This comprehensive sister volume to Cliff Matthews' highly successful Handbook of Mechanical Works Inspection gives a detailed coverage of pressure equipment and other mechanical plant such as cranes and rotating equipment. Key features: * Accessible source of information * Lavishly illustrated with numerous diagrams, photographs, and tables * A wealth of valuable information * Detailed, comprehensive coverage * Written in easily accessible style * A 'must buy' reference book The Handbook of Mechanical In-Service Inspection is a vital source of information for: * plant owners and operators…mehr
This comprehensive sister volume to Cliff Matthews' highly successful Handbook of Mechanical Works Inspection gives a detailed coverage of pressure equipment and other mechanical plant such as cranes and rotating equipment. Key features: * Accessible source of information * Lavishly illustrated with numerous diagrams, photographs, and tables * A wealth of valuable information * Detailed, comprehensive coverage * Written in easily accessible style * A 'must buy' reference book The Handbook of Mechanical In-Service Inspection is a vital source of information for: * plant owners and operators maintenance engineers * inspection engineers from insurance companies and 'competent bodies' who perform in-service inspection * health and safety operatives * engineers operating pressure systems and mechanical plant * all those concerned with the safe and efficient operation of machinery, plant, and pressure equipment. All engineering pressure systems and other types of mechanical equipment must be installed, operated, and maintained properly. It must be safe and comply with standards, regulations, and guidelines. In-service inspection is more formally controlled by statutory requirements than other types of inspection. The Handbook of Mechanical In-service Inspection puts a good deal of emphasis on the 'compliance' aspects and the 'duty of care' requirements placed on plant owners, operators, and inspectors. The book is suitable for those who operate pressure systems, lifting equipment, and similar mechanical plant are subject to rigorous inspection from external bodies as a matter of course. All operators have a duty to conduct in-service checks and internal inspection procedures to ensure the safe, reliable, and economic running of their equipment.
Introduction--The Handbook of In-Service Inspection xiii Essential Principles In-Service Inspection--The Concept 3 ISI--why bother? 3 ISI and integrity management 4 In-service inspection versus construction inspection 5 In-service--predictive or defensive measure? 7 The Inspection Business--Who Does What? 11 The driving forces 11 The regulators 12 Accreditation bodies 14 Standards organizations 16 Classification societies 17 Insurance companies 19 Inspection organizations 24 Conclusion--the in-service inspection business 30 Roles and Duties of the In-Service Inspector 31 The inspector's duty of care 31 Liability--inspector versus employer 33 Inspector competence 35 The technical skills of the inspector 40 The Management of In-Service Inspection 49 The technical competence (TC) model 50 The procedures, paperwork and audits (PPA) model 51 TC versus PPA--decision or balancing act? 53 The Pressure Systems Safety Regulations (PSSRs): 2000 57 The PSSRs--what are they? 57 Content of the PSSRs 60 Bibliography 91 Non-Destructive Testing (NDT) 93 How reliable is site NDT? 93 The inspector as NDT technician? 95 Visual inspection 100 In-service inspection of welds 103 Surface crack detection 106 Volumetric NDT 115 NDT standards 147 Risk-Based Inspection (RBI) 149 So what is RBI? 149 Before we start--some important concepts 150 RBI--the basic techniques 157 The RBI programme itself 158 RBI standards and published documents 178 Failure 185 Failure mechanisms 185 Failure statistics 185 Fatigue 191 Creep 193 Corrosion 195 Useful references 206 Fitness-For-Purpose/Service Assessment 213 FFP assessments--what are they? 213 FFP assessment standards 218 Analysing fracture--the failure assessment diagram (FAD) 219 Analysing fatigue 225 Analysing creep 227 Analysing corrosion 230 API 579:1999 232 Sample BS 7910 calculation procedure 240 Bibliography 245 Technical Disciplines Pressure Testing 249 Pressure testing--safety first 249 Types of pressure test 251 Vacuum leak testing 256 Volumetric expansion testing 258 Pressure tests--technical aspects 258 In-service test procedures for pressure-equipment types 267 Pressure Vessel Inspections: API 510 277 How is API 510 used in in-service inspection? 