|
MINISTRY OF
LABOR, INVALIDS AND SOCIAL AFFAIRS
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THE SOCIALIST
REPUBLIC OF VIETNAM
Independence – Freedom - Happiness
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No.
54/2016/TT-BLDTBXH
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Hanoi, December
28, 2016
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CIRCULAR
30
PROCEDURES FOR INSPECTION OF SAFETY OF MACHINERY, EQUIPMENT AND SUPPLIES TO
WHICH STRICT OCCUPATION SAFETY REQUIREMENTS ARE APPLIED UNDER ADMINISTRATION OF
MINISTRY OF LABOUR, INVALIDS AND SOCIAL AFFAIRS
Pursuant to the Law on Occupational Safety and
Health dated June 25, 2016;
Pursuant to the Decree No.106/2012/ND-CP dated
December 20, 2012 of the Prime Minister on functions, tasks, powers and
organizational structure of the Ministry of Labour, Invalids and Social
Affairs;
Pursuant to the Decree No.44/2016/ND-CP dated
May 15, 2016 of the Government on some specific articles of the Law on
Occupational Safety and Health on occupational safety inspection, provision of
training in occupational safety and occupational hygiene, and working
environment observation;
At the request of general director of Department
of Occupational Safety;
The Minister of Labour, Invalids and Social
Affairs promulgates the circular on 30 procedures for inspection of safety of
machinery, equipment and supplies to which strict occupation safety
requirements are applied under administration of Ministry of Labor, Invalids
and Social Affairs.
Article 1. Scope and regulated
entities
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2. This Circular shall be applied to organizations
and individuals inspecting occupational safety of machinery, equipment and
supplies to which strict occupation safety requirements are applied under
administration of Ministry of Labor, Invalids and Social Affairs.
Article 2. Effect
1. This Circular shall come into force from June 1,
2017.
2. This Circular replaces the Circular
No.07/2014/TT-BLDTBXH and Circular No. 46/2015/TT-BLĐTBXH.
Article 3. Implementation
1. The Department of Occupational Safety affiliated
to the Ministry of Labor, War Invalids and Social Affairs organizations
carrying out occupational safety inspection and relevant organizations and
individuals are responsible for implementation of this Circular.
2. Any problem that arises during the
implementation of this Circular should be reported to the Ministry of Labor,
Invalids and Social Affairs./.
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PROCEDURES FOR INSPECTION OF SAFETY OF ROLLER COASTERS
QTKĐ: 27- 2016/BLĐTBXH
Preface
Procedures for inspection of safety of roller
coasters are drafted by Department of Occupational Safety and promulgated
together with the Circular No. 54/2016/TT-BLDTBXH dated December 28, 2016 of
The Ministry of Labour, Invalids and Social Affairs.
PROCEDURES FOR
INSPECTION OF SAFETY OF ROLLER COASTER
1. SCOPE AND REGULATED
ENTITIES
1.1. Scope
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1.2. Regulated entities
- Organizations carrying out occupational safety
inspection;
- Occupational safety inspectors
2. REFERENCES
- TCVN 4244:2005, Lifting appliances – Design
construction and survey;
- TCVN 9361:2012, Foundation works - Check and
acceptance;
- TCXD 170:2007, Steel structures – Fabrication,
assembly, check and acceptance – Technical requirements;
- QCXDVN 05:2008/BXD, Dwellings and Public
Buildings - Occupational Health and Safety;
- TCVN 5638:1991, Evaluation of quality of building
and installation activities – Basic principles.
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- TCVN 9358:2012 Installation of equipment earthing
system for industrial projects - General requirements;
- TCXDVN 9385:2012: Protection of structures
against lightning - Guide for design, inspection and maintenance;
- Standard GB 8408: 2008, Amusement device safety
code
In the cases where national technical standards and
regulations referred to in this document are amended or replaced, regulations
of the latest documents shall apply.
Other standards may be applied to roller coaster
safety inspection at the request of its manufacturer or owner if such standards
contain the same or higher safety criteria than those in the national standards
referred to in this document.
3. TERMS AND DEFINITIONS
In addition to terms in the above invoked and
referenced documents, the following terms are used in description of this
procedure:
3.1. Roller coaster:
An amusement ride in which a train use initial
kinetic energy or potential energy to move on a rail system. The train is fixed
on a rail for traveling only along the rail and without travelling in other
directions.
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Nominal load is 90 kg, which is equivalent to a
person
3.3 Dummy load:
A dummy load is an object with a suitable shape and
size for loaded test, which has the weight of 100% or 110% of the nominal load.
3.4. Roller coaster for children;
Maximum height of a rider is 1375 mm.
3.5. Roller coaster for adults:
Minimum height of a rider is 1320 mm
3.6. First safety inspection:
First safety inspection is inspection of safety of the
ride according to national technical standards and technical safety standards
after its installation and before its first use.
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Periodic safety inspection is inspection of safety
of the ride according to national technical standards and technical safety
standards after expiration of the last safety inspection result.
3.8. Unscheduled safety inspection:
Unscheduled safety inspection is inspection of
safety of the ride according to national technical standards and technical
safety standards and will be carried out:
- after a repair or upgrade that affects the safety
of the ride;
- after relocation of the ride; and
- at the request of the owner or a competent
authority.
4. INSPECTION STEPS
Safety inspection shall be carried out in the
following order:
- Inspection of the profile of the roller coaster;
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- Technical inspection – No-load test;
- Loaded test – Test methods;
- Inspection of rescue process in case of an
accident;
- Processing inspection result.
Note: only take the next step if the previous step
is passed. The result of each step shall be recorded according to the form in
the Appendix 1 and retained by the inspecting organization.
5. INSPECTION EQUIPMENT
Inspection equipment shall be inspected and
calibrated in accordance with regulations and law.
Inspection equipment includes:
- Altometer;
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- Distance measuring equipment
- Geometric inspection equipment;
- Photometer;
- Force meter and hand scale;
- Insulation resistance meter;
- Ground resistance tester
- Multimeter
- Clamp meters;
- Nondestructive flaw detector (if necessary);
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- Automatic level (if necessary)
6. CONDITIONS FOR INSPECTION
The inspection must not be carried out unless the
following conditions are met:
6.1 The ride is ready for inspection.
6.2 Documents about the ride are adequate.
6.3 The inspection is not affected by weather.
6.4. Occupational safety and occupational hygiene
operation of the ride are met.
7. PREPARATION FOR INSPECTION
7.1. Before carrying out the inspection, the
inspecting organization and the owner shall reach an agreement on an inspection
plan and prepare for the inspection and assign staff to participate in and
witness the inspections.
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The documents to be inspected vary according to the
inspection. To be specific:
7.2.1 Regarding first inspection:
- The profile of a roller coaster, which consists
of the following documents:
+ Certificates of the metals used for the ride and
welding;
+ Calculation of strength of load-bearing parts;
+ Structural drawings which specify all main
dimensions;
+ Guidelines for operation and maintenance.
- Release documents:
+ Certificates of the metals used for the ride and
welding;
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+ Commissioning record;
+ As-built document;
- Reports on calibration of measurement equipment;
record on inspection of insulation resistance and protective devices (if any).
- Documents on safety measurement results of
equipment and relevant systems: earthing, lightning protection, electricity and
other protective systems (drafted according to the manufacturer’s documents or
documents approved by competent authorities)
- Documents on foundation: Documents on foundation
commissioning (the design approved by competent authorities, as-built drawings
and other testing results, if any).
- Documents on installation: as-built drawings,
commissioning record
- Certificate of conformity issued by authorized
organizations in accordance with regulations and law.
Regarding periodic inspection:
- The previous profile, inspection record and
inspection result;
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Regarding unscheduled inspection:
- In case of upgrade or repair: documents on design
and renovation, repair and commissioning record.
- In case of relocation: installation documents.
- The inspection record issued by competent
authority (if any).
The result is considered satisfactory if the
documents are adequate and requirements specified in 7.2. are satisfied. If the
inspection result is unsatisfactory, the owner shall take remedial actions.
7.3. Prepare suitable and adequate equipment for
inspection.
7.4. Develop measures for ensuring safety and reach
an agreement with the owner before inspection. Provide adequate personal
protective equipment to ensure safety during the inspection.
8. INSPECTION PROCESS
An inspection shall be carried out in the following
order:
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8.1.1. Inspect the structure:
- Inspect the foundation, supports and their
connection.
- Inspect the joints connecting the parts in the
system by specialized tools.
- Use nondestructive testing methods (penetration
testing, ultrasound, or radiography) to inspect important welding joints such
as those of the rail, the support, main bearing structure.
8.1.2. Inspection of the propelling system:
- Maximum linear velocity at the cabin: 45km/h for
roller coasters for adults and 16km/h for roller coasters for children.
- Inspect parameters of the propelling system with
specialized equipment.
- Inspect insulation resistance of the engine at
various voltage levels:
Nominal voltage
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Insulation
resistance
≤250
250
≥0.25
≤500
500
≥0.5
>500
1000
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- Inspect the transmission parts of the propelling
system, which generates necessary potential energy.
- Inspect the brake systems.
8.1.3. Inspection of cars:
- Inspection of labels in each car, maximum
capacity and load.
- Structure of the cars.
- Wheels.
- Riders’ seats.
- Inspect the restraints and seat belts.
- Inspection of the safety mechanism that prevent
the axles from breaking, which may results in derailment.
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8.1.4 Inspect the station and electrical systems,
including:
- The handrails and signs.
- Inspect the roof.
- Inspect the control room
- Inspect the parking floor and access from parking
lot to the cars
- Inspect the power supply layout
- Inspect the earthing system: ≤ 4.0 Ω
- Inspect the control circuits.
- Inspect the lighting equipment.
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- Inspect the compliance with applicable regulations
on fire protection.
8.1.5. Inspect the safety systems:
- Inspect the safety lock in the cars.
- Inspect the seatbelts.
- Inspect the alarm system and signalling system.
The result is considered satisfactory if no damage
or defect is found, all parts are working as designed and the requirements in
section 8.1 are met.
No-load testing:
- Inspection of insulation resistance of the ride.
- No-load testing shall be run only when external
inspection is done and the result is satisfactory.
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The inspection result is satisfactory if the
parameters are corrects, and all functions work as designed without signs of
errors.
8.3 Overload testing:
- Test at 110% of normal load.
- Load norm of a car equals its testing load
multiplied by capacity.
- Based on distribution of cars, load them to
create random imbalance of the train in all 4 directions (front, rear, left,
right). Each time imbalance is created, run the ride 3 rounds to evaluate its
operation. Pay attention to the parts bearing heavier load.
The inspection result is considered satisfactory if
the ride operates stably without signs of errors or damage affecting its safety
and cars stop at to correct position.
Inspection of rescue function:
- Run the ride at 100% of at the positions that are
most difficult for the rescue staff. Inspect the removal of the safety parts to
take riders back to the station safely.
- Inspect the backup power generator and batteries
that are used for removal of safety parts if they are available.
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9.1 Prepare an inspection record which contains
sufficient information according to the form in the Appendix 02 hereto
attached.
9.3. Approve the inspection record:
Mandatory participants in the process of approving
the inspection record:
- The representative or a person authorized by the
ride owner;
- A witness;
- The inspector.
When the record is approved, the inspectors, the witness,
and the representative or a person authorized by the ride owner shall append
their signatures and seals (if any) on the record The record shall be made into
02 copies, one for each party.
9.3. Write the brief inspection result to the
profile of the roller coaster (including full names of inspectors and the date
of inspection).
9.4. Put on the inspection stamp: if the inspection
result of a roller coaster is satisfactory, inspectors shall put an inspection
stamp on it at a noticeable position.
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9.5.1. If the inspection result is satisfactory,
the inspecting organization shall issue the certificate of inspection results
to the roller coaster within 5 working days from the day on which the
inspection record is approved.
9.5.2. If the inspection result is not
satisfactory, only the steps in 9.1 and 9.2 shall be taken and the inspection
record must specify the explanation for unsatisfactory result, necessary
remedial actions and a deadline for taking such actions. The inspection shall
be sent to the employment authority of the area where the roller coaster is
located.
10. INSPECTION INTERVAL
10.1 A roller coaster has to be inspected every 3
years. Notice: The following inspection tasks shall be carried out on an annual
basis: external inspection, no-load testing and rescue testing (according to
Clause 1, 2 and 4 of Section 8 of this procedure).
10.2. In the case where a shorter interval is
demanded by the manufacturer or owner, such interval shall apply.
10.3. If the inspection interval is shortened, the
inspector shall provide explanation in the inspection record
10.4. If the inspection interval is specified in
national technical regulations, such regulations shall apply.
APPENDIX 01
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(Name of
inspecting organization)
THE SOCIALIST
REPUBLIC OF VIETNAM
……….., ………
ON-SITE
RECORD
No.: …………….
(written by the
inspector)
1- General information
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Name of the
owner:....................................................................
Address (head office of the
owner):……………………………………………………
Address (location) of the
ride:……………………………………………………………………
Content of the meeting with the owner:
- Representative: ( information)
- Witnesses:
2- Basic parameters
-
Code:............................................
- Maximum players/car:……………..
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- Maximum load:…………………kg
- Production year:
.................................
- Total track length: ....................... m
- Manufacturer:
.....................................
- Maximum /minimum height: ................... m
- Number of cars: ...........................
- Diameter of helix:………………………….m
- Maximum speed:………………. Km/h
- Uses:
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- Machine profile:…………………………………………………………………………………
- Technical documents:
- Inspection of design and as-built document.
- Measurement results of earthing and lightning
protection systems:……….
4- Code of measurement equipment:
5- Ride inspection:
a. External inspection:
+ Inspection of structure:
+ Inspection of the propelling system:
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+ Inspection of the station and electrical system:
+ Inspection of safety system:
b. Technical inspection:
+ Inspection of speed:
c. Testing at 110% load
+ Brake:
+ Metal structure:(
+ Stop position of cabin:
d. Rescue testing:
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7. Processing and evaluation of inspection results.
8- Remedial actions: (if any)
WITNESS
(Signature and full name)
INSPECTOR
(Signature and full name)
APPENDIX 02
SPECIMEN OF THE SAFETY INSPECTION RECORD
( Name of
inspecting organization)
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……………., ……..
SAFETY INSPECTION
RECORD
( ROLLER COASTER)
No.:………………..
(According to on-site record No:……………….)
We are:
1. ……………………………………..Inspector
number:.........................................................
2. …………………………………….. Inspector
number…………………………………………
Inspecting
organization:……………………………………………………………………………
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Name of the inspected ride:………………………..
…………………………………
Name of the ride owner:…………………………………………………………..
Address (head office of the
owner):…………………………………………………………..
Address (location) of the
ride:……………………………………………………………………
Inspection procedures, applied standards:
.......................................................................
Witness:……………………………………………………
1……………………………………..
Position:…………………………….
2……………………………………….
Position:……………………………….
I-BASIC
PARAMETERS OF EQUIPMENT
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- Maximum players/ car:……………..
- Number of fabrication:……………………
- Maximum load:……………….kg
- Year of production:……………………..
- Total track length: ........................ m
-
Manufacturer:………………………….
- Maximum / minimum height: .....................
m
- Number of
cars:…………………
- Diameter of helix: ......................... m
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- Uses:…………………………………………..
II- FORMS OF
INSPECTION
First
time
Periodic Unscheduled
Reasons for unscheduled
inspection:……………………………………………………………
III- INSPECTION
CONTENT:
Document inspection:
No.
Inspection content
Satisfactory
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Note
No.
Inspection content
Satisfactory
Unsatisfactory
Note
1
Lift profile
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3
Document on
foundation structure
2
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No:
4
Documents on
management and operation
B. External inspection; no-load testing :
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Inspected parts
Satisfactory
Unsatisfactory
Note
No.
Inspected parts
Satisfactory
Unsatisfactory
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1
Foundation,
supports and support connection
8
Electrical system
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2
Cars
(Structures, wheels, restraints)
9
Lighting devices
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3
Guiding rail system
10
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4
Station
(Structure, fence, signs)
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Earthing and
lightning prevention system
5
Steel structure
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12
Signalling system
6
Electrodynamics
system
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13
Lubrication system
7
Control system
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14
Pneumatic brake
system
C- Load testing: parameters check:
No.
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Satisfactory
Unsatisfactory
Note
No.
Inspected parts
Satisfactory
Unsatisfactory
Note
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Steel structure
system
6
Brake system
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2
Velocity
7
Motor current
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3
Cars (Structures,
wheels, restraints)
8
Connection
between the cars
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4
Propelling system
9
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5
Control system
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Rescue plan
IV- CONCLUSIONS
AND RECOMENDADTIONS
1. Result: Satisfactory □
Unsatisfactory □
Maximum load:…………….. kg/person
2. Inspection stamp No:…………… At:……………
3. Necessary remedial actions:…………………
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V- INSPECTION
INTERVAL
Date of next inspection :
Reasons for shortened interval (if any):
The record is approved on:
At:…………………………………
The record is made into of ……copies, each party
holds…. copies./.
Owner
(commitment to implementationf the
recommendations)
(Signataure and stamp)
Witness
(Signature and full name)
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PROCEDURES FOR INSPECTION OF SAFETY OF ELECTRIC LIFT
QTKD: 21- 2016/BLDTBXH
Foreword
Procedures for inspection of safety
of electric lift are drafted by the Department of Occupational Safety and
promulgated together with the Circular No. 54/2016/TT-BLDTBXH dated December
28, 2016 of the Ministry of Labour, Invalids and Social Affairs.
PROCEDURES
FOR INSPECTION OF SAFETY OF ELECTRIC LIFT
1. SCOPE AND REGULATED ENTITIES
1.1. Scope
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Such procedures shall not apply to
wheel lifting equipment, mining lifts, stage lifts, ship lifts, exploratory
lifting platforms, onshore drilling rigs, construction lifts and other special
types. Such procedures shall not apply to some special cases such as: explosive
atmospheres, extreme weather, seismic hazard, carriage of dangerous objects,
class V lift classified under TCVN 7628: 2007, equipment whose guide rails form
an angle of more than 15 degrees relative to the perpendicular.
1.2. Regulated entities
- Organizations carrying out
occupational safety inspection;
- Occupational safety inspectors.
2. 2. REFERENCES
- QCVN 02:2011/BLDTBXH, National
technical regulation on safe work for electric lift;
- TCVN 6395:2008, Safety
requirements for the construction and installation;
- TCVN 6904:2001, Electric lift -
Test methods for the safety requirements of construction and installation;
- TCVN 7628:2007 (ISO 4190), Lift
installation;
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- TCVN 9358: 2012 Installation of
equipment earthing system for industrial projects - General requirements;
- TCVN 9385:2012: Protection of
structures against lightning - Guide for design, inspection and maintenance
In the cases where national
technical standards and regulations referred to in this document are amended or
replaced, regulations of the latest documents shall apply.
Other standards may be applied to
electric lift safety inspection at the request of its manufacturer or owner if
such standards contain the same or higher safety criteria than those in the
national standards referred to in this document.
3. TERMS AND DEFINITIONS
In addition to terms in the above
invoked and referenced documents, the following terms are used in description
of this procedure:
3.1. “lift” is the lifting
equipment that carries people to specific landing floors, has a cabin with
suitable dimensions and system to carry people and objects and move along guide
rails placed in vertical directions or forming an angle of 15 degree at maximum
relative to the perpendicular.
3.2. “first safety inspection” is
inspection of safety of the lift according to national technical standards and
technical safety standards after its installation and before its first use.
3.3. “periodic safety inspection”
is inspection of safety of the lift according to national technical standards
and technical safety standards after expiration of the last safety inspection
result.
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- after a repair or upgrade that
affects the safety of the lift;
- at the request of the owner or a
competent authority.
4. INSPECTION STEPS
Safety inspection shall be carried
out in the following order:
- Inspection of the profile of the
lift;
- External inspection;
- Technical inspection – No-load
test;
- Loaded test – Test methods;
- Inspection result processing.
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5. INSPECTION EQUIPMENT
Inspection equipment shall be
inspected and calibrated in accordance with regulations and law. Inspection
equipment includes:
- Altometer (speedometer);
- Distance measuring equipment;
- Geometric inspection equipment;
- Thermometer;
- Photometer;
- Insulation resistance meter;
- Ground resistance tester;
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- Clamp meters;
- Automatic level (if necessary).
6. CONDITIONS FOR INSPECTION
The inspection must not be carried out
unless the following conditions are met:
6.1. The lift is ready for
inspection.
6.2. Documents about the lift are
adequate.
6.3. The inspection is not affected
by weather.
6.4. Occupational safety and
occupational hygiene operation of the lift are met.
7. PREPARATION FOR INSPECTION
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7.2. Inspect the profile of the
lift, which consists of the following documents.
The documents to be inspected vary
according to the inspection. To be specific:
7.2.1 Regarding first inspection:
7.2.1.1. The profile of a lift,
which consists of the following documents:
- General representation that
displays product codes; production year; number of floors served, rated load
and main technical specifications of the lifting system, e.g. controlling,
safety equipment, pull machine, rope, durability.
- Layout of installation of
component sets, cable and parts installation diagram.
- Plan for perspective view of an
electric lift that shows its sizes, main parameters and cabin dimensions;
- Operating principle diagram;
- Instructions for operation and
emergency response;
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7.2.1.2. Documents on installation:
- As-built drawings and
commissioning records;
- Results of ground resistance test
and insulation resistance test (if any).
7.2.2 Regarding periodic
inspection:
- The previous profile and
inspection result;
- Documents on the use, operation
and maintenance of the lift; inspection record (if any).
7.2.3 Regarding unscheduled
inspection:
- Documents on design, renovation
and repair;
- Commissioning record after
renovation and repair;
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The result is considered
satisfactory if the documents are adequate and requirements specified in 7.2.1,
7.2.2, 7.2.3 are satisfied. If the inspection result is unsatisfactory,
the owner shall take remedial actions.
7.3. Prepare suitable and adequate
equipment for inspection.
7.4. Develop measures for ensuring
safety and reach an agreement with the owner before inspection. Provide
adequate personal protective equipment to ensure safety during the inspection.
8. INSPECTION PROCESS
An inspection shall be carried out
in the following order:
8.1. External inspection, which
includes the following tasks:
8.1.1. Inspect the adequacy and
uniformity of the lift: carry out an assessment according to Article 3.2 of
TCVN 6904: 2001.
8.1.2. Inspect the accuracy of the
manufacturer’s documents and installation versus reality (regarding parameters,
technical criteria and trademark).
8.1.3. Inspect defects and
deformation of parts and machinery (if any).
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The result is considered
satisfactory if the lift is uniform and installed in accordance with the
design, no damage, defect or error is found and requirements specified in 8.1
are satisfied.
8.2. Technical inspection – No-load
test:
8.2.1. Inspect machine room and
equipment in the machine room:
- Inspect the installation of
equipment in the machine room: carry out an assessment according to Articles
5.1.1 and 5.1.2 of TCVN 6395:2008;
- Inspect the entrance of the
machine room, levels of the handrails and stairs in the machine room: carry out
an assessment according to Sections 5.1 and 5.2 of TCVN 6395: 2008;
- Inspect location of machinery,
electrical enclosures, measurement of safe distance between them and building
structures in the machine room: carry out an assessment according to Section
5.3.2 of TCVN 6395: 2008;
- Inspect insulation resistance:
carry out according to Article 11.1.5 of TCVN 6395:2008;
- Inspect travelling cable -
counterweight: diameter, wear, cable fixation, etc.: carry out an assessment
according to 7.9.1 TCVN 6395:2008;
- Inspect the rope of the overspeed
governor: carry out an assessment according to Section 9.3.6 of TCVN 6395-2008;
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- Inspect electric brake: technical
condition of brake drum, brake shoe, brake string and carry out an assessment
according to Sections 10.3.3.1, 10.3.3.2, 10.3.3.4, 10.3.3.7 of TCVN 6395:
2008;
- Inspect pulleys, direction of
rope and rope shielding: carry out an assessment according to clauses 7.9.6.1
and 7.9.6.2 of TCVN 6395: 2008;
- Inspect the arrangement of
distribution boards and switches in the machine room: carry out an assessment
according to Sections 11.4.1, 11.4.2 and 11.4.3 of TCVN 6395:2008;
- Inspect the electrical wiring
installation from the main distribution boards to the electrical enclosures,
from electrical enclosures to components of machines: carry out an assessment
according to Sections from 11.5.1 to 11.5.12 of TCVN 6395:2008.
8.2.2. Inspect cabin and equipment
in cabin
- Inspect the gap between the two
cabin doors, gap between the door and the cabin frame: carry out an assessment
according to Article 7.5.4 of TCVN 6395:2008.
- Regarding the hinged doors:
Inspect and assess according to Article 7.5.5 of TCVN 6395-2008;
- Inspect technical condition and
operation of toe guard: carry out an assessment according to Article 7.5.10.2.3
of TCVN 6395-2008;
- Inspect electrical equipment
safety, control the opening and closing operation of cabin door: carry out an
assessment according to Article 7.5.11.1 of TCVN 6395-2008;
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- Inspect horizontal safe distance
between the cabin door sill and floor sill, which shall not exceed 35 mm.
8.2.3. Inspect cabin roof and
relevant equipment
- Inspect the space of the top of
headroom: carry out an assessment according to Article 4.6.1 of TCVN 6395:2008.
- Inspect the cable fixed points at
the cabin and counterweight.
- Inspect the trapdoor on the cabin
roof and condition of electrical safety contact, control the opening and
closing operation of trapdoor: carry out an assessment according to Sections
7.6.1 and 7.6.3 of TCVN 6395:2008.
- Inspect the balustrade on the
cabin roof: carry out an assessment according to Section 7.3.5.3 of TCVN
6395:2008;
- Inspect the counterweight frame,
installation of counterweight plates in the frame and fixation of plates in the
frame.
- Inspect the cabin guide rails and
counterweight: carry out an assessment according to Section 7.10.2 of TCVN
6395:2008.
- Inspect the safe distance between
the cabin and counterweight, including the overhanging part of the two
components, which shall not be less than 0.05 mm.
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- Inspect other equipment installed
in the well: carry out an assessment according to Article 4.1.3 of TCVN
6395:2008.
- Inspect the well cover: carry out
an assessment according to Article 4.2.1 of TCVN 6395:2008.
- Inspect the rescue doors and
inspection doors: carry out an assessment according to Article 4.2.2 of TCVN
6395:2008.
- Well ventilation: the section of
a ventilation hole shall not be less than 1% of the cross-sectional area of the
well.
- Inspect installation and
operation of the upper travel control equipment.
8.2.5. Inspect landing doors.
- Inspect the gap between the two
wings, between the wing and frame: it shall not exceed 10 mm.
- Inspect the equipment for control
the opening and closing operation of landing doors: inspect technical
condition, mechanical interlocks and electrical contacts.
8.2.6. Inspect pit.
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- Inspect technical condition,
location of main distribution board in the pit bottom, including switches and
sockets.
- Inspect installation and
operation of the lower travel control equipment.
- Inspect the pit depth and
vertical distance between the pit bottom and the lowest part of cabin bottom:
carry out an assessment according to Section 4.6.3.5 of TCVN 6395: 2008.
- Inspect buffer: Inspect
electrical contact of position control system (in case of energy absorber) and
inspect the compression stroke of the buffer (Appendix L-TCVN 6395:2008).
- Inspect pulley, counterweight
overspeed governor rope:
+ Condition of articulation of
counterweight balanced beam;
+ Protection of pulley;
+ Slack-rope device.
8.2.7. No-load testing:
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The result is considered
satisfactory if the equipment works as designed without signs of errors.
8.3. Loaded test – Test methods:
8.3.1. In-motion loading test
wherein the lift carries 100% of rated load:
Load the cabin floor evenly, let
the lift operate at rated speed and then check the following parameters:
- Motor current of the lift: assess
and compare it with the profile of the lift;
- Cabin velocity: assess according
to Section 10.7.1 of TCVN 6395:2008;
- Cabin safety gear (applied to
instantaneous safety gear and instantaneous safety gear with buffered effect):
tested at the testing speed, test methods and assessment carried out under
Section 4.2.3.1.2 of TCVN 6904: 2001;
The result is considered
satisfactory if the lift operates as designed and requirements set forth in
Section 8.3.1 are satisfied.
8.3.2. In-motion loading test
wherein the lift carries 125% of rated load:
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- Electromagnetic brake: test
methods and assessment carried out under Article 4.2.1- of TCVN 6904-2001;
- Overspeed governor: test methods
and assessment carried out under Article 4.2.2 of TCVN 6904-2001;
- Cabin safety gear: tested at the
speed which is below the rated speed (applied to progressive safety gear): test
methods and assessment carried out under Section 4.2.3.1.2 of TCVN 6904: 2001;
- Pull: test methods and assessment
carried out under Article 4.2.4 of TCVN 6904-2001;
The result is considered
satisfactory if the lift operates as designed without signs of errors and
requirements set forth in Section 8.3.2 are satisfied.
8.3.3. Measure the floor-landing
deviation: carry out an assessment according to Section 8.7 of TCVN 6395:2008.
8.3.4. Inspect overload protection
equipment: carry out the inspection and assessment according to Section 11.8.6
of TCVN 6395-2008.
8.3.5. Test the counterweight
safety gear (if any): test methods and assessment carried out under Article
4.2.3.2.2 of TCVN 6904-2001.
8.3.6. Test automatic rescue device
(if any): test and assess according to Section 4.2.6 of TCVN 6904:2001.
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8.3.8. Test special operating modes
of the lift (if any).
- Operating mode of the lift in
case of fire or earthquake;
- Prioritized operating mode.
9. INSPECTION RESULTS PROCESSING
9.1. Prepare an inspection record
which contains sufficient information according to the form in the Appendix 02
hereto attached.
9.2. Approve the inspection record:
Mandatory participants in the
process of approving the inspection record:
- The representative or a person
authorized by the lift owner;
- A witness;
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When the record is approved, the
inspectors, the witness, and the representative or a person authorized by the
lift owner shall append their signatures and seals (if any) on the record. The
record shall be made into 02 copies, one for each party.
9.3. Write the brief inspection
result to the profile of the electric lift (including full names of inspectors
and the date of inspection).
9.4. Put on the inspection stamp:
if the inspection result of a lift is satisfactory, inspectors shall put an
inspection stamp on it at a noticeable position.
9.5. Issuance of certificate of
inspection results:
9.5.1. If the inspection result is
satisfactory, the inspecting organization shall issue the certificate of
inspection results to the lift within 5 working days from the date on which the
inspection record is approved.
9.5.2. If the inspection result is
not satisfactory, only the steps in 9.1 and 9.2 shall be taken and the
inspection record must specify the explanation for unsatisfactory result,
necessary remedial actions and a deadline for taking such actions. The inspection
shall be sent to the employment authority of the area where the lift is
located.
10. INSPECTION INTERVAL
10.1. An electric lift has to be
inspected every 03 years. For the electric lift that has been used for more
than 10 years, it has to be inspected every 02 years. For the electric lift
that has been used for more than 20 years, it has to be inspected every year.
10.2. In the case where a shorter
interval is demanded by the manufacturer or owner, such interval shall apply.
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10.4. If the inspection interval is
specified in national technical regulations, such regulations shall apply.
APPENDIX 01
SPECIMEN
OF THE ON-SITE RECORD
(Name
of inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
………..[place],
………[date]
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No.:…………
(written
by the inspector)
1- General information
Name of the lift:………………………………………………………………………………….
Name of the
owner:....................................................................
Address (head office of the
owner):……………………………………………………
Address (location) of the
lift:……………………………………………………………………
Content of the meeting with the
owner:
- Representative: (information)
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2- Basic parameters:
Code:........................................
Manufacturing year:
........................................
Rated speed: ........................................
Number of stops:
........................................
Number of fabrication:
........................................
Rated load:
Manufacturer:
.....................................
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3- Document inspection:
- - Machine profile:
……………………………………………………………….
- Technical documents:
……………………………………………………………….
4- Code of measurement equipment:
5- External inspection:
- Insulation resistance:
- Machine room:
- Motor parameters:
Capacity: ..................................
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Rated current:
........................................
Code:.........................................
Serial number:.....................................
Voltage:
.....................................
Manufacturer:
.....................................
Rotational speed:
.....................................
