance
to industry.
(b) Updated information for New Zealand regulatory matters, seismic, wind and snow
loading.
(c) An informative Appendix I on the use of equivalents when referring to various
internationally available pressure equipment standards.
(d) Revision to Appendix A where ‘LP Gas fuel vessels for automotive use’ are now
specifically mentioned as being covered by this Standard and where clarifications
have been added for some equipment not covered by this Standard (regarding gas
cylinders, miniature boilers and pressurized machines).
(e) Removal of the process for requesting opinions, interpretations or rulings. Readers
will now need to make contact with Standards Australia as per information provided
inside the front cover of this Standard.
(f) ‘Safety requirements’ changed from informative to normative.
(g) Updated Table 2.1, Standards for pressure equipment used in Australia and New
Zealand.
(h) Detailed comparison between various equipment Standards available globally.
(i) Replacement of Appendix G, ‘Organization of Australian, New Zealand and Other
Pressure Equipment Standards’ with a new Appendix ‘Australian Pressure Equipment
Practice’.
This edition retains the role of the Standard as a major reference document and also to
provide common requirements for pressure equipment that promote safety and uniformity
throughout Australia and New Zealand.
The terms ‘normative’ and ‘informative’ have been used in this Standard to define the
application of the appendix to which they apply. A ‘normative’ appendix is an integral part
of a Standard, whereas an ‘informative’ appendix is only for information and guidance.
Statements expressed in mandatory terms in notes to tables and figures are requirements of
this Standard.
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CONTENTS
Page
APPENDICES
A EQUIPMENT COVERED BY THIS STANDARD ................................................... 11
B DEFINITIONS........................................................................................................... 13
C LIST OF REFERENCED DOCUMENTS.................................................................. 18
D MATERIALS FOR USE UNDER THIS STANDARD .............................................. 22
E NOT ALLOCATED................................................................................................... 24
F COMPARISON OF PRESSURE EQUIPMENT STANDARDS ................................ 25
G AUSTRALIAN PRESSURE EQUIPMENT PRACTICE ........................................... 30
H NEW ZEALAND REQUIREMENTS ........................................................................ 33
I THE USE OF EQUIVALENT STANDARDS ........................................................... 34
J SAFETY REQUIREMENTS ..................................................................................... 35
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Pressure equipment
S E C T I O N 1 S C O P E A N D G E N E R A L
1.1 SCOPE
This Standard is a ‘parent’ document for use by the pressure equipment industry in
Australia and New Zealand. It covers the design, materials, manufacture, examination,
testing, installation, conformity assessment, commissioning, operation, inspection,
maintenance, repair, alteration and disposal of pressure equipment (boilers, pressure vessels
and pressure piping), but excluding gas cylinders and other equipment as set out in
Appendix A.
This Standard specifies detailed requirements for various pressure equipment by direct
reference to a range of Australian, New Zealand and other Standards.
NOTES:
1 Appendix F provides a comparison of pressure equipment Standards.
2 Appendix G provides guidance on Australian pressure equipment practice.
1.2 OBJECTIVE
The purpose of this Standard is to provide requirements and guidance expressed in
specification form, suitable for use in contracts or other documentation, in order to—
(a) achieve safe, economic and equitable supply and use of this equipment in Australia
and New Zealand;
(b) provide various means to assist in complying with basic requirements (see
Clause 2.1); and
(c) incorporate the experience and knowledge from Australia and New Zealand, and
world practice.
1.3 APPLICATION
This Standard applies to the pressure equipment specified in Appendix A.
Equipment with hazard level E to AS 4343 may be covered by one or more of the following
methods:
(a) Standards referenced in this Standard.
(b) Other applicable Standards.
(c) Sound engineering practice that achieves a comparable level of safety.
Users of this Standard are reminded that it has no legal authority in its own right, but may
acquire legal standing when—
(i) adopted by a government or other authority having jurisdiction;
(ii) specified in a contract; or
(iii) a manufacturer, importer, supplier, purchaser/owner or user states that pressure
equipment is in accordance with this Standard or its referenced Standards.
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1.4 DEFINITIONS
For the purpose of this Standard and its referenced Standards, the definitions in Appendix B
apply. Reference should be made to the particular pressure equipment Standards for
definitions covering specific applications.
1.9 TOLERANCES
Tolerances on numerical values shall be in accordance with the applicable Standard, and as
specified in drawings or other documents which satisfy Clause 1.10.
1.10 CONCESSIONS
Concessions or departures from required numerical values are permitted by this Standard
provided—
(a) the parties concerned are in agreement;
(b) the appropriate design verifying body, manufacture inspection body, or independent
in-service inspection body states in writing that the concession is acceptable and
gives details of the concession, the reasons justifying acceptance and any conditions
applicable;
(c) the concession relates to a specific design under specified conditions or a particular
item of pressure equipment only and is not required as an on-going basis for
continued concessions on new designs or each item produced;
(d) a review of all relevant factors and risk assessment is undertaken to ensure that the
concession will not result in equipment that is unsafe, unreliable or with inadequate
performance (see Note);
(e) the documented concession is made available to the owner or user, any quality system
auditor and, where required, to the regulator; and
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S E C T I O N 2 B A S I C R E Q U I R E M E N T S A N D
C O M P L I A N C E S T A N D A R DS
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TABLE 2.1
STANDARDS FOR PRESSURE EQUIPMENT USED IN AUSTRALIA
AND NEW ZEALAND (see Note 7)
1 General
AS/NZS 1200 Pressure equipment
AS 4942 Pressure equipment—Glossary of terms
AS 4343 Pressure equipment—Hazard levels
2 Design and manufacture
AUSTRALIAN AND JOINT AUSTRALIAN/ OR INTERNATIONAL STANDARDS
NEW ZEALAND STANDARDS (see Note 2) (see Note 2)
AS 1228 Boilers ASME BPV-I; BS 855; BS 1113; BS 2790;
EN 12952; EN 12953
AS 1210 Pressure vessels ASME BPV-VIII (see Note 4); PD 5500;
BS 853; BS 5169; BS 3970; EN 13445;
GB 150; ISO 21029-1; ISO 20421-1
AMBSC Code Miniature Boilers Parts 1–4 —
AS 2593 Boilers—Safety management and ASME BPV-I (see Note 5)
supervisory systems (see Note 5)
AS 3857—1999 Heat exchanger—Tube plate design TEMA; ASME BPV-VIII-1-UHX; EN 13445
AS 2971 Pressure vessels—Serially produced EN 286-1 (air or nitrogen)
AS/NZS 3509 Pressure vessels—LP Gas auto vessels —
ADG Code Pressure vessels—Transport of dangerous NZS 5418; IMDG Code
goods
AS 4041 Pressure piping ASME B31.1; ASME B31.3; ASME B31.5
(see Note 6); BS 806; EN 13480
AS 2872 Atmospheric heating of vessels —
AS 4458 PE Manufacture ISO 14731 (see Note 1)
AS/NZS 3992 PE Welding and brazing qualification ASME BPV-IX; EN 287; ISO 15607,
ISO 9606-1
AS 1796 Certification of welders and supervisors —
AS 4037 PE Examination and testing ASME BPV-V (see Note 1)
AS 3998 Certification of NDT personnel ISO 9712
AS 3892 PE Installation NZS 5351
AS 1548 Steel plates for PE EN 10028 (see Note 1)
AS 2556 ERW steel air heater tubes —
AS 1271 Safety valves and fittings for PE —
AS 1358 Bursting discs —
AS 1732 Fusible plugs —
(continued)
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3 Conformity assessment
Conformity assessment of pressure equipment covered by this Standard shall be carried out where required or
where specified by the parties concerned.