277 The content of API 510 279 In-service inspection of pressure vessles--engineering aspects 283 Protective Devices 293 Protective device categories 293 PRV types 294 PRVs--principles of operation 296 In-service inspection of PRVs 299 PRV technical standards 311 PRVs--glossary of terms 322 Pipework and Pipelines 325 Pipework types and classifications 326 Pipework in-service inspection 328 High-integrity pipework 334 Pipeline inspection 338 Glass re-inforced plastic (GRP) re-lining 349 Small-bore tubing systems 356 Storage Tanks 363 Codes and standards 363 Construction features 366 Tank inspections 372 Heat Recovery Steam Generators (HRSGs) 397 HRSG construction 397 HRSG corrosion 400 HRSG materials of construction 403 HRSG damage mechanisms 405 High-temperature HRSG headers 408 HRSG steam drums 427 HRSG tube banks 432 Low-temperature headers 436 Attemporators 442 HRSG remnant life assessment 444 Heat Exchangers 457 Shell-tube exchangers--construction features 458 'Fin-fan' coolers--construction features 459 Technical codes and standards 465 In-service inspection of heat exchangers 467 NDT techniques 478 Transportable Pressure Equipment (TPE) 489 TPRs--the statutory background 489 In-service inspection of transportable pressure equipment 493 Industrial Cranes 505 Introduction 505 The LOLER regulations 505 Crane types and construction 508 Crane test, inspection, and repair 519 Codes and standards: cranes 529 Mobile Cranes 533 Mobile crane types 533 Load rating 535 Mobile crane tests 536 Common terminology 547 Mobile crane standards 551 Passenger and Goods Lifts 553 Lift types 553 Lift inspections 555 Bibliography 556 Motor vehicle repair equipment 558 Small Industrial Lifting Tackle 573 Statutory requirements 574 The role of the in-service inspectors 575 Reference standards 585 Diesel Engines 587 Diesel engine FFP criteria 587 Appendices The CSWIP Plant Inspector Certification Scheme 613 CSWIP plant inspector certification scheme training syllabus 617 Websites--quick reference 621 Organizations and associations 621 General technical information 623 Directives and legislation 625 Summary of in-service inspection requirements worldwide 627 EEMUA publications for mechanical plant and equipment 629 SAFeD publications and fact sheets 633 The European Pressure Equipment Directive (PED): summary 637 Introduction--what's the PED all about? 637 The driving forces behind the PED and similar European directives 638 The EU 'new approaches' 638 The role of technical standards 639 The situation for manufacture of new pressure equipment 640 Vessel 'statutory' certification 640 The CE mark--what is it? 643 PED--its purpose 643 Degradation mechanisms (refining/petrochemical applications) as defined in API RP 580 653 European and American associations and organizations relevant to pressure equipment and inspection activities 669 Index 683
Introduction--The Handbook of In-Service Inspection xiii Essential Principles In-Service Inspection--The Concept 3 ISI--why bother? 3 ISI and integrity management 4 In-service inspection versus construction inspection 5 In-service--predictive or defensive measure? 7 The Inspection Business--Who Does What? 11 The driving forces 11 The regulators 12 Accreditation bodies 14 Standards organizations 16 Classification societies 17 Insurance companies 19 Inspection organizations 24 Conclusion--the in-service inspection business 30 Roles and Duties of the In-Service Inspector 31 The inspector's duty of care 31 Liability--inspector versus employer 33 Inspector competence 35 The technical skills of the inspector 40 The Management of In-Service Inspection 49 The technical competence (TC) model 50 The procedures, paperwork and audits (PPA) model 51 TC versus PPA--decision or balancing act? 53 The Pressure Systems Safety Regulations (PSSRs): 2000 57 The PSSRs--what are they? 57 Content of the PSSRs 60 Bibliography 91 Non-Destructive Testing (NDT) 93 How reliable is site NDT? 93 The inspector as NDT technician? 