- Inspection of traveling cable -
counterweight:
- Inspection of pulley:
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- Pit:
- Distance from the pit bottom to
the top of fully compressed buffer:
- Distance from the bottom of
counterweight to the top of fully compressed buffer:
- Distance from the pit bottom to
the lowest part of cabin bottom:
- Distance from the cabin roof to
the lowest part of well ceiling:
- Distance between the floor sill
and the cabin door sill:
- Distance from counterweight to
cabin:
7- Technical inspection:
- No-load testing:
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+ Speed:
+ Maximum floor-landing deviation:
- Testing at 125% load: +
Electromagnetic brake:
+ Cabin safety gear:
+ Traction testing:
- Automatic rescue device testing:
- Overload protection equipment:
- Lift operating mode testing in
case of fire or earthquake (if any):
8- Remedial actions: (if any)
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WITNESS
INSPECTOR
APPENDIX 02
SPECIMEN
OF THE SAFETY INSPECTION RECORD
(Name
of inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
………..[place],
………[date]
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SAFETY
INSPECTION RECORD
(ELECTRIC LIFT)
No.:
…………….
(According to on-site record No:……………….)
We are:
1. 1. ……………………………………..Inspector
number:...................................................
2. 2.……………………………………..Inspector
number:....................................................
Inspecting organization:.…………….……………………….…………….…………………….
Registration for certificate of the
inspecting organization No:………………………………..
Name of the inspected
lift:……………………….. ……………….. ……………………………
Name of the lift
owner:…………………………………………………………..
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Address (location) of the
lift:……………………………………………………………………
Inspection procedures, applied
standards:
.........................................................................
Witness:……………………………………………………
1………………………………………
Position: ………………………
2………………………………………
Position: ………………………
I- PARAMETERS OF LIFT
Lift Class:
Manufacturing year:
........................................
Rated speed (m/ph):
........................................
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Number of fabrication:
........................................
Rated load (kg):
........................................
Manufacturer:
........................................
Number of stops: ........................................
Uses:
........................................
II-
FORMS OF INSPECTION
First
time □ ; Periodic □
; Unscheduled □
Reasons for unscheduled inspection:.…………….……………………
III-
INSPECTION CONTENT
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- Remark:
.…………….……………………….…………….……………………………………..
- Evaluation of inspection results:
No.
INSPECTION
CONTENT
SATISFACTORY
UNSATISFACTORY
NOTE
1
Profile
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2
Technical documents
2. EXTERNAL INSPECTION:
- Remark:
.…………….……………………….…………….…………………………………….
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Defects - deformation:
…………………………..…………….……………………………….
- Evaluation of inspection
results Satisfactory
□
Unsatisfactory □
3. TECHNICAL INSPECTION –
NO-LOAD TEST:
- Remark:
.…………….……………………….…………….…………………………………..
- Evaluation of inspection results:
No.
INSPECTION
CONTENT
SATISFACTORY
UNSATISFACTORY
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1
Well
2
Machine room
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3
Motor
4
Speed reducer
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5
Electromagnetic brake
6
Pulley
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7
Overspeed governor
8
Counterweight travelling cable
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9
Fixed points
10
Cabin
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11
Counterweight
12
Buffer
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13
Safety gear
14
Electricity system
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15
Travel control equipment
16
Landing door - control of opening
and closing operation of door
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17
Distance between the pit bottom
and the lowest part of cabin
18
Distance between the cabin roof
and the lowest part of well ceiling
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19
Distance between the floor sill
and the cabin door sill:
4. TEST AT 100% OF RATED LOAD:
- Remark:
.…………….……………………….…………….……………………………………..
- Evaluation of inspection results:
+ Cabin speed: ........................................
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Unsatisfactory □
+ Motor current:
Result: Satisfactory □
Unsatisfactory □
+ Maximum floor-landing
deviation:
Result: Satisfactory □
Unsatisfactory □
+ Instantaneous safety gear and
instantaneous safety gear with buffered effect:
Result: Satisfactory □
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5. IN-MOTION LOADING TEST
WHEREIN THE LIFT CARRIES 125% OF RATED LOAD:
- Remark:
.…………….……………………….…………….……………………………………..
- Evaluation of inspection results:
+ Electromagnetic brake
Result: Satisfactory □
Unsatisfactory □
+ Progressive safety gear
Result: Satisfactory □
Unsatisfactory □
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Result: Satisfactory □
Unsatisfactory □
6. RESCUE SYSTEM TESTING:
- Remark:
.…………….……………………….…………….……………………………………..
- Evaluation of inspection results:
+ Automatic rescue device (if
any)
Result: Satisfactory □
Unsatisfactory □
+ Communication system (bell,
internal telephone)
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Unsatisfactory □
IV-
CONCLUSIONS AND RECOMENDADTIONS
1. Result: Satisfactory □
; Unsatisfactory □
Eligibility for operation with the
maximum load:…………….(kg)
2. 2. Inspection stamp No:……………
At:……………
3. Remedial actions (if any):
………………………………………
Deadline for taking remedial
actions: …………………………………….
V-
INSPECTION INTERVAL
Date of next inspection: …………………………
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The record is approved on:
………….………….
At: ……………………………………………………………………………...
The record is made into of
……copies, each party holds…. copies./.
OWNER
(Signature and full name)
WITNESS
(Signature and full name)
INSPECTOR
(Signature and full name)
PROCEDURES FOR INSPECTION OF TECHNICAL SAFETY OF
THERMAL OIL HEATERS
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Foreword
Procedures for inspection of
technical safety of thermal oil heaters are drafted by the Department of Work
Safety and promulgated together with the Circular No. 54/2016/TT-BLDTBXH dated
December 28, 2016 of the Ministry of Labor - Invalids and Social Affairs.
PROCEDURES FOR INSPECTION OF TECHNICAL SAFETY OF
THERMAL OIL HEATERS
1. SCOPE AND REGULATED ENTITIES
1.1. Scope
Such procedures shall be used for
first, periodic and unscheduled inspection of thermal oil heaters with a
working pressure of oil above 0.7 bar under state management of the Ministry of
Labor - Invalids and Social Affairs.
Such procedures shall not apply to
thermal oil heaters installed on trains, ships and other means of transport.
1.2. Regulated entities
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- Occupational safety inspectors.
2. NORMATIVE REFERENCES
- QCVN 01:2008 - BLDTBXH - National
technical regulation on safe work of steam boilers and pressure vessels;
- TCVN 7704: 2007 - Boilers -
Technical requirements for design, construction, manufacture, installation,
operation, maintenance;
- TCVN 8366: 2010 - Pressure
vessels - Requirement of design and manufacture;
- TCVN 6155: 1996 - Pressure
vessels - Safety engineering requirements of erection, use, repair;
- TCVN 6156: 1966 - Pressure
vessels - Safety engineering requirements of erection, use, repair. Testing
method;
- TCVN 6158:1996 - Pipe lines for
vapour and hot water - Technical requirements;
- TCVN 6159:1996 - Pipe lines for
vapour and hot water - Test methods;
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- TCVN 9385:2012 - Protection of
structures against lightning - Guide for design, inspection and maintenance;
- TCVN 9358: 2012 - Installation of
equipment earthing system for industrial projects - General requirements.
In the cases where any of the
national technical regulations and national standards referred to in this
inspection procedure is amended or replaced, the newest one shall apply.
Other standards may be applied to
inspection of technical safety of a thermal oil heater at the request of its
user or manufacturer if such standards contain the same or higher safety
criteria than those in the national standards referred to in this document.
3. TERMS AND DEFINITIONS
For the purposes of this document,
the terms and definitions given in the abovementioned normative references and
the following shall apply:
3.1. Thermal oil heater:
A piece of equipment which is used
to heat the heat transfer oil to high temperature and the heat source of which
is provided by the combustion of fuels and by the heat of exhaust gas, including
all parts related to the closed circulation process of heat transfer oil.
3.2. First safety inspection:
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3.3. Periodic safety inspection:
An evaluation of technical safety
of a thermal oil heater according to national technical standards and technical
safety standards after expiration of the last safety inspection result.
3.4. Unscheduled safety inspection:
An evaluation of technical safety
of a thermal oil heater according to national technical standards and technical
safety standards:
- When re-using the thermal oil
heater that has been out of use for 12 months or more;
- After repair, upgradation or
renovation that affects the technical safety of the thermal oil heater;
- After change of the installation
location;
- At the request of the
establishment or a competent authority.
4. INSPECTION STEPS
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- Examine documents and profiles of
pieces of equipment;
- Conduct external and internal
technical inspection;
- Conduct technical testing;
- Conduct operational inspection;
- Process the inspection result.
Note: The next inspection
step is taken only when the result of the previous step is passed. The result
of each step shall be fully documented according to the form in the Appendix 01
and fully retained by the inspecting organization.
5. INSPECTION EQUIPMENT AND
INSTRUMENTS
Inspection equipment and
instruments shall be inspected and calibrated in accordance with regulations. Inspection
equipment and instruments include the following:
- Hydraulic test pump;
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- Endoscope testing equipment for
defect detection;
- Ultrasonic thickness gauge;
- Non-destructive testing equipment
for defect detection;
- Apparatus for checking geometric
dimensions;
- Testing hammer;
- Lead sealing plier;
- Insulation resistance meter;
- Ground resistance meter;
- Mustimeter;
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- Thermometer;
- Sound level meter;
- Luminous intensity meter.
6. CONDITIONS FOR INSPECTION
The inspection of a thermal oil
heater must not be carried out unless the following conditions are met:
6.1. The thermal oil heater is at
the ready for inspection.
6.2. Documents of the thermal oil
heater are adequate.
6.3. The inspection is not affected
by environment or weather.
6.4. Requirements concerning
occupational safety and health are met.
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Before carrying out the inspection,
it is required to make the following preparations:
7.1. Agree to the inspection plan
and preparations and cooperate with the establishment in:
7.1.1. Preparing documents of the
thermal oil heater.
7.1.2. Cleaning the inside and
outside of the thermal oil heater, flushing and cleaning the heat transfer oil
piping system, expansion tank, and other parts in the system.
7.1.3. Removing handholes (if any).
7.1.4. Preparing facilities to
ensure that all parts of the thermal oil heater are examined.
7.1.5. Providing personnel and
materials for inspection; assigning personnel to participate in and witnessing
the inspection.
7.2. Examining documents and
profile of the thermal oil heater.
Rely on the inspection forms to
examine and consider the following documents and technical documents of the
thermal oil heater:
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7.2.1.1. Profile of the thermal oil
heater. The following documents should be considered:
- Indicators concerning manufacturing
metals, heat transfer oil piping system, welding metals; thermal oil used;
- Calculation of strength of
pressure retaining components;
- Manufacturing drawings; schematic
diagram;
- Guidelines on operation,
maintenance and repair, table of physical and chemical properties of heat
transfer oil used;
- Certificate of conformity issued
by the designated organization as prescribed in the case where the competent
authority has promulgated a national technical regulation applicable to the
inspected thermal oil heater.
7.2.1.2. Release documents of
the boiler or thermal oil heater:
- Certificate related to
manufacturing metals, welding metals;
- Weld quality test results;
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7.2.1.3. Measuring equipment
calibration reports; records on inspection of grounding, lightning protection
and protection equipment (if any).
7.2.1.4. Installation documents:
- Name of the installer and
establishment;
- Characteristics of materials
added upon installation;
- Welding data such as welding technology,
welding electrode code, welder's name and weld quality test results;
- Inspection record for each part
of the thermal oil heater (if any);
- Other documents on inspection of
parts of the thermal oil heater and heat transfer oil piping system; table of
physical and chemical properties of heat transfer oil used.
7.2.2. Upon periodic safety
inspection:
7.2.2.1. Previous profile,
inspection record and certificate of inspection result.
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7.2.3. Upon unscheduled safety
inspection: Documents shall be examined as if it is the unscheduled inspection
and other documents shall be additionally examined in the following cases:
7.2.3.1. In case of repair,
renovation or upgradation: documents on repair, renovation or upgradation;
post-repair, -renovation or -upgradation acceptance record.
7.2.3.2. In case of change of the
installation location: installation documents.
The document and profile inspection
result is passed if:
- The profile is adequate and
complies with the requirements of 7.2 above;
- If failed, the establishment
shall take additional corrective actions.
7.3. Prepare suitable and adequate
facilities for inspection.
7.4. Develop safety measures and
reach an agreement thereon with the establishment before inspection. Provide
adequate personal protective equipment to ensure safety during the inspection.
8. INSPECTION PROCESS
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8.1. External technical inspection:
8.1.1. Check the installation area
and location.
8.1.2. Check the operation lighting
system.
8.1.3. Check work platform, stairs
(if any)
8.1.4. Check hanging wires, racks,
insulation coating, heat transfer oil pipe symbol.
8.1.5. Check the electrical safety
grounding and lightning protection system (if any).
8.1.6. Check technical
specifications on the thermal oil heater’s label against those specified in its
profile.
8.1.7. Check the condition of
safety, measuring and ancillary equipment in terms of its quantity, type and
technical specifications against those specified in the design and prescribed
standard.
8.1.8. Check valves mounted on the
thermal oil heater in terms of their quantity, type and technical
specifications against those specified in the design and prescribed standard.
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8.1.10. Check the condition of
welds and metal surfaces of pressure retaining components of the thermal oil
heater. If any suspicion exists, request the establishment to take appropriate
additional inspection measures to provide a more accurate evaluation.
8.1.11. Check the condition of the
thermal insulation coating.
8.1.12. Check joints.
Evaluation: The thermal oil
heater passes the external technical inspection if:
- It complies with the
manufacturer's design and normative references;
- No crack, bulge, dent,
deformation or corrosion in excess of the prescribed limits on the pressure
retaining components, external welds and joints of the thermal oil heater.
8.2. Internal technical inspection:
8.2.1. Check the inner structure
and heating elements of the thermal oil heater.
8.2.2. Check the inner metal of
pressure retaining components of the thermal oil heater for rust or corrosion
(if possible).
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8.2.4. For locations where an
internal inspection is not feasible during inspection, a technical condition
check shall be carried out in accordance with the manufacturer's technical
documentation.
8.2.5. If it is not possible to
conduct an internal inspection due to the structural characteristics of the
thermal oil heater, it is permitted to replace the internal inspection with a
hydraulic test at the prescribed test pressure.
8.2.6. When there is any suspicion
about the technical condition of the pressure retaining components of the
thermal oil heater, the user should partially or entirely remove the insulation
layers and some suspicious components for inspection.
8.2.7. In case of detecting any
defect that reduces the strength of the pressure retaining components, it is
needed to reduce the operating parameters of the thermal oil heater. Parameter
reduction must rely on the reassessment of strength based on actual data.
Evaluation: The thermal oil
heater is passed if:
- It complies with the
manufacturer's design and normative references;
- No crack, bulge, dent,
deformation or corrosion in excess of the prescribed limits on the pressure
retaining components, external welds and joints of the thermal oil heater.
8.3. Technical inspection,
testing:
8.3.1. The thermal oil heater will
be exempt from strength testing during the first inspection if the test time at
the factory does not exceed 24 months, and it has been well preserved and show
no signs of impact or distortion during transport and installation. The
inspection record must clearly state the reason and attach the hydraulic test
reports of the manufacturer and the installation acceptance record.
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8.3.3. Strength test:
A strength test shall be conducted
at least once every 6 years. In the case of an unscheduled inspection, the
strength test is required.
8.3.3.1. The test medium is any of
the following: water; heat transfer oil; inert gas. Temperature of the test
medium must be less than 50°C and must not fall below the ambient temperature
by more than 5°C.
8.3.3.2. Test pressure and test
pressure holding time are specified in table 1 below:
Table
1: Strength test pressure and test pressure holding time after first
installation
Design
pressure
(bar)
Test
pressure
(bar)
Holding
time (min)
P
≤ 5
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20
P
> 5
1.5P but not less than 10 bar
20
Strength
test pressure and test pressure holding time during periodic and unscheduled
inspection
Nominal
working pressure
(bar)
Test
pressure
(bar)
Holding
time
(min)
Plv
≤ 5
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05
Plv
> 5
1.25 p but not less than Plv
+ 3 bar
05
Notes:
Plv is the
pressure of oil in the manifold.
8.3.3.3. Strength test process:
8.3.3.3.1. Fill the test medium:
fully fill the thermal oil heater with the test medium (paying attention to
releasing gases if the test medium is a liquid).
8.3.3.3.2. Increase the pressure up
to the test pressure (paying attention to increasing the pressure gradually to
avoid sudden expansion that may damage the thermal oil heater and avoiding hammering
while applying the test pressure). Monitor and detect unusual events during the
test. (For gaseous media, safety procedures must be followed when conducting
the strength test).
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8.3.3.3.4. Reduce pressure slowly
to the working pressure, maintain this pressure during the test. Then reduce
the pressure to 0 (zero); correct the deficiencies (if any) and check the
result.
8.3.3.4. The strength test with gas
is permitted only when the external and internal inspection give a good result
and the strength is calculated and tested using the data obtained from direct
measurement of the system.
8.3.3.4.1. When conducting a gas
test, the following safety measures must be taken:
- Valves and press gauge on the pipe
filled with test gas should be moved away from the pipe location or outside the
pipe room;
- During the period of applying gas
test pressure, unauthorized persons must move to a safe place.
8.3.3.4.2. Tightness shall be
checked using appropriate methods.
Evaluation: The strength
test is passed if:
- No crack is found;
- No air bubble, water spray or
leakage of water through welds or joints is found;
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- The allowable pressure drop
during the period of maintaining the test pressure is ≤ 0.5% of the test
pressure.
8.3.4. Tightness test:
8.3.4.1. Test medium: Air or inert
gas.
8.3.4.2 The test pressure is equal
to the nominal working pressure, the test pressure holding time must be long
enough to achieve the stability of the test medium pressure and the test time but
must not be less than 30 minutes.
8.3.4.3. Fill the system with the
test medium and increase the pressure up to the test pressure.
8.3.4.4. Check the tightness using
appropriate methods.
Evaluation: The tightness test
is passed if:
- No gas leak is detected.
- The allowable pressure drop
during the period of maintaining the test pressure is ≤ 0.5% of the test
pressure.
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8.4.1. Inspect the satisfaction of
all conditions for putting the thermal oil heater into operation.
8.4.2. Check the working condition
of the thermal oil heater and accompanied ancillary equipment; the validity
period of inspection, calibration, and the operation of measuring instruments
and protection equipment.
8.4.3. When the thermal oil heater
operates steadily, pressure is raised to check and adjust the working pressure
of safety valves, and perform sealing of safety valves.
Safety valves on specialized
equipment may be adjusted and sealed and must be installed in the thermal oil
heater before the operational inspection.
8.4.4. The set pressure of a safety
valve is not greater than 1.1 times the maximum working pressure of the thermal
oil heater.
Evaluate results: the result is
passed if the thermal oil heater, ancillary equipment, measuring instruments
and protection equipment operate normally and maintain specifications stably.
9. PROCESSING OF INSPECTION
RESULTS
9.1. Prepare an inspection record
which contains sufficient information according to the form in the Appendix 02
enclosed herewith.
9.2. Approve the inspection record:
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- The representative of the
establishment or a person authorized by the establishment.
- The witness;
- Inspectors conducting the
inspection.
As the record is approved, the
inspectors, the witness, and the representative of the establishment or a
person authorized by the establishment shall append their signatures and seals
(if any) to the record. The record shall be made into two (02) copies, each
party shall keep 01.
9.3. Write the brief inspection
result to the profile of the thermal oil heater (including full names of the
inspectors and the date of inspection).
9.4. Affix the inspection stamp: if
the boiler or water heater passes the test, the inspector shall affix an
inspection stamp to it at a noticeable position.
9.5. Certify the inspection result:
9.5.1. If the thermal oil heater
passes the test, the inspecting organization shall issue the certificate of
inspection result to the thermal oil heater within 05 working days from the
date on which the inspection record is approved at the establishment.
9.5.2. If the thermal oil heater
fails the test, only the steps 9.1 and 9.2 shall be taken and only the
inspection record which must specify the explanation for failed result,
necessary remedial actions and a deadline for taking such actions is issued to
the establishment. Such inspection record and written notification shall be
also sent to the employment authority of the area where the thermal oil heater
is installed and used.
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10.1. The technical safety
inspection interval is 02 (two) years. For a thermal oil heater that has been
used for more than 12 (twelve) years, the technical safety inspection interval
is 01 (one) year.
10.2. In the case where a shorter
interval is demanded by the manufacturer or establishment, such interval shall
apply.
10.3. If the inspection interval is
shortened, the inspector shall specify explanation in the inspection record and
reach an agreement on the shortened interval with the establishment.
10.4. If the inspection interval is
specified in national technical regulations, such national technical
regulations shall apply.
10.5. Cases of unscheduled
inspections are regulated in 3.4 of these inspection procedures.
Appendix
01
SPECIMEN
OF ON-SITE RECORD
(FOR INSPECTION OF TECHNICAL SAFETY OF THERMAL OIL HEATERS)
(Name
of the inspecting organization)
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..............,
[place], ………[date]
ON-SITE
RECORD
No.
...................
(The
inspector is required to fully write details of assessment, and inspection and
testing parameters according to the inspection process)
I- General information
Name of the equipment: .…………….……………………….…………….……………………………………….
Name of the applicant:
.…………….……………………….…………….………………….
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Installation address (location):
.…………….……………………….…………….…………………………….
Details of the meeting with the
establishment:
- Representative: (information)
- Witness:
II. Basic specifications of the
thermal oil heater
Code: ……………………………… Design pressure
.…………….……………………… bar
Manufacture number:……………………………
Working pressure ……………………………………. bar
Manufacturer: …………………………. Year of
manufacture: .…………….…………………………..
Capacity: ……………………………. Medium: .…………….………………………………..
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III. Documentation:
1. Upon first inspection:
- Release documents.
- Profile.
- Structural drawing.
- Certificates of quality inspection
of manufacturing materials, welding materials, heat transfer oil.
- Installation documents,
installation acceptance record.
- Welds inspection record
- Measuring instrument inspection
report
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- Record on inspection of
protection equipment
2. Upon periodic inspection:
- Previous profile, inspection
record and certificate of inspection result.
- Operation logbook, repair and
maintenance logbook; inspection or examination record (if any).
3. Upon unscheduled inspection:
- Previous profile, inspection
record and certificate of inspection result.
- Operation logbook, repair and
maintenance logbook; inspection or examination record (if any).
- Repair design documents,
post-repair acceptance record.
- Installation documents (in case
of change of installation location).
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+ Installation distance and
location:
+ Operation lighting:
+ Ventilation:
+ Stairs, work platform:
+ Insulation coating:
+ Ancillary parts:
+ Safety valves:
+ Pressure gauge:
+ Level meter:
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+ Condition of metal surfaces of
pressure retaining components:
+ Condition of welds:
+ Oil supply system:
+ Expansion tank
+ Oil collection tank (other
containers, if any).
+ Air fan, smoke fan:
+ Fuel supply system:
+ Slag discharge system:
V. Test:
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Test
pressure (bar)
Test
medium
Holding
time (min)
Strength test
Tightness test
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Operational test
VI. Operational test: in
.... minute
- Working condition of the thermal
oil heater:
- Working condition of
ancillary equipment:
+ Circulating oil pump:
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+ Expansion tank, collection tank,
backup pump:
+ Feeding and slag discharge
equipment:
+ Flue:
- Working condition of
safety equipment:
+ Safety valves:
+ Pressure limiter:
- Working condition of
metering equipment:
+ Pressure gauge:
+ Level meter:
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- Working condition of
automatic equipment:
- Working condition of valves:
WITNESS
(Signature, full name)
INSPECTOR
(Signature, full name)
Appendix
02
SPECIMEN
OF RECORD ON INSPECTION OF TECHNICAL SAFETY OF THERMAL OIL HEATER
(Name
of the inspecting organization)
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..............,
[place], ………[date]
RECORD
ON INSPECTION OF TECHNICAL SAFETY OF THERMAL OIL HEATER
No.
………………….
(According
to the on-site record No. …………)
We are:
1. .…………….……………………… Inspector
number: .…………….………………………
2. .…………….……………………… Inspector
number: .…………….………………………
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Registration certificate number of
the inspecting organization: .…………….…………………………………….
Have inspected:.…………….…………………………………..
User:
.…………….……………………….…………….………………………………….
Address (head office): .…………….……………………….…………….…………………………….
Installation address (location):
.…………….……………………….…………….…………………………….
Inspection procedures applied: .…………….……………………….…………….……………………
Individuals witnessing the
inspection and approving the record: .…………….………………………………………..
1. ……………………………….……………………… Position:
.…………….………………………
2. ……………………………….……………………… Position:
.…………….………………………
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Type, code: .…………….…………………..
Design pressure: …………………………. bar
Manufacture number: .…………….………………………
Working pressure: …………………………. bar
Year of manufacture:
……………………………………
Capacity: .…………….………………… Kcal/h
Manufacturer: ……………………………………
Fuel used: ………………………….
Design temperature: ……………………………..oC
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Heat transfer medium:
…………………………….. Uses: ……………………………………
Date of last inspection: ………………………,
by.…………….……………………….
Date of last strength test:
…………………………,
by.…………….……………………….
II
- FORMS OF INSPECTION
First
time □ ; Periodic □ ; Unscheduled □
Reason for unscheduled inspection:
.…………….………………………………………
III
- INSPECTION CONTENT
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- Remarks:
.…………….……………………….…………….………………………………………..
- Result evaluation: Passed
□ Failed □
2. External and internal
technical inspection:
Item
Passed
Failed
Distance
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Stairs, work platform
Operation lighting
Safety grounding and lightning
protection system
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Condition of welds, joints
Condition of pressure retaining
components
Circulating pump system
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Ancillary equipment and parts
Safety valves
Pressure gauge
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Temperature meter
Other measuring instruments,
protection equipment, automatic equipment
Result evaluation:
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- Result evaluation: Passed
□ Failed □
3. Test:
Type
of test
Test
pressure (bar)
Holding
time (min)
Strength test
Tightness test
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Operational test
Result evaluation:
- Remarks:
.…………….……………………….…………….………………………………………..
- Result evaluation: Passed
□ Failed □
IV
- CONCLUSIONS AND RECOMMENDATIONS
1. Result of inspection of the
thermal oil heater: Passed □ Failed □ ;
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3. Permissible working pressure:
…………………… (bar)
4. Working pressure of oil
….…………………°C
5. Safety valve’s set pressure:
Location
Opening
pressure (bar)
Closing
pressure (bar)
On thermal oil heater
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6. Recommendations:
………………………………………..…………….………………………………..
Deadline for implementation of
recommendations: …………………………..…………….……………………………….
V
- INSPECTION INTERVAL
Date of periodic inspection……….
[date]
Reason for shortening the interval
(if any): …………………………..…………….………………………
The record is approved on ……. [date]
At:.…………….……………………….…………….……………………………………………….
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We, the inspectors who conducted
the inspection are fully responsible for the accuracy of the inspection results
written in this record./.
ESTABLISHMENT
OWNER
(Signature and seal)
WITNESS
(Signature, full name)
INSPECTOR
(Signature, full name)
PROCEDURES FOR INSPECTION OF TECHNICAL SAFETY OF GAS
PREPARATION, STORAGE AND FILLING SYSTEMS
QTKD: 03-2016/BLDTBXH
Foreword
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PROCEDURES FOR INSPECTION OF TECHNICAL SAFETY OF GAS
PREPARATION, STORAGE AND FILLING SYSTEMS
1. SCOPE
1.1. Scope
Such procedures shall be used for
first, periodic and unscheduled inspection of liquefied and dissolved gas
preparation, storage and filling systems under state management of the Ministry
of Labor - Invalids and Social Affairs.
Such procedures shall not apply to
liquefied petroleum gas (LPG) preparation, storage and filling systems.
1.2. Regulated entities
- Organizations carrying out
technical inspection of occupational safety;
- Occupational safety inspectors.
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- QCVN 01:2008/BLDTBXH - BLDTBXH -
National technical regulation on safe work of steam boilers and pressure
vessels;
- TCVN 8366: 2010 - Pressure vessels
- Requirement of design and manufacture;
- TCVN 6155: 1996 - Pressure
vessels - Safety engineering requirements of erection, use, repair;
- TCVN 6156: 1996 - Pressure
vessels - Safety engineering requirements of erection, use, repair. Testing
method;
- TCVN 2622:1995 - Fire prevention
and protection for buildings and structures - Design requirements;
- TCVN 4245: 1996 - Safety
enginering requirements in production and utilization of oxygen, acetylene;
- TCVN 6290:1997 - Gas cylinders -
Cylinders for permanent gases - Inspection at time of filling;
- TCVN 6713:2000 - Gas cylinders.
Safe handling;
- TCVN 6715:2000 - Cylinder for
dissolved acetylene - Inspection at time of filling;
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- TCVN 9385:2012 - Protection of
structures against lightning - Guide for design, inspection and maintenance;
- TCVN 9358: 2012 - Installation of
equipment earthing system for industrial projects - General requirements.
In the cases where any of the
national technical regulations and national standards referred to in this
inspection procedure is amended or replaced, the newest one shall apply.
Other standards may be applied to
inspection of technical safety of a gas preparation, storage and filling system
at the request of its user or manufacturer if such standards contain the same
or higher safety criteria than those in the national standards referred to in
this document.
3. TERMS AND DEFINITIONS
For the purposes of this document,
the terms and definitions given in the abovementioned normative references and
the following shall apply:
3.1. Gas preparation, storage and
filling system
A system of equipment used to carry
out thermal or chemical processes for preparation and storage of gases, liquefied
gases and filling thereof into pressure vessels with a pressure greater than
atmospheric pressure.
3.2. First safety inspection:
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3.3. Periodic safety inspection:
An evaluation of technical safety
of a system according to national technical standards and technical safety
standards after expiration of the last safety inspection result.
3.4. Unscheduled safety inspection:
An evaluation of technical safety
of a system according to national technical standards and technical safety
standards:
- After repair, upgradation or
renovation that affects the technical safety of the system;
- After change of the installation
location;
- When re-using the system that has
been out of use for 12 months or more;
- At the request of the
establishment or a competent authority.
4. INSPECTION STEPS
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- Examine documents and profile of
the gas preparation, storage and filling system;
- Conduct external and internal
technical inspection;
- Conduct technical testing;
- Conduct operational inspection;
- Process the inspection result.
Note: The next inspection step is
taken only when the result of the previous step is passed. The result of each
step shall be fully documented according to the form in the Appendix 01 and
fully retained by the inspecting organization.
5. INSPECTION EQUIPMENT AND
INSTRUMENTS
Inspection equipment and
instruments shall be inspected and calibrated in accordance with regulations. Inspection
equipment and instruments include the following:
- Hydraulic test pump;
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- Endoscope testing equipment for
defect detection;
- Apparatus for checking geometric
dimensions;
- Lead sealing plier;
- Insulation resistance meter;
- Ground resistance meter;
- Mustimeter;
- Clamp meter;
- Temperature measuring instrument;
- Luminous intensity meter;
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- Ultrasonic thickness gauge
(if needed);
- Non-destructive testing equipment
for defect detection (if needed).
6. CONDITIONS FOR INSPECTION
The inspection of a gas
preparation, storage and filling system must not be carried out unless the
following conditions are met:
6.1. The gas preparation, storage
and filling system is at the ready for inspection.
6.2. Documents of the system are
adequate.
6.3. The inspection is not affected
by environment or weather.
6.4. Requirements concerning
occupational safety and health are met.
7. PREPARATION FOR INSPECTION
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7.1. Agree to the inspection plan
and preparations and cooperate with the establishment in:
7.1.1. Preparing documents of the
gas preparation, storage and filling system.
7.1.2. Removing the medium,
cleaning the inside and outside of the gas preparation, storage and filling
system.
7.1.3. Partially or entirely
removing the thermal insulation coating if there is any suspicion that the wall
metal is damaged. Removing manholes and handholes (if any).
7.1.4. Preparing facilities to
ensure that all parts of the gas preparation, storage and filling system are
examined.
7.1.5. If it is difficult to
examine vessels in the underground gas preparation, storage and filling system,
appropriate examination measures must be taken.
7.1.6. In case vessels in the
underground gas preparation, storage and filling system have electrical heating
elements or moving parts, such elements or parts must be separated from the
vessels.
7.1.7. For the gas preparation,
storage and filling system working with a toxic, flammable or explosive medium,
removing the medium from the system without affecting persons conducting the
inspection.