NOTE: Below Standards may be used as guidance:
(a) AS 3920 for conformity assessment of pressure equipment in Australia, and the Health and Safety in
Employment (Pressure Equipment, Cranes and Passenger Ropeways) Regulations 1999 in New Zealand.
(b) AS/NZS ISO/IEC 17020 for inspection bodies.
(c) AS/NZS 4481 for pressure equipment inspector competencies.
(d) ASME BPV Code.
(e) EU-PED Pressure Equipment Directive.
(f) EU-PED for Simple Pressure vessels.
4 Use
AS 3873 PE Operation and maintenance OR
NS for LPPHRW National Standard for Licencing Persons
or Performing High Risk Work
—
NOHSC 1006 National Occupational Health and Safety
(see Note 3) Certification Standard Certification for
users and Operators of Industrial Equipment
AS/NZS 3788 PE In-service inspection NBIC
AMBSC Code for miniature boilers
NOTES:
1 Where an international design Standard is applied and it provides PE manufacturing requirements and PE
examination/testing requirements within the design Standard itself, then those requirements are also applicable.
2 Other published national Standards may be used provided they satisfy the requirements of Clause 2.1.
3 NOHSC 1006 has been archived by Safe Work Australia and has been replaced by NS for LPPHRW; however,
NOHSC 1006 may still be referenced by authorities in some states.
4 For water tube boilers only in New Zealand, quality assurance, certification, marking and materials shall satisfy
the requirements of the New Zealand regulatory authority.
5 Accepted in New Zealand only as permitted within the scope of the New Zealand Approved Code of Practice
for the Design, Safe Operation, Maintenance and Servicing of Boilers.
6 In New Zealand, inspection and testing shall be to ASME B31.1.
7 For additional requirements applicable to New Zealand, refer Appendix H.
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APPENDIX A
EQUIPMENT COVERED BY THIS STANDARD
(Normative)
A2 EXAMPLES
The following are examples of pressure equipment covered specifically by this Standard:
(a) Boilers—watertube, firetube, shell, miscellaneous, electric, electrode, hot water,
locomotive, waste heat boilers, heat recovery steam generators, fired steam sterilizers
and fired pressure cookers.
(b) Pressure vessels—air receivers, reactors, digesters, pressurized storage vessels,
process vessels, heat exchangers, jacketed pans, fired heaters, air-water vessels,
pressurized sterilizers, deaerators, autoclaves, pressurized transportable vessels (road
or rail tankers, ISO tank containers, but not gas cylinders), vessels for human
occupancy, LP Gas fuel vessels for automotive use.
(c) Pressure piping—steam, high and low temperature liquid, gases and mixtures
(e.g. slurries and powders).
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APPENDIX B
DEFINITIONS
(Normative)
B1 GENERAL
The definitions of the more important terms relating to pressure equipment, actions and
personnel mentioned in this Standard and other Australian and New Zealand pressure
equipment Standards are listed in Paragraph B2.
NOTES:
1 These definitions are aimed to align, where possible, with the Australian Work Health and
Safety Act and Regulations and the New Zealand Health and Safety in Employment (Pressure
Equipment, Cranes and Passenger Ropeways) Regulations. These documents or state/territory
regulations should be referred to for the actual definitions that apply in the respective
jurisdiction.
2 For the definition of terms not listed in this Appendix, refer to AS 4942.
B2 DEFINITIONS
For the purpose of this Standard, the definitions below apply.
B2.1 Alter
To change the design of, add to or take away from the pressure equipment where the change
may reduce health or safety but does not include routine maintenance, repairs or
replacements.
B2.2 Boiler
A vessel or an arrangement of vessels and interconnecting parts, wherein steam or other
vapour is generated, or water or other liquid is heated at a pressure above that of the
atmosphere, and at a temperature at or above the normal atmospheric boiling temperature of
the liquid, by the application of fire, the products of combustion, electrical power, or
similar high temperature means. It also includes superheaters, reheaters, economizers,
boiler piping, supports, mountings, valves, gauges, fittings, controls, the boiler setting and
directly associated equipment. It excludes fired heaters.
NOTES:
1 The New Zealand, definition of hot water boiler (see Paragraph B2.11) approximates the
above but applies only to the generation of steam heated by a directly applied combustion
process or by heated gases.
2 See also ‘fired heater’, which may be more appropriate for some equipment in which steam or
other vapour is generated.
B2.3 Commissioning
Performing the necessary adjustments, tests and inspections to ensure pressure equipment is
in full working order to specified requirements before the pressure equipment is used.
Commissioning includes re-commissioning.