95 Visual inspection 100 In-service inspection of welds 103 Surface crack detection 106 Volumetric NDT 115 NDT standards 147 Risk-Based Inspection (RBI) 149 So what is RBI? 149 Before we start--some important concepts 150 RBI--the basic techniques 157 The RBI programme itself 158 RBI standards and published documents 178 Failure 185 Failure mechanisms 185 Failure statistics 185 Fatigue 191 Creep 193 Corrosion 195 Useful references 206 Fitness-For-Purpose/Service Assessment 213 FFP assessments--what are they? 213 FFP assessment standards 218 Analysing fracture--the failure assessment diagram (FAD) 219 Analysing fatigue 225 Analysing creep 227 Analysing corrosion 230 API 579:1999 232 Sample BS 7910 calculation procedure 240 Bibliography 245 Technical Disciplines Pressure Testing 249 Pressure testing--safety first 249 Types of pressure test 251 Vacuum leak testing 256 Volumetric expansion testing 258 Pressure tests--technical aspects 258 In-service test procedures for pressure-equipment types 267 Pressure Vessel Inspections: API 510 277 How is API 510 used in in-service inspection? 277 The content of API 510 279 In-service inspection of pressure vessles--engineering aspects 283 Protective Devices 293 Protective device categories 293 PRV types 294 PRVs--principles of operation 296 In-service inspection of PRVs 299 PRV technical standards 311 PRVs--glossary of terms 322 Pipework and Pipelines 325 Pipework types and classifications 326 Pipework in-service inspection 328 High-integrity pipework 334 Pipeline inspection 338 Glass re-inforced plastic (GRP) re-lining 349 Small-bore tubing systems 356 Storage Tanks 363 Codes and standards 363 Construction features 366 Tank inspections 372 Heat Recovery Steam Generators (HRSGs) 397 HRSG construction 397 HRSG corrosion 400 HRSG materials of construction 403 HRSG damage mechanisms 405 High-temperature HRSG headers 408 HRSG steam drums 427 HRSG tube banks 432 Low-temperature headers 436 Attemporators 442 HRSG remnant life assessment 444 Heat Exchangers 457 Shell-tube exchangers--construction features 458 'Fin-fan' coolers--construction features 459 Technical codes and standards 465 In-service inspection of heat exchangers 467 NDT techniques 478 Transportable Pressure Equipment (TPE) 489 TPRs--the statutory background 489 In-service inspection of transportable pressure equipment 493 Industrial Cranes 505 Introduction 505 The LOLER regulations 505 Crane types and construction 508 Crane test, inspection, and repair 519 Codes and standards: cranes 529 Mobile Cranes 533 Mobile crane types 533 Load rating 535 Mobile crane tests 536 Common terminology 547 Mobile crane standards 551 Passenger and Goods Lifts 553 Lift types 553 Lift inspections 555 Bibliography 556 Motor vehicle repair equipment 558 Small Industrial Lifting Tackle 573 Statutory requirements 574 The role of the in-service inspectors 575 Reference standards 585 Diesel Engines 587 Diesel engine FFP criteria 587 Appendices The CSWIP Plant Inspector Certification Scheme 613 CSWIP plant inspector certification scheme training syllabus 617 Websites--quick reference 621 Organizations and associations 621 General technical information 623 Directives and legislation 625 Summary of in-service inspection requirements worldwide 627 EEMUA publications for mechanical plant and equipment 629 SAFeD publications and fact sheets 633 The European Pressure Equipment Directive (PED): summary 637 Introduction--what's the PED all about? 637 The driving forces behind the PED and similar European directives 638 The EU 'new approaches' 638 The role of technical standards 639 The situation for manufacture of new pressure equipment 640 Vessel 'statutory' certification 640 The CE mark--what is it? 643 PED--its purpose 643 Degradation mechanisms (refining/petrochemical applications) as defined in API RP 580 653 European and American associations and organizations relevant to pressure equipment and inspection activities 669 Index 683
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