7.1.8. Providing personnel and
materials for inspection; assigning personnel to participate in and witnessing
the inspection.
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Rely on the inspection forms to
examine and consider the following documents and technical documents of the gas
preparation, storage and filling system:
7.2.1. Upon first safety
inspection:
7.2.1.1. Profiles of vessels in the
gas preparation, storage and filling system: As per QCVN: 01-2008 - BLDTBXH. The
following documents should be considered:
- Indicators concerning
manufacturing metals, welding metals;
- Calculation of strength of
pressure retaining components;
- Structural drawings showing all
main dimensions;
- Guidelines on operation,
maintenance and repair;
- Certificate of conformity issued
by the designated organization as prescribed in the case where the competent
authority has promulgated a national technical regulation applicable to the
inspected system.
7.2.1.2. Release documents of
vessels in the gas preparation, storage and filling system:
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- Weld quality test results;
- Factory acceptance record;
- Release documents of other parts
in the gas preparation, storage and filling system.
7.2.1.3. Measuring instrument
calibration and inspection reports; records on inspection of grounding,
lightning protection and protection equipment (if any).
7.2.1.4. Installation documents:
- Name of the installer and establishment;
- Schematic diagram illustrating
the working principle of the gas preparation, storage and filling system.
- Installation design;
- Characteristics of materials
added upon installation;
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- Inspection record for each part
of the gas preparation, storage and filling system (if any);
- Entire gas preparation, storage
and filling system acceptance record.
7.2.1.5. Check processes:
- Process for pre-fill check of
cylinders;
- Filling process;
- Documents on fire prevention and
fighting.
7.2.2. Upon periodic safety
inspection:
7.2.2.1. Previous profile of the
gas preparation, storage and filling system, inspection record and certificate
of inspection result.
7.2.2.2. Documents on the use,
operation and maintenance; inspection or examination record (if any).
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7.2.3.1. In case of repair,
renovation or upgradation: design documents on repair, renovation or
upgradation; post-repair, -renovation or -upgradation acceptance record.
7.2.3.2. In case of change of the
installation location: installation documents.
The document and profile inspection
result is passed if:
- The profiles of vessels are
adequate and comply with 2.4 of QCVN: 01- 2008/BLDTBXH;
- If failed, the establishment
shall take additional corrective actions according to 3.2.2 of QCVN 01-2008/BLDTBXH.
7.3. Prepare suitable and adequate
facilities for inspection.
7.4. Develop safety measures and
reach an agreement thereon with the establishment before inspection. Provide
adequate personal protective equipment to ensure safety during the inspection.
8. INSPECTION PROCESS
The inspection must be carried out
in the following order:
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8.1.1. Check the installation area
and location.
8.1.2. Check the operation lighting
system.
8.1.3. Check work platform, stairs,
racks, walkways,
etc.
8.1.4. Safety grounding and
lightning protection system.
8.1.5. Check technical
specifications on the system’s label and vessels against those specified in its
design and profile.
8.1.6. Check the condition of
safety, measuring and ancillary equipment in terms of its quantity, type and
technical specifications against those specified in the design and prescribed
standard.
8.1.7. Check pipes, valves and pipe
fittings mounted on the system in terms of their quantity, type and technical
specifications against those specified in the design and prescribed standard.
8.1.8. Check the condition of other
accompanied ancillary equipment serving operation of the gas preparation,
storage and filling system.
8.1.9. Check the condition of welds
and metal surfaces of pressure retaining components. If any suspicion exists,
request the establishment to take appropriate additional inspection measures to
provide a more accurate evaluation.
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8.1.11. Check joints.
8.1.12. If the gas preparation,
storage and filling system uses a toxic or explosive medium, check the
ventilation system for the compressor room, storage tanks and outlets of safety
valves.
8.1.13. Check the cooling systems
for the cylinders (if any). Check filling racks and parts holding cylinders
during filling. Check the system for checking and determining the quantity of
gases filled.
Evaluation: The gas preparation,
storage and filling system is passed if:
- The acetylene system complies
with the requirements set out under 4.1. of TCVN 4245:1996;
- The oxygen system complies with
the requirements set out under 4.2. of TCVN 4245:1996;
- The acetylene and oxygen pipes
comply with the requirements set out under 4.3. of TCVN 4245:1996;
- Other gas preparation and filling
systems comply with the requirements set out under standards applied;
- Pressure vessels in the system
comply with the regulations set forth under section 3 of TCVN 6155:1996 and
section 8 of TCVN 8366:2010;
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8.2. Internal technical inspection:
8.2.1. Check the condition of welds
and metal surfaces of pressure retaining components. If any suspicion exists,
request the establishment to take appropriate additional inspection measures to
provide a more accurate evaluation.
8.2.2. Check the inner metal of
pressure retaining components for scale deposit, rust or corrosion.
8.2.3. For locations where an
internal inspection is not feasible during inspection, a technical condition
check shall be carried out in accordance with the manufacturer's technical
documentation. The following shall be documented: inspection items, method and
process.
8.2.4. In case the pressure vessels
in the system consist of a tube bundle: if there is any suspicion about the
technical condition of the tube bundle, the establishment is requested to
partially or entirely remove the tube bundle for inspection.
8.2.5. If it is not possible to
conduct an internal inspection due to the structural characteristics of the
system, it is permitted to replace the internal inspection with a strength test
at the prescribed test pressure and inspect examinable components.
Evaluation: The gas preparation,
storage and filling system is passed if:
- Pressure vessels in the system
comply with the regulations set forth under section 3 of TCVN 6155:1996 and
section 8 of TCVN 8366:2010;
- No crack, bulge, dent,
deformation or corrosion in excess of the prescribed limits on the pressure
retaining components, external welds and joints of the thermal oil heater.
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8.3.1. If the system has multiple segments
working at different pressure levels, a separate test must be performed for
each segment under the corresponding different pressure levels.
8.3.2. During the inspection,
isolation measures must be taken to ensure that automatic protection equipment
and measuring instruments are not damaged at the test pressure. If not, such
equipment and instruments shall be removed.
8.3.3. Strength test.
The pressure vessels in the system
will be exempt from the strength test during the first inspection if the test
time at the factory does not exceed 18 months, and it has been well preserved
and shows no signs of impact or deformation during transport and installation. The
inspection record must clearly state the reason and attach the strength test
reports of the manufacturer and the installation acceptance record (if any). A
strength test shall be conducted at least once every 6 years according to the following
requirements (including unscheduled inspection):
8.3.3.1. The test medium is a
liquid (water, non-corrosive, non-toxic liquid), gas (inert gas or air),
temperature of the test medium must be less than 50°C and must not fall below
the ambient temperature by more than 5°C.
8.3.3.2. Test pressure and test
pressure holding time are specified in table 1.
Table
1
Strength test pressure and test
pressure holding time after first installation.
No.
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Test
pressure (bar)
Holding
time (min)
1
Gas generators and equipment working
with acetylene gas with Plv ≤ 0.7 bar
Plv
10
2
Gas generators and equipment working
with acetylene gas with Plv > 0.7 bar
1.5
Plv but not less than 2 bar
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3
Low and medium pressure acetylene
gas pipelines (Plv < 1.5 bar)
13(Plv
+1)-1
10
4
Oxygen pipelines
1.5
Plv but not less than 2 bar
10
5
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1.5
Plv but not less than 2 bar
10
6
Gas containers.
Plv <5 bar
1.5
Plv but not less than 2 bar
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Plv ≥5 bar
1.5
Plv but not less than Plv +3
05
Strength
test pressure and test pressure holding time during periodic and unscheduled
inspection.
No.
Name
of equipment
Test
pressure (bar)
Holding
time (min)
1
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Plv
10
2
Low and medium pressure acetylene
gas pipelines (Plv < 1.5 bar)
13
(Plv +1) -1
10
3
Acetylene gas containers with Plv
> 0.7 bar
1.5
Plv but not less than 2 bar
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4
Oxygen pipelines
1.5
Plv but not less than 2 bar
10
5
Pipelines for other gases
1.5
Plv but not less than 2 bar
10
6
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Plv < 5bar
1.5
Plv but not less than 2 bar
05
Plv ≥ 5bar
1.25
Plv but not less than Plv +3
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Plv - Working
pressure. Ptk - Design pressure.
8.3.3.3. Strength test process:
8.3.3.3.1. Fill the test medium:
fully fill the system with the test medium (paying attention to releasing gases
if the test medium is a liquid).
8.3.3.3.2. Increase the pressure up
to the test pressure (paying attention to increasing the pressure gradually to
avoid sudden expansion that may damage equipment and avoiding hammering while
applying the test pressure). Monitor and detect unusual events during the test.
8.3.3.3.3. Maintain the test
pressure as prescribed.
8.3.3.3.4. Reduce pressure slowly
to the working pressure, maintain this pressure during the test. Then reduce
the pressure to 0 (zero); correct the deficiencies (if any) and check the
result.
8.3.3.4. In case it is not feasible
to conduct a strength test using a liquid due to the stress on the footing or
floor or the difficulty in discharging the test medium and the system using refrigerant
does not permit the test with water, the strength test with gas (air or inert
gas) is permitted.
8.3.3.4.1. The strength test with
gas is permitted only when the external and internal inspection give a good
result and the strength is tested and calculated using the data obtained from
direct measurement.
8.3.3.4.2. When conducting a gas
test, the following safety measures must be taken:
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- During the period of applying the
gas test pressure, unauthorized persons must move to a safe place.
8.3.3.4.3. Tightness shall be
checked using soap solution or other methods. Hammering on the vessel wall
while applying gas pressure is prohibited.
8.3.3.5. In case it is impossible
to conduct the strength test with liquid medium for the reasons stated in
8.3.3.4 or safety conditions cannot be satisfied when conducting the test with
gas medium, other alternative testing methods may be applied when the
manufacturer provides separate instructions.
Evaluation: The strength test is
passed if:
- No crack is found;
- No air bubble, water spray or
leakage of water through welds or joints is found;
- No distortion is detected;
- The allowable pressure drop
during the period of maintaining the test pressure is ≤ 0.5% of the test
pressure.
8.3.4. Tightness test:
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8.3.4.1. Test medium: Air or inert
gas.
8.3.4.2. Test pressure and test
pressure holding time are specified in table 2.
Table
2: Tightness test pressure, medium and holding time
No.
Name
of equipment
Test
pressure (bar)
Holding
time (hr)
1
Low and medium pressure acetylene
gas pipelines. (Plv <1.5 bar)
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34
2
High pressure acetylene gas pipelines.
(Plv > 1.5 bar)
Plv
34
3
Pipelines for other gases
Plv
Maintained
during the test, but not less than 30 minutes
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Gas containers
Plv
Maintained
during the test, but not less than 30 minutes
Plv - Working
pressure.
Notes:
- The tightness test holding time
must be long enough to achieve the stability of the test medium pressure and
the test time.
- Oxygen separators undergo the
tightness test as required by the manufacturer.
8.3.4.3. Fill the system with the
test medium and increase the pressure up to the test pressure.
8.3.4.4. Detect the leaks using
soap solution or other methods.
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- No gas leak is detected.
- The allowable pressure drop
during the period of maintaining the tightness test pressure is:
+ For the system having oxygen
pipelines with Plv >1bar: ≤ 5%;
+ For the system having oxygen
pipelines with Plv ≤ 1bar: < 1%;
+ For the system having acetylene
pipelines: ≤ 0.5%;
+ For other explosive and toxic
gases: ≤ 0.5%;
+ For other gases: ≤ 3%.
8.4. Operational inspection:
8.4.1. Inspect the satisfaction of
all conditions for putting the system into operation.
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8.4.3. When the system operates
stably, pressure is raised to check and adjust the working pressure of safety
valves, and perform sealing of safety valves (except for the system working
with toxic, flammable and explosive media).
8.4.4. Safety valves may be
adjusted and sealed separately from the operational inspection.
8.4.5. Each safety valve is
adjusted and sealed as follows: The set pressure of each safety valve must not
exceed:
- Plv + 0.5 bar - When
the working pressure is 3 bar;
- Plv + 15% Plv
- When the working pressure is above 3 bar to 60 bar;
- Plv + 15% Plv -
When the working pressure is above 60 bar;
- Each gas filling rack is adjusted
and sealed with a set pressure prescribed by the manufacturer;
- Safety valves of compression
stages on the compressor are adjusted and sealed as required by the
manufacturer.
Evaluate results: the result is
passed if the system, ancillary equipment, measuring instruments and protection
equipment operate normally and maintain specifications stably.
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9.1. Prepare an inspection record
which contains sufficient information according to the form in the Appendix 02
enclosed herewith.
9.2. Approve the inspection record:
Mandatory participants in the
process of approving the inspection record include:
- The representative of the establishment
or a person authorized by the establishment;
- The witness;
- Inspectors conducting the
inspection.
As the record is approved, the
inspectors, the witness, and the representative of the establishment or a
person authorized by the establishment shall append their signatures and seals
(if any) to the record. The record shall be made into two (02) copies, each
party shall keep 01.
9.3. Write the brief inspection
result to the profile of the system (including full names of the inspectors and
the date of inspection).
9.4. Affix the inspection stamp: if
the system passes the test, the inspector shall affix an inspection stamp to it
at a noticeable position.
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9.5.1. If the gas preparation,
storage and filling system passes the test, the inspecting organization shall
issue the certificate of inspection result to the gas preparation, storage and
filling system within 05 working days from the date on which the inspection
record is approved at the establishment.
9.5.2. If the gas preparation,
storage and filling system fails the test, only the steps 9.1 and 9.2 shall be
taken and only the inspection record which must specify the explanation for
failed result, necessary remedial actions and a deadline for taking such actions
is issued to the establishment. Such inspection record and written notification
shall be also sent to the employment authority of the area where the gas
preparation, storage and filling system is installed and used.
10. INSPECTION INTERVAL
10.1. The technical safety
inspection interval is 03 (three) years. For the gas preparation, storage and
filling system working with corrosive, explosive and toxic substances
(Chlorine, Hydrogen Sulfide, etc.), all inspection steps must be taken. The
technical safety inspection interval is 02 years.
10.2. For a gas preparation,
storage and filling system that has been used for more than 12 (twelve) years,
the technical safety inspection interval is 02 (two) years.
10.2. For a gas preparation,
storage and filling system that has been used for more than 12 (twelve) years
and works with a corrosive, explosive or toxic medium and a system that has
been used for more than 24 years, the technical safety inspection interval is 01
year.
10.4. In the case where a shorter
interval is demanded by the manufacturer or establishment, such interval shall
apply.
10.5. If the inspection interval is
shortened, the inspector shall specify explanation in the inspection record
10.6. If the inspection interval is
specified in national technical regulations, such national technical
regulations shall apply.
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Appendix
01
SPECIMEN
OF ON-SITE RECORD
(FOR INSPECTION OF TECHNICAL SAFETY OF GAS PREPARATION, STORAGE AND FILLING
SYSTEMS)
(Name
of the inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
..............,
[place], ………[date]
ON-SITE
RECORD
No.
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I. General information
Name of the equipment:
.…………….……………………….…………….……………………………………….
Name of the applicant:
.…………….……………………….…………….………………….
Address (head office of the
establishment): .…………….……………………….…………….………………
Installation address (location):
.…………….……………………….…………….…………………………….
Details of the meeting with the
establishment:
- Representative: (information)
- Witness:
II. Document inspection:
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a. Release documents.
- Profile of the gas preparation,
storage and filling system.
- Schematic diagram illustrating
the working principle of the system.
- Structural drawings of pressure equipment
of the system.
- Guidelines on operation and maintenance.
- Certificates of quality
inspection of manufacturing metals.
- Certificates of inspection of
welding metals and welds.
b. Installation documents:
- Installation design.
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- Process for pre-fill check of
cylinders.
- Filling process.
- Documents on fire prevention and
fighting.
c. Certificates of
measurement-related inspection:
- Measuring instrument inspection
report.
- Records on inspection of
grounding, lightning protection.
- Record on inspection of
protection equipment.
2. Upon periodic inspection:
a. Previous profile, inspection record
and certificate of inspection result.
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c. Repair and maintenance logbook;
inspection or examination record (if any).
3. Upon unscheduled inspection:
a. The same documents as those upon
periodic inspection.
b. Documents on repair; records on
post-repair and -change quality.
c. Installation documents (in case
of change of installation location).
III. External technical
inspection:
1. Installation location (distance
between walls and equipment).
2. Operation lighting.
3. Specifications against those
specified in the profile. (Code, manufacture number, country of manufacture,
month and year of manufacture, design pressure, working pressure, temperature,
capacity, medium, etc.)
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5. Safety valves (Quantity, type, DN,
PN, adjusted pressure)
6. Pressure gauge. (Quantity,
Scale, unit of measurement, accuracy, calibration stamp number, inspection
stamp number)
7. Level meter (quantity, type)
8. Ventilation system for the
compressor room.
9. Storage tanks.
10. Outlets of safety valves.
11. Cooling system for the
cylinders (if any).
12. Filling racks and parts holding
cylinders during filling.
13. System for checking and
determining the quantity of gases filled.
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1. Scale deposit.
2. Metal surfaces: dent, bulge,
rust, crack.
V. Strength test, tightness
test:
1. Test medium:
2. Test pressure:
3. Test time:
4. Pressure gauge: Scale, unit of
measurement, accuracy, inspection stamp number
5. Medium supply equipment: Type,
number.
6. Result:
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+ Pressure drop.
+ Deformation.
VI. Operational test:
1. Condition of the system:
2. Preparation pressure:
3. Filling pressure:
4. Working condition of
safety equipment:
5. Working condition of metering equipment:
6. Working condition of filling
racks:
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WITNESS
(Signature, full name)
INSPECTOR
(Signature, full name)
Appendix
02
SPECIMEN
OF RECORD ON INSPECTION OF TECHNICAL SAFETY OF GAS PREPARATION, STORAGE AND
FILLING SYSTEM
(Name
of the inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
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SPECIMEN
OF RECORD ON INSPECTION OF TECHNICAL SAFETY
(GAS PREPARATION, STORAGE AND FILLING SYSTEM)
No.
………………….
(According
to the on-site record No. …………)
We are:
1. .…………….……………………… Inspector
number: .…………….………………………
2. .…………….……………………… Inspector
number: .…………….………………………
Of:
Registration certificate number of
the inspecting organization: .…………….…………………………………….
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Of (specify name of the
establishment) : .…………….……………………….…………….……………………….…
Address (head office of the
establishment): .……………………….…………….…………………………….
Installation address (location):
.…………….……………………….…………….…………………………….
Inspection procedures applied:
.…………….……………………….…………….……………………
Individuals witnessing the
inspection and approving the record: .…………….………………………………………..
1. ……………………………….……………………… Position:
.…………….………………………
2. ……………………………….……………………… Position:
.…………….………………………
I
- BASIC SPECIFICATIONS OF THE SYSTEM
Code: ……….……Manufacture
number……………..
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Manufacturer:
.…………….……………………….…………….…………………………………………
Preparation pressure: ………………… bar
Maximum storage pressure: …………………
bar
Filling
pressure: …………………………….Bar
Storage capacity: …………………………
tonnes
Filling capacity: ………………kg/h
Type of gas: ……………. Number of
filling racks: ……………..
Number of filling inlets:
…………………………………..
Uses: .…………….……………………….…………….…………………………………………
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By .…………….……………………… ………….
II
- FORMS OF INSPECTION
First
time □ ; Periodic □ ; Unscheduled □
Reason for unscheduled inspection:
.…………….………………………………………
III
- INSPECTION CONTENT
1. Document inspection:
- Remarks:
.…………….……………………….…………….………………………………………..
- Result evaluation: Passed
□ Failed □
2. External and internal
technical inspection:
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Passed
Failed
Installation location, distance
Operation lighting
Ventilation
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Floor, stairs
Grounding and lightning
protection system
Storage tanks, cylinders, vessels
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Condition of metal surfaces of
pressure retaining components
Condition of welds and joints on
pressure retaining components
Compressors, ancillary parts
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System, equipment and facilities
for explosion prevention and fighting
Measuring instruments, protection
and safety equipment, automatic equipment
Result evaluation:
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- Result evaluation: Passed
□ Failed □
3. Test:
Type
of test
Part
Test
medium
Test
pressure (bar)
Holding
time (min)
Strength
test
Tanks,
cylinders
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Pipelines
Tightness
test
Tanks,
cylinders
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Pipelines
Operational
test
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Result evaluation:
- Remarks:
.…………….……………………….…………….………………………………………..
- Result evaluation: Passed
□ Failed □
IV
- CONCLUSIONS AND RECOMMENDATIONS
1. Result of inspection of the
system: Passed □ Failed □
2. Has an inspection stamp No.
……………… Affixed at: …………………………….…………
3. Working pressure:
+ Preparation: …………… bar.
+ Storage: ……….. bar + Filling: …………. bar
4. Safety valve’s set pressure:
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Opening
pressure (bar)
Closing
pressure (bar)
Preparation
Storage
Filling
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5. Recommendations:.…………….……………………….…………….………………………………
Deadline for implementation of
recommendations: .…………….……………………….…………….……………….
V
- INSPECTION INTERVAL
Date of periodic inspection……….
[date]
Reason for shortening the interval:
…………………………..…………….…………………………………..
The record is approved on …….
[date]
At:.…………….……………………….…………….……………………………………………….
The record is made into ………..
copies, each party holds ………. copies./.
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ESTABLISHMENT
OWNER
Undertaking to fully implement recommendations by the deadline
(Signature and seal)
WITNESS
(Signature, full name)
INSPECTOR
(Signature, full name)
PROCEDURES FOR INSPECTION OF TECHNICAL SAFETY OF STEAM
AND HOT WATER PIPING SYSTEMS
QTKD: 04 - 2016/BLDTBXH
Foreword
Procedures for inspection of
technical safety of steam and hot water piping systems are drafted by the
Department of Work Safety and promulgated together with the Circular No.
54/2016/TT-BLDTBXH dated December 28, 2016 of the Ministry of Labor - Invalids
and Social Affairs.
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1. SCOPE AND REGULATED ENTITIES
1.1. Scope
Such procedures shall be used for
first, periodic and unscheduled inspection of metal piping systems carrying
steam and hot water with a working pressure equal to or greater than 0.7 bar
and a temperature greater than 115°C (hereinafter referred to as “piping
systems”) under state management of the Ministry of Labor - Invalids and Social
Affairs.
The procedures do not apply to piping
systems in boilers, piping on locomotives, piping systems on ships and
watercraft, exhaust pipes and heat pipes, steam pipes in steam turbines, pipes
in nuclear power plants and nuclear reactors, grade 1 pipes with an outside
diameter of less than 51 mm and pipes of other grades with an outside diameter
of less than 76 mm (classified according to TCVN 6158:1996 - Pipe lines for
vapour and hot water - Technical requirements).
1.2. Regulated entities
- Organizations carrying out
technical inspection of occupational safety;
- Occupational safety inspectors.
2. NORMATIVE REFERENCES
- TCVN 6158:1996 - Pipe lines for
vapour and hot water - Technical requirement;
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- TCVN 6008-2010 - Pressure equipment
- Welds - Technical requirements and testing methods;
In the cases where any of the
national technical regulations and national standards referred to in this
inspection procedure is amended or replaced, the newest one shall apply.
Other standards may be applied to
inspection of technical safety of a steam and hot water piping system at the
request of its user or manufacturer if such standards contain the same or
higher safety criteria than those in the national standards referred to in this
document.
3. TERMS AND DEFINITIONS
For the purposes of this document,
the terms and definitions given in the abovementioned normative references and
the following shall apply:
3.1. Steam and hot water piping
system
A system consisting of pipes, pipe
fittings and valves used to carry steam and hot water from one location to
another.
3.2. First safety inspection
An evaluation of technical safety
of a piping system according to national technical regulations and technical
safety standards after its installation and before its first use.
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An evaluation of technical safety
of a piping system according to national technical standards and technical
safety standards after expiration of the last safety inspection result.
3.4. Unscheduled safety inspection
An evaluation of technical safety
of a piping system according to national technical standards and technical
safety standards:
- After repair, upgradation or
renovation that affects the technical safety of the piping system;
- After change of the installation
location;
- The piping system has been out of
service for 12 months or more;
- At the request of the
establishment or a competent authority.
4. INSPECTION STEPS
Upon conducting a technical safety
inspection of the piping system, the following steps shall be taken in turn:
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- Conduct external and internal
technical inspection;
- Conduct technical testing;
- Conduct operational inspection;
- Process the inspection result.
Note: The next inspection step is
taken only when the result of the previous step is passed. The result of each
step shall be fully documented according to the form in the Appendix 01 and
fully retained by the inspecting organization.
5. INSPECTION EQUIPMENT AND
INSTRUMENTS
Inspection equipment and
instruments shall be inspected and calibrated in accordance with regulations. Inspection
equipment and instruments include the following:
- Hydraulic test pump;
- Sample pressure gauge, testing
pressure gauge;
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- Apparatus for checking geometric
dimensions;
- Lead sealing plier;
- Insulation resistance meter;
- Ground resistance meter;
- Mustimeter;
- Clamp meter;
- Temperature measuring instrument;
- Luminous intensity meter;
- Ultrasonic thickness gauge
(if needed);
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6. CONDITIONS FOR INSPECTION
The inspection of a piping system
must not be carried out unless the following conditions are met:
6.1. The piping system is at the
ready for inspection.
6.2. Documents of the piping system
are adequate.
6.3. The inspection is not affected
by environment or weather.
6.4. Requirements concerning
occupational safety and health are met.
7. PREPARATION FOR INSPECTION
Before carrying out the inspection,
it is required to make the following preparations:
7.1. Agree to the inspection plan
and preparations and cooperate with the establishment in:
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7.1.2. Removing the medium,
cleaning the inside and outside of the piping system.
7.1.3. Preparing facilities to
ensure that all parts of the piping system are examined.
7.1.4. Providing personnel and
materials for inspection; assigning personnel to participate in and witnessing
the inspection.
7.2. Examine documents and profile
of the piping system
Rely on the inspection forms to
examine and consider the following technical documents of the piping system:
7.2.1. Upon first safety inspection
7.2.1.1. Profile of the piping
system. The following documents should be considered:
- Indicators concerning
manufacturing metals, welding metals;
- Calculation of strength of
pressure retaining components;
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- Guidelines on operation,
maintenance and repair;
- Certificates of quality
inspection of manufacturing metals, welding metals;
- Weld quality test results;
- Certificate of conformity issued
by the designated organization as prescribed in the case where the competent
authority has promulgated a national technical regulation applicable to the
inspected piping system.
7.2.1.2. Measuring instrument
calibration reports; records on inspection of grounding, lightning protection
and protection equipment (if any).
7.2.1.3. Installation documents:
- Name of the installer and
establishment;
- Installation design, as-built
drawing;
- Characteristics of materials
added upon installation;
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- Entire piping system acceptance
record, as-built drawing.
7.2.2. Upon periodic safety
inspection
7.2.2.1. Previous profile,
inspection record and certificate of inspection result.
7.2.2.2. Documents on the use,
operation and maintenance; inspection or examination record (if any).
7.2.3. Upon unscheduled safety
inspection: Documents shall be examined as if it is the unscheduled inspection
and other documents shall be additionally examined in the following cases:
7.2.3.1. In case of repair,
renovation or upgradation: design documents on repair, renovation or
upgradation; post-repair, -renovation or -upgradation acceptance record.
7.2.3.2. In case of change of the
installation location: installation documents.
The document and profile inspection
result is passed if:
- The profile is adequate, complies
with the requirements above and conforms to the design;
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7.3. Prepare suitable and adequate
facilities for inspection.
7.4. Develop safety measures and
reach an agreement thereon with the establishment before inspection. Provide
adequate personal protective equipment to ensure safety during the inspection.
8. INSPECTION PROCESS
The inspection must be carried out
in the following order:
8.1. External technical inspection:
8.1.1. Check the installation area
and location.
8.1.2. Check the operation lighting
system.
8.1.3. Check work platform, stairs,
racks.
8.1.4. Check the electrical safety
grounding and lightning protection system (if any).
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8.1.6. Check the condition of
safety, measuring and ancillary equipment in terms of its quantity, type and
technical specifications against those specified in the design and prescribed
standard.
8.1.7. Check pipes, valves and pipe
fittings mounted on the piping system in terms of their quantity, type and
technical specifications against those specified in the design and prescribed
standard.
8.1.8. Check the condition of other
accompanied ancillary equipment serving operation of the piping system.
8.1.9. Check the condition of welds
and metal surfaces of pressure retaining components of the piping system. If
any suspicion exists, request the establishment to take appropriate additional
inspection measures to provide a more accurate evaluation.
8.1.10. Check the technical
condition of the paint and thermal insulation coating (if any); check for signs
of water stagnation under the thermal insulation coating;
8.1.11. Check joints.
Evaluation: The piping system is
passed if:
- No crack, bulge, dent,
deformation or corrosion in excess of the prescribed limits or sign of medium
leakage on the pressure retaining components of the piping system is found.
- Measuring instruments, safety equipment
and ancillary equipment are adequate and conform to the design.
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8.2.1. Check the condition of metal
surfaces of pressure retaining components.
8.2.2. Check the inner metal of the
piping system for scale deposit, rust or corrosion.
8.2.3. For locations where an
internal inspection is not feasible during inspection, a technical condition
check shall be carried out in accordance with the manufacturer's technical
documentation. The following shall be documented: inspection items, method and
process.
8.2.4. If it is not possible to
conduct an internal inspection due to the structural characteristics of the
piping system, it is permitted to replace the internal inspection with a
hydraulic test at the prescribed test pressure and inspect examinable
components.
The piping system passes the test
if the piping system is in normal working condition and no crack, bulge, dent
or no crack, bulge, dent, deformation or corrosion in excess of the prescribed
limits on the pressure retaining components of the piping system is found.
8.3. Technical inspection, testing.
8.3.1. If the piping system has
multiple segments working at different pressure levels, a separate test must be
performed for each segment.
8.3.2. During the inspection,
isolation measures must be taken to ensure that automatic protection equipment
and measuring instruments are not damaged at the test pressure. If not, such
equipment and instruments shall be removed.
8.3.3. Strength test.
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8.3.3.1. The test medium is a
liquid (water, non-corrosive, non-toxic liquid), gas (inert gas or air), temperature
of the test medium must be less than 50°C and must not fall below the ambient
temperature by more than 5°C.
8.3.3.2. Test pressure: 1.5 Plv.max
(maximum working pressure).
8.3.3.3. Test pressure holding
time: 10 minutes.
8.3.3.4. Strength test process
8.3.3.4.1. Fill the test medium:
fully fill the piping system with the test medium (paying attention to
releasing gases if the test medium is a liquid).
8.3.3.4.2. Increase the pressure up
to the test pressure (paying attention to increasing the pressure gradually to
avoid sudden expansion that may damage equipment and avoiding hammering while
applying the test pressure). Monitor and detect unusual events during the test.
8.3.3.4.3. Maintain the test
pressure as prescribed.
8.3.3.4.4. Reduce pressure slowly
to the working pressure, maintain this pressure during the test. Then reduce
the pressure to 0 (zero); correct the deficiencies (if any) and check the
result.
8.3.3.5. In case it is not feasible
to conduct a strength test using a liquid due to the stress on the footing or
floor or difficulty in draining water, the hydraulic test may be replaced
with the test using gas pressure (air or inert gas). The strength test with gas
is permitted only when the external and internal inspection give a good result
and the strength is calculated and tested using the data obtained from direct
measurement of the piping system.
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- Valves and press gauge on the
pipe filled with test gas should be moved away from the pipe location or
outside the pipe room;
- During the period of applying gas
test pressure, unauthorized persons must move to a safe place.
- Hammering on components of the
piping system while applying gas pressure is prohibited.
8.3.3.5.2. Tightness shall be
checked using soap solution or other methods after reducing the test pressure
to the working pressure.
Evaluation: The strength test is
passed if:
- No crack is found;
- No air bubble, water spray or
leakage of water through welds or joints is found;
- No distortion is detected;
- The allowable pressure drop
during the period of maintaining the test pressure does not exceed 3% of the
test pressure.
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8.4.1. Inspect the satisfaction of
all conditions for putting the piping system into operation.
8.4.2. Check the working condition
of the piping system and accompanied ancillary equipment, and the operation of
measuring instruments and protection equipment.