B2.4 Competent person
A person who has acquired through education, training, qualification or experience, or a
combination of these, the knowledge and skills enabling that person to perform the task
required.
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B2.15 Maintain
To keep pressure equipment in a safe and satisfactory condition; includes replacement and
repair.
B2.16 Manufacturer
A body corporate, firm or person who manufactures pressure equipment.
NOTE: The manufacturer may include the designer.
B2.17 May
Indicates that a statement is optional.
B2.18 Nationally recognized
A document or organization that is recognized in its country of origin.
B2.19 Operate
To use or operate pressure equipment and includes operational supervision and surveillance.
B2.20 Owner
A body corporate, firm or person who has right of title to, or management of, or control
over the pressure equipment and includes a person exercising such management or control
as an agent of the owner. (See also definition of ‘purchaser’.)
NOTE: In the NZ regulations the term ‘controller’ is used and in Australia the term ‘Person
Conducting a Business or Undertaking’ (PCBU) is used.
B2.21 Parties concerned
The purchaser, designer, importer, manufacturer, design verifying and inspection bodies,
supplier, installer, owner, user and other persons, as appropriate. Where regulatory matters
are involved, this may include the regulator.
B2.22 Practicable
Having regard to taking into account and weighing up all relevant matters including—
(a) the likelihood of the hazard or the risk occurring;
(b) the degree of harm that might result from the hazard or risk; and
(c) what the person concerned knows, or ought reasonably to know, about—
(i) the hazard or risk; and
(ii) ways of eliminating or minimizing the risk; and
(d) the availability and suitability of ways to eliminate or minimize the risk; and
(e) after assessing the extent of the risk and the available ways of eliminating or
minimizing the risk, the cost associated with available ways of eliminating or
minimizing the risk, including whether the cost is grossly disproportionate to the risk.
B2.23 Pressures
Gauge pressures are relative to atmospheric pressure, unless otherwise identified.
B2.24 Pressure equipment
Boilers, pressure vessels and pressure piping.
NOTE: New Zealand regulations also include certain fired heaters, hot water boilers, gas and
steam turbines, steam engines, pumps and compressors. See Appendix H.
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B2.34 Shall
Indicates that a statement is mandatory.
B2.35 Should
Indicates a recommendation.
NOTE: For this Standard and its associated Standards, it indicates an action that when performed
is generally considered to be good practice. ‘Should’ is used to provide flexibility and is not
mandatory or normative unless agreed.
B2.36 Supplier
A body corporate, firm or a person who supplies pressure equipment by way of sale, lease,
exchange or hire, whether as a principal or agent for another.
B2.37 User
A body corporate, firm or person who uses and has operational control of pressure
equipment.
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APPENDIX C
LIST OF REFERENCED DOCUMENTS
(Normative)
AS
1210 Pressure vessels
1228 Pressure equipment—Boilers
1271 Safety valves, other valves, liquid level gauges, and other fittings for boilers
and unfired pressure vessels
1358 Bursting discs and bursting disc devices—application, selection and
installation
1410 Sterilizers—Steam—Pre-vacuum
1548 Fine grained, weldable steel plates for pressure equipment
1692 Tanks for flammable and combustible liquids
1732 Fusible plugs for boilers
1796 Certification of welders and welding supervisors
1940 The storage and handling of flammable and combustible liquids
2030 Gas cylinders (series)
2182 Sterilizers—Steam—Benchtop
2192 Sterilizers—Steam—Downward displacement
2278 Aerosol containers
2278.1 Part 1: Metal aerosol dispensers of capacity 50 mL to 1000 mL inclusive
2487 Dry heat sterilizers
2556 Electric resistance welded steel air heater tubes
2593 Boilers—Safety management and supervision systems
2706 Numerical values—Rounding and interpretation of limiting values
2872 Atmospheric heating of vessels containing fluids—Estimation of maximum
temperature
2885 Pipelines—Gas and liquid petroleum (series)
2971 Serially produced pressure vessels
3500 National plumbing and drainage
3500.4.1 Part 4.1: Hot water supply systems—Performance requirements
3857 Heat exchangers—Tubeplates—Method of design
3873 Pressure equipment—Operation and maintenance
3892 Pressure equipment—Installation
3920 Pressure equipment—Conformity assessment
3998 Non-destructive testing—Qualification and certification of personnel
4037 Pressure equipment—Examination and testing
4041 Pressure piping
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AS
4343 Pressure equipment—Hazard levels
4458 Pressure equipment—Manufacture
4942 Pressure equipment—Glossary of terms
Z30 Interconversion of inch and metric dimensions
AS ISO
1000 The international system of units (SI) and its application
AS/NZS
1841 Portable fire extinguishers (series)
3509 LP Gas fuel vessels for automotive use
3788 Pressure equipment—In-service inspection
3992 Pressure equipment—Welding and brazing qualification
4481 Pressure equipment—Competencies of inspectors
4692 Electric water heaters
4692.1 Part 1: Energy consumption, performance and general requirements
60335 Household and similar electrical appliances—Safety
60335.2.21 Part 2.21: Particular requirements for storage water heaters
60335.2.35 Part 2.35: Particular requirements for instantaneous water heaters
AS/NZS ISO
3834 Quality requirements for fusion welding of metallic materials
3834.2 Part 2: Comprehensive quality requirements
31000 Risk management—Principles and guidelines
AS/NZS ISO/IEC
17020 Conformity assessment—Requirements for the operation of various types of
bodies performing inspection
NZS
1170.5 Structural design actions—Earthquake actions—New Zealand
4219 Seismic performance of engineering systems in buildings
5351 Code of practice for the installation, operation and maintenance of building
service and small industrial boilers
5418 Transportation containers for hazardous substances (series)
ISO
9606 Qualification testing of welders—Fusion welding
9606-1 Part 1: Steels
9712 Non-destructive testing—Qualification and certification of NDT personnel
14731 Welding coordination—Tasks and responsibilities
15607 Specification and qualification of welding procedures for metallic
materials—General rules
16528 Boilers and pressure vessels (Parts 1 and 2)
20421 Cryogenic vessels—Large transportable vacuum-insulated vessels
20421-1 Part 1: Design, fabrication, inspection and testing
21029 Cryogenic vessels—Transportable vacuum insulated vessels of not more
than 1 000 litres volume
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ANSI/API
STD 620 Design and construction of large, welded, low-pressure storage tanks
STD 650 Welded steel tanks for oil storage
ASME
B31.1 Power piping
B31.3 Process piping
B31.5 Refrigeration piping and heat transfer components
BPV-I Boilers and pressure vessel code
Section I: Rules for construction of power boilers
BPV-V Boilers and pressure vessel code
Section V: Nondestructive examination
BPV-VIII-1 Boilers and pressure vessel code
Section VIII: Rules for construction of pressure vessels. Division 1
BPV-VIII-2 Boilers and pressure vessel code
Section VIII: Rules for construction of pressure vessels.