8.4.3. Each safety valve is adjusted
and sealed as follows:
The set pressure of a safety valve
is not greater than 1.1 times the maximum working pressure.
Evaluate results: the result is
passed if the piping system, ancillary equipment, measuring instruments and
protection equipment operate normally and maintain specifications stably.
9. PROCESSING OF INSPECTION
RESULTS
9.1. Prepare an inspection record
which contains sufficient information according to the form in the Appendix 02
enclosed herewith.
9.2. Approve the inspection record:
Mandatory participants in the
process of approving the inspection record include:
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- The witness;
- Inspectors conducting the
inspection.
As the record is approved, the
inspectors, the witness, and the representative of the establishment or a
person authorized by the establishment shall append their signatures and seals
(if any) to the record. The record shall be made into two (02) copies, each
party shall keep 01.
9.3. Write the brief inspection
result to the profile of the piping system (including full names of the
inspectors and the date of inspection).
9.4. Affix the inspection stamp: if
the piping system passes the test, the inspector shall affix an inspection
stamp to it at a noticeable position.
9.5. Certify the inspection result:
9.5.1. If the piping system passes
the test, the inspecting organization shall issue the certificate of inspection
result to the piping system within 05 working days from the date on which the
inspection record is approved at the establishment.
9.5.2. If the piping system fails
the test, only the steps 9.1 and 9.2 shall be taken and only the inspection
record which must specify the explanation for failed result, necessary remedial
actions and a deadline for taking such actions is issued to the establishment.
Such inspection record and written notification shall be also sent to the
employment authority of the area where the piping system is installed and used.
10. INSPECTION INTERVAL
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10.2. In the case where a shorter
interval is demanded by the manufacturer or establishment, such interval shall
apply.
10.3. If the inspection interval is
shortened, the inspector shall specify explanation in the inspection record
10.4. If the inspection interval is
specified in national technical regulations, such national technical regulations
shall apply.
Appendix
01
SPECIMEN
OF ON-SITE RECORD
(FOR INSPECTION OF TECHNICAL SAFETY OF STEAM AND HOT WATER PIPING SYSTEMS)
(Name
of the inspecting organization)
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THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
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ON-SITE
RECORD
No.
……………
(The inspector is required to fully write details of assessment, and inspection
and testing parameters according to the inspection process)
1- General information
Name of the equipment:
.…………….……………………….…………….……………………………………….
Name of the applicant:
.…………….……………………….…………….………………….
Address (head office of the
establishment): .…………….……………………….…………….………………
Installation address (location):
.…………….……………………….…………….…………………………….
Details of the meeting with the
establishment:
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- Witness:
2. Basic specifications of
equipment
- Type, code: .…………….………………………
- Design pressure: …………………… bar
- Piping system symbol:
…………………………………….
- Working pressure: …………………… bar
- Installer: .…………….………………………
- Inside diameter:………………………
- Year of installation:
.…………….………………………
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3. Inspection form: Please
write first, periodic or unscheduled inspection (in case of unscheduled
inspection, write the reason therefor)
4. Noted and detected details:
Details
4.1 Technical document
inspection:
1. First inspection:
a. Installation documents:
- Installation design (if any)
- Acceptance record (if any)
- Certificates of quality
inspection of manufacturing metals, welding metals, welds.
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- Measuring instrument inspection
report.
- Records on inspection of
grounding, lightning protection (if any).
- Record on inspection of
protection equipment (if any)
2. Periodic inspection:
a. Previous profile, inspection
record and certificate of inspection result.
b. Operation logbook.
c. Repair and maintenance
logbook; inspection or examination record (if any).
3. Unscheduled inspection:
a. The same documents as those
upon periodic inspection.
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c. Installation documents (in
case of change of installation location)
4.2. Visual inspection: (if
conducted using measuring instrument, specific figures and identification
code are required)
4.2.1 Related parts:
Wires, supports:
Safety distance
Drainage holes
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Lighting
4.2.2 Piping system:
Valves, pipe connections,
expansion compensators
Measuring instruments, protection
equipment
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Rust
Condition of welds
4.3. Testing:
Measuring instruments for testing
Instrument name
Identification
code
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Inspection
deadline
Pressure gauge
Pump
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Testing
Specify whether the test is
conducted, not conducted, or the result provided by a third party is used
Type
of test
Test
pressure (bar)
Test
time (min)
Hydraulic
test
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4.4 Safety valves:
Safety valves
Opening
pressure (bar)
Closing
pressure (bar)
Safety
valves
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WITNESS
(Signature, full name)
INSPECTOR
(Signature, full name)
Appendix
02
SPECIMEN
OF RECORD ON INSPECTION OF TECHNICAL SAFETY OF STEAM AND HOT WATER PIPING
SYSTEM
(Name
of the inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
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SPECIMEN
OF RECORD ON INSPECTION OF TECHNICAL SAFETY
(STEAM AND HOT WATER PIPING SYSTEM)
No.
…………….
(According to the on-site record No. ………………..)
We are:
1. .…………….……………………… Inspector number:
.…………….………………………
2. .…………….……………………… Inspector
number: .…………….………………………
Of:
Registration certificate number of
the inspecting organization: .…………….…………………………………….
Have inspected
……………………………….…………….…………………………………..
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Address (head office of the
establishment): .…………….……………………….…………….……………….
Installation address (location):
.…………….……………………….…………….…………………………….
Inspection procedures applied:
.…………….……………………….…………….……………………
Individuals witnessing the
inspection and approving the record: .…………….………………………………………..
1. ……………………………….……………………… Position:
.…………….………………………
2. ……………………………….……………………… Position:
.…………….………………………
I
- BASIC SPECIFICATIONS OF THE SYSTEM
Code, Symbol: .…………….…………………
Design pressure: ………………………….bar
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Working pressure: …………………………. bar
Design temperature: ……………………………..
oC
Working temperature:
…………………………….. oC
Total length:…………………………………. m
Working medium: ……………………………..
Manufacturer (installer):
………………………………
Year of manufacture
(installation): ……………………………………
Uses:
…………….……………………….…………….……………………………………………
Date of last inspection:
………………………….
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Date of last strength
test:…………………………….
By……………………………………..
II
- FORMS OF INSPECTION
First
time □ ; Periodic □ ; Unscheduled □
Reason for unscheduled inspection:
.…………….………………………………………
III-
INSPECTION CONTENT
1. Document inspection:
- Remarks:
.…………….……………………….…………….………………………………………..
- Result evaluation: Passed
□ Failed □
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Item
Passed
Failed
Note
Installation location, distance
Operation lighting
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Floor, stairs
Grounding and lightning
protection system
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Racks, hanging wires
Insulation coating.
Metal
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Condition of welds, joints
Valves, pipe fittings
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Safety valves
Pressure gauge
Other measuring instruments,
protection and safety equipment, automatic equipment
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- Remarks:
.…………….……………………….…………….………………………………………..
- Result evaluation: Passed
□ Failed □
3. Test:
Details
Test
medium
Test
pressure
(bar)
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Strength test
Operational test
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- Result evaluation: Passed
□ Failed □
IV
- CONCLUSIONS AND RECOMMENDATIONS
1. Result of inspection of the
piping system: Passed □ Failed □
2. Has an inspection stamp No.
…………………. Affixed at: …………….………………………
3. Working pressure:
………………………………bar Working temperature: ……………………..°C.
4. Safety valve’s set
pressure:.…………….……………………………………………………. bar
5. Recommendations:.…………….……………………….…………….…………………………………….
Deadline for implementation of
recommendations: .…………….……………………….…………….……………………
V
- INSPECTION INTERVAL
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Reason for shortening the interval:
…………………………..………………….…….………………………
The record is approved on …….
[date]
At:.…………….……………………….…………….……………………………………………….
The record is made into ………..
copies, each party holds ………. copies./.
ESTABLISHMENT
OWNER
Undertaking to fully implement recommendations by the deadline
(Signature and seal)
WITNESS
(Signature, full name)
INSPECTOR
(Signature, full name)
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QTKD: 05 - 2016/BLDTBXH
Foreword
Procedures for inspection of
technical safety of medical gas pipeline systems are drafted by the Department
of Work Safety and promulgated together with the Circular No.
54/2016/TT-BLDTBXH dated December 28, 2016 of the Ministry of Labor - Invalids
and Social Affairs.
PROCEDURES FOR INSPECTION OF TECHNICAL SAFETY OF
MEDICAL GAS PIPELINE SYSTEMS
1. SCOPE AND REGULATED ENTITIES
1.1. Scope
Such procedures shall be used for
first, periodic and unscheduled inspection of medical gas pipeline systems (MGPS)
with an outside diameter of no more than 150 mm (hereinafter referred to as
“pipeline systems”) under state management of the Ministry of Labor - Invalids
and Social Affairs.
MGPS consist of:
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- Compressed air (for breathing)
pipeline system;
- Vacuum pipeline system;
- Systems for other medical gases
(anesthetic gases; mixtures of oxygen and anesthetic gases; gases for driving
surgical tools).
1.2. Regulated entities
- Organizations carrying out
technical inspection of occupational safety;
- Occupational safety inspectors.
2. NORMATIVE REFERENCES
- TCVN 8022-1: 2009 - Medical gas
pipeline systems - Part 1: Pipeline systems for compressed medical gases and
vacuum;
- TCVN 7742: 2007 - Oxygen
concentrator supply systems for use with medical gas pipeline systems;
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In the cases where any of the
national technical regulations and national standards referred to in this
inspection procedure is amended or replaced, the newest one shall apply.
Other standards may be applied to
inspection of technical safety of an MGPS at the request of its user or
manufacturer if such standards contain the same or higher safety criteria than
those in the national standards referred to in this document.
3. TERMS AND DEFINITIONS
For the purposes of this document,
the terms and definitions given in the abovementioned normative references and
the following shall apply:
3.1. Medical gas
Any gas or mixture of gases used to
supply patients or medical equipment for the purpose of treatment, anesthesia,
diagnosis, disease prevention, research, experimentation, etc. in the medical
field.
3.2. Medical gas pipeline system
A pipeline system starting behind the source shut-off valve to the
terminal units at the points where medical gases or vacuum may be required,
including pipe fittings such as: shut-off valves, one-way valves, fire dampers,
pressure reducing valves, safety valves, condensate drain valves, mixed gas
drain valves, measuring instruments, alarm equipment, terminal units and other fittings.
3.3. First safety inspection
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3.4. Periodic safety inspection:
An evaluation of technical safety
of an MGPS according to national technical standards and technical safety
standards after expiration of the last safety inspection result.
3.5. Unscheduled safety inspection
An evaluation of technical safety
of an MGPS according to national technical standards and technical safety
standards:
- After repair, upgradation or
renovation that affects the technical safety of the MGPS;
- After change of the installation
location;
- At the request of the
establishment or a competent authority.
4. INSPECTION STEPS
Upon conducting a technical safety
inspection of the MGPS, the following steps shall be taken in turn:
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- Examine diagram of the pipeline
system;
- Conduct external and internal
technical inspection (if any):
- Conduct technical testing;
- Process the inspection result.
Note: The next inspection step is
taken only when the result of the previous step is passed. The result of each
step shall be fully documented according to the form in the Appendix 01 and
fully retained by the inspecting organization.
5. INSPECTION EQUIPMENT AND
INSTRUMENTS
Inspection equipment and
instruments shall be inspected and calibrated in accordance with regulations. Inspection
equipment and instruments include the following:
- Hydraulic test pump;
- Sample pressure gauge, testing
pressure gauge;
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- Apparatus for checking geometric
dimensions;
- Lead sealing plier;
- Insulation resistance meter;
- Ground resistance meter;
- Mustimeter;
- Clamp meter;
- Temperature measuring instrument;
- Luminous intensity meter;
- Gas leak detector;
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- Non-destructive testing equipment
for defect detection (if needed).
6. CONDITIONS FOR INSPECTION
The inspection of an MGPS must not
be carried out unless the following conditions are met:
6.1. The pipeline system is at the
ready for inspection.
6.2. Documents of the pipeline
system are adequate.
6.3. The inspection is not affected
by environment or weather.
6.4. Requirements concerning
occupational safety and health are met.
7. PREPARATION FOR INSPECTION
Before carrying out the inspection,
it is required to make the following preparations:
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7.1.1. Preparing documents of the
pipeline system.
7.1.2. The pipeline system is at
the ready for inspection.
7.1.3. Providing personnel and
materials for inspection; assigning personnel to participate in and witnessing
the inspection.
7.2. Examine documents and profile
of the pipeline system
Rely on the inspection forms to
examine and consider the following technical documents of the pipeline system:
7.2.1. Upon first safety
inspection:
- Profile of the pipeline
system. The following documents should be considered:
+ Design drawing, piping diagram
and components of the system;
+ Description of working pressure
at each level, specifications and pipe length of the pipeline system;
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+ Indicators concerning
manufacturing metals, welding metals, fasteners, flanges.
- Pipeline system installation
documents: installation design, piping diagram, as-built dossiers, overall
system acceptance record.
+ Results of strength and tightness
test of each component and item during installation (if any);
+ Weld quality test results (if
any).
- Measuring instrument calibration
reports; records on inspection of grounding, lightning protection and
protection equipment (if any).
- Certificate of conformity issued
by the designated organization as prescribed in the case where the competent
authority has promulgated a national technical regulation applicable to the
inspected pipeline system.
7.2.2. Upon periodic safety
inspection:
- Previous profile, inspection
record and certificate of inspection result.
- Documents on the use, operation
and maintenance; inspection or examination record (if any).
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- In case of repair: repair
documents, post-repair record (documenting the welding and replacement of
pressure retaining components);
- In case of change of the
installation location: installation documents;
The document and profile inspection
result is passed if they are adequate and comply with technical safety regulations
and standards applied. If failed, the establishment shall take additional
corrective actions.
7.3. Prepare suitable and adequate
facilities for inspection.
7.4. Develop safety measures and
reach an agreement thereon with the establishment before inspection. Provide
adequate personal protective equipment to ensure safety during the inspection.
8. INSPECTION PROCESS
The inspection must be carried out
in the following order:
8.1. Conduct external and internal
technical inspection (if any):
Perform visual inspection and use
necessary tools such as: magnifying glass, rulers (hard rulers, tape measures,
calipers, vernier calipers, micrometer rulers) and specialized lighting.
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8.1.2. Location of pipe installation,
arrangement of pipe supports, pipe hangers, arrangement of pipes passing
through floors, walls, foundations, arrangement of expansion compensation
mechanisms, cabinets of pressure reducing valves, isolation valves, emission
drain valves, condensate drain valves or valves for draining other impurities.
8.1.3. Check paint color and markings:
Paint color, symbols and direction
of movement of medical gas markings attached to pipelines from the source to
the point of use of the pipeline system. Markings shall be attached in such a
manner as to identify medical gases in areas where inspection is feasible. The
marking shall comply with the regulations laid down in Article 10.2 under TCVN
8022-1:2009 as follows:
- At gas supply stations, control
and reducer panels or isolation cabinets;
- Adjacent to shut-off valves, at
junctions and changes of direction, before and after walls and partitions;
- The distance between 02 markings
should not be more than 10m and should be adjacent to terminal units.
8.1.4. Check the electrical safety
grounding and lightning protection system (if any).
8.1.5. Check the technical
condition of installation.
- Pipelines shall not be used as
support for, nor shall they be supported by, other pipelines or conduits.
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- Check the technical condition of
pipelines, valves, flanges, joints and other fittings, detect signs of crack,
bulge, corrosion, misalignment, and leaks including:
+ Defects during processing and
installation: conduct a check to detect mechanical defects, signs of damage on
surface of the pipes, joints, welds, visible distortions and fittings;
+ Misalignment: check and record
excessive misalignment which may cause leakage and damage, usually present in
locations of pipe support installation due to pipes’ slipping off the supports,
foundation subsidence, in expansion compensation locations, and locations of
valve and fitting installation;
+ Corrosion: Check the outside and
inside of pipes (if feasible), record any local or general corrosion that may
occur on the pipe lines. Focus on contact points between pipes and supports,
locations of damaged paint layers, protective coatings, junctions between pipes
buried in the ground, in walls and pipes exposed to the air, pipe sections in
ditches, and humid environment. In case of detecting corrosion, ultrasonic
thickness testing of pipes can be performed in suspicious areas to confirm the
technical condition of the pipes.
8.1.6. Check and record the
technical condition and normal operation of shut-off valves, drain valves,
safety valves, pressure gauges, pressure reducing valves, fire dampers (oxygen
pipes), gas detectors and other fittings. Safety valves and pressure gauges
must be calibrated, inspected and sealed as prescribed and have not reached the
end of their service life.
8.1.7. Check valves mounted on
equipment in terms of their quantity, type and technical specifications against
those specified in the design and prescribed standard.
8.1.8. Check the condition of other
accompanied ancillary equipment serving operation of the piping system.
8.1.9. Carefully check locations of
welds and joints, focusing on the heat affected zone of the welds and locations
where free expansion conditions are not satisfied to detect possible cracks. If
any suspicion is detected, the establishment may be requested to perform
additional tests: penetration test, etc. to form a basis for conclusion of the
defect status.
8.1.10. Check the tightness of
joints.
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8.2. Technical inspection, testing:
8.2.1. In case the installer has
conducted the test, the test result may be accepted in part or in full without conducting
the test again when the test result complies with the requirements of the
applicable standard.
8.2.2. If the system has multiple
segments working at different pressure levels, a separate test must be
performed for each segment.
8.2.3. During the inspection,
isolation measures must be taken to ensure that automatic protection equipment
and measuring instruments are not damaged at the test pressure. If not, such
equipment and instruments shall be removed.
8.2.4. Strength test.
8.2.4.1. The test medium is water
or non-corrosive or non-toxic liquid. The test medium may be inert gas or air. Temperature
of the test medium must be less than 50°C and must not fall below the ambient
temperature by more than 5°C.
8.3.4.2. Pressure and holding time
are specified as follows:
Pipe
type
Test
pressure (bar)
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For pipelines with decomposable
fittings such as non-metallic materials or with spontaneously combustible
impurities
1.5
Plv but not less than 5
10
Normal pipelines with a pressure
of 0.7 bar or more
1.2
Plv but not less than 5
10
Vacuum pipelines
5
10
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- Fill the test medium and increase
the pressure gradually to prevent sudden expansion which may damage the
pipeline system. Monitor and detect distortion, crack, etc. during the strength
test.
- Reduce pressure slowly to the
working pressure, maintain this pressure during the test. Use a test hammer to
tap on suspected locations, and then reduce the pressure to (0); correct the
deficiencies (if any) and check the result.
Evaluation: The strength test is
passed if:
- No distortion is detected;
- No crack is found;
- No air bubble, water spray or
leakage of water through joints is found;
- The pressure does not drop while
the test pressure is maintained.
8.2.5. Tightness test of compressed
air and oxygen pipelines:
8.2.5.1. Test medium: Air or inert
gas.
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8.2.5.3. Test pressure holding
time: from 2h to 4h.
8.2.5.4. Process:
- Fully fill the test medium,
slowly increase the pressure to working pressure, and disconnect the source of
supply;
- Conduct the test with soapy
water, foam spray; check welds, flanges, threaded joints, valve joints, medical
gas outlets first. If no leakage is found after all tests have been run and the
pressure still drops, then check the intact pipelines.
8.2.6. Vacuum pipeline tightness
test: Vacuum to the working pressure, disconnect the vacuum source. Maintain
this throughout the process.
Evaluation: The tightness test is
passed if:
- No gas leak is detected;
- For a medical compressed air
pipeline system:
+ Medium and low pressure:
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From 2h to 24h, the tightness test
pressure drops by no more than 0.6%/h with a flexible hose.
+ High pressure:
From 2h to 24h, the tightness test
pressure drops by no more than 0.025%/h;
- For vacuum pipelines, the
tightness test pressure must not increase by 0.2 bar/hour.
8.2.6. During the strength and
tightness test, safety valves may be adjusted and sealed.
8.2.7. Safety valves may be
adjusted and sealed separately from the strength and tightness process.
The opening pressure of safety
valves depends on the technological process. It, in any case, must not exceed
1.1 times the allowable working pressure of the pipelines.
9. PROCESSING OF INSPECTION
RESULTS
9.1. Prepare an inspection record
which contains sufficient information according to the form in the Appendix 02
enclosed herewith.
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Mandatory participants in the
process of approving the inspection record include:
- The representative of the
establishment or a person authorized by the establishment;
- The witness;
- Inspectors conducting the
inspection.
As the record is approved, the
inspectors, the witness, and the representative of the establishment or a
person authorized by the establishment shall append their signatures and seals
(if any) to the record. The record shall be made into two (02) copies, each
party shall keep 01.
9.3. Write the brief inspection
result to the profile of the pipeline system (including full names of the
inspectors and the date of inspection).
9.4. Affix the inspection stamp: if
the pipeline system passes the test, the inspector shall affix an inspection
stamp to it at a noticeable position.
9.5. Certify the inspection result:
9.5.1. If the pipeline system
passes the test, the inspecting organization shall issue the certificate of
inspection result to the piping system within 05 working days from the date on
which the inspection record is approved at the establishment.
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10. INSPECTION INTERVAL
10.1. The technical safety
inspection interval is 03 (three) years. For a pipeline system that has been
used for more than 12 (twelve) years, the technical safety inspection interval
is 02 (two) years. For a pipeline system that has been used for more than 24
(twenty-four) years, the technical safety inspection interval is 01 (one) year.
10.2. In the case where a shorter
interval is demanded by the manufacturer or establishment, such interval shall
apply.
10.3. If the inspection interval is
shortened, the inspector shall specify explanation in the inspection record
10.4. If the inspection interval is
specified in national technical regulations, such national technical
regulations shall apply.
Appendix
01
SPECIMEN
OF ON-SITE RECORD
(FOR INSPECTION OF TECHNICAL SAFETY OF MEDICAL GAS PIPELINE SYSTEMS)
(Name
of the inspecting organization)
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..............,
[place], ………[date]
ON-SITE
RECORD
No.
……………
(The inspector is required to fully write details of assessment, and inspection
and testing parameters according to the inspection process)
1. General information
Name of the equipment:
.…………….……………………….…………….……………………………………….
Name of the applicant:
.…………….……………………….…………….………………….
Address (head office of the
establishment): .…………….……………………….…………….………………
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Details of the meeting with the
establishment:
- Representative: (information)
- Witness:
2. Basic specifications of
equipment
- Type, code: .…………….………………………
- Design
pressure: bar
- Pipeline system symbol:
…………………………………….
- Working
pressure: bar
- Installer: .…………….………………………
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- Year of installation:
.…………….………………………
- Total length: ………………………….
3. Inspection form: Please
write first, periodic or unscheduled inspection (in case of unscheduled
inspection, write the reason therefor)
4. Noted and detected details:
Details
4.1 Technical document
inspection:
1. First inspection:
a. Installation documents:
- Installation design (if any)
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- Certificates of quality
inspection of manufacturing metals, welding metals, welds.
b. Certificates of
measurement-related inspection:
- Measuring instrument inspection
report.
- Records on inspection of
grounding, lightning protection (if any).
- Record on inspection of
protection equipment (if any)
2. Periodic inspection:
a. Previous profile, inspection
record and certificate of inspection result.
b. Operation logbook.
c. Repair and maintenance
logbook; inspection or examination record (if any).
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a. The same documents as those
upon periodic inspection.
b. Documents on repair; records
on post-repair and -change quality.
c. Installation documents (in
case of change of installation location)
4.2. Visual inspection: (if
conducted using measuring instrument, specific figures and identification
code are required)
4.2.1 Related parts:
Wires, supports:
Safety distance
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Stairs, handrails, work platform
Lighting
4.2.2 Pipeline system:
Valves, pipe connections,
expansion compensators
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Metal surface
Rust
Condition of welds
4.3. Testing:
Measuring instruments for
testing
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Identification
code
Inspection
certificate number
Inspection
deadline
Pressure gauge
Pump
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Test
Specify whether the test is conducted,
not conducted, or the result provided by a third party is used
Type
of test
Test
pressure (bar)
Test
time (min)
Hydraulic test
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4.4 Safety valves:
Safety valves
Opening
pressure (bar)
Closing
pressure (bar)
Safety valves
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WITNESS
(Signature, full name)
INSPECTOR
(Signature, full name)
Appendix
02
SPECIMEN
OF RECORD ON INSPECTION OF TECHNICAL SAFETY OF MEDICAL GAS PIPELINE SYSTEM
(Name
of the inspecting organization)
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THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
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..............,
[place], ………[date]
RECORD
ON INSPECTION OF TECHNICAL SAFETY
(MEDICAL GAS PIPELINE SYSTEM)
No.
………………….
(According to the on-site record No. ………………..)
We are:
1. .…………….……………………… Inspector
number: .…………….………………………
2. .…………….……………………… Inspector
number: .…………….………………………
Of:
.…………….……………………….…………….………………………………………………
Registration certificate number of
the inspecting organization: .…………….…………………………………….
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Of (specify name of the
establishment): .…………….……………………….…………….……………………….…
Address (head office of the
establishment): .…………….……………………….…………….……………….
Installation address (location):
.…………….……………………….…………….…………………………….
Inspection procedures applied:
.…………….……………………….…………….……………………
The witness:
Have witnessed the inspection and
approved the record: .…………….………………………………………..
1. ……………………………….……………………… Position:
.…………….………………………
2. ……………………………….……………………… Position:
.…………….………………………
I
- BASIC SPECIFICATIONS OF THE SYSTEM
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Pipeline system
code: ………………Year of manufacture (installation): …………………
Design
pressure: High pressure:……bar, Medium pressure:……bar, Low pressure:……bar,
Working
pressure: High pressure:……bar, Medium pressure:……bar, Low pressure:……bar,
Working
medium: …………………………….. Design temperature (oC):………………….…
Diameter
(mm): …………………………... Total length (m):………………………
Uses:
………………………………………………………………………………………
Date of last
inspection:………………………By:…………………………………………
II
- FORMS OF INSPECTION
First
time □ ; Periodic □ ; Unscheduled □
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III
- INSPECTION CONTENT
1. Document inspection:
- Remarks:
.…………….……………………….…………….………………………………………..
- Result evaluation: Passed
□ Failed □
2. External and internal
technical inspection:
Item
Passed
Failed
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Passed
Failed
Wires, supports
Lighting
Safety distance
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Ventilation
Stairs, handrails, work platform
Equipment and facilities for fire
and explosion prevention and control
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Measuring
instruments, automatic equipment, protection and safety equipment
Valves, pipe connections,
expansion compensators
Condition of pipes, surfaces of
welds
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fire dampers (for oxygen and
explosive gases)
- Remarks:
.…………….……………………….…………….………………………………………..
- Result evaluation: Passed
□ Failed □
3. Test:
Type
of test
Part
Test
medium
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Holding
time (hr)
Strength test
High pressure
Medium pressure
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Low pressure
Tightness test
High pressure
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Medium pressure
Low pressure
Vacuum
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- Remarks:
.…………….……………………….…………….………………………………………..
- Result evaluation: Passed
□ Failed □
IV
- CONCLUSIONS AND RECOMMENDATIONS
1. Result of inspection of the
system: Passed □ Failed □
2. Has an inspection stamp No.
…………………. Affixed at: …………….………………………
3. Working pressure:
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+ Low pressure:………….. bar
+ Vacuum: ………bar
4. Safety valve’s set pressure:
Location
Opening pressure (bar)
Closing pressure (bar)
High
pressure
Medium
pressure
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Low
pressure
5. Recommendations:………………………………………………………………………………...
Deadline for implementation of
recommendations:……………………………………………………………..……
V
- INSPECTION INTERVAL
Date of periodic inspection……….
[date]
Reason for shortening the interval:
…………………………..………………….…….………………………
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At:.…………….……………………….…………….……………………………………………….
The record is made into ………..
copies, each party holds ………. copies./.
ESTABLISHMENT
OWNER
Undertaking to fully implement recommendations by the deadline
(Signature and seal)
WITNESS
(Signature, full name)
INSPECTOR
(Signature, full name)
PROCEDURES FOR INSPECTION OF TECHNICAL SAFETY OF
INDUSTRIAL GAS CYLINDERS
QTKD: 06 - 2016/BLDTBXH
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Procedures for inspection of
technical safety of industrial gas cylinders are drafted by the Department of
Work Safety and promulgated together with the Circular No. 54/2016/TT-BLDTBXH
dated December 28, 2016 of the Ministry of Labor - Invalids and Social Affairs.
PROCEDURES FOR INSPECTION OF TECHNICAL SAFETY OF
INDUSTRIAL GAS CYLINDERS
1. SCOPE AND REGULATED ENTITIES
1.1. Scope
Such procedures shall be used for
first, periodic and unscheduled inspection of industrial gas cylinders with a
working pressure of oil above 0.7 bar under state management of the Ministry of
Labor - Invalids and Social Affairs.
Such procedures shall not apply to
liquefied petroleum gas (LPG) cylinders.
1.2. Regulated entities
- Organizations carrying out
technical inspection of occupational safety;
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2. NORMATIVE REFERENCES
- QCVN 01:2008/BLDTBXH - BLDTBXH -
National technical regulation on safe work of steam boilers and pressure
vessels;
- TCVN 8366: 2010 - Pressure
vessels - Requirement of design and manufacture;
- TCVN 6155: 1996 - Pressure
vessels - Safety engineering requirements of erection, use, repair;
- TCVN 6156: 1996 - Pressure
vessels - Safety engineering requirements of erection, use, repair. Testing
method;
- TCVN 6292:2013 - Gas cylinders -
Refillable welded steel cylinders;
- TCVN 6294:2007 - Gas cylinders.
Welded carbon steel gas cylinders - Periodic inspection and testing;
- TCVN 6295:1997 - Gas cylinders.
Seamless gas cylinders - Safety and performance criteria. (of capacity between
0.5 l and 150 l, unlimited pressure);
- TCVN 7388-1:2013; TCVN
7388-2:2013; TCVN 7388-3:2013, Vietnam’s standards on gas cylinders - Refillable
seamless steel gas cylinders - Design, construction and testing;
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- TCVN 6871:2007 - Gas cylinders - Transportable
cylinders for dissolved acetylene - Periodic inspection and maintenance;
- TCVN 6008-2010 - Pressure
equipment - Welds - Technical requirements and testing methods;
- TCVN 7472-2005 - Welding - Fusion
- welded joints in steel, nickel, titanium and their alloys (beam welding
excluded). Quality levels for imperfections.
In the cases where any of the national
technical regulations and national standards referred to in this inspection
procedure is amended or replaced, the newest one shall apply.
Other standards may be applied to
inspection of technical safety of an industrial gas cylinder at the request of
its user or manufacturer if such standards contain the same or higher safety
criteria than those in the national standards referred to in this document.
3. TERMS AND DEFINITIONS
For the purposes of this document,
the terms and definitions given in the abovementioned normative references and
the following shall apply:
3.1. Gas cylinder:
A cylinder which is used to contain
and transport gases, liquefied gas or dissolved gas (industrial gas) at a pressure
above atmospheric pressure and with a water capacity of up to 150 liters,
manufactured and labeled in accordance with the provisions of TCVN 6292:2013; TCVN
6295:1997.
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An evaluation of technical safety
of an industrial gas cylinder according to national technical regulations and
technical safety standards after its manufacture and before its first use.
3.3. Periodic safety inspection:
An evaluation of technical safety
of equipment according to national technical standards and technical safety
standards after expiration of the last safety inspection result.
3.4. Unscheduled safety inspection:
An evaluation of technical safety
of equipment according to national technical standards and technical safety
standards:
- After repair or renovation that
affects the technical safety of the cylinder;
- At the request of the
establishment or a competent authority.
4. INSPECTION STEPS
Upon conducting a technical safety
inspection of the industrial gas cylinder, the following steps shall be taken
in turn:
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- Conduct external technical
inspection.
- Conduct technical inspection of
pressure resistance (strength test).
- Conduct volumetric expansion
test.
- Inspect valves.
- Conduct tightness test.
- Carry out degassing and
vacuuming.
- Check tare weight of the
cylinder.
- Process the inspection result.
Note: The next inspection
step is taken only when the result of the previous step is passed. The result
of each step shall be fully documented according to the form in the Appendix 01
and fully retained by the inspecting organization.
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Inspection equipment and
instruments shall be inspected and calibrated in accordance with regulations. Inspection
equipment and instruments include the following:
- Non-destructive thickness gauge.
- Equipment for treating
in-cylinder residual gases.
- Equipment for cylinder valve
installation and removal.
- Hydraulic testing equipment.
- Cylinder leak tester.
- Volumetric expansion tester.
- Internal cylinder cleaning equipment.
- Equipment for in-cylinder
examination by endoscopic method.
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- Electronic scale.
6. CONDITIONS FOR INSPECTION
The inspection of an industrial gas
cylinder must not be carried out unless the following conditions are met:
6.1. The cylinder is at the ready
for inspection.
6.2. Documents of the cylinder are
adequate.
6.3. The inspection is not affected
by environment or weather.
6.4. Requirements concerning
occupational safety and health are met.
7. PREPARATION FOR INSPECTION
Before carrying out the inspection,
it is required to make the following preparations:
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7.1.1. Preparing documents of the
cylinder.
7.1.2. Determining the cylinders to
be inspected:
- Regarding first safety
inspection: Randomly select 5% of the batch of cylinders to be inspected (the
selected cylinders must be representative of the sub-batches of cylinders). If
any of the inspected cylinders is found failed, 100% of the cylinders in the
batch must be inspected (according to point 4.2 TCVN 6156:1996).
- Regarding periodic or unexpected
inspection: inspect 100% of the cylinders.
7.1.3. Prepare a delivery record
and make preparations in respect of human resources and vehicles for transport
of cylinders to the place of inspection.
7.1.4. Preliminary inspection and
instructions:
- Immediately reject any cylinder
which is not owned by the establishment or the inspection of which is not
requested by the authorized establishment;
- Reject cylinders which are not
listed or on which specifications are unavailable or unclear, cylinders with
defects exceeding the rejection limits such as: bulge, dent, intersecting cut
or gouge, crack, fire damage, arc or torch burns;
- Proceed to release and treat the
residual gases in the cylinders, making sure the cylinders are free of pressure
and residual gases;
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7.1.5. For cylinders that have been
filled with storage gas, when the periodic inspection is due, such cylinders
must be inspected at a rate of 5%.
- If the inspected cylinders are
passed, the remaining cylinders may be stored for no more than one year;
- If any of the inspected cylinders
is failed, 100% of the remaining cylinders must be inspected. The period of gas
release for inspection of 100% of the cylinders must not exceed one month.
7.1.6. Making preparations in
respect of human resources, supplies and equipment to serve the inspection;
appoint personnel to participate in and witness the inspection.
7.2. Examine documents and profile
of a cylinder batch.
Rely on the inspection forms to
examine and consider the following technical documents:
7.2.1. Upon first safety
inspection:
7.2.1.1. Profile of the cylinder
batch, technical documents of the manufacturer: (according to the form under
QCVN: 01-2008- BLDTBXH). The following documents should be considered:
- Indicators concerning
manufacturing metals, welding metals;
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- Structural drawings showing all
main dimensions;
- Guidelines on operation,
maintenance and repair (if any);
- Certificate of conformity issued
by the designated organization as prescribed in the case where the competent
authority has promulgated a national technical regulation applicable to the
inspected pipeline system.
7.2.1.2. Release documents of
the cylinder batch:
- Certificate of the manufacturer,
standards applied;
- Name and address of the owner of
the cylinder batch;
- Certificate of manufacturing metals;
- Record and sheet of the strength
and tightness test results for the batch of cylinders;
- Report on examination of
mechanical properties of welds;
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- Record of the explosion test
results;
- Record of the thickness and weld
test results (if any).
7.2.2. Upon periodic safety
inspection:
7.2.2.1. Previous profile of the
cylinder batch, inspection record and certificate of inspection result or
information and documents about the cylinders.
7.2.2.2. Documents on the use,
operation and maintenance; inspection or examination record (if any).
7.2.3. Upon unexpected safety
inspection: Examine the previous profile of the cylinder batch, certificate of
inspection result and inspection record and examine additional documents in the
following specific cases:
7.2.3.1. Documents on the use,
operation and maintenance; inspection or examination record (if any).
7.2.3.2. Documents on repair,
post-repair acceptance record documenting the welding or replacement of
pressure retaining components.
Result evaluation: The document
inspection result is passed if the regulations specified in 2.4 of QCVN:
01/2008/BLDTBXH are complied with. If failed, the establishment shall take
additional corrective actions.
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7.4. Develop safety measures and
reach an agreement thereon with the establishment before inspection. Provide
adequate personal protective equipment to ensure safety during the inspection.
8. INSPECTION PROCESS
The inspection must be carried out
in the following order:
8.1. External technical inspection:
8.1.1. Check the technical
specifications stamped on the handle or neck of each cylinder, compare them
with the technical data on the cylinder on the list of cylinders to be
inspected. Reject cylinders not included in the list of cylinders to be
inspected and cylinders on which specifications are missing or blurred.
8.1.2. Check the condition of the
surface, welds, base, and handles (if any).
8.1.3. When there is any suspicion
during the visual inspection, additional tests or examination measures must be
applied such as: ultrasonic testing of thickness or welds (if any) or other
non-destructive testing measures.
Evaluation: A cylinder is passed if
its components remain normal, there is not any unusual sign and specifications
on the cylinder are consistent with those on documents. Reject cylinders
according to 4.8 of TCVN 6156:1996.
8.2. Internal technical inspection:
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- Cylinders containing inert gas,
non-toxic and non-flammable gases may be placed in direct release position.
- Cylinders containing toxic and
flammable gases must be treated using specialized equipment. The recovered
gases may be used or treated safely and must not be released directly into the
environment.
8.2.2. Remove valves from the
cylinder head, prevent impact that can cause deformation or damage to the
cylinder’s valve or neck thread.
8.2.3. Examine the tightness of the
valves and safety parts (if any); reject failed valves.
8.2.4. Clean the inside of the
cylinders. For acetylene cylinders containing porous mass, the cleaning step is
not required but the quality of the porous mass must be checked according to
the manufacturer's instructions.
8.2.5. Check the inside of the
cylinders with an endoscope to evaluate the metal surface and welds. In case of
any suspicion, request the establishment to adopt other appropriate measures.
Evaluation: A cylinder is passed if
its inside remains normal and there is not any unusual sign. Reject cylinders
according to 4.8 of TCVN 6156:1996.
8.3. Technical inspection, testing.
8.3.1. Strength test.
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Table
1: Strength test pressure, test media and test holding time
Type
of equipment
Test
medium
Test
pressure (bar)
Holding
time (min)
Normal welded cylinder
water
1.5
maximum working pressure
≥
0,5
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air
or inert gas
1.5
maximum working pressure
≥
0,5
Seamless cylinder
water
1.5
maximum working pressure
≥
2
8.3.1.2. Temperature of the test
medium must be less than 50°C and must not fall below the ambient temperature
by more than 5°C.
8.3.1.3. The pressure shall be
increased or decreased slowly so as not to cause sudden expansion, thereby
affecting the cylinder’s strength.
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8.3.1.4.1. Before performing test
with gas, the strength must be calculated according to actual measurements of
the cylinder.
8.3.1.4.2. Safety measures in case
of test with gas:
- Before testing acetylene
cylinders, it is required to build a vault and submerge them in water;
- The gas supply valve and sample
pressure gauge on the gas inlet line must be placed away from the cylinder
location;
- A prohibition sign “No unauthorized
entry to the test area” must be erected;
- A safe gas supply must be
ensured.
Evaluation: A cylinder is passed if
the pressure does not decrease when maintained at the test pressure, there is
no leakage from the cylinder body or welds or there is no deformation in excess
of the prescribed limits.
- For welded cylinders: satisfy 9.1
of TCVN 6292:2013;
- For seamless cylinders:
satisfy C.4.3 of TCVN 6295:1997.
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8.3.2.1. Water jacket method:
Enclose the water-filled cylinder in a jacket that is also filled with water. The
total and any permanent volumetric expansion of the cylinder are measured as to
the amount of water displaced by the expansion of the cylinder when under
pressure and after the pressure is released (Article C.5.2.1 of TCVN
6295:1997).
8.3.2.2. Non-water jacket method:
Measure the amount of water passed into the cylinder as it is pressurized to
test pressure and measure the amount of water expelled from the cylinder to
reduce the pressure to atmospheric pressure. First measure the amount of water
while increasing the water pressure in the cylinder to determine the total
expansion of the cylinder at test pressure, then measure the amount of water
expelled from the cylinder, subtract that amount of water from the total
expansion to determine the permanent volumetric expansion (Article C.5.2.2 of
TCVN 6295:1997).
Evaluation: the result is passed if
C.5.3 of TCVN 6295:1997 is satisfied.
For a seamless cylinder (of a
capacity between 12 and 55 l), rely on the increase in volume or decrease in
weight of the cylinder shell to reduce the working pressure of the cylinder or
reject it according to the provisions in 4.10 of TCVN 6156:1996.
Note: The volumetric expansion test
on seamless cylinders shall be conducted together with the strength test.
8.3.3. Remove and clean the test
medium; dry the inside of the cylinder.
8.3.4. Install the tested valves on
the cylinder.
8.3.5. Tightness test:
8.3.5.1. Test medium: Air or inert
gas.
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8.3.5.2. For seamless cylinders:
Fill the cylinders with compressed air or inert gas to a pressure of 50% to 60%
of the maximum working pressure, hold this pressure for 01 minute.
8.3.5.4. Check the tightness of the
connectors, valve joints, etc. of the cylinders with soap solution or in a
specialized tank. Leaking cylinders must be treated and their tightness must be
re-tested.
Evaluation: The result is passed
when:
- For welded cylinders: satisfying
9.2 of TCVN 6292:2013;
- For seamless cylinders:
satisfying C.6.3 of TCVN6295:1997.
8.3.6. If a cylinder is passed,
proceed to completely degas the cylinder, dry its outside; vacuum and fill the
cylinder with shielding gas (if required).
8.3.7. Checking tare weight of
cylinders:
- Weigh each cylinder and determine
its tare weight (according to point 10.2 of TCVN 6292:2013). Check and compare
it with the tare weight stamped by the manufacturer on the cylinder;
- For welded cylinders: satisfy
14.3 of TCVN 6294:2007;
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9. PROCESSING OF INSPECTION
RESULTS
9.1. Prepare an inspection record
and a list of cylinders and cylinder batches which contain sufficient
information according to the form specified in the Appendices 02 and 03 to the
inspection procedures.
9.2. Approve the inspection record:
Mandatory participants in the
process of approving the inspection record include:
9.2.1. When inspecting cylinders at the inspecting
organization's facility:
- Facility's head directly
inspecting cylinders;
- Inspectors supervising the
inspection of cylinders;
- Head of the technician team
directly inspecting cylinders.
As the record is approved, these
members shall sign it.
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- The representative of the
establishment or a person authorized by the establishment;
- The witness;
- Inspectors conducting the
inspection.
As the record is approved, the
inspectors, the witness, and the representative of the establishment or a person
authorized by the establishment shall append their signatures and seals (if
any) to the record. The record shall be made into two (02) copies, each party
shall keep 01.
9.3. Write the brief inspection
result to the profile of the cylinder batch (including full names of the
inspectors and the date of inspection).
9.4. Affix an inspection symbol:
9.4.1. Stamp information about
inspection results on the handle or shoulder of each cylinder in the correct
size and in the same row in the following order: Symbol of the inspecting
organization-month/year of inspection-month/year of next inspection (according
to 14.4 of TCVN 6294:2007 or 4.12 of TCVN 6156:1996).
Such information must not cover
existing numbers on the cylinder’s handle or shoulder.
9.4.2. For cylinders with reduced
working pressure, new specifications regarding weight, capacity and working
pressure must be engraved. These specifications shall be engraved in a row
below the row of information on inspection results. Old numbers must be deleted
by stamping two slashes.
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9.6. Certify the inspection result:
If an inspected cylinder passes the
test, the inspecting organization shall issue the certificate of inspection
result to the cylinder or cylinder batch within 05 working days from the date
on which the inspection record is approved.
9.5.2. If the cylinders or cylinder
batch fails the test, only the steps 9.1 and 9.2 shall be taken and only the
inspection record which must specify the explanation for failed result,
necessary remedial actions and a deadline for taking such actions is issued to
the establishment.
9.7. Cooperate with the
establishment in handling rejected cylinders as prescribed in 9.4. Dossiers on
rejected cylinders must be archived at the inspecting organization; the
inspection record and notification shall be sent to the employment authority of
the area where the inspection facility is located.
10. INSPECTION INTERVAL
10.1. The technical safety
inspection interval is 05 (five) years. For cylinders that have been used for
more than 20 (twenty) years and cylinders that contain corrosive and toxic
gases such as Chlorine, Hydrogen Sulfide, Methane Chloride, Phosphine, Sulfuric
Anhydride and Hydrogen Chloride, the technical safety inspection interval is 02
years.
10.2. For cylinders that contain
corrosive and toxic gases such as Chlorine, Hydrogen Sulfide, Methane Chloride,
Phosphine, Sulfuric Anhydride and Hydrogen Chloride that have been used for
more than 20 (twenty) years, the technical safety inspection interval is 01
(one) year.
10.3. In the case where a shorter
interval is demanded by the manufacturer or establishment, such interval shall
apply.
10.4. If the inspection interval is
shortened, the inspector shall specify explanation in the inspection record.
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Appendix
01
SPECIMEN
OF ON-SITE RECORD
INSPECTION OF TECHNICAL SAFETY OF INDUSTRIAL GAS CYLINDERS
(Name
of the inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
..............,
[place], ………[date]
ON-SITE
RECORD
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(The
inspector is required to fully write details of assessment, and inspection and
testing parameters according to the inspection process)
Forms of inspection: First time □ ; Periodic □ ;
Unscheduled □
User
Cylinder/Cylinder batch
manufacture
number:
(1)
Month and year of
manufacture: (2)
Cylinder type: (By
capacity) Hydraulic test pressure: (Bar)
Tightness test pressure: (Bar)
Inspector in charge
Signature
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Signature
Person in charge of hydraulic
test
Signature
Person in charge of tightness
test
Signature
No.
Code
Manufacture
number
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Manufacturer
Weight
(kg)
Capacity
(liter)
Inspection
result
On
cylinder
Actual
On
cylinder
Actual
Passed
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Failed
(Specify reason)
1
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(3)
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(4)
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• (1),(2) For cylinders undergoing
first safety inspection
• (3): E.g, 02 years, due to
containing corrosive or explosive gas
• (4): E.g, Failed due to damage to
neck thread
1- At the inspecting
organization's facility:
INSPECTOR
(Signature, full name)
TECHNICIAN
(Signature, full name)
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WITNESS
(Signature, full name)
INSPECTOR
(Signature, full name)
Appendix
02
SPECIMEN
OF RECORD ON INSPECTION OF TECHNICAL SAFETY OF INDUSTRIAL GAS CYLINDERS
(Name
of the inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
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..............,
[place], ………[date]
RECORD
ON INSPECTION OF TECHNICAL SAFETY OF INDUSTRIAL GAS CYLINDERS
(According to the on-site record No. …………)
We are:
1. .…………….……………………… Inspector
number: .…………….………………………
2. .…………….……………………… Inspector
number: .…………….………………………
Of:
.…………….……………………….…………….………………………………………………
Registration certificate number of
the inspecting organization: .…………….…………………………………….
Have inspected
……………………………….…………….…………………………………..
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Address (head office of the
establishment): .…………….……………………….…………….……………….
Location of inspection:
….…………….……………………….…………….…………………………..
Inspection procedures applied:
.…………….……………………….…………….……………………
Have witnessed the inspection and
approved the record: .…………….………………………………………..
1. ……………………………….……………………… Position:
.…………….………………………
2. ……………………………….……………………… Position:
.…………….………………………
I
- BASIC SPECIFICATIONS OF CYLINDERS
Name and address of the
manufacturer:……………………………………………………………………………
Month and year of
manufacture:……………………………………………………………………………………
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Quantity and list of inspected
sample cylinders:....................................................…………………
Name of brand stamped on
cylinders:....................................................................………………….
Working pressure:…………..
bar Test pressure:
.........................................bar
Capacity: ……………….liter
Tare weight: ………………………kg
Uses:………………….…...........................................................................................
Date of last
inspection:…......................…………….. By: ……………….……..…………
II
- FORMS OF INSPECTION
First
time □ ; Periodic □ ; Unscheduled □
Reason for unscheduled inspection:
…………………………………………………
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1. Document
and profile examination:
Item
Passed
Failed
Item
Passed
Failed
List of cylinders
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Record of cylinder batch inspection
result
Sheet of the strength and
tightness test results
Volumetric expansion test result
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Explosion test record
Thickness test result
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Results of analysis of mechanical
and chemical properties of materials
Cylinder batch profile
Documents on use and inspection,
other information about cylinders
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Other documents
Result evaluation:
- Remarks:
.…………….……………………….…………….………………………………………..
- Result evaluation: Passed
□ Failed □
2. External and internal
technical inspection:
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Failed
Item
Passed
Failed
Condition of handles
Condition of outer metal surface
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Condition of bases
Condition of inner metal surface
Valves:
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- Remarks:
.…………….……………………….…………….………………………………………..
- Result evaluation: Passed
□ Failed □
3. Test:
Details
Test
medium
Test
pressure (bar)
Holding
time (min)
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Volumetric expansion test
Tightness test
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- Remarks:
.…………….……………………….…………….………………………………………..
- Result evaluation: Passed
□ Failed □
IV - CONCLUSIONS AND RECOMMENDATIONS
1. Batch (quantity of cylinders) inspected:
Passed □ Failed □
2. Has an inspection symbol affixed
at: …………………………………………….
3. Working pressure: …………………… bar
4. Recommendations:
……………………………………………………………………………..
5. Deadline for implementation of
recommendations: …………………………………………………………….
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Date of periodic inspection……….
[date]
The record is approved on…………
[date]
At (specify the place of
inspection): ………………………………………………………….../.
1- At the inspecting
organization's facility:
HEAD
OF FACILITY
(Signature, full name)
INSPECTOR
(Signature, full name)
TECHNICIAN
(Signature, full name)
2- At the establishment:
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WITNESS
(Signature, full name)
INSPECTOR
(Signature, full name)
Appendix
03
LIST OF INSPECTED SAMPLE CYLINDERS
Cylinder batch:
Quantity of cylinders:
Manufacture number:
From………………..to……………………….
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(Enclosed
with inspection record or certificate of inspection No. …… dated…)
No.
Manufacture
number
Month
and year of manufacture
Manufacturer
Weight
(kg)
Capacity
(liter)
Result
Passed
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2
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LIST OF CYLINDERS NOT INCLUDED IN BATCHES (or LIST OF
CYLINDER BATCHES)
Cylinder batch:
Quantity of cylinders not included
in cylinder batches:
User (manager):
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No.
Manufacture
number
No.
Manufacture
number
No.
Manufacture
number
No.
Manufacture
number
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Notes:
+ When a cylinder batch is
continuously numbered, the quantity of cylinders not included in batches is
small (since some cylinders were taken out by the manufacturer for mechanical
testing, destructive testing, etc.), write “DANH SÁCH CÁC CHAI KHÔNG CÓ TRONG
LÔ” (“LIST OF CYLINDERS NOT INCLUDED IN BATCHES”. When a cylinder batch is not
continuously numbered, write “DANH SÁCH LÔ CHAI” (“LIST OF CYLINDER BATCHES”)
and fully write numbers of cylinders in the batches.
+ If the quantity of cylinders is
small, write it in the record. An enclosed list of cylinders is not required.
Note: This list of cylinders must
not be erased or modified and must bear a seal at the upper left corner or seal
on adjoining edges of pages.
LIST OF INSPECTED CYLINDER BATCHES
Cylinder batch:
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Manufacture number:
From………………..to……………………….
User (manager):
(Enclosed
with inspection record or certificate of inspection No. …… dated…)
No.
Manufacture
number
Month
and year of manufacture
Manufacturer
Weight
(Kg)
Result
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Failed
(Specify reason)
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2
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PROCEDURES FOR INSPECTION OF PRESSURE VESSEL
QTKD: 07 - 2016/BLDTBXH
Foreword
Procedures for inspection of safety
of pressure vessel are drafted by the Department of Occupational Safety and
promulgated together with the Circular No. 54/2016/TT-BLDTBXH dated December 28,
2016 of the Ministry of Labour, Invalids and Social Affairs.
PROCEDURES
FOR INSPECTION OF PRESSURE VESSEL
1. SCOPE AND REGULATED ENTITIES
1.1. Scope
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Such procedures shall not apply to
vessels used for storing and transporting compressed gases, liquefied petroleum
gases, dissolved gases, vessels with the product of volume (in liters) and
pressure (in bars) not exceeding 200 bar litres, and vessels with a volume of
less than 25 liters.
1.2. Regulated entities
- Organizations carrying out occupational
safety inspection;
- Occupational safety inspectors.
2. REFERENCES
- QCVN 01:2008 - BLDTBXH - National
technical regulation on safe work of steam boiler and pressure vessel;
- TCVN 8366:2010 - Pressure vessels
- Requirement of design and manufacture;
- TCVN 6155:1996 - Pressure vessels
- Safety engineering requirements of erection, use, repair;
- TCVN 6156:1996 - Pressure vessels
- Safety engineering requirements of erection, use, repair, testing methods;
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In the cases where national
technical standards and regulations referred to in this document are amended or
replaced, regulations of the latest documents shall apply.
Other standards may be applied to
pressure vessel safety inspection at the request of its manufacturer or owner
if such standards contain the same or higher safety criteria than those in the
national standards referred to in this document.
3. TERMS AND DEFINITIONS
In addition to terms in the above
invoked and referenced documents, the following terms are used in description
of this procedure:
3.1. “pressure vessel” is the
equipment used for carrying out thermal or chemical processes, storing and
transporting solvents with pressure greater than atmospheric pressure.
3.2. “first safety inspection” is
inspection of safety of the vessel according to national technical standards
and technical safety standards after its installation and before its first use.
3.3. “periodic safety inspection”
is inspection of safety of the vessel according to national technical standards
and technical safety standards after expiration of the last safety inspection
result.
3.4. “unscheduled safety
inspection” is inspection of safety of the vessel according to national technical
standards and technical safety standards and will be carried out:
- after a repair or upgrade that
affects the safety of the vessel;
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- after relocation of the vessel
(for the fixed vessel);
- at the request of the owner or a
competent authority.
4. INSPECTION STEPS
Safety inspection shall be carried
out in the following order:
- Inspection of the profile of the
pressure vessel;
- External and internal
inspection;
- Technical inspection and testing;
- Operational inspection;
- Processing inspection results.
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5. INSPECTION EQUIPMENT
Inspection equipment shall be
inspected and calibrated in accordance with regulations and law. Inspection
equipment includes:
- Hydraulic test pump;
- Manometer, test meters;
- Endoscopic flaw detector;
- Geometric inspection equipment;
- Insulation resistance meter;
- Ground resistance tester;
- Thermometer (if necessary);
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- Clamp meter;
- Lead sealing plier;
- Ultrasonic thickness meter;
- Nondestructive flaw detector (if
necessary).
6. CONDITIONS FOR INSPECTION
The inspection must not be carried
out unless the following conditions are met:
6.1. The pressure vessel is ready
for inspection.
6.2. Documents about the vessel are
adequate
6.3. The inspection is not affected
by weather.
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7. PREPARATION FOR INSPECTION
Before carrying out inspection of a
pressure vessel, the following tasks shall be performed:
7.1. Reach an agreement on an
inspection plan, preparation for the inspection and cooperation between the
inspecting organization and the owner, including the following tasks:
7.1.1. Prepare the documents about
the vessel.
7.1.2. Remove solvents, clean the
inside and outside of the vessel.
7.1.3. Remove part or whole of the
thermal insulation layer if the surface of metal is suspected of being damaged.
Remove the access doors or cleaning door (if any). 7.1.4. Prepare equipment for
inspection of all components of the vessel.
7.1.4. In case of difficulty in
inspecting the underground vessel, lift the vessel if possible or take other
appropriate measures for inspection.
7.1.5. In case of the vessel with
electric heaters or moving parts, remove them from the vessel.
7.1.6. For the vessel containing
toxic and flammable solvents, dispose them so that the inspector is not
affected.
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7.2. Inspect the profile of the
pressure vessel.
The documents to be inspected vary
according to the inspection. To be specific:
7.2.1 Regarding first inspection:
7.2.1.1. The profile of a vessel
(under QCVN: 01-2008 - BLDTBXH), which consists of the following documents:
- Criteria for metals used for the
vessel and welding,
- Calculation of strength of
load-bearing parts;
- Structural drawings which specify
all main dimensions;
- Guidelines for operation and
maintenance;
- Certificate of conformity issued
by authorized organizations in accordance with regulations and law in case a
competent authority has issued national technical regulations on the inspected
entity.
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- Certificates of the metals used
for the vessel and welding;
- Weld inspection result;
- Commissioning record.
7.2.1.3. Reports on calibration of
measurement equipment; record on inspection of insulation resistance and
protective devices (if any).
7.2.1.4. Documents on installation:
Applied to the fixed vessel.
- Name of the manufacturer or
owner;
- Characteristics of the additional
materials used for installation;
- Welding data: welding technology,
welding electrode code, name of the welder and welding-testing results;
- Records on inspection of each
component of the vessel (if any).
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7.2.2.1. The previous profile,
inspection record and Certificate of inspection results.
7.2.2.2. Documents on the use,
operation and maintenance of the vessel; inspection record (if any).
7.2.3. Regarding unscheduled
inspection: Inspect the documents as if in the periodic inspection and other
documents prescribed in the following cases:
7.2.3.1. In case of repair,
renovation and upgrade: Documents on design, repair, renovation and upgrade; commissioning
record after repair, renovation and upgrade;
7.2.3.2. In case of relocation:
Installation documents.
The result is considered
satisfactory if:
- The profile of the pressure
vessel is adequate and satisfies Article 2.4 of QCVN 01- 2008/BLDTBXH.
- If the inspection result is
unsatisfactory, the owner shall take remedial actions according to Article
3.2.2 of QCVN 01-2008/BLDTBXH.
7.3. Prepare suitable and adequate
equipment for inspection.
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8. INSPECTION PROCESS
An inspection shall be carried out
in the following order:
8.1. External inspection.
8.1.1. Inspect ground and position
location of the pressure vessel.
8.1.2. Inspect operational lighting
system.
8.1.3. Inspect working platform,
stairs, hangers, etc.
8.1.4. Inspect electrical
safety-grounding system and lightning protection system.
8.1.5. Check technical specifications
specified on the label of the pressure vessel versus the profile of the vessel.
8.1.6. Inspect condition of the
safety equipment, measuring equipment and auxiliary equipment in terms of
quantity, types and technical specifications versus the design and prescribed
standards.
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8.1.8. Inspect condition of other
auxiliary equipment in service of operations of the vessel.
8.1.9. Inspect condition of welds,
and the metallic surface of load-bearing parts of the pressure vessel. In case
of suspicion of damage, request the owner to carry out appropriate inspection.
8.1.10. Inspect technical condition
of the insulation layer (if any).
8.1.11. Inspect joints.
The result is considered
satisfactory if:
- the regulations specified in
Section 3 of TCVN 6155:1996 are met;
- the regulations specified in
Section 8 of TCVN 8366:2010 are met;
- there are no cracks, blisters,
dents, excessive wear and tear, leaks of solvent of the load-bearing parts,
welds and joints.
8.2. Internal inspection
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8.2.2. Inspect residues, rust, corrosion
affecting the internal metallic surface of the pressure vessel.
8.2.3. Inspect condition of welds
and metallic surface of the load-bearing parts. In case of suspicion of damage,
request the owner to carry out appropriate inspection.
8.2.4. For the locations where
internal inspection fails to be carried out, inspect technical condition
according to the technical documentation of the manufacturer. The documentation
shall clearly specify: inspection items, methods and procedures.
8.2.5. In case of shell-and-tube
pressure vessel and suspicion of technical condition of the shell and tube,
request the owner to remove part or whole of the shell and tube for inspection.
8.2.6. In case of failure to carry
out internal inspection due to structural characteristics of the pressure
vessel, replace the internal inspection with a hydrostatic test with the
prescribed test pressure and inspection of the inspectable parts.
8.2.7. In case of detection of the
flaws that reduce the strength of pressure wall (thin wall, eroded joints,
etc.), the parameters of the pressure vessel shall be reduced by calculating
the strength according to collected data.
The result is considered
satisfactory if:
- the regulations specified in
Section 3 of TCVN 8366: 2010 are met.
- there are no cracks, blisters,
dents, excessive wear and tear, leaks of solvent of the load-bearing parts,
welds and joints.
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8.3.1. The pressure vessel shall be
exempted from strength test upon the first inspection if the duration of
factory testing is within 18 months, the vessel is well maintained and shows no
signs of impact and deformation after transport and installation. The
inspection record shall clearly specify reasons and records on the
manufacturer’s factory testing and record on installation commissioning (if
any) shall be attached.
8.3.2. The vessel's chambers that
operate at different pressure levels shall be separately tested.
8.3.3. During the inspection,
isolation measures shall be taken to ensure that the automatic protective
devices and measurement equipment are not damaged under the test pressure. In
case of failure to ensure so, such equipment must be dismantled.
8.3.4. Strength test.
The strength of the pressure vessel
shall be tested for every 6 years at the maximum and the strength shall be
tested in accordance with the following requirements (including the unscheduled
inspection according to Section 3.12 of TCVN 6156:1996):
8.3.4.1. The test solvent is liquid
(water, non-corrosive and non-toxic liquid), gas (inert gas, air). The
temperature of the test solvent is below 50°C and not 5°C lower than ambient
temperature.
8.3.4.2. The test pressure and time
for maintaining test pressure are specified in Table 1 below.
Table
1: Test pressure and time for maintaining test pressure
Types
of vessel
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Test
pressure (bar)
Maintenance
time
(minute)
Vessels with a wall temperature
of up to 200°C
(Except
for the cast vessels)
<
5
1.5Plv
but not less than 2 bar
5
≥
5
1.25
Plv but not less than Plv + 3 bar
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Vessels with a wall temperature
of from 200°C to 400°C
Regardless
of working pressure
Not
less than 1.5 Plv
5
Vessels with a wall temperature
of above 400°C
Regardless
of working pressure
Not
less than 2 Plv
5
Cast vessels
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1.5
Plv but not less than than 3 bar
5
Enameled vessels
Regardless of working pressure
Tested
according to regulations of the manufacturer, but not less than Plv.
5
Plv - Working
pressure.
8.3.4.3. Procedures for strength
test:
8.3.4.3.1. Fill test solvent:
Fill the vessel with test solvent. (pay attention to the discharge of gas when
tested with fluid)
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8.3.4.3.3. Maintain the test
pressure as prescribed.
8.3.4.3.4. Gradually drop the
pressure to the working pressure and maintain it throughout the inspection.
Drop the pressure to (0); repair the damage (if any) and re-inspect.
8.3.4.4. In case of failure to run
the strength test with fluid due to the stress on prestressed bed or inlaid
floor or difficulty in discharging liquid solvent or due to the inner liner
preventing the liquid solvent from entering the vessel, run the strength test
with gas.
8.3.4.4.1. The strength test with
gas shall only be allowed to run if the external and internal inspection show
good results and the strength shall be calculated and inspected according to
the measurements obtained.
8.3.4.4.2. The following safety
measures shall be taken when the strength test with gas is run:
- Valves and meters on the gas
intake pipe must be removed from the place where the vessel is located or
outside the booth where the vessel is located;
- Throughout the test, unauthorized
persons must stay away from the vessel.
8.3.4.4.3. Test for gas leak by
using soap solution or taking other measures. Do not hammer the vessel wall
throughout the test.
The test result is considered
satisfactory if:
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- gas bubbles, water spray or leak
through welds and joints are not found;
- deformation is not found;
- the pressure is not reduced while
the test pressure is maintained. If the test pressure is reduced until 3% due
to the leak through valves, flanges, etc., the strength test is also considered
satisfactory.
8.3.5. Leak test:
The leak test shall only be applied
in case of technological requirements, the vessels containing toxic or
flammable solvents or at the request of the manufacturer.
8.3.5.1. Pressure, solvent and
maintenance time are specified in Table 2.