Division 2: Alternative rules
BPV-IX Boiler and pressure vessel code
Section IX: Qualification standard for welding and brazing procedures,
welders, brazers, and welding and brazing operators
NB
NBIC National Board Inspection Code
BS
806 Specification for design and construction of ferrous piping installations for
and in connection with land boilers
853 Specification for vessels for use in heating systems (series)
855 Specification for welded steel boilers for central heating and indirect hot
water supply (rated output 44 kW to 3 MW)
1113 Specification for design and manufacture of water-tube steam generating
plant (including superheaters, reheaters, and steel tube economizers)
1746 Specification for domestic pressure cookers
2790 Specification for design and manufacture of shell boilers of welded
construction
3970 Sterilizing and disinfecting equipment for medical products (series)
5169 Specification for fusion welded steel air receivers
PD
5500 Specification for unfired fusion welded pressure vessels
EN
286 Simple unfired pressure vessels designed to contain air or nitrogen
286.1 Part 1: Pressure vessels for general purposes
287 Approval testing of welders for fusion welding (series)
12952 Water-tube boilers and auxiliary installations
12953 Shell boilers
13445 Unfired Pressure vessels
13480 Metallic industrial piping
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ADG
Australian Code for the Transport of Dangerous Goods by Road and Rail (ADG Code)
IMDG
International Maritime Dangerous Goods Code (IMDG Code)
SAC Standardization Administration of the People’ Republic of China
GB 150 Pressure vessels
Safe Work Australia
NOHSC 1006 National Occupational Health and Safety Standard for Users and Operators
of Industrial Equipment
TEMA Tubular Exchanger Manufacturers Association (TEMA) Standards
TEMA Code Code for the Design of Shell/Tube Exchanger Tubesheets
Australian Miniature Boiler Safety Committee
AMBSC Code Part 1: Copper Boilers
Part 2: Steel Boilers
Part 3: Sub-Miniature Boilers
Part 4: Duplex Steel Boilers
NS for LPPHRW—National Standard for Licencing Persons Performing High Risk Work
New Zealand Health and Safety in Employment (Pressure Equipment, Cranes and
Passenger Ropeways) Regulations
New Zealand Approved Code of Practice for the Design, Safe Operation, Maintenance and
Servicing of Boilers
New Zealand Approved Code of Practice for Pressure Equipment (Excluding Boilers)
Institute of Professional Engineers NZ Practice Note 19—Seismic Resistance of Pressure
Equipment
EU-PED European Union—Pressure Equipment Directive
Work Health and Safety Act and Regulations (various States and territories)
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APPENDIX D
MATERIALS FOR USE UNDER THIS STANDARD
(Normative)
D2 NEW MATERIAL
D2.1 Amendment or Supplement
To allow the development and use of a new material (not covered by existing national
Standards) within the scope of Australian and New Zealand Standards, the parties
concerned shall consider the following issues in determining the acceptability of the
material:
(a) The material is commercially available and can be purchased within the specified
range of chemical composition, mechanical properties and other requirements
outlined in the material specification.
(b) There will be a reasonable demand for the material by industry or that there exists an
urgency for acceptance.
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(c) The acceptance of the material clearly describes it in specification format, including
such items as the process of manufacture, conditions for delivery, heat treatment,
chemical composition range, minimum mechanical properties, tests (methods and
requirements), workmanship, finish, marking, inspection and rejection, and
documentation.
(d) The limits of an intended application in terms of service conditions, pressure,
temperature, contents and thickness ranges are clearly stated.
D2.2 Mechanical properties
The parties concerned shall have adequate data to enable design strength to be determined.
The data shall include, as appropriate, values of the tensile strength, yield strength, impact
toughness, elongation and creep rupture strength of the metal and of welded joints over the
range of temperatures at which the material is to be used. Any heat treatment that is
required to produce the mechanical properties shall be fully described. Adequate data on the
notch toughness in the proposed range of service temperatures shall be submitted. Service
experience in the temperature range contemplated shall be considered.
Statistical data shall give the range of chemical and mechanical properties and the number
of heats or batches, or both, tested.
If the material is to be used in equipment to operate under conditions where buckling may
occur (e.g. external pressure), stress-strain curves (tension or compression) shall be
furnished for the range of design temperatures desired.
Where appropriate, information on machinability should also be considered.
D2.3 Weldability
If the material is to be welded, the enquirer shall submit complete data on the weldability of
the material. Data shall include details of results of procedure and welder qualification tests
made in accordance with the requirements of AS/NZS 3992 or other equivalent Standard.
Welding tests shall be made over the full range of thickness in which the material is to be
used. Pertinent information such as heat treatment required, susceptibility to air hardening,
and the amount of experience in welding the material shall be supplied.
D2.4 Physical changes
Information on any significant physical changes that may occur with the material during
manufacture or service shall be available. It is important to know the structural stability and
the degree of retention of properties with exposure at operating temperature. The influence
of manufacture practices, such as forming, welding and thermal treatments on the
mechanical properties, ductility and microstructure of the material, is important,
particularly where degradation in properties may be encountered. In some materials certain
process conditions (such as heat treatment, cooling rates mechanical working and/or
combinations thereof) are known to cause significant changes in mechanical properties.
These conditions may occur during manufacture or in the service life of the material. It is
important to draw attention to those conditions that are prohibited in service or in the
manufacture of parts or equipment from the material. Data on susceptibility to other forms
of degradation, e.g. creep, corrosion or erosion, shall be available.