Table
2. Pressure, solvent and maintenance time for leak test
Types
of vessel
Test
pressure (bar)
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Maintenance
time (minute)
Vessel of all types
Plv
Air
or inert gas
Maintained
throughout the test but not less than 30 minutes
Plv - Working pressure.
8.3.5.2. Fill the vessel with solvent
and increase the pressure to test pressure.
8.3.5.3. Detect leak by using soap
solution or taking other measures.
The test result is considered
satisfactory if:
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- the allowable pressure drop
during the maintenance of test pressure is less than or equal to 0.5% test
pressure.
8.4. Operational inspection.
8.4.1. Inspect the satisfaction of
all conditions for the first use of the vessel.
8.4.2. Inspect the operation of the
vessel and its accessories; operation of protective devices and measurement
equipment.
8.4.3. When the vessel operates
stably, increase the pressure for inspection, adjust the working pressure of
safety valves and seal the safety valves with lead (except for the vessel
containing toxic or flammable solvents).
8.4.4. It is not required to adjust
and seal the safety valve during the test.
8.4.5. Safety valve adjustment
value: The installed pressure of a safety valve shall not exceed the following
value:
- Plv + 0.5 bar - When
the working pressure reaches 3 bar.
- Plv +15% Plv
- When the working pressure reaches from 3 bar to 60 bar.
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The result is considered
satisfactory if the pressure vessel, auxiliary equipment and measurement equipment
operate normally and the indicators are stable.
9. PROCESSING INSPECTION RESULTS
9.1. Prepare an inspection record
which contains sufficient information according to the form in the Appendix 02
hereto attached.
9.2. Approve the inspection record:
Mandatory participants in the
process of approving the inspection record:
- The representative or a person
authorized by the vessel owner;
- A witness;
- The inspector.
When the record is approved, the
inspectors, the witness, and the representative or a person authorized by the
vessel owner shall append their signatures and seals (if any) on the record.
The record shall be made into 02 copies, one for each party.
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9.4. Put on the inspection stamp:
if the inspection result of a pressure vessel is satisfactory, inspectors shall
put an inspection stamp on it at a noticeable position.9.5. Issuance of
certificate of inspection results:
9.5.1. If the inspection result is
satisfactory, the inspecting organization shall issue the certificate of
inspection results to the pressure vessel within 5 working days from the day on
which the inspection record is approved.
9.5.2. If the inspection result is
not satisfactory, only the steps in 9.1 and 9.2 shall be taken and the
inspection record must specify the explanation for unsatisfactory result,
necessary remedial actions and a deadline for taking such actions. The
inspection shall be sent to the employment authority of the area where the
pressure vessel is located.
10. INSPECTION INTERVAL
10.1. A pressure vessel has to be
inspected every 3 years. For the vessel that contains corrosive or inflammable
solvents and vessel that has been used for more than 12 years, they have to be
inspected every 02 years.
10.2. For the vessel that contains
corrosive or inflammable solvents and has been used for more than 12 years, and
vessel that has been used for more than 24 years, they have to be inspected
every year.
10.3. In the case where a shorter
interval is demanded by the manufacturer or owner, such interval shall apply.
10.4. If the inspection interval is
shortened, the inspector shall provide explanation in the inspection record.
10.5. If the inspection interval is
specified in national technical regulations, such regulations shall apply.
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PROCEDURES FOR INSPECTION OF
TECHNICAL SAFETY OF BRIDGE TYPE LIFTING EQUIPMENT (BRIDGE CRANES, GANTRY
CRANES, SEMI-GANTRY CRANES AND ELECTRIC HOISTS)
QTKD:09- 2016/BLDTBXH
Foreword
Procedures for inspection of
technical safety of bridge type lifting equipment are drafted by the Department
of Work Safety and promulgated together with the Circular No.
54/2016/TT-BLDTBXH dated December 28, 2016 of the Ministry of Labour, Invalids
and Social Affairs.
PROCEDURES FOR INSPECTION OF TECHNICAL SAFETY OF
BRIDGE TYPE LIFTING EQUIPMENT
1. SCOPE AND REGULATED ENTITIES
1.1. Scope
Such procedures shall be used for first,
periodic and unscheduled inspection of bridge type lifting equipment (including
bridge cranes, gantry cranes, semi-gantry cranes and electric hoists) and under
state management of the Ministry of Labour, Invalids and Social Affairs.
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According to such procedures,
organizations carrying out occupational safety inspection shall directly apply
or establish specific and detailed procedures for each model and type of bridge
type lifting equipment provided that those procedures are not contrary to those
specified in this document.
1.2. Regulated entities
- Organizations carrying out
occupational safety inspection;
- Occupational safety inspectors.
2. Normative references
- QCVN 7: 2012/BLDTBXH, National
technical regulation on safe work of lift appliances.
- QCVN 30: 2016/BLDTBXH, National
technical regulation on safe work for overhead, gantry cranes;
- TCVN 4244:2005, Lifting
appliances - Design construction and survey;
- TCVN 8242-1:2009 (ISO
4306-1:2007) Cranes - Vocabulary - Part 1: General;
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- TCVN 5206:1990, Loading crane
- Safety requirements for counter - weight and ballast;
- TCVN 5207:1990, Loading crane -
Safety requirements;
- TCVN 5209:1990, Loading crane -
Safety requirements for electrical equipment;
- TCVN 5179:90, Hoisting cranes -
Test requirements of hydraulic equipment for safety;
- TCVN 9358:2012, Installation of
equipment earthing system for industrial projects - General requirements;
- TCVN 9385:2012, Protection of
structures against lightning - Guide for design, inspection and maintenance;
In the cases where the
abovementioned normative references are amended or replaced, regulations of the
latest documents shall apply.
Other standards may be applied to
bridge type lifting equipment inspection at the request of its user or
manufacturer if such standards contain the same or higher safety criteria than
those in the national standards referred to in this document.
3. TERMS AND DEFINITIONS
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3.1. “bridge type lifting
equipment” includes bridge cranes, gantry cranes, semi-gantry cranes and
electric hoists.
3.2. “first safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after its installation and
before its first use.
3.3. “periodic safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after expiration of the last
safety inspection result.
3.4. “unscheduled safety
inspection” means the inspection of technical safety of equipment according to
national technical standards and technical safety standards and will be carried
out:
- after a repair, upgrade or
renovation that affects the safety of equipment;
- after change of the location of
installation;
- at the request of the user or a
competent authority.
4. INSPECTION STEPS
Safety inspection shall be carried
out in the following order:
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- External inspection;
- Technical inspection - No-load
test;
- Load test - Test methods;
- Inspection result processing.
Note: Only take the next step if
the equipment passes the test in the previous step. The result of each step shall
be documented according to the form in the Appendix 01 and retained by the
inspecting organization.
5. INSPECTION EQUIPMENT
Inspection equipment shall be
inspected and calibrated in accordance with regulations. Inspection equipment
includes:
- Theodolite;
- Altimeter (speedometer);
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- Geometric inspection equipment;
- Dynamometer or hanging scale;
- Insulation resistance meter;
- Ground resistance tester;
- Multimeter;
- Clamp meter;
- Automatic level (if necessary).
6. CONDITIONS FOR INSPECTION
The inspection must not be carried
out unless the following conditions are met:
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6.2. Documents about the equipment
are adequate.
6.3. The inspection is not affected
by environment or weather.
6.4. Requirements concerning
occupational safety and health are met.
7. PREPARATION FOR INSPECTION
7.1. Before carrying out the
inspection, the inspecting organization and the user shall reach an agreement
on an inspection plan and prepare for the inspection and assign staff to
participate in and witness the inspection.
7.2. Inspect the equipment profile
and documents. The following documents shall be inspected according to
inspection regulations:
7.2.1. Regarding first inspection:
- The bridge type lifting equipment
profile and documents. The following documents shall be considered:
+ Calculation of strength of
load-bearing parts (if any);
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+ Operating principle diagram and
main technical specifications of electric, hydraulic or pneumatic transmission
system, and control devices and arrangement of safety devices;
+ Assembly drawings of lifting
equipment, wiring diagram;
+ Guidelines for operation and
maintenance.
- Release documents:
+Certificates of the metals used
for the equipment and welding (according to 3.1.2 of TCVN 4244: 2005);
+ Welding joint inspection result
(according to 3.3.4 of TCVN 4244: 2005);
+ Factory acceptance record.
- Reports on results and records on
inspection of earthing, lightning protection, motor insulation resistance and
protective devices (if any);
- Documents on installation;
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7.2.2. Regarding periodic
inspection:
- The previous profile, inspection
record and certificate of inspection result;
- Documents on the use, operation
and maintenance of the equipment; inspection record (if any).
7.2.3. Regarding unscheduled
inspection:
- In case of renovation or repair:
documents on renovation or repair and commissioning record.
- In case of relocation:
installation documents;
- The inspection record issued by
competent authority (if any).
The document inspection result is
satisfactory if the documents are adequate and the regulations of QCVN
7:2012/BLDTBXH are observed. If the result is unsatisfactory, the user shall
take remedial actions.
7.3. Prepare suitable and adequate
equipment for inspection.
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8. INSPECTION PROCESS
An inspection shall be carried out
in the following order:
8.1. External inspection:
8.1.1. Check the location of
installation of equipment, electrical system, user manual, protective fences,
ground, distance and safety measures, notable obstacles during the inspection;
conformity of the parts and specifications of the equipment with those
specified in the profile and documents.
8.1.2. Check all mechanisms or
parts of the lifting equipment individually, pay particular attention to the
condition of the following parts:
- Metal structure of lifting equipment,
welds, riveted joints (if any), bolted joints of metal structures, control
rooms, ladders, floors and guards;
- Hooks and parts of hooks
(Appendix 13A, 13B, 13C TCVN 4244: 2005);
- Ropes inspected and discarded
according to TCVN 10837:2015;
- Rope fixing parts: meet the
manufacturer's requirements or refer to Annex 18C, 21 TCVN 4244: 2005;
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- Rails (Appendix 5 TCVN 4244 :
2005);
- Safety devices (hoisting limiter,
lowering limiter; travelling and traversing limiter; anti-overload devices);
- Earth resistance which must not
exceed 4.0Ω, electric motor’s insulation resistance which is at least 0.5 M Ω
(test voltage 500V);
- Brakes inspected according to
1.5.3.3 of TCVN 4244:2005.
The equipment passes the test if it
is installed according to technical documentation, no damage or defect is found
and the requirements in section 8.1 are met.
8.2. Technical inspection - No-load
test:
- Conduct no-load tests of
mechanisms and equipment, including all electrical mechanisms and equipment,
safety devices, brakes, control and lighting devices, signals, sounds;
- Conduct the abovementioned tests
at least 03 (three) times.
The equipment passes the test if
its mechanisms and safety devices operate according to their specifications and
design.
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8.3.1. Static test:
- Conduct static test of bridge
type lifting equipment according to 4.3.2- TCVN 4244: 2005.
- Test load is 125% of Qtk or 125%
of Qsd, where:
+ Qtk: design load;
+ Qsd: load required by the user
(the load required by the user must be less than the design load and depend on
the actual quality of the device).
The equipment passes the test if
the load remains constant while it is being held for 10 (ten) minutes and after
the load is lowered, the structures and parts of equipment have no crack,
residual strain or other damage (according to 4.3.2-TCVN 4244-2005).
8.3.2. Dynamic test:
- Conduct dynamic test of bridge
type lifting equipment depending on the type of equipment and according to
4.3.2- TCVN 4244: 2005.
- Test load is 110% of Qtk or 110%
of Qsd. Hoist and lower the test load three times and check other mechanisms
bearing such load.
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8.3.3. For lifting equipment
operating in special environment:
8.3.3.1. Regarding lifting
equipment only used to hoist and lower load (lifting irrigation and hydropower
sluice gates):
- Conduct static test according to
8.3.1;
- Conduct dynamic test with a load
of 110% of the design load or load recommended by the user (according to 4.3.2-
TCVN 4244: 2005) when the equipment and trolley are not moved. Hoist and lower
the load three times and check hoisting and lowering mechanisms bearing such
load.
The equipment passes the test if
its mechanisms and parts of equipment operate as designed, requirements of
applicable technical safety standard are met and no crack, residual strain or
other damage is found.
8.3.3.2. When conducting static and
dynamic tests of bridge cranes serving thermal power plants, hydropower plants
and irrigation stations, specialized equipment may be used to create test load
without using load (hydraulic cylinders and pistons are commonly used to create
test load).
In this case, the equipment user or
provider or installation service provider must establish a procedure for operating
the equipment to create test load and such procedure must be confirmed by the
parties concerned. All measuring, interlocking and safety devices of the
equipment for creating test load shall be inspected in accordance with
regulations.
- Conduct static test according to
8.3.1;
- Conduct dynamic test with a load
of 110% of the design load or load recommended by the user at least 01 (one)
full turn around the drum. Hoist and lower the load three times and check
hoisting and lowering mechanisms bearing such load.
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9. INSPECTION RESULT PROCESSING
9.1. Prepare an inspection record
which contains sufficient information according to the form in the Appendix 02
enclosed herewith.
9.2. Approve the inspection record:
Mandatory participants in the
process of approving the inspection record:
- The representative of the user or
a person authorized by the user;
- A witness;
- The inspectors.
When the record is approved, the
inspector, the witness, and the representative of the user or a person
authorized by the user shall append their signatures and seals (if any) on the
record. The record shall be made into two (02) copies, each party shall keep
01.
9.3. Write the brief inspection
result to the profile of the bridge type lifting equipment (including full
names of the inspectors and the date of inspection).
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9.5. Issuance of certificate of
inspection results:
9.5.1. If the equipment passes the
test, the inspecting organization shall issue the certificate of inspection
result to the lifting equipment within 05 working days from the date on which
the inspection record is approved.
9.5.2. If the equipment fails the
test, only the steps in 9.1 and 9.2 shall be taken and the inspection record
must specify the explanation for the failure, necessary remedial actions and a
deadline for taking such actions. The inspection record shall be sent to the
employment authority of the area where the bridge type lifting equipment is
installed and located.
10. INSPECTION INTERVAL
10.1. Bridge type lifting equipment
has to be inspected every 03 years. For the type lifting equipment that has
been used for more than 12 years, it has to be inspected every year.
10.2. In the case where a shorter
interval is demanded by the manufacturer or user, such interval shall apply.
10.3. If the inspection interval is
shortened, the inspector shall specify explanation in the inspection record.
10.4. If the inspection interval is
specified in national technical regulations, such regulations shall apply.
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SPECIMEN
OF THE ON-SITE RECORD
(INSPECTION OF TECHNICAL SAFETY OF BRIDGE TYPE LIFTING EQUIPMENT)
(Name
of inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
………..[place],
………[date]
ON-SITE
RECORD
No.
...................
(written
by the inspector)
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Name of the equipment:
.…………….……………………….…………….……………………………………….
Name of the user: .…………….……………………….…………….………………….
Address (head office of the user):
.…………….……………………….…………….………
Address (location) of the
equipment: .…………….……………………….…………….…………………………….
Content of the meeting with the
user:
- Representative: (information)
- Witnesses:
2. Basic specifications
-
Code:........................................
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- Production
number:....................................
- Equipment
speed:.................m/min
- Production year:
..............................
- Aperture,
cantilever:................................m
- Manufacturer:
..................................
- Lifting height of (main and
auxiliary) hooks:............. m
- Design load:.....................
tonnes
- Load at cantilever’s free end:
…………tonnes
- Lifting
speed:.........................m/min
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- Machine profile:
- Technical documents:
4- Code of measuring and testing
equipment:
5- Equipment inspection:
a. External inspection:
+ Metal structure:
+ Hook and pulley assembly:…
+ Wire ropes and wire rope
fixation:…
+ Protective earthing:
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+ Brakes:….
+ Safety devices:
b. Technical inspection:
- 125% load test:(10-minute hold)
+ Brakes: ……
+ Metal structure:….
- 110% dynamic test:
+ Brakes (load holding)
+ Mechanisms and parts:
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6- Inspection of limiters, load
indicator, overload indicator.
7. Processing and evaluation of
inspection results.
8- Recommendation(s): (if any)
WITNESS
(Signature and full name)
INSPECTOR
(Signature and full name)
Appendix
02
SPECIMENT
OF RECORD ON INSPECTION OF TECHNICAL SAFETY OF BRIDGE TYPE LIFTING EQUIPMENT
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THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
………..[place],
………[date]
TECHNICAL
SAFETY INSPECTION RECORD
(FOR BRIDGE TYPE LIFTING EQUIPMENT)
No.
…………….
(According to the On-site Record No. ………………..)
We are:
1. .…………….……………………… Inspector
number: .…………….………………………
2. .…………….……………………… Inspector
number: .…………….………………………
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Registration certificate No.
……………………………………….…………….
Name of the inspected
equipment:……………………………. ………………………………
Name of the user:
.…………….……………………….…………….………………….
Address (head office of the
user):…………………………………………………………… …
Address (location) of the
equipment:……………………………………………………………
Inspection procedure and standards
applied: …………………………………………………
Individuals witnessing and
approving the record:………………………………… …………
1………………………………………
Position:………………………
2………………………………………
Position:………………………
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-
Code:............................................
- Trolley
speed:......................m/min
- Production
number:....................................
- Equipment
speed:.................m/min
- Production year:
..............................
- Aperture,
cantilever:................................m
- Manufacturer:
..................................
- Lifting height of (main and
auxiliary) hooks:............. m
- Design
load:........................... tonnes
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- Hoisting/Lowering
speed:.........................m/min
II-
FORMS OF INSPECTION
First
time □ ;
Periodic □ ;
Unscheduled □
Reasons for unscheduled inspection:
.…………….………………………………………
III-
INSPECTION CONTENT:
A- Technical document inspection:
-
Comments:…………………………………………………………………….......................
- Result evaluation:
No.
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Passed
Failed
Note
1
Profile
B-Technical inspection; no-load
test:
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- Result evaluation:
No.
Mechanism;
part
Passed
Failed
Note
No.
Mechanism;
part
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Failed
Note
1
Main hook/auxiliary hook
12
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2
Pulley assembly
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Auxiliary hoist mechanism
3
Main hoist rope
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14
Trolley motion mechanism
4
Auxiliary hoist rope
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15
Crane travelling mechanism
5
Main hoist brake
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16
Rail clip
6
Auxiliary hoist brake
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17
Whistle (bell)
7
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18
Height limiter
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Rail, rail gauge
19
Trolley traversing limiter
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9
Metal structure of main girders;
attachments to the building
20
Electrical system
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10
Crane frame
21
Control system
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11
Crane brake
22
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C-Load test: (design/uses)
-
Comments:……………………………………………………………………………..............
- Result evaluation:
No.
Load
holding position and test result
Passed
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Equivalent
load (tonnes)
Static
test (tonnes)
Dynamic
load test (tonnes)
1
Mid-aperture
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2
At cantilever’s free end
3
Stability
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No.
Result
evaluation
Passed
Failed
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No.
Result
evaluation
Passed
Failed
Note
1
Metal structure
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5
Hoist brake
2
Control system
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6
Trolley brake
3
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7
Crane brake
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Hoist rope
...
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IV-
CONCLUSIONS AND RECOMMENDATIONS
1. Result: Passed
□ Failed □
Maximum load: ........... tonnes.
2. Inspection stamp No:……………
At:……………
3. Recommendations:
……..……..……..……..……..……..……..……..
Deadline for implementation of
recommendations:…….. ……..
V-
INSPECTION INTERVAL
Date of next inspection:
Reasons for shortened interval (if
any):
...
...
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At:…………………………….
The record is made into of
……copies, each party holds…. copies.
EQUIPMENT
USER
(Signature and seal)
(Undertaking to fulfill recommendations in sufficient and timely manner)
PROCEDURES FOR TECHNICAL INSPECTION OF SAFETY OF
MOBILE CRANES
QTKD: 10- 2016/BLDTBXH
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Procedures for inspection of
technical safety of mobile cranes are drafted by the Department of Work Safety
and promulgated together with the Circular No. 54/2016/TT-BLDTBXH dated
December 28, 2016 of the Ministry of Labour, Invalids and Social Affairs.
PROCEDURES FOR TECHNICAL INSPECTION OF SAFETY OF
MOBILE CRANES
1. SCOPE AND REGULATED ENTITIES
1.1. cope
Such procedures shall be used for
first, periodic and unscheduled inspection of mobile cranes under state
management of the Ministry of Labour, Invalids and Social Affairs.
Such procedures shall not apply to
the abovementioned mobile cranes placed on floating work platforms.
1.2. Regulated entities
- Organizations carrying out
occupational safety inspection;
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2. NORMATIVE REFERENCES
- QCVN 7: 2012/BLDTBXH, National
technical regulation on safe work of lift appliances;
- QCVN 29: 2016/BLDTBXH, National
technical regulation on safe work for Cranes;
- TCVN 8590-2:2010 (ISO
4301-2:2009), Part 2: Mobile cranes.
- TCVN 8242-2:2009, Cranes -
Vocabulary - Part 2, Mobile cranes;
- TCVN 10837:2015, Cranes - Wire
ropes - Care and maintenance, inspection and discard;
- TCVN 8855-2:2011. Cranes and
lifting appliances. Selection of wire ropes. Part 2: Mobile cranes. Coefficient
of utilization;
- TCVN 4244:2005, Lifting
appliances – Design construction and survey;
- TCVN 5206:1990, Loading crane
- Safety requirements for counter - weight and ballast;
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- TCVN 5179:1990, Hoisting cranes -
Test requirements of hydraulic equipment for safety.
In the cases where the
abovementioned normative references are amended or replaced, regulations of the
latest references shall apply.
Other standards may be applied to
mobile cranes at the request of their user or manufacturer if such standards
contain the same or higher safety criteria than those in the national standards
referred to in this document.
3. TERMS AND DEFINITIONS
For the purposes of this document,
the terms and definitions given in the abovementioned normative references and
the following shall apply:
3.1. “mobile crane” means a boom
type crane, which may be fitted with a mast (tower attachment) capable of
travelling, laden or unladen, without the need for fixed runways and which
relies on gravity for stability.
3.2. “first safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after its installation and
before its first use.
3.3. “periodic safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after expiration of the last
safety inspection result.
3.4. “unscheduled safety
inspection” means the inspection of technical safety of equipment according to
national technical standards and technical safety standards and will be carried
out:
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- after change of the location of
installation;
- at the request of the user or a
competent authority.
4. INSPECTION STEPS
Safety inspection shall be carried
out in the following order:
- Inspection of the equipment
profile and documents;
- External inspection;
- Technical inspection - No-load
test;
- Load test - Test methods;
- Inspection result processing.
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5. INSPECTION EQUIPMENT
Inspection equipment shall be
inspected and calibrated in accordance with regulations. Inspection equipment
includes:
- Theodolite;
- Altimeter (speedometer);
- Distance measuring equipment;
- Geometric inspection equipment;
- Dynamometer or hanging scale;
- Ground resistance meter;
- Multimeter;
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- Automatic level (if necessary).
6. CONDITIONS FOR INSPECTION
The inspection must not be carried
out unless the following conditions are met:
6.1. The equipment is at the ready
for inspection.
6.2. Documents about the equipment
are adequate.
6.3. The inspection is not affected
by environment or weather.
6.4. Requirements concerning
occupational safety and health are met.
7. PREPARATION FOR INSPECTION
7.1. Before carrying out the
inspection, the inspecting organization and the user shall reach an agreement
on an inspection plan and prepare for the inspection and assign staff to
participate in and witness the inspection.
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7.2.1. Regarding first inspection:
- The profile and technical
documents on the equipment (inspected under 3.1 of QCVN 29:2016/BLDTBXH and
3.5.1.5 of QCVN 7: 2012/BLDTBXH).
- Certificate of conformity issued
by the designated organization as prescribed.
7.2.2. Regarding periodic
inspection:
- The profile and technical
documents on the equipment
- Documents on the use, operation
and maintenance of the equipment, results of previous inspections.
7.2.3. Regarding unscheduled
inspection:
- Profile and technical documents
on the equipment (in case of renovation or repair, documents on renovation,
documents on renovation or repair and commissioning records are required).
- Documents on the use, operation
and maintenance of the equipment, results of previous inspections.
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The document inspection result is
satisfactory if the documents are adequate and the regulations in 7.2 are
observed. If the result is unsatisfactory, the user shall take remedial
actions.
7.3. Prepare suitable and adequate
equipment for inspection.
7.4. Develop measures for ensuring
safety and reach an agreement with the user before inspection. Provide adequate
personal protective equipment to ensure safety during the inspection.
8. INSPECTION PROCESS
An inspection shall be carried out
in the following order:
8.1. External inspection:
8.1.1. Check the location of the
equipment, protective fences, distance and notable obstacles during the
inspection.
8.1.2. Check the conformity of
parts of the equipment with those specified in the documents/profile.
8.1.3. Check all mechanisms or
parts of the lifting equipment individually, pay particular attention to the
condition of the following parts:
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- Hooks and parts of hook assembly
(inspected and assessed according to Appendix 13A, 13B, 13C of TCVN 4244:
2005).
- Ropes inspected and discarded
according to TCVN 10837:2015;
- Rope fixing parts (meeting the
manufacturer's requirements or referring to Appendices 18C and 21 of TCVN 4244:
2005).
- Pulleys, shafts and parts used to
fix the shaft sleeves (Appendices 19A, 20A and 20B of TCVN 4244: 2005).
- Safety devices (overload limiter;
hoisting limiter, lowering limiter; derricking device, telescoping limiter);
- Brake mechanisms.
- Counter-weight and counter-weight
frames: assessed according to TCVN 5206:1990.
The equipment passes the test if no
damage or defect affecting its mechanisms and parts is found and the
requirements in section 8.1 are met.
8.2. Technical inspection - No-load
test:
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- Hook and boom hoisting and
lowering mechanisms, slewing mechanism, equipment travelling mechanism (in the
case of a crawler crane).
- Safety devices: hook hoisting and
lowering limiter, boom hoisting and lowering limiter, overload limiter (if
any), radius indicator and corresponding load.
- Brakes for boom and hook hoisting
and lowering mechanisms.
- Control and lighting devices,
signals, sounds.
- Conduct the abovementioned tests
at least 03 times.
The equipment passes the test if
its mechanisms and safety devices operate according to their specifications and
design and satisfy the regulations set out in 8.2.
8.3. Load test - Test methods:
8.3.1. Static test:
- Test load: at 125% of SWL or 125%
of Q(sd), where:
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+ Q(sd): the load required by the
user must not be greater than the design load and depend on the actual quality
of the equipment.
- When hoisting the load, check the
function of the overload limiter at these positions. The overload limiter must
prevent mechanisms from continuing to operate beyond the equipment's safe
limits and such mechanisms are only permitted to operate in the opposite
direction to bring the load back to a safe level.
- Hold the load at two positions at
the minimum and maximum radius based on the characteristics of the equipment’s
load and comply with the regulations enshrined in 4.3.2 of TCVN 4244:2005.
The equipment passes the test if,
during the 10 minute load test period, there is no crack, permanent deformation
or other damage and the regulations set out in 4.3.2 of TCVN 4244:2005 are
satisfied.
8.3.2. Dynamic test:
- Test load: at 110% of SWL or 110%
of Q(sd).
- Hold the load at two positions at
the minimum and maximum radius based on the characteristics of the equipment’s
load and comply with the regulations enshrined in 4.3.2 and 4.3.3 of TCVN
4244:2005.
The equipment passes the test if
the load remains constant during the test period and no crack, permanent
deformation or other damage are present on its mechanisms and parts after the
load is lowered, and the regulations set out in 4.3.2 and 4.3.3 of TCVN
4244-2005 are satisfied.
9.1. Prepare an inspection record which
contains sufficient information according to the form in the Appendix 02
enclosed herewith.
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Mandatory participants in the
process of approving the inspection record:
- The representative of the user or
a person authorized by the user;
- A witness;
- The inspectors.
When the record is approved, the
inspectors, the witness, and the representative of the user or a person
authorized by the user shall append their signatures and seals (if any) on the
record. The record shall be made into two (02) copies, each party shall keep
01.
9.3. Write the brief inspection
result to the profile of the equipment (including full names of the inspectors
and the date of inspection).
9.4. Put on the inspection stamp:
if the equipment passes the test, the inspector shall put an inspection stamp
on it at a noticeable position.
9.5. Issuance of certificate of
inspection result:
9.5.1. If the equipment passes the
test, the inspecting organization shall issue the certificate of inspection
result to the equipment within 05 working days from the date on which the
inspection record is approved.
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10. INSPECTION INTERVAL
10.1. A mobile crane has to be
inspected every 02 years. For the mobile crane that has been used for more than
10 years, it has to be inspected every year.
10.2. In the case where a shorter
interval is demanded by the manufacturer or user, such interval shall apply.
10.3. If the inspection interval is
shortened, the inspector shall specify explanation in the inspection record.
10.4. If the inspection interval is
specified in national technical regulations, such regulations shall apply.
Appendix
01
SPECIMEN
OF THE ON-SITE RECORD
(FOR MOBILE CRANES)
(Name
of inspecting organization)
-------
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…………..
[place], ………[date]
ON-SITE
RECORD
(written
by the inspector)
1- General information
Name of the equipment:
.…………….……………………….…………….……………………………………….
Name of the user:
.…………….……………………….…………….………………….
Address (head office of the user):
.…………….……………………….…………….…………
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Content of the meeting with the
user:
- Representative: (information)
- Witness:
2- Basic specifications
-
Code:
………………
- Slewing speed:
……
rpm
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………………
- Crane travel speed (for mobile
equipment):
……
m/min
- Production
year:
………………
- Radius (max):
……
m
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………………
- Lifting height of (main and
auxiliary) hooks:
……
m
- Design load(max)
…………tonnes
- Load at the maximum radius:
……
tonnes
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…………m/min
- Uses:
……………
3- Document inspection:
- Machine profile:
- Technical documents:
4- Code of measuring and testing
equipment:
5- Equipment inspection:
a. External inspection:
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- Hook and pulley assembly:…
- Wire ropes and wire rope
fixation:…
- Hydraulic cylinders and pistons:…
- Brakes:….
- Counterweight:….
- Safety devices:
b. Technical inspection:
- 125% load test:(10-minute hold)
- Brakes: ……
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- 110% dynamic test:
- Brakes (load holding)
- Mechanisms and parts:
- Metal structure:
6- Inspection of limiters, load
indicator, overload indicator.
7. Processing and evaluation of
inspection results.
8- Recommendations: (if any).
WITNESS
(Signature and full name)
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Appendix
02
SPECIMEN
OF RECORD ON INSPECTION OF TECHNICAL SAFETY
(FOR MOBILE CRANES)
(Name
of inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
…………..
[place], ………[date]
TECHNICAL
SAFETY INSPECTION RECORD
(FOR MOBILE CRANES)
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We are:
1. .…………….……………………… Inspector
number: .…………….………………………
2. .…………….……………………… Inspector
number: .…………….………………………
Inspecting organization:
.…………….…………………….…………….………………………
Registration certificate No.
……………………………………….……………
Name of the inspected
equipment:……………………………. ………………………………
Name of the user:
.…………….……………………….…………….………………….
Address (head office of the user):
.…………….……………………….…………….………
Address (location) of the
equipment: .…………….……………………….…………….……………………………. ……………
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Individuals
witnessing and approving the record:………………….………………… ………
1…………………………………
Position:………….…………………
2……………
……………………
Position:……………………………
I-
BASIC SPECIFICATIONS
-
Code:
………………
- Slewing speed:
……
rpm
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………………
- Crane travel speed (for mobile
equipment):
……
m/min
- Production
year:
………………
- Actual/design radius:
……
...
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-
Manufacturer:
………………
- Actual/design lifting height of
(main and auxiliary) hooks:
……
m
- Design load(max)
…………tonnes
- Load at the maximum
actual/design radius:
……
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- Lifting speed:
…………m/min
- Uses:
……………
II-
FORMS OF INSPECTION
First
time □ ;
Periodic □ ;
Unscheduled □
III- INSPECTION CONTENT
A.
Document inspection:
No.
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Passed
Failed
Note
No.
Item
1
Profile
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2
License
plate
………..
B. External inspection;
no-load test:
No.
Mechanisms; parts
Passed
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Note
No.
Mechanisms; parts
Passed
Failed
Note
1
Main hook/auxiliary hook
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15
Auxiliary hoisting mechanism
2
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16
Boom hoisting mechanism
...
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Main hoist rope
17
Telescoping mechanism
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4
Auxiliary hoist rope
18
Leg (Chain)
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5
Tie rod
19
Whistle/bell
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6
Boom hoist rope
20
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7
Main hoisting mechanism
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Crane frame
8
Wind speed meter
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22
Auxiliary hoist brake
9
Height limiter
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23
Boom hoist brake
10
Boom angle limiter
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24
Radius and corresponding load
indicator
11
Counterweight
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25
Control system
12
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26
Hydraulic system
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Main hoist brake
27
Slewing mechanism
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14
Travel brake
28
Slewing mechanism brake
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C-Load test:
No.
Load
holding position and test result
Passed
Failed
Radius
(m)
Corresponding
load
(tonnes)
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Dynamic
test load
(tonnes)
1
Minimum radius
R=
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Maximum radius
R=
3
Auxiliary boom
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4
Main boom length
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5
Stability
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No.
Result
evaluation
Passed
Failed
Note
No.
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Passed
Failed
Note
1
Metal structure
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Slewing mechanism brake
2
Load hoist brake
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7
Travel brake
3
Boom hoist brake
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8
Leg (Chain)
4
Overload limiter (if any)
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9
Hydraulic system
5
Load hoist rope
...
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10
Control system
IV
- CONCLUSIONS AND RECOMMENDATIONS
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2. Inspection stamp No:……………
At:……………
3. Maximum load: ...........
tonnes, corresponding to radius:…. m.
4. Recommendations:……..
Deadline for implementation of
recommendations:……..
V
- INSPECTION INTERVAL
Date of next inspection:
Reasons for shortened interval (if
any):
The record is approved on:
At:.…………….……………………….…………….……
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We, the inspectors who inspect
the equipment are responsible for the accuracy of the comments on and
evaluation of the inspection results specified in this record./.
EQUIPMENT
USER
Undertaking to fulfill recommendations in sufficient and timely manner
(signature and seal)
WITNESS
(signature and full name)
INSPECTOR
(signature and full name)
PROCEDURES FOR TECHNICAL INSPECTION OF SAFETY OF
LIFTING TABLES
QTKD: 11- 2016/BLDTBXH
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Procedures for inspection of
technical safety of lifting tables are drafted by the Department of Work Safety
and promulgated together with the Circular No. 54/2016/TT-BLDTBXH dated
December 28, 2016 of the Ministry of Labour, Invalids and Social Affairs.
PROCEDURES FOR TECHNICAL INSPECTION OF SAFETY OF
LIFTING TABLES
1. SCOPE AND REGULATED ENTITIES
1.1. Scope
Such procedures shall be used for
first, periodic and unscheduled inspection of lifting tables (including:
lifting tables, lifting platforms and lifting bridges used to lift goods) under
state management of the Ministry of Labour, Invalids and Social Affairs.
Such procedures shall not apply to
the lifting tables placed on floating work platforms.
1.2. Regulated entities
- Organizations carrying out
occupational safety inspection;
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2. NORMATIVE REFERENCES
- TCVN 4244:2005, Lifting
appliances - Design, construction and survey.
- TCVN 5209:1990, Loading crane -
Safety requirements for electrical equipment.
- TCVN 4755:1989, Cranes - Safety
requirements for hydraulic equipment.
- TCVN 5179:90, Hoisting cranes -
Test requirements of hydraulic equipment for safety.
- TCVN 9358 : 2012 Installation of
equipment earthing system for industrial projects - General requirements.
- QCVN 22:2010/BGTVT,
National technical regulation on construction and survey of lifting appliances;
- BSEN 1570:1998+A2: 2009 - Safe
requirements for lifting table.
In the cases where the
abovementioned normative references are amended or replaced, regulations of the
latest references shall apply.
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3. TERMS AND DEFINITIONS
For the purposes of this document,
the terms and definitions given in the abovementioned normative references and
the following shall apply:
3.1. “lifting table” means a
lifting device used to raise and/or lower goods. A lifting table includes such
main mechanisms and parts as platform surface, base frame, lifting frame system
(X-shaped type with one or more layers, cylinder type or fork type, etc.),
drive system (hydraulic, mechanical, etc.).
3.2. “first safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after its installation and
before its first use.
3.3. “periodic safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after expiration of the last
safety inspection result.
3.4. “unscheduled safety
inspection” means the inspection of technical safety of equipment according to
national technical standards and technical safety standards and will be carried
out:
- after a repair, upgrade or
renovation that affects the safety of equipment;
- after change of the location of
installation;
- at the request of the user or a
competent authority.
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Safety inspection shall be carried
out in the following order:
- Inspection of the equipment
profile/documents;
- External inspection;
- Technical inspection - No-load
test;
- Load test - Test methods;
- Inspection result processing.
Note: Only take the next step if
the equipment passes the test in the previous step. The result of each step
shall be documented according to the form in the Appendix 01 and retained by
the inspecting organization.
5. INSPECTION EQUIPMENT
Inspection equipment shall be
inspected and calibrated in accordance with regulations. Inspection equipment
includes:
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- Automatic level;
- Altimeter (speedometer);
- Distance measuring equipment;
- Geometric inspection equipment;
- Dynamometer or hanging scale;
- Insulation resistance meter;
- Ground resistance meter;
- Multimeter;
- Clamp meter;
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The inspection must not be carried
out unless the following conditions are met:
6.1. The equipment is at the ready
for inspection.
6.2. Documents about the equipment
are adequate.
6.3. The inspection is not affected
by environment or weather.
6.4. Requirements concerning
occupational safety and health are met.
7. PREPARATION FOR INSPECTION
7.1. Before carrying out the
inspection, the inspecting organization and the user shall reach an agreement
on an inspection plan and prepare for the inspection and assign staff to
participate in and witness the inspection.
7.2. Inspect the equipment profile
and documents. The following documents shall be inspected according to
inspection regulations:
7.2.1. Regarding first inspection:
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+ Drawings specifying main
dimensions;
+ Transmission principle diagram;
+ Guidelines for operation and
maintenance.
+ Factory acceptance test results
(if any).
- Reports on results of and records
on inspection of insulation grounding and resistance of the motor.
- Certificate of conformity issued
by the designated organization as prescribed.
7.2.2. Regarding periodic
inspection:
- The previous profile, inspection
record and inspection result report;
- Documents on the use, operation
and maintenance of the equipment; inspection record (if any).
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- In case of renovation or repair:
documents on renovation or repair and commissioning record;
- In case of relocation:
installation documents;
- The inspection record issued by
competent authority (if any).
The document inspection result is
satisfactory if the documents are adequate and the regulations in 7.2 are
observed. If the result is unsatisfactory, the user shall take remedial
actions.
7.3. Prepare suitable and adequate
equipment for inspection.
7.4. Develop measures for ensuring
safety and reach an agreement with the user before inspection. Provide adequate
personal protective equipment to ensure safety during the inspection.
8. INSPECTION PROCESS
An inspection shall be carried out
in the following order:
8.1. External inspection:
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8.1.2. Check the conformity of
parts and technical specifications of the equipment with those specified in the
documents/profile.
8.1.3. Check all mechanisms or
parts of the lifting equipment individually, pay particular attention to the
condition of the following parts:
- Metal structure of the lifting
frame and platform surface (Appendix 17 of TCVN 4244 : 2005).
- Welds, riveted joints (if any),
bolted joints of the connection structure.
- Rope fixing parts (meeting the
manufacturer's requirements or referring to Appendices 18C and 21 of TCVN 4244:
2005).
- Pulleys, shafts and fixing parts
(Appendices 19A, 20A and 20B of TCVN 4244: 2005).
- Check the results of measurement
of grounding resistance and insulation resistance.
- Hydraulic system:
+ Check the technical condition of
the hydraulic cylinder: no deformation, no hydraulic oil leak.
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- Check the control system:
location of installation, priority, homogeneity between mechanism and control
mode.
- Safety devices: Safety valve,
relief valve, lifting and lowering limiter, overload limiter, mechanical
braking mechanism, etc.
- Rails, anti-slip, anti-roll and
anti-fall devices (according to the manufacturer's design).
The equipment passes the test if it
is installed according to the technical documents, no damage or defect is found
and the requirements in section 8.1 are met.
8.2. Technical inspection - No-load
test:
Let the equipment to operate
without load and check the operation of systems and structures:
- Check the operating status of the
work platform hoisting and lowering mechanisms.
- Hydraulic system: inspected and
assessed according to TCVN 5179:1990.
- Drive system and control system
of the equipment.
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- Safety devices.
- Conduct the abovementioned tests
at least 03 (three) times.
The equipment passes the test if
its mechanisms and safety devices operate according to their specifications and
design and no damage is found.
8.3. Load test - Test methods:
8.3.1. Static test:
Only conduct a static test if the
equipment fails the no-load test.
- Test load: 125% of SWL (the safe
working load must not be greater than the design load)
- The platform height during load
test: ≤ 200 mm from the lowest lowering position of the work platform (in the
position where the mechanical braking mechanism has not yet acted).
- Arrange a load test on the
platform surface:
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+ For a lifting table designed to
lift a specific type of load, the test load is arranged at the same positions
as in the working process.
- Run the load test for 10 minutes
The equipment passes the static
load test if its metal structure shows no crack or permanent deformation; the
lifting platform does not drift; the equipment remains stable; shows no sign of
oil leak.
8.3.2. Dynamic test:
- Test load: at 110% of SWL.
- Conduct the test throughout
operation of the equipment.
- Conduct abovementioned test at
least 03 times.
The equipment passes the static
load test if its mechanisms and parts operate according to the design; its
metal structure shows no crack or permanent deformation; the lifting platform
does not drift; the equipment remains stable; shows no sign of oil leakage;
shows no damage.
8.3.3. Other requirements:
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- If the equipment has a platform
that can be tilted at an angle, conduct static and dynamic tests on the work
platform tilting mechanism and the friction between the work platform and the
working load shall be checked.
9. INSPECTION RESULT PROCESSING
9.1. Prepare an inspection record
which contains sufficient information according to the form in the Appendix 02
enclosed herewith.
9.2. Approve the inspection record:
Mandatory participants in the
process of approving the inspection record:
- The representative of the user or
a person authorized by the user;
- A witness;
- The inspectors.
When the record is approved, the
inspector, the witness, and the representative of the user or a person
authorized by the user shall append their signatures and seals (if any) on the
record. The record shall be made into two (02) copies, each party shall keep
01.
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9.4. Put on the inspection stamp:
if the lifting table passes the test, the inspector shall put an inspection stamp
on it at a noticeable position.
9.5. Issuance of certificate of
inspection results:
9.5.1. If the lifting table passes
the test, the inspecting organization shall issue the certificate of inspection
result to the equipment within 05 working days from the date on which the
inspection record is approved.
9.5.2. If the lifting table fails
the test, only the steps in 9.1 and 9.2 shall be taken and the inspection
record must specify the explanation for failed result, necessary remedial
actions and a deadline for taking such actions. The inspection record shall be
sent to the employment authority of the area where the lifting table is
installed and located.
10. INSPECTION INTERVAL
10.1. A lifting table has to be
inspected at least every 02 years. For the lifting table that has been used for
more than 10 years, it has to be inspected every year.
10.2. In the case where a shorter
interval is demanded by the manufacturer or user, such interval shall apply.
10.3. If the inspection interval is
shortened, the inspector shall specify explanation in the inspection record.
10.4. If the inspection interval is
specified in national technical regulations, such regulations shall apply.
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Appendix
01
SPECIMEN
OF ON-SITE RECORD
(TECHNICAL INSPECTION OF SAFETY OF LIFTING TABLES)
(Name
of inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
…………..
[place], ………[date]
ON-SITE
RECORD
No.
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1- General information
Name of the equipment:
.…………….……………………….…………….……………………………………….
Name of the user:
.…………….……………………….…………….………………….
Address (head office of the user):
.…………….……………………….…………….………………
Address (location) of the
equipment: .…………….……………………….…………….…………………………….
Content of the meeting with the
user:
- Representative: (information)
- Witness:
2. Basic specifications
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- Design/actual lifting height:
……….... m
- Production number:
...................................
- Lifting speed: …………….…….. m/min
- Production year:
..............................
- Dimension of lifting table:
………….….m
- Manufacturer:
...................................
- Uses:
..............................................
- Design
load:.....................
tonnes
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- Machine profile:
- Technical documents:
4- Code of measuring and testing
equipment:
5- Equipment inspection:
a. External inspection:
+ Metal structure of lifting table
and frame::..
+ Connection between frame and
fixed base:..
+ Wire ropes and wire rope
fixation, pulleys:…
+ Protective grounding:…
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+ Rails, safety fences…
+ Travel mechanism:…
+ Brakes:….
+ Safety devices, mechanical
braking mechanism:…
b. Technical inspection:
- Load test at 125%: (10-minute
hold)
+ Brakes: ……
+ Metal structure:….
- Dynamic load test at 110%:
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+ Mechanisms and parts:
+ Metal structure:
6- Inspection of limiters, overload
limiter (if any).
7. Processing and evaluation of
inspection results.
8- Recommendations: (if any)
WITNESS
(Signature and full name)
INSPECTOR
(signature and full name)
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(SPECIMEN OF RECORD ON
INSPECTION OF TECHNICAL SAFETY OF LIFTING TABLE)
(Name
of inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
…………..
[place], ………[date]
RECORD
ON TECHNICAL INSPECTION OF SAFETY OF LIFTING TABLE
No.
…………….
(According to the on-site record No. ………………..)
We are:
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2. .…………….……………………… Inspector
number: .…………….………………………
Inspecting organization:
.…………….…………………….…………….………………………
Registration certificate No.
……………………………………….……………
Name of the inspected
equipment:……………………………. ………………………………
Name of the user:
.…………….……………………….…………….………………….
Address (head office of the user):
.…………….……………………….…………….…………
Address (location) of the
equipment: .…………….……………………….…………….…………………………….
Inspection procedure and standards
applied: …………………………………………………
Individuals
witnessing and approving the record:………………….………………… ………
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2………………………………………
Position:………….…………………
I- BASIC SPECIFICATIONS
- Code:
.......................................
- Design/actual lifting height:
……….... m
- Production number:
...................................
- Lifting speed: …………….…….. m/min
- Production year:
..............................
- Dimension of lifting table:
………….….m
- Manufacturer:
...................................
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- Design
load:.....................
tonnes
II-
FORMS OF INSPECTION
First
time □ ;
Periodic □ ;
Unscheduled □
Reason for unscheduled inspection:
.…………….………………………………………
III-
INSPECTION CONTENT:
A-Technical document
inspection:
- Comments:
………………………………………………………………….......................
- Result evaluation:
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Item
Passed
Failed
Note
1
Profile
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- Comments:
…………………………………………………………………………...
- Result evaluation:
No.
Mechanisms; parts
Passed
Failed
Note
No.
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Passed
Failed
Note
1
Lifting table (lifting platform,
lifting boom)
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Rope pulley (chain)
2
Metal structure of lifting frame
and post
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10
Load wire rope (load chain)
3
Hydraulic system
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11
Hoisting mechanism brake,
hydraulic brake valve assembly
4
Cylinder and piston of hoisting
and lowering mechanism
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12
Connection between post body and
factory floor
5
Nuts and screws of hoisting and
lowering mechanism
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13
Electrical system
6
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14
Control system
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Safety devices
15
Rails, safety fences
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8
Mechanical braking mechanism
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C-Load test:
- Comments:
…………………………………………………………………………...
- Result evaluation:
No.
Load
holding position and test result
Passed
Failed
Working
load
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Dynamic
load test
1
Lifting table, lifting platform
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2
Stability
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Result
evaluation
Passed
Failed
Note
No.
Result
evaluation
Passed
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Failed
Note
1
Lifting table (lifting platform,
lifting boom)
5
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2
Metal structure of lifting frame
and post
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Electrical system
3
Hydraulic system
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7
Control system
4
Load hoisting and lowering
mechanism
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8
Safety devices
IV-
CONCLUSIONS AND RECOMMENDATIONS
1. Result: Passed
□ Failed □
Maximum load: ........... tonnes.
...
...
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3. Recommendations: ……..
Deadline for implementation of
recommendations: ……..
V
- INSPECTION INTERVAL
Date of next inspection:
Reasons for shortened interval (if
any):
The record is approved on:
At:.…………….……………………….…………….……………………………………………….
The record is made into of
……copies, each party holds…. copies./.
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WITNESS
(Signature and full name)
INSPECTOR
(Signature and full name)
PROCEDURES FOR TECHNICAL INSPECTION OF SAFETY OF
SUSPENDED WORKING PLATFORMS
QTKD: 12 - 2016/BLDTBXH
Foreword
Procedures for inspection of
technical safety of suspended working platforms are drafted by the Department
of Work Safety and promulgated together with the Circular No.
54/2016/TT-BLDTBXH dated December 28, 2016 of the Ministry of Labour, Invalids
and Social Affairs.
PROCEDURES FOR TECHNICAL INSPECTION OF SAFETY OF
SUSPENDED WORKING PLATFORMS
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1.1. Scope
Such procedures shall be used for
first, periodic and unscheduled inspection of suspended working platforms under
state management of the Ministry of Labour, Invalids and Social Affairs.
1.2. Regulated entities
- Organizations carrying out
occupational safety inspection;
- Occupational safety inspectors.
2. NORMATIVE REFERENCES
- QCVN 07: 2012/BLDTBXH, National
technical regulation on safe work of lift appliances;
- QCVN 20: 2015/BLDTBXH, National
technical regulation on safe work of Elevating Platform for lifting people;
- TCVN 4244:2005 - Lifting
appliances - Design construction and survey;
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- China National Standard GB/T
5972-2006/ISO 4309:1990: Cranes - Wire ropes - Code of practice for examination
and discard;
- Code of Practice for Safe Use and
Operation of Suspended Working Platforms of Hong Kong - China.
In the cases where the
abovementioned normative references are amended or replaced, regulations of the
latest references shall apply.
Other standards may be applied to
suspended working platforms at the request of their user or manufacturer if
such standards contain the same or higher safety criteria than those in the
national standards referred to in this document.
3. TERMS AND DEFINITIONS
For the purposes of this document,
the terms and definitions given in the abovementioned normative references and
the following shall apply:
3.1. “suspended working platform”
means a structure consisting of a working platform, suspension beam assembly,
winch assembly, counterweights, wire ropes and other safety mechanisms and
components to provide a working space for people and tools when working at
height. It is commonly known as gondola.
3.2. “first safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after its installation and
before its first use.
3.3. “periodic safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after expiration of the last
safety inspection result.
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- after a repair, upgrade or
renovation that affects the safety of equipment;
- after change of the location of
installation or after its main assemblies are dismantled;
- at the request of the user or a
competent authority.
4. INSPECTION STEPS
Safety inspection shall be carried
out in the following order:
- Inspection of the equipment
profile/documents;
- External inspection;
- Technical inspection - No-load
test;
- Load test - Test methods;
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Note: Only take the next step if
the equipment passes the test in the previous step. The result of each step
shall be documented according to the form in the Appendix 01 and retained by
the inspecting organization.
5. INSPECTION EQUIPMENT
Inspection equipment shall be
inspected and calibrated in accordance with regulations. Inspection equipment
includes:
- Theodolite (if necessary);
- Altimeter (speedometer);
- Distance measuring equipment;
- Geometric inspection equipment;
- Dynamometer or hanging scale (if
necessary);
- Insulation resistance meter;
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- Multimeter;
- Clamp meter;
6. CONDITIONS FOR INSPECTION
The inspection must not be carried
out unless the following conditions are met:
6.1. The equipment is at the ready
for inspection.
6.2. Documents about the equipment
are adequate.
6.3. The inspection is not affected
by environment or weather.
6.4. Requirements concerning
occupational safety and health are met.
7. PREPARATION FOR INSPECTION
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7.2. Inspect the equipment profile
and documents. The following documents shall be inspected according to
inspection regulations:
7.2.1. Regarding first inspection:
7.2.1.1. Equipment profile and
documents;
- The profile must specify the
code, place of production, year of production, permissible load, travel
capacity, operating principle, drive and control type, speed, counterweight,
main dimensions (work platform, suspension beams) and main technical
characteristics of the system (control devices, necessary safety devices,
overload limiter).
- Technical documents, including
operating principle diagram, layout of installation of structural assemblies,
general drawings containing main dimensions and specifications and technical
characteristics.
- Documents on technical
management, operation, maintenance and inspection.
- Guidelines for installation,
operation and emergency response.
- Certificate of conformity issued
by the designated organization as prescribed.
7.2.1.2. Installation documents:
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- As-built drawing, technical
acceptance records.
- Results of inspection of
insulation grounding and resistance of the motor (if any).
7.2.2. Regarding periodic
inspection:
- The previous profile and
inspection result.
7.2.2.2. Documents on the use,
operation and maintenance of the equipment; inspection record (if any).
7.2.3. Regarding unscheduled
inspection:
- Document on innovation or repair.
- Post-renovation or post-repair
commissioning record, test results.
- The inspection record issued by
competent authority.
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7.3. Prepare suitable and adequate
equipment for inspection.
7.4. Develop measures for ensuring
safety and reach an agreement with the user before inspection. Provide adequate
personal protective equipment to ensure safety during the inspection.
8. INSPECTION PROCESS
An inspection shall be carried out
in the following order:
8.1. External inspection:
- Check the location of equipment
location: The ground where the equipment is placed must ensure the equipment’s
bearing capacity. It is required to maintain a safe distance between the
location of installation and the power transmission line (according to 1.5.7.1.9
of TCVN 4244:2005);
- Measure and check the erection
dimensions of the suspended working platform: The erection must be carried out
in a stable manner and according to the manufacturer's design.
- Check weather condition: there is
no rain, the temperature does not exceed 40°C, the wind speed does not exceed
8.3 m/s.
- Check the adequacy and conformity
of the parts, assemblies and technical specifications on the equipment with
those specified in the equipment profile/documents and pay particular attention
the technical condition of the following parts:
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+ Bolted joints of the connections:
carry out visual inspection of the assembly of the parts in accordance with the
manufacturer's manual;
+ Check the welded connections:
carry out visual inspection and discover external damage or defects;
+ Wire ropes: the type specified by
the manufacturer. The outer diameter wear should be less than 10% of the rope
diameter, the number of broken wires should not exceed 5% of the total number
of wires in a length which is 10 times the rope diameter;
+ Fixation of the wire rope ends:
follow the manufacturer's normative references or the standard method of
attaching wire rope clips in the Appendix 18C of TCVN 4244:2005;
+ Check the turnbuckle for any
deformation or defect in the body and head of the turnbuckle and evaluate them
according to Appendix 15 of TCVN 4244:2005
+ Check the weight of the
counterweight on the suspension beam and the fixed anchorage of the
counterweight in the frame;
+ Check the installation of load
and safety rope tensioning counterweights: it is required to be firmly fixed
without slipping or according to the manufacturer's instructions;
+ Assemblies of hoisting and
slewing mechanisms: metal structure of the mechanisms and installation thereof
according to the manufacturer's manual;
+ Manual rescue means;
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+ Winch brake, emergency brake,
overspeed governor;
+ Pulleys, shafts and pulley shaft
fixings;
+ Tracks, wheels and drive
components;
+ Safety devices: lifting and
lowering limiter, overload limiter;
+ Electric cables, control panel:
electrodynamic cables must conform to the manufacturer's type, the connectors
in the control panel must be tightened and ensure electrical safety
regulations;
+ Hydraulic system of boom hoisting
mechanism: Detect hydraulic oil leaks from parts, check the installation of
valve assemblies and pipelines.
The equipment passes the test if it
is sufficiently installed according to the design, no damage or defect is found
and the requirements in section 8.1 are met.
8.2. Technical inspection - No-load
test:
- Check and assess the insulation
resistance of the dynamic electric circuit by the voltage level. To be
specific:
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Test
voltage (V)
Insulation
voltage (MΩ)
≤250
250
≥0,25
≤500
500
≥0,5
>500
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≥1,0
- Conduct abovementioned test at
least 03 (three) times.
- Determine specifications of the
equipment motor: speed, motor current and compare them with those specified in
the equipment documents.
- The equipment passes the no-load
load test if its mechanisms, parts and safety devices operate according to the
manufacturer’s design.
The equipment passes the test if
its dimensions, safety devices and mechanisms operate according to the
manufacturer’s design and the requirements in 8.2 are satisfied.
- Dimensions, safety devices and
mechanisms operating according to the design.
8.3. Load test:
8.3.1. Static load:
Only conduct a static test if the
equipment fails the no-load test.
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- Arrange test load on the work
platform: the test load is evenly distributed on the work platform.
- Lifting height: from 100 to 200
mm from the foot of the work platform support to the ground.
- Run the load test for 10 minutes.
The equipment passes the test if
the work platform does not drift, the equipment remains stable and its metal
structure show no crack or deformation.
8.3.2. Dynamic load test:
The test load is 125% of the
working load, let the suspended working platform operate in both up and down
directions.
8.3.2.1. Test the entire operation
of the hoisting and lowering mechanism.
- Let the suspended working
platform operate in both up and down directions at least 03 times.
The equipment passes the test if
its mechanisms operate according to its design, there is no abnormal function
and the brake does not drift.
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Connect the external controller to
the control panel, check the operation of the safety lock at 125% of the
working load.
The equipment passes the test if it
is only suspended on the safety wire rope with a work platform incline of less
than 25% or within the limits specified by the manufacturer.
8.3.2.3. Test the overspeed governor
(if any): if the suspended working platform is equipped with an overspeed
governor, check the operation of overspeed governor. Let the loaded work
platform operate in the down direction, impose force on the speed governor and
check the holding of the work platform.
The equipment passes the test if
the work platform does not drift.
9. INSPECTION RESULT PROCESSING
9.1. Prepare an inspection record
which contains sufficient information according to the form in the Appendix 02
enclosed herewith.
9.2. Approve the inspection record:
Mandatory participants in the
process of approving the inspection record:
- The representative of the user or
a person authorized by the user;
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- The inspectors.
When the record is approved, the
inspector, the witness, and the representative of the user or a person
authorized by the user shall append their signatures and seals (if any) on the
record. The record shall be made into two (02) copies, each party shall keep
01.
9.3. Write the brief inspection
result to the profile of the equipment (including full names of the inspectors
and the date of inspection).
9.4. Put on the inspection stamp:
if the equipment passes the test, the inspector shall put an inspection stamp
on it at a noticeable position.
9.5. Issuance of certificate of
inspection results:
9.5.1. If the equipment passes the
test, the inspecting organization shall issue the certificate of inspection
result to the equipment within 05 working days from the date on which the
inspection record is approved.
9.5.2. If the equipment fails the
test, only the steps in 9.1 and 9.2 shall be taken and the inspection record
must specify the explanation for failed result, necessary remedial actions and
a deadline for taking such actions. The inspection record shall be sent to the
employment authority of the area where the equipment is installed and located.
10. INSPECTION INTERVAL
10.1. A suspended working platform
has to be inspected every year. For the suspended working platform that has
been used for more than 10 years, it has to be inspected every 06 months.
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10.3. If the inspection interval is
shortened, the inspector shall specify explanation in the inspection record.
10.4. If the inspection interval is
specified in national technical regulations, such regulations shall apply.
Appendix
01
SPECIMEN
OF THE ON-SITE RECORD
(FOR SUSPENDED WORKING PLATFORM)
(Name
of inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
…………..
[place], ………[date]
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ON-SITE
RECORD
No.
...................
(written
by the inspector)
1- General information
Name of the equipment:
.…………….……………………….…………….……………………………………….
Name of the user:
.…………….……………………….…………….………………….
Address (head office of the user):
.…………….……………………….…………….………………
Address (location) of the
equipment: .…………….……………………….…………….…………………………….
Content of the meeting with the
user:
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- Witness:
2- Basic specifications of the
equipment: Motor: Motor capacity; production number; production year; safety
lock: production number, manufacturer.
A- DOCUMENT INSPECTION:
…………………………………
B- EXTERNAL INSPECTION:
………………………………….
C- TECHNICAL INSPECTION - NO-LOAD
TEST:
1-Installation:
- Dimensions of the suspension
frame: (length, radius and distance)
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- Rope locks:
2. Measurement of parameters:
- Lifting and lowering speed
- Travel speed.
- Motor insulation.
- Ropes: diameter, condition.
D- LOAD TEST:
- At 150% of the working load:
(Structure, stability)
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(Brakes, safety locks, overspeed
governor, etc.)
Recommendation(s) (if any):
WITNESS
(Signature and full name)
INSPECTOR
(Signature and full name)
Appendix
02
SPECIMEN
OF RECORD ON TECHNICAL SAFETY INSPECTION
(FOR SUSPENDED WORKING PLATFORM)
(Name
of inspecting organization)
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…………..
[place], ………[date]
SPECIMEN
OF RECORD ON TECHNICAL SAFETY INSPECTION
(FOR SUSPENDED WORKING PLATFORM)
No.
…………….
(According to the on-site record No. ………………..)
We are:
1. .…………….……………………… Inspector
number: .…………….………………………
2. .…………….……………………… Inspector
number: .…………….………………………
Inspecting organization:
.…………….…………………….…………….…………………………….
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Name of the inspected
equipment:……………………………. …………………………………
Name of the user:
.…………….……………………….…………….………………….
Address (head office of the user):
.…………….……………………….…………….………………
Address (location) of the
equipment: .…………….……………………….…………….…………………………….
Inspection procedure and standards
applied: ………………………………………………………………
Individuals
witnessing and approving the record:………………….………………… …………………..
1………………………………………
Position:………….…………………
2………………………………………
Position:………….…………………
I-
BASIC SPECIFICATIONS
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- Travel speed: ……………….m/min
- Production number: ……………………………
- Actual/design lifting height:
…/… m
- Production year: ……………………………
- Dimensions of work
platform:(DxRxC )…………
- Manufacturer: ……………………………
- Suspension beam length: …………..
m
- Design/working load: …/…….kg
- Cantilever length: ……….. m
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- Counterweight: …………kg
- Work platform lifting speed:
…………….…….. m/min
- Uses: ……………………….
II-
FORMS OF INSPECTION
First
time □ ;
Periodic □ ;
Unscheduled □
Reason for unscheduled inspection:
.…………….………………………………………
III
- INSPECTION CONTENT
A- DOCUMENT INSPECTION:
No.
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PASSED
FAILED
NOTE
1
Profile
2
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B- EXTERNAL INSPECTION:
- Adequacy of the equipment:
………………………………………
- Defects - deformations:
………………………………………..…………
C- TECHNICAL INSPECTION -
NO-LOAD TEST:
No.
Mechanism;
part
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Failed
Note
No.
Mechanism;
part
Passed
Failed
Note
1
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10
Load hoist brake
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Metal structure of frame and boom
11
Slewing mechanism brake
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3
Load and boom hoisting mechanism
12
Travel mechanism brake
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4
Hydraulic system
13
Whistle/bell
...
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5
Load hoist rope
14
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6
Anti-fall wire rope
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Control system
7
Platform hoisting and lowering
limiter
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16
Anti-fall lock
8
Travel mechanism
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18
Overspeed governor
9
Slewing mechanism
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17
Counterweight
D- Load test:
No.
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Passed
Failed
Working
load
(Qlv)
Static
test
(150% of Qlv)
Dynamic
load (125% of Qlv)
1
Work platform
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2
Stability
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No.
Result
evaluation
Passed
Failed
Note
No.
Result
evaluation
Passed
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Note
1
Work platform
5
Anti-fall lock
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2
Metal structure of lifting frame
and boom
6
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3
Hydraulic system
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Electrical system
4
Load and boom hoisting mechanism
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8
Overspeed governor
IV
- CONCLUSIONS AND RECOMMENDATIONS
1. Conclusion:
Result:
Passed □ Failed □
- Maximum hoisting load on work
platform: …...……………. Kg.
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2. Inspection stamp No. ……………
At:……………
3.
Recommendations:………………………………………................................................................
Deadline for implementation of
recommendations: …………………..........
V-
INSPECTION INTERVAL
Date of next inspection: .........
/......... /20.......
Reasons for shortened interval (if
any):
The record is approved
at:.............................on …
The record is made into of
……copies, each party holds…. copies./.