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APPENDIX E
NOT ALLOCATED
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APPENDIX F
COMPARISON OF PRESSURE EQUIPMENT STANDARDS
(Informative)
F1 INTRODUCTION
This Appendix gives a comparison of the main elements of some nationally recognized
Standards for metallic pressure equipment used in Australian industry. Some of these are
shown in Table F1. Nuclear and aerospace equipment are excluded.
F2 PURPOSE
This Appendix seeks to provide all parties with information and guidance on the main
differences between these Standards so that better decisions may be made on the provision
and use of pressure equipment. This is to help Australian industry improve safety,
performance and economy.
F3 RECOGNIZED STANDARDS
The Standards listed in this Appendix are pressure equipment Standards that are well
recognized, accepted, used in their country of origin, and which have been extensively used
or critically examined and accepted in Australia.
F5 BOILER STANDARDS
The Australian boiler Standard is AS 1228 and those mainly used globally are ASME
BPVC-I, EN 12952 and EN 12953. All have a similar basis:
(a) ASME is most commonly used globally, is more comprehensive and more frequently
updated. It has safety factors similar to AS 1228 and EN 12952 except the safety
factor on specified design tensile strength at design temperature (R mT) is 3.5.
(b) AS 1228 has a safety factor on specified design tensile strength at design temperature
(R mT) of 2.7.
(c) EN 12952 is not well known in Australia but has the same safety factors as AS 1228.
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F8 OBSERVATIONS/RECOMMENDATIONS
All Standards listed in this Appendix are reasonable, comparable, have a sound basis, and
have been proven by experience. Frequently, they result in identical pressure equipment but
in other cases there could be significant differences in details.
It is often the case that pressure equipment manufactured overseas and intended for use in
Australia is more costly when applying Australian Standards; however, using overseas
standards requires greater care and more attention to conformity assessment.
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TABLE F1
COMPARISON OF MAIN ELEMENTS OF PRESSURE VESSEL STANDARDS
Origin Australia ISO USA European Union UK China
1 Standard (Note 1) AS 1210 ISO 20421-1 ASME BPVC-VIII EN 13445 PD 5500 GB 150
2 Title Pressure vessels Cryogenic vessels Pressure vessels Unfired pressure Unfired pressure Steel pressure vessels
vessels vessels
3 Date 2010 (418) + AS 4458—1997 (100) 2004 (170) 2015 (704 + 763 + 343) 2014 (1137) 2012 (1023) 2011 (342)
(and No. of pages)
4 Application Static, transportable, fired, unfired. All except nuclear and Cryogenic vessels, Similar to AS 1210 All except nuclear, All except nuclear, Static, non-fatigue
aircraft static and aircraft and fired aircraft and fired service. Transportable
transportable and nuclear vessel are
excluded
5 Class, division or IH 2H 1S 2S 1 2A 2B 3 — Div 1 Div 2 Div 3 1, 2 3 4 Cat 1 Cat 2 Cat 3 Part 1, 2, 3 and 4
testing group
6 Maximum pressure No limit — 20 No limit >70 No limit No limit 35 MPa
(MPa)
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7 Max. temperature No limit 400°C No limit 50°C No limit No limit No No 300°C 900°C
27
(°C) limit limit
8 Maximum thickness No limit 30 No limit 32 32 20 30 No limit No limit No 40 13 No limit
(mm) limit
9 Materials (metallic) All Stainless steel All Steel and All Steel Steel and aluminium Steel
aluminium
10 Design strength 2.35 2.5 3.5 2.4 3.5 2.4 2.4 2.35 5.0 2.7
safety factor
SF = R m /f
11 Thickness under Yes Yes Y Y Y Y Yes Yes Yes Yes Yes
tolerance
12 Corrosion allowance As Nil As required Nil As required As required As required ≥1 mm carbon steel
c (mm) required or low alloy steel
vessel for air, water,
steam
(continued)
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TABLE F1 (continued)
Origin Australia ISO USA European Union UK China
13 Joint efficiency or 1.0 1.0 1.0 1.0 1.0 0.85 0.8 0.70 1.0 1.0 0.85 0.7 1.0 1.0 1.0 0.85 0.70 1.0 0.9 or 1.0 0.8 or 0.85
factor, η for full for spot
NDT NDT
14 Manufacture— Well covered in AS 4458 All similar
General
15 Thickness above 32 32 No PWHT 32; 50 Not required No HT 32; 40 35 Depending on
which Post Weld material type,
Heat Treatment thickness of weld
(PWHT) is required joint and design
(mm) (Note 2) requirements
e.g. >32 mm for
carbon steel
16 RT or UT %: 100 Spot 0 100 20
– Longitudinal weld 100 100 100 100 100 10 0 0 100 100 10 0 100 100 100 10 0
– Circumferential 100 20 100 20 100 10 0 0 100 100 10 0 100 100 100 5 0
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17 Weld production test Yes Yes Yes Yes Yes Yes No Yes Only for low temperature Yes, for some Only if ordered Yes for—
plate
(a) containing
extremely or
highly toxic
medium;
(b) R m ≥540 MPa;
(c) low temperature
service;
(d) heat treatment
required to
improve or restore
the mechanical
properties; or
(e) required by
design drawings.
(continued)
TABLE F1 (continued)
Origin Australia ISO USA European Union UK China
18 Hydrostatic test 1.25P f 20 /f r 1.5P 1.43P f 20 /f r 1.3P 1.3P f 20 /f r 1.25P f 20 /f r 1.25P f 20 /f r 1.25P f 20 /f r × t/(t-c) 1.25P f 20 /f r
pressure, minimum
19 Conformity AS 3920—Design verification (DV) specified Not specified. ASME Quality system and EU-PED, and Inspecting authority. Safety licence for
assessment Technical Standard authorized inspector. notified bodies. No DV specified designer and
only. No DV specified DV specified manufacturer.
No DV specified Supervisory
inspection during
construction by
inspecting authority.
No DV specified
20 Example PV 5.91 N/A 9.8 11.4 21.1 19.7 9.8 11.4 19.7 7.0 7 8.1 9.6 6.9 6.9 13.7 7.80 9.0
thickness (mm) (Note 4) (η = 1.0) (η = 1.0) (η = 0.85)
(Note 3)
LEGEND:
SF = minimum safety factor on specified minimum tensile strength R m for ferritic steels
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f = design strength
c = corrosion allowance
P = design pressure
N/A = not applicable
NOTES:
1 Most standards provide for some variation to the listed features under specific conditions.
2 Figures shown are for carbon steel and other materials will differ. In some Standards, minimum thickness for PWHT is increased when certain specific conditions apply.
3 This example is the shell thickness calculation for a horizontal dry air receiver with design pressure = 2 MPa; design temperature = 50°C, internal diameter = 1000 mm. Material is
carbon steel with R m = 400 MPa. Corrosion allowance is 1 mm unless otherwise noted.
4 Thickness figures for Class 1S or 2S thickness would be misleading because thickness is not dependent on R m and SF but is determined by cold stretching increasing R e and by
partly taking into account actual R e and R m.
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APPENDIX G
AUSTRALIAN PRESSURE EQUIPMENT PRACTICE
(Informative)
G1 GENERAL
Table G1 is for guidance on Australian practice for pressure equipment of all hazard levels.
Design, manufacture, conformity assessment of pressure equipment to be used overseas
should be in accordance with the requirements of the overseas user/purchaser and the laws
of the country of use and ISO 16528.
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TABLE G1
AUSTRALIAN PRESSURE EQUIPMENT (PE) PRACTICE
Element Practice
1 Overall need — Appropriate state/territory/federal work health and safety (WHS)
laws for hazardous plant and with federal trade, competition,
contract, civil, criminal and other applicable laws
— Meet purchaser’s requirements and specifications
2 Supply of PE — Manufactured within or outside Australia
— Company registration according to Australian laws
3 Design and manufacture — Capable of designing and manufacturing to the specified Standard
and contract; may subcontract work
— May or may not have certified quality system (e.g. to ISO 9001,
AS/NZS ISO 3834.2, or equivalent)
— Responsible for suitable PE risk assessment
— Be acceptable to the purchaser
4 Designer and manufacturer
(a) Acceptable Standards or Codes — Table 2.1—in full; or to a mix of such Standards as per Clause 2.3
— Agreed by supplier and purchaser and where required by the
Regulator
— Australian Standards are preferred for manufacture and use in
Australia. Designs for specific applications can be done in less
time and with lower cost, retains more know-how and skills, and
ensures capability for future repairs and modification
(b) If Australian funding/resources are — Project details (Government requirements may apply)
needed for the project
(c) Materials, components, manufacture — Australian Standards or equivalent ISO, regional or national PE
and testing Standards
— Acceptable to parties concerned
— UT and RT complying with nationally recognized testing body
(e.g. National Association of Testing Authorities, Australia) or
equivalent
(d) Reports and marking — Manufacturer data report (MDR) or conformity declaration
(to purchaser)
— Drawings and calculations to purchaser if contracted—not to
Regulator unless specified
— As for Element 4(a), plus design registration number plus
conformity assessment marks
(e) Operating and maintenance — As necessary to purchaser (owner and user)
instructions
— MDR available to enable owner to meet WHS requirements
(continued)
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TABLE G1 (continued)
Element Practice
5 Conformity assessment
(a) Design verification (DV) with — For pressure equipment with AS 4343 Hazard levels A, B, C
signed certificate/declaration to and D
satisfy Regulator, performed by a
— Done by DV Body. AS 3920 and AS/NZS ISO/IEC 17020
person—
provides guidance
(i) with competence; — DV Body normally nominated by the manufacturer
(ii) with no input to design; and
(iii) not engaged/employed by the
designer unless design body
has a certified quality
management system,
e.g. ISO 9001.
(b) Design registration — For boilers and pressure vessels with AS 4343, Hazard level A, B,
(registration number issued) C, and D—based on DV certificate or declaration
— By Australian or state/territory Acts and Regulations in location
where PE is to be used
(c) Manufacture inspection (MI) — For PE with AS 4343 Hazard Levels A, B and C
(signed certificate or MDR)
— Done by an MI Body. See AS 3920 and AS/NZS ISO/IEC 17020
6 Use
(a) Commissioning inspection — Done by a competent inspection body—usually an in-service
inspection body/inspector similar to an MI body in Element 5(c)
(b) Operation and maintenance — Safety management system—Safe equipment; trained, instructed,
supervised personnel and risk management
— Boiler attendants need a High Risk Work Licence, where required
by WHS Regulations
(c) In-service inspection — AS/NZS 3788 by competent inspector, similar to Element 6(a)
(d) Registration of equipment — For PE with AS 4343 Hazard Levels A, B and C
— Based on reports from Elements 6(a) and 6(c)
— By Australian State/Territory Act and Regulations in location
where PE is to be used
7 For PE with AS 4343 Hazard Level E — Apply all above elements as for Hazard Level D, or exercise good
engineering practice to ensure safety and minimize risk
— DV, MI and design registration are not required
NOTE: Item 1 to Item 6 apply to pressure equipment with Hazard Levels A to D.
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APPENDIX H
NEW ZEALAND REQUIREMENTS
(Normative)
H1 GENERAL
In New Zealand, the authority requires pressure equipment to comply with the Health and
Safety in Employment (Pressure Equipment, Cranes, and Passenger Ropeways) Regulations
1999 [PECPR Regulations] before being operated. It is expected, but not mandatory, that
pressure equipment will also comply with the following, as appropriate:
(a) Approved Code of Practice for Pressure Equipment (Excluding Boilers).
(b) Approved Code of Practice for the Design, Safe Operation, Maintenance and
Servicing of Boilers.
For New Zealand, pressurized machines (see Note at Paragraph B2.24) are included in the
coverage of the PECPR Regulations as pressure equipment; however, in some instances
with reduced compliance requirements.
For equipment to be used in New Zealand, the user should consult the New Zealand
regulator prior to placing reliance on any standard that is not referenced in the appropriate
New Zealand Code of Practice.
NOTE: See Notes to Table 2.1 and Appendix B as appropriate.
H2 SPECIFIC REQUIREMENTS
H2.1 Design verification
In general, pressure equipment is subject to design verification by an inspection body
recognized for that function under the PECPR Regulations.
H2.2 Fabrication inspection
In general, pressure equipment is subject to fabrication inspection by an inspection body
recognized for that function under the PECPR Regulations.
H2.3 Certificate of inspection
In general, pressure equipment shall have a current certificate of inspection issued by an
inspection body recognized for that function under the PECPR Regulations.
H3 SEISMIC LOADINGS
Seismic design requirements for New Zealand shall be determined, as appropriate, from
NZS 1170.5 with guidance from Institute of Professional Engineers NZ Practice Note 19.
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APPENDIX I
THE USE OF EQUIVALENT STANDARDS
(Informative)
I1 GENERAL
This Appendix provides guidance for the purchaser and manufacturer when agreed to the
use of equivalent Standards. For this Standard, it is intended that the equivalent Standard is
acceptable to the parties concerned and recorded.
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APPENDIX J
SAFETY REQUIREMENTS
(Normative)
J1 GENERAL
This Appendix specifies in performance terms the safety requirements necessary for the
safe design, manufacture and use of pressure equipment.
This Appendix deals with specific requirements related to the equipment itself, but other
safety requirements may be needed to satisfy applicable laws and regulations.
NOTE: For this Appendix, reference has been made to EU-PED but modifications have been
made to suit Australian and New Zealand circumstances.
J2 GENERAL REQUIREMENTS
J2.1 Design and manufacture
Pressure equipment shall be designed, manufactured, installed with all required ancillaries
and commissioned in such a way as to ensure its safety when put into service, in accordance
with the designer’s/manufacturer’s instructions.
In choosing the most appropriate solutions, the principles set out below shall apply:
(a) Eliminate or minimize hazards and associated risks as far as reasonably practicable.
NOTE: Main hazards are the potential for—
(a) equipment rupture leading to effects of blast and projectiles on people, plant and the
environment; and
(b) loss of containment leading to suffocation, infection, poisoning, fire, explosion or burns.
(b) Apply appropriate protection measures (i.e. safeguards) against hazards that cannot be
eliminated.
(c) Where appropriate, inform users of residual hazards and special measures necessary
to minimize risks at the time of installation, commissioning and use.
Where the potential for misuse is known, the pressure equipment shall be designed to
prevent danger from such misuse. If that is not possible, adequate warning should be given
to ensure the pressure equipment is not misused in such a way.
J2.2 Use
Pressure equipment shall be commissioned, operated, maintained, inspected, cleaned and
otherwise generally used in such a way as to control risk and ensure safety.
J3 DESIGN
J3.1 General
The pressure equipment shall be properly designed taking all relevant factors into account
in order to ensure that the equipment will be safe throughout its intended life.
The design shall incorporate appropriate safety coefficients using comprehensive methods
that are known to incorporate adequate safety margins against all relevant failure modes in
a consistent manner. Such safety coefficients and margins shall be equivalent with those
applied by the standards listed in Table 2.1 or as per Paragraph J7.
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The test programme shall be clearly defined prior to testing. Where design verification is a
requirement, the test programme shall be acceptable to the design verifier.
This programme shall define test conditions and criteria for acceptance and rejection. The
actual values of the essential dimensions and characteristics of the materials that constitute
the equipment tested shall be measured before the test.
Where appropriate, during tests, the critical zones of the pressure equipment shall be
capable of being observed using instrumentation capable of registering strains and stresses
with sufficient precision.
The test programme shall include the following:
(a) A pressure strength test, the purpose of which is to check that, if a pressure with a
defined safety margin in relation to the design pressure is applied, the equipment does
not deform beyond agreed thresholds, or exhibit significant leaks. The test pressure
shall be determined on the basis of the differences between the values of the
geometrical and material characteristics measured under test conditions and the
values used for design purposes. Design values shall take into account the differences
between the test and design temperatures.
(b) Where the risk of creep or fatigue exists, appropriate tests determined on the basis of
the service conditions laid down for the equipment, e.g. hold time at specified
temperatures, number of cycles at specified stress-levels and the like.
(c) Where necessary, additional tests concerning other factors referred to in
Paragraph J3.2.1 such as corrosion, external damage and the like.
J3.3 Design for safe handling and operation
The design method of operation specified for pressure equipment shall be such as to
preclude any risk in operation of the equipment. Particular attention shall be paid, where
appropriate, to the following:
(a) Closures and openings.
(b) Dangerous discharge of pressure relief devices.
(c) Devices to prevent physical access while pressure or a vacuum exists.
(d) Surface temperature taking into consideration the intended use.
(e) Decomposition of unstable fluids.
In particular, pressure equipment fitted with an access door shall be equipped with an
automatic or manual device enabling the user to easily ascertain that the opening will not
present any hazard. Furthermore, where the opening can be operated quickly, the pressure
equipment shall be fitted with a device to prevent it being opened whenever the pressure or
temperature of the fluid presents a hazard.
J3.4 Means of examination
Pressure equipment shall be designed and manufactured so that all necessary examinations
during manufacture and in-service can be safely carried out.
The means of determining the internal condition of the equipment shall be available, where
this is necessary to ensure the safety of the equipment, such as access openings, allowing
physical access to the inside of the pressure equipment so that appropriate examinations can
be carried out safely and ergonomically.
Other means of ensuring safety of the pressure equipment may be applied—
(a) where it is too small for physical internal access;
(b) where opening the pressure equipment would adversely affect the inside; or
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(c) where the substance contained has been shown not to be harmful to the material from
which the pressure equipment is made and no other internal degradation mechanisms
are identified.
J3.5 Means of isolation, draining and venting
Adequate means shall be provided for the isolation, draining and venting of pressure
equipment, where necessary to—
(a) avoid harmful effects such as water hammer, vacuum collapse, corrosion and
uncontrolled chemical reactions (all stages of operation and testing, particularly
pressure testing shall be considered); and
(b) permit cleaning, inspection and maintenance in a safe manner.
J3.6 Corrosion or other chemical attack
Where necessary, adequate allowance or protection against corrosion or other chemical
attack shall be provided, taking due account of the intended use.
J3.7 Wear
Where severe conditions of erosion or abrasion may arise, adequate measures shall be taken
to—
(a) minimize that effect by appropriate design, e.g. additional material thickness, or by
the use of wear plates, liners or cladding materials;
(b) permit replacement of affected parts as appropriate; and
(c) draw attention, in the operating instructions referred to in Paragraph J4.4, to measures
necessary for continued safe use.
J3.8 Provisions for filling and discharge
Where appropriate, the pressure equipment shall be so designed and provided with
accessories, or provision made for their fitting, as to ensure safe filling and discharge in
particular with respect to hazards such as the following:
(a) On filling—
(i) overfilling or over-pressurization, having regard, in particular, to the filling
ratio and to vapour pressure at the reference temperature; and
(ii) instability of the pressure equipment.
(b) On discharge—the uncontrolled release of the pressurized fluid.
(c) On filling or discharge—unsafe connection and disconnection.
J3.9 Protection against exceeding allowable limits
Where, under reasonably foreseeable conditions, the allowable limits, e.g. pressure,
temperature or mass flow, could be exceeded, the pressure equipment shall be fitted with, or
provision made for the fitting of, suitable protective devices, unless the equipment is
intended to be protected by other protective devices.
The suitable device or combination of such devices shall be determined on the basis of the
particular characteristics of the equipment or assembly.
Suitable protective devices and combinations comprise the following:
(a) Safety accessories that are devices designed to protect pressure equipment against the
allowable limits being exceeded. These include—
(i) devices for direct pressure limitation including safety valves, bursting discs,
buckling rods, controlled safety pressure relieving systems; and
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J4 MANUFACTURE
J4.1 Manufacturing procedures
J4.1.1 General
The pressure equipment shall be manufactured in accordance with the provisions set out at
the design stage by applying the appropriate techniques and procedures, especially with a
view to the aspects set out in this Paragraph (J4.1).
J4.1.2 Preparation of the component parts
Preparation of the component parts, e.g. cutting, forming and chamfering, shall be done in
such a manner as to avoid imperfections or changes in the mechanical characteristics
detrimental to the safety of the pressure equipment.
J4.1.3 Permanent joining
The permanent joints and adjacent zones shall be free of any surface or internal
imperfection detrimental to the safety of the equipment.
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The properties of permanent joints shall meet the minimum properties specified for the
materials to be joined unless other relevant property values or variations are specifically
taken into account in establishing the design.
Permanent joining of components that contribute to the pressure resistance of the equipment
and components that are directly attached to them shall be carried out by suitably qualified
personnel and joining procedures.
J4.1.4 Non-destructive tests
Non-destructive tests of permanent joints shall be carried out, where specified in the design,
by suitably qualified personnel.
J4.1.5 Heat treatment
Where there is a risk that the manufacturing process may change the material properties to
an extent that would unacceptably lower the safety of the pressure equipment, suitable heat
treatment shall be applied at the appropriate stage of manufacture.
J4.1.6 Traceability
Procedures shall be established and maintained for identifying the material making up the
components of the equipment that contribute to pressure resistance by suitable means from
receipt through production, up to the final test of the manufactured pressure equipment.
J4.1.7 Repair
Where unacceptable imperfections or material damage occurs, repairs shall be made with
suitable qualified procedures and personnel, and the equipment shall be re-inspected.
J4.2 Final assessment
J4.2.1 General
Pressure equipment shall be subjected to final assessment as described in Paragraph J4.2.
J4.2.2 Final inspection
Pressure equipment shall undergo a final examination by the manufacturer and appropriate
final inspection.
The inspection shall assess visually and by examination of the accompanying documents,
compliance with the requirements of the design. Tests carried out during manufacture shall
be taken into account. The final inspection shall be carried out internally and externally on
every part of the equipment, and where appropriate in the course of manufacture (e.g. where
examination during the final inspection is no longer possible).
J4.2.3 Proof test
Final assessment of pressure equipment shall include a test for strength and pressure
containment, which will normally take the form of a hydrostatic pressure test at a suitable
pressure. See Paragraph J7.
Where the hydrostatic pressure test is harmful or impractical, other equivalent tests may be
carried out. For tests other than the hydrostatic pressure test additional measures, such as
non-destructive tests or other methods of equivalent validity, shall be applied before those
tests are carried out.
J4.3 Marking and labelling
The following information shall be provided where required:
(a) For all pressure equipment—
(i) the identification of the manufacturer;
(ii) the year of manufacture;
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J5 MATERIALS
J5.1 General
Materials used for the manufacture of equipment shall be suitable for their application for
the duration of their scheduled lifetime unless replacement is foreseen.
Welding consumables and other joining materials need fulfil only the relevant parts of
Paragraphs J5.2, J5.3 and J5.4 in an appropriate way, both individually and in a joined
structure.
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J8 USE
J8.1 General
At all times during various operations over its life, pressure equipment shall be used by
each person involved with the equipment in a manner that minimizes the risk of harm to the
health and safety of all persons, property and the environment (i.e. ensures safety).
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NOTES
AS/NZS 1200:2015 48
NOTES
Standards Australia
Standards Australia is an independent company, limited by guarantee, which prepares and publishes
most of the voluntary technical and commercial standards used in Australia. These standards are
developed through an open process of consultation and consensus, in which all interested parties are
invited to participate. Through a Memorandum of Understanding with the Commonwealth
government, Standards Australia is recognized as Australia’s peak national standards body.
International Involvement
Standards Australia and Standards New Zealand are responsible for ensuring that the Australian
and New Zealand viewpoints are considered in the formulation of international Standards and that
the latest international experience is incorporated in national and Joint Standards. This role is vital
in assisting local industry to compete in international markets. Both organizations are the national
members of ISO (the International Organization for Standardization) and IEC (the International
Electrotechnical Commission).
www.standards.org.au www.standards.co.nz
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Phone (02) 9237 6000 8 Gilmer Terrace Wellington 6011
Fax (02) 9237 6010 (Private Bag 2439 Wellington 6140)
Email mail@standards.org.au Freephone 0800 782 632
Internet www.standards.org.au Phone (04) 498 5990
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