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WITNESS
(Signature and full name)
INSPECTOR
(Signature and full name)
PROCEDURES FOR INSPECTION OF TECHNICAL SAFETY OF CHAIN
BLOCKS
QTKD: 13-2016/BLDTBXH
Foreword
Procedures for inspection of
technical safety of chain blocks are drafted by the Department of Work Safety
and promulgated together with the Circular No. 54/2016/TT-BLDTBXH dated
December 28, 2016 of the Ministry of Labour, Invalids and Social Affairs.
PROCEDURES FOR INSPECTION OF TECHNICAL SAFETY OF CHAIN
BLOCKS
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1.1. Scope
Such procedures shall be used for
first, periodic and unscheduled inspection of chain blocks with a load capacity
of 1,000kg or more under state management of the Ministry of Labour, Invalids
and Social Affairs.
1.2. Regulated entities
- Organizations carrying out
occupational safety inspection;
- Occupational safety inspectors.
2. NORMATIVE REFERENCES
- QCVN 7: 2012/BLDTBXH, National
technical regulation on safe work of lift appliances;
- TCVN 4244:2005, Lifting
appliances – Design construction and survey;
- TCVN 5207:1990, Loading crane -
Safety requirements.
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Other standards may be applied to
chain blocks at the request of their user or manufacturer if such standards
contain the same or higher safety criteria than those in the national standards
referred to in this document.
3. TERMS AND DEFINITIONS
For the purposes of this document,
the terms and definitions given in the abovementioned normative references and
the following shall apply:
3.1. “chain block with a load
capacity of 1,000kg or more” means a type of lifting equipment consisting of a
hoisting and lowering mechanism, in many cases equipped with a travel
mechanism, which is manually driven through a traction chain, speed reducer and
chain hoist.
The chain block with a load
capacity of 1,000kg is hereinafter referred to as “chain block”.
3.2. “first safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after its installation and
before its first use.
3.3. “periodic safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after expiration of the last
safety inspection result.
3.4. “unscheduled safety
inspection” means the inspection of technical safety of equipment according to
national technical standards and technical safety standards and will be carried
out:
- after a repair, upgrade or
renovation that affects the safety of equipment;
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- at the request of the user or a
competent authority.
4. INSPECTION STEPS
Safety inspection shall be carried
out in the following order:
- Inspection of the equipment
profile/documents;
- External inspection;
- Technical inspection - No-load
test;
- Load test - Test methods;
- Inspection result processing.
Note: Only take the next step if
the equipment passes the test in the previous step. The result of each step
shall be documented according to the form in the Appendix 01 and retained by
the inspecting organization.
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Inspection equipment shall be
inspected and calibrated in accordance with regulations. Inspection equipment
includes:
- Distance measuring equipment;
- Geometric inspection equipment;
- Dynamometer or hanging scale;
- Theodolite (if necessary).
6. CONDITIONS FOR INSPECTION
The inspection must not be carried
out unless the following conditions are met:
6.1. The equipment is at the ready
for inspection.
6.2. Documents about the equipment
are adequate.
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6.4. Requirements concerning
occupational safety and health are met.
7. PREPARATION FOR INSPECTION
7.1. Before carrying out the
inspection, the inspecting organization and the user shall reach an agreement
on an inspection plan and prepare for the inspection and assign staff to
participate in and witness the inspection.
7.2. Inspect the equipment profile
and documents. The following documents shall be inspected according to
inspection regulations:
7.2.1. Regarding first inspection:
- Chain block profile/documents,
especially the documents specified under QCVN 7:2012/BLDTBXH.
- Installation and release
documents (for the chain block which does not have a travel mechanism and are
mobile, it is not required to inspect the installation documents):
+ Calculation of strength of
load-bearing structures and parts (if any);
+ Structural drawings which specify
all main dimensions;
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+ Factory acceptance record of the
hoisting mechanism - chain block (if any);
+ Certificates of fabricated metal,
weld metal and quality inspection of welds (according to 3.1.2 and 3.3.4 of
TCVN 4244: 2005) of the load-bearing suspension system. For the chain block
with attached travelling parts, there must be a track acceptance record;
+ Guidelines for operation and
maintenance.
- Certificate of conformity issued
by the designated organization as prescribed.
7.2.2. Regarding periodic
inspection:
- The previous profile, inspection
record and inspection result report;
- Documents on the use, operation
and maintenance of the equipment; inspection record (if any).
7.2.3. Regarding unscheduled
inspection:
- In case of renovation or repair:
documents on renovation or repair and commissioning record;
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- The inspection record issued by
competent authority (if any).
The document inspection result is
satisfactory if the regulations in 7.2 of this document are satisfied and the
equipment's technical documents specified in QCVN 07:2012/BLDTBXH are complied
with. If the result is unsatisfactory, the user shall take remedial actions.
7.3. Prepare suitable and adequate
equipment for inspection.
7.4. Develop measures for ensuring
safety and reach an agreement with the user before inspection. Provide adequate
personal protective equipment to ensure safety during the inspection.
8. INSPECTION PROCESS
An inspection shall be carried out
in the following order:
8.1. External inspection:
8.1.1. Check the installation
location, electrical system, instruction manual, protective fences, ground,
distance and safety measures, notable obstacles during inspection; conformity
of parts and specifications of the equipment with those specified in the
profile/documents.
8.1.2. Check all mechanisms or
parts of the chain block individually, pay particular attention to the
condition of the following parts:
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- Hooks and parts of the hook
assembly (Appendices 13A, 13B and 13C of TCVN 4244: 2005);
- Load chain, pull chain and rope
fixing parts (meeting the manufacturer's requirements or referring to the
Appendix 7 of TCVN 4244: 2005);
- Pulleys, shafts and parts used to
fix the shaft sleeves (Appendices 19A, 20A and 20B of TCVN 4244: 2005);
- Brakes and parking pawls:
inspected according to 1.5.3.3 of TCVN 4244:2005.
The equipment passes the test if it
is installed according to the technical documents, no damage or defect is found
and the requirements in section 8.1 are met.
8.2. Technical inspection - No-load
test:
- Conduct no-load tests of
structures and equipment, including all structures, safety devices, parking
pawls and other equipment;
- Conduct the abovementioned tests
at least 03 (three) times.
The equipment passes the test if
its mechanisms and safety devices operate according to their specifications and
design.
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For the chain block fixed on
load-bearing structures (such as crane girders, fixed suspension girders, etc.)
the load test is the same as that of normal lifting equipment. To be specific:
8.3.1. Static test
Test load: at 125% of Q(tk) or 125%
of Q(sd), where:
- Q(tk) is the design load;
- Q(sd): the load is required by
the user (it must not be greater than the design load) and depends on the
actual quality of the equipment;
The equipment passes the test if
the load remains constant while it is being held for 10 (ten) minutes and after
the load is lowered, the structures and parts of equipment have no crack,
deformation or other damage (according to 4.3.2 of TCVN 4244-2005).
8.3.2. Dynamic test:
- Conduct a dynamic test according
to 4.3.2 of TCVN 4244: 2005 at 110% of Q(tk) or 110% of Q(Sd), where:
+ Q(tk) is the design load;
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- Hoist and lower the load three
times and check operation of other structures bearing such load.
The equipment passes the test if
its structure and parts operate according to the design, the requirements
specified by the applicable technical regulations are met and no crack,
deformation or other damage is found.
If the chain block is dedicated to
serving initial assembly and repair work (permanently installed in an
irrigation pumping station, power plant’s machine room, special machine
assembly, etc.) and due to the ground, the load cannot be introduced for test
or the chain block is mobile (removed from the load-bearing structure and
transported elsewhere for use), specialized testing equipment may be used.
9. INSPECTION RESULT PROCESSING
9.1. Prepare an inspection record
which contains sufficient information according to the form in the Appendix 02
enclosed herewith.
9.2. Approve the inspection record
Mandatory participants in the
process of approving the inspection record:
- The representative of the user or
a person authorized by the user;
- A witness;
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When the record is approved, the
inspector, the witness, and the representative of the user or a person
authorized by the user shall append their signatures and seals (if any) on the
record. The record shall be made into two (02) copies, each party shall keep
01.
9.3. Write the brief inspection
result to the profile of the chain block (including full names of the
inspectors and the date of inspection).
9.4. Put on the inspection stamp:
if the equipment passes the test, the inspector shall put an inspection stamp
on it at a noticeable position.
9.5. Issuance of certificate of
inspection results:
9.5.1. If the equipment passes the
test, the inspecting organization shall issue the certificate of inspection
result to the equipment within 05 working days from the date on which the
inspection record is approved.
9.5.2. If the equipment fails the
test, only the steps in 9.1 and 9.2 shall be taken and the inspection record
must specify the explanation for failed result, necessary remedial actions and
a deadline for taking such actions. The inspection record shall be sent to the
employment authority of the area where the equipment is installed and located.
10. INSPECTION INTERVAL
10.1. For a stationary chain block
installed in a sheltered place, it has to be inspected every 3 years.
For a chain block that is
permanently installed outdoor, is mobile or has been used for more than 12
years, it has to be inspected every year.
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10.3. If the inspection interval is
shortened, the inspector shall specify explanation in the inspection record.
10.4. If the inspection interval is
specified in national technical regulations, such regulations shall apply.
Appendix
01
SPECIMEN
OF ON-SITE RECORD
(INSPECTION OF TECHNICAL SAFETY OF CHAIN BLOCK WITH LOAD CAPACITY OF 1,000 KG
OR MORE)
(Name
of inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
…………..
[place], ………[date]
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ON-SITE
RECORD
No.
...................
(written
by the inspector)
1- General information
Name of the equipment:
.…………….……………………….…………….……………………………………….
Name of the user:
.…………….……………………….…………….………………….
Address (head office of the user):
.…………….……………………….…………….………………
Address (location) of the
equipment: .…………….……………………….…………….…………………………….
Content of the meeting with the
user:
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- Witness:
2- Basic specifications:
- Type, Code:..........
- Design
load:.....................
tonnes
- Production number:
...................................
- Load used: ……….. tonnes
- Production year:
..............................
- Lifting speed: ..hand
pulling....
- Manufacturer:
...................................
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- Uses:
..............................................
3- Document inspection:
- Chain block profile:
- Technical documents:
4- Code of measuring and testing
equipment:
5- Inspection process:
a. External inspection:
+ Metal structure:
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+ Travel mechanism (if any): ……
+ Chain and chain fixation:…
+ Brakes, parking pawls....
+ Safety devices (if any):
b. Technical inspection:
- 125% load test: (10-minute hold)
+ Brakes, parking pawls: …
+ Metal structure:….
- 110% dynamic test:
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+ Mechanisms and parts:
+ Metal structure:
6- Processing and evaluation of
inspection results.
7- Recommendations: (if any).
WITNESS
(Signature and full name)
INSPECTOR
(Signature and full name)
Appendix
02
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(Name
of inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
…………..
[place], ………[date]
SPECIMEN
OF RECORD ON INSPECTION OF TECHNICAL SAFETY OF CHAIN BLOCK WITH LOAD CAPACITY
OF 1,000 KG OR MORE
No.
…………….
(According to the on-site record No. ………………..)
We are:
1. .…………….……………………… Inspector
number: .…………….………………………
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Inspecting organization:
.…………….…………………….…………….…………………………….
Registration certificate No.
……………………………………….……………
Name of the inspected
equipment:……………………………. …………………………………
Name of the user:
.…………….……………………….…………….………………….
Address (head office of the user):
.…………….……………………….…………….………………
Address (location) of the
equipment: .…………….……………………….…………….…………………………….
Inspection procedure and standards
applied: ………………………………………………………………
Individuals
witnessing and approving the record:………………….………………… …………………..
1………………………………………
Position:………….…………………
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I-
BASIC SPECIFICATIONS
- Type and Code:
.......................................
- Design
load:.....................
tonnes
- Production number:
...................................
- Load used: ……….. tonnes
- Production year:
..............................
- Lifting
speed:...................hand pulling...
- Manufacturer:
...................................
- Lifting height:............. m
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II-
FORMS OF INSPECTION
First
time □
Periodic
□
Unscheduled □
Reason for unscheduled inspection:
.…………….………………………………………
III-
INSPECTION CONTENT:
A-Technical document inspection:
No.
Item
Passed
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Note
1
Equipment profile
A. EXTERNAL INSPECTION, NO-LOAD
TEST:
No.
Mechanism;
part
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Failed
Note
No.
Mechanism;
part
Passed
Failed
Note
1
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7
Frame
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Hook latch
8
Brake
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3
Chain wheel
9
Metal structure of girder
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4
Hoisting chain
10
Load hoisting mechanism
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5
Chain end fixture
11
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6
Slipping clutch
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Travelling limiter
B. LOAD TEST:
No.
Load
holding position and test result
Passed
Failed
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Static
test load
(tonnes)
Dynamic
test load
(tonnes)
1.
In the middle of span
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At the end of the
cantilever
3.
Stability
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No.
Result
evaluation
Passed
Failed
Note
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Hanging and hoisting hook
2.
Metal structure
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Load hoisting mechanism
4.
Hoisting chain
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Load hoist brake
6.
Parking pawl
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1. Result: Passed
□ Failed □
Maximum load: ........... tonnes.
2. Inspection stamp No. ……………… At:
…………………………….…………
3. Recommendations:
.…………….………………………
Deadline for implementation of
recommendations: …………………..........
V -
INSPECTION INTERVAL
Date of next inspection:
Reasons for shortened interval (if
any):
The record is approved on:
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The record is made into of
……copies, each party holds…. copies./.
EQUIPMENT
USER
(Full name and signature)
(Undertaking to fulfill recommendations in sufficient and timely manner)
WITNESS
(Signature and full name)
INSPECTOR
(Signature and full name)
PROCEDURES FOR TECHNICAL INSPECTION OF SAFETY OF
ELECTRIC HOISTS
QTKD: 14- 2016/BLDTBXH
Foreword
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PROCEDURES FOR TECHNICAL INSPECTION OF SAFETY OF
ELECTRIC HOISTS
1. SCOPE AND REGULATED ENTITIES
1.1. Scope
Such procedures shall be used for
first, periodic and unscheduled inspection of electric hoists (hereinafter
referred to as “equipment) under state management of the Ministry of Labour,
Invalids and Social Affairs.
Such procedures do not apply to:
- Manual hoists, inclined and
vertical shafts.
- Hoists with a load capacity of
10,000 N or more used in underground mining operations.
1.2. Regulated entities
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- Occupational safety inspectors.
2. NORMATIVE REFERENCES
- QCVN 7: 2012/BLDTBXH, National
technical regulation on safe work of lift appliances.
- QCVN 01: 2011/BCT, National
technical regulation on safety in underground coal mining;
- TCVN 4244:2005, Lifting
appliances - Design construction and survey.
- TCVN 5206:1990, Loading crane
- Safety requirements for counter - weight and ballast.
- TCVN 5207:1990, Loading crane -
Safety requirements.
- TCVN 5209:1990, Loading crane -
Safety requirements for electrical equipment.
- TCVN 5179:90, Hoisting cranes -
Test requirements of hydraulic equipment for safety.
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- TCVN 9385:2012, Protection of
structures against lightning - Guide for design, inspection and maintenance.
- TCVN 6780-2:2009, Safety
requirements on underground mine of ore and non-ore exploitation - Part 2:
Transport of mine.
- TCVN 6997: 2002, Mine hoist -
Correction and verification.
In the cases where the
abovementioned normative references are amended or replaced, regulations of the
latest references shall apply.
Other standards may be applied to
electric hoists at the request of their user or manufacturer if such standards
contain the same or higher safety criteria than those in the national standards
referred to in this document.
3. TERMS AND DEFINITIONS
For the purposes of this document,
the terms and definitions given in the abovementioned normative references and
the following shall apply:
3.1. “electric hoist” means a piece
of electrically driven lifting equipment which is permanently installed and
used to hoist loads, consisting of a mechanical transmission driven by a drum
or a chain wheel.
3.2. “first safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after its installation and
before its first use.
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3.4. “unscheduled safety
inspection” means the inspection of technical safety of equipment according to
national technical standards and technical safety standards and will be carried
out:
- after a repair, upgrade or
renovation that affects the safety of equipment;
- after change of the location of
installation;
- at the request of the user or a
competent authority.
4. INSPECTION STEPS
Safety inspection shall be carried
out in the following order:
- Inspection of the equipment
profile/documents;
- External inspection;
- Technical inspection - No-load
test;
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- Inspection result processing.
Note: Only take the next step if
the equipment passes the test in the previous step. The result of each step
shall be documented according to the form in the Appendix 01 and retained by
the inspecting organization.
5. INSPECTION EQUIPMENT
Inspection equipment shall be
inspected and calibrated in accordance with regulations. Inspection equipment
includes:
- Altimeter (speedometer);
- Distance measuring equipment;
- Geometric inspection equipment;
- Dynamometer or hanging scale;
- Insulation resistance meter;
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- Multimeter;
- Clamp meter.
6. CONDITIONS FOR INSPECTION
The inspection must not be carried
out unless the following conditions are met:
6.1. The equipment is at the ready
for inspection.
6.2. Documents about the equipment
are adequate.
6.3. The inspection is not affected
by environment or weather.
6.4. Requirements concerning
occupational safety and health are met.
7. PREPARATION FOR INSPECTION
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7.2. Inspect the equipment profile
and documents. The following documents shall be inspected according to
inspection regulations:
7.2.1. Regarding first inspection:
- Equipment profile/documents,
especially the following documents (under QCVN 7:2012/BLDTBXH):
+ Calculation of strength of
load-bearing parts (if any);
+ Structural drawings which specify
all main dimensions;
+ Guidelines for operation and
maintenance.
- Equipment release documents:
+ Certificates of fabricated metal
and weld metal (under 3.1.2 of TCVN 4244 : 2005);
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+ Factory acceptance record.
- Reports on results of and records
on inspection of insulation grounding, lightning protection and resistance of
the motor, protection devices (if any);
- Installation documents;
- Certificate of conformity issued
by the designated organization as prescribed.
7.2.2. Regarding periodic
inspection:
- The previous profile, inspection
record and inspection result report;
- Documents on the use, operation
and maintenance of the equipment; inspection record (if any).
7.2.3. Regarding unscheduled inspection:
- In case of renovation or repair:
documents on renovation or repair and commissioning record;
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- The inspection record issued by
competent authority (if any).
The document inspection result is
satisfactory if the documents are adequate and the regulations of QCVN
7:2012/BLDTBXH are observed. If the result is unsatisfactory, the user shall
take remedial actions.
7.3. Prepare suitable and adequate
equipment for inspection.
7.4. Develop measures for ensuring
safety and reach an agreement with the user before inspection. Provide adequate
personal protective equipment to ensure safety during the inspection.
8. INSPECTION PROCESS
An inspection shall be carried out
in the following order:
8.1. External inspection:
8.1.1. Check the installation
location, electrical system, instruction manual, protective fences, ground,
distance and safety measures, notable obstacles during inspection; conformity
of parts and specifications of the equipment with those specified in the
profile/documents.
8.1.2. Check all mechanisms or
parts of the lifting equipment individually, pay particular attention to the
condition of the following parts:
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8.1.2.1. Load wire rope/chain:
8.1.2.1.1. Load wire rope:
- Type and diameter of the wire
rope installed according to the equipment document;
- Wear and reduction in the cross
section of the steel wire rope according to Articles 90-6a, b of QCVN 01:
2011/BCT and 6.3 of TCVN 6780-2: 2009;
- Number of broken wires per braid
according to Article 90 6.b QCVN 01: 2011/BCT and 6.2.3 of TCVN 6780-2: 2009;
- Rust or other damage to wire rope
according to Article 6.3.1 of TCVN 6780-2: 2009;
- Wire rope clamps. (meeting the
manufacturer's requirements or referring to Appendices 18C and 21 of TCVN 4244:
2005 and Article 7.6 of TCVN 6780-2: 2009;
- Condition of wire rope on drum;
- Rope fixing parts (meeting the
manufacturer's requirements or refer to Appendices 18C and 21 of TCVN 4244:
2005).
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8.1.2.2. Hook connection
mechanisms: according to Clause 1 Article 92 of QCVN 01:2011/BCT. Hooks and
parts of hook assembly (Appendices 13A, 13B and 13C of TCVN 4244: 2005);
8.1.2.3. Pulleys supporting and
redirecting wire rope, parts used to fixed the pulley shaft: inspected and
assessed according to Article 82-12 of QCVN 01:2011/BCT; Appendices 19A, 20A
and 20B of TCVN 4244: 2005.
8.1.2.4. Gearbox:
- Abnormal noise (according to
Article 4.3.6 of TCVN 6997 - 2002);
- Surface temperature of the gearbox
(according to Article 4.3.6 of TCVN 6997 - 2002), meeting the equipment
manufacturer's criteria.
8.1.2.2. Electric motor, according
to Article 99 of QCVN 01:2011/BCT.
8.1.2.6. Wire rope reels and
attached equipment, according Articles 68 and 84 of QCVN 01: 2011/BCT; Clause 6
Article 7 of TCVN 6780-2: 2009.
8.1.2.7. Protective earthing and
lightning protection system:
- Grounding resistance not
exceeding exceed 4.0Ω, the electric motor’s insulation resistance not exceeding
0.5 MΩ (test voltage 500V);
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- Result of measurement of the lightning
protection system according to TCXDVN 9385:2012.
8.1.2.8. Coupling between the motor
and the gearbox, between the gear box and the wire rope reel.
8.1.2.9. Working brakes:
- Installation and specifications;
- Thickness of the working brake
pads;
- Clearance of the working brake
pads according to Clause 3.1 Article 4 of TCVN 6997 - 2002;
- Brakes to be inspected according
to 1.5.3.3 of TCVN 4244:2005.
The equipment passes the test if it
is installed according to the technical documents, no damage or defect is found
and the requirements in section 8.1 are met.
8.2. Technical inspection - No-load
test:
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- Conduct the abovementioned tests
at least 03 (three) times.
The equipment passes the test if
its mechanisms and safety devices operate according to their specifications and
design.
8.3. Load test - Test methods:
8.3.1. Static test:
- Conduct a static test at 125%
(4.3.2 of TCVN 4244 : 2005) of the design load or the load required by the user
(the load required by the user must be less than the design load) and depending
on the actual quality of the equipment;
- Conduct the static test according
to 4.3.2 of TCVN 4244: 2005.
The equipment passes the test if
the load remains constant while it is being held for 10 (ten) minutes and after
the load is lowered, the structures and parts of equipment have no crack, deformation
or other damage (according to 4.3.2 of TCVN 4244-2005).
8.3.2. Dynamic test:
- Conduct a static test at 110% of
the design load or the load required by the user (according to 4.3.2 of TCVN
4244: 2005), hoist and lower the load three times and inspect operation of
other structures bearing such load;
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The equipment passes the test if
its structure and parts operate according to the design, the requirements
specified by the applicable technical regulations are met and no crack,
deformation or other damage is found.
The equipment passes the test if
its structure and parts operate according to the design, the requirements
specified by the applicable technical regulations on safety are met and no
crack, residual strain or other damage is found.
9. INSPECTION RESULT PROCESSING
9.1. Prepare an inspection record
which contains sufficient information according to the form in the Appendix 02
enclosed herewith.
9.2. Approve the inspection record:
Mandatory participants in the
process of approving the inspection record:
- The representative of the user or
a person authorized by the user;
- A witness;
- The inspectors.
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9.3. Write the brief inspection
result to the profile of the equipment (including full names of the inspectors
and the date of inspection).
9.4. Put on the inspection stamp:
if the equipment passes the test, the inspector shall put an inspection stamp
on it at a noticeable position.
9.5. Issuance of certificate of
inspection results:
9.5.1. If the equipment passes the
test, the inspecting organization shall issue the certificate of inspection
result to the equipment within 05 working days from the date on which the
inspection record is approved.
9.5.2. If the equipment fails the
test, only the steps in 9.1 and 9.2 shall be taken and the inspection record
must specify the explanation for failed result, necessary remedial actions and
a deadline for taking such actions. The inspection record shall be sent to the
employment authority of the area where the equipment is installed and located.
10. INSPECTION INTERVAL
10.1. An electric hoist has to be
inspected every 02 years. For the electric hoist that has been used for more
than 12 years, it has to be inspected every year.
10.2. In the case where a shorter
interval is demanded by the manufacturer or user, such interval shall apply.
10.3. If the inspection interval is
shortened, the inspector shall specify explanation in the inspection record.
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Appendix
01
SPECIMEN
OF ON-SITE RECORD
(INSPECTION OF TECHNICAL SAFETY OF ELECTRIC HOISTS)
(Name
of inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
…………..
[place], ………[date]
ON-SITE
RECORD
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(written
by the inspector)
1- General information
Name of the equipment:
.…………….……………………….…………….……………………………………….
Name of the user:
.…………….……………………….…………….………………….
Address (head office of the user):
.…………….……………………….…………….………………
Address (location) of the
equipment: .…………….……………………….…………….…………………………….
Content of the meeting with the
user:
- Representative: (information)
- Witness:
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- Code:
.......................................
- Design
load:..................... tonnes
- Production number:
...................................
- Lifting speed: …………….……..
m/min
- Production year:
..............................
- Lifting height of (main and
auxiliary) hooks:............. m
- Manufacturer:
...................................
- Uses:
..............................................
3- Document inspection:
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- Technical documents:
4- Code of measuring and testing
equipment:
5- Equipment inspection:
a. External inspection:
+ Metal structure
+ Hook and pulley assembly:…
+ Wire ropes and wire rope
fixation:…
+ Protective grounding:…
+ Rail and rail fixation:
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+ Safety devices:
b. Technical inspection:
- 125% load test: (10-minute hold)
+ Brakes: ……
+ Metal structure:….
- Dynamic load test at 110%:
+ Brakes (load holding)
+ Mechanisms and parts:
+ Metal structure:
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7. Processing and evaluation of
inspection results.
8- Recommendations: (if any).
WITNESS
(Signature and full name)
INSPECTOR
(Signature and full name)
Appendix
02
SPECIMEN
OF RECORD ON INSPECTION OF TECHNICAL SAFETY OF ELECTRIC HOIST
(Name
of inspecting organization)
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…………..
[place], ………[date]
RECORD
ON INSPECTION OF TECHNICAL SAFETY OF ELECTRIC HOIST
No.
…………….
(According
to the on-site record No. ………………..)
We are:
1. .…………….……………………… Inspector
number: .…………….………………………
2. .…………….……………………… Inspector
number: .…………….………………………
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Registration certificate No.
……………………………………….……………
Name of the inspected
equipment:……………………………. ………………………………
Name of the user:
.…………….……………………….…………….………………….
Address (head office of the user):
.…………….……………………….…………….…………
Address (location) of the
equipment: .…………….……………………….…………….…………………………….
Inspection procedure and standards
applied: …………………………………………………
Individuals
witnessing and approving the record:………………….………………… ………
1………………………………………
Position:………….…………………
2………………………………………
Position:………….…………………
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- Code: .......................................
- Design
load:.....................
tonnes
- Production number:
...................................
- Lifting speed: …………….……..
m/minute
- Production year:
..............................
- Lifting height of (main and
auxiliary) hooks:............. m
- Manufacturer:
...................................
- Uses:
..............................................
II-
FORMS OF INSPECTION
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Reason for unscheduled inspection:
.…………….………………………………………
III-
INSPECTION CONTENT:
A- Technical document
inspection:
- Comments:
…………………………………………………………………………...
- Result evaluation:
No.
Item
Passed
Failed
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1
Profile
B- External inspection; no-load
test:
- Comments:
…………………………………………………………………………...
- Result evaluation:
No.
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Passed
Failed
Note
No.
Mechanism;
part
Passed
Failed
Note
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Main hook/auxiliary hook
7
Main hoist mechanism
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2
Pulley assembly
8
Whistle (bell)
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3
Main hoist rope
9
Height limiter
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4
Main hoist brake
10
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5
Metal structure of main girder;
connection with the building
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Control system
6
Crane frame
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C-Load test:
- Comments:
…………………………………………………………………………...
- Result evaluation:
No.
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Passed
Failed
Corresponding
load
(tonnes)
Static
test load
(tonnes)
Dynamic
test load
(tonnes)
1
Load test
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2
Stability
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No.
Result
evaluation
Passed
Failed
Note
No.
Result
evaluation
Passed
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Note
1
Metal structure
4
Load hoist rope
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2
Control system
5
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3
Overload limiter
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IV
- CONCLUSIONS AND RECOMMENDATIONS
1. Result: Passed
□ Failed □
Maximum load: ........... tonnes.
2. Inspection stamp No. ……………… At:
…………………………….…………
3. Recommendations:
.…………….………………………
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V-
INSPECTION INTERVAL
Date of next inspection:
Reasons for shortened interval (if
any):
The record is approved on:
At:.…………….……………………….…………….……
The record is made into of ....
copies, each party holds.... copies./.
EQUIPMENT
USER
(Full name and signature)
(Undertaking to fulfill recommendations in sufficient and timely manner)
WITNESS
(Signature and full name)
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PROCEDURES FOR INSPECTION OF TECHNICAL SAFETY OF
ELECTRIC WINCHES FOR PULLING LOADS ON INCLINED PLANES
QTKD: 15- 2016/BLDTBXH
Foreword
Procedures for inspection of
technical safety of electric winches for pulling loads on inclined planes are
drafted by the Department of Work Safety and promulgated together with the
Circular No. 54/2016/TT-BLDTBXH dated December 28, 2016 of the Ministry of
Labour, Invalids and Social Affairs.
PROCEDURES FOR INSPECTION OF TECHNICAL SAFETY OF
ELECTRIC WINCHES FOR PULLING LOADS ON INCLINED PLANES
1. SCOPE AND REGULATED ENTITIES
1.1. Scope
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Such procedures do not apply to inclined
shafts used in underground mining operations.
1.2. Regulated entities
- Organizations carrying out
occupational safety inspection;
- Occupational safety inspectors.
2. NORMATIVE REFERENCES
- TCVN 4244:2005, Lifting
appliances - Design construction and survey.
- TCVN 5206:1990, Loading crane
- Safety requirements for counter - weight and ballast.
- TCVN 6780-2:2009, Safety
requirements on underground mine of ore and non-ore exploitation;
- TCVN 5207:1990, Loading crane -
Safety requirements.
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- TCVN 5179:90, Hoisting cranes -
Test requirements of hydraulic equipment for safety.
- TCVN 9358: 2012, Installation of
equipment earthing system for industrial projects - General requirements.
- TCVN 9385:2012, Protection of
structures against lightning - Guide for design, inspection and maintenance.
- QCVN 7: 2012/BLDTBXH, National
technical regulation on safe work of lift appliances;
- QCVN 01: 2011/BCT, National
technical regulation on safety in underground coal mining.
In the cases where the
abovementioned normative references are amended or replaced, regulations of the
latest references shall apply.
Other standards may be applied to
the equipment at the request of its user or manufacturer if such standards
contain the same or higher safety criteria than those in the national standards
referred to in this document.
3. TERMS AND DEFINITIONS
For the purposes of this document,
the terms and definitions given in the abovementioned normative references and
the following shall apply:
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3.2. “first safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after its installation and
before its first use.
3.3. “periodic safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after expiration of the last
safety inspection result.
3.4. “unscheduled safety
inspection” means the inspection of technical safety of equipment according to
national technical standards and technical safety standards and will be carried
out:
- after a repair, upgrade or
renovation that affects the safety of equipment;
- after change of the location of
installation;
- at the request of the user or a
competent authority.
4. INSPECTION STEPS
Safety inspection shall be carried
out in the following order:
- Inspection of the equipment
profile/documents;
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- Technical inspection - No-load
test;
- Load test - Test methods;
- Inspection result processing.
Note: Only take the next step if
the equipment passes the test in the previous step. The result of each step
shall be documented according to the form in the Appendix 01 and retained by
the inspecting organization.
5. INSPECTION EQUIPMENT
Inspection equipment shall be
inspected and calibrated in accordance with regulations. Inspection equipment
includes:
- Theodolite;
- Altimeter (speedometer);
- Distance measuring equipment;
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- Dynamometer or hanging scale;
- Insulation resistance meter;
- Ground resistance meter;
- Multimeter;
- Clamp meter
6. CONDITIONS FOR INSPECTION
The inspection must not be carried
out unless the following conditions are met:
6.1. The equipment is at the ready
for inspection.
6.2. Documents about the equipment
are adequate.
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6.4. Requirements concerning
occupational safety and health are met.
7. PREPARATION FOR INSPECTION
7.1. Before carrying out the
inspection, the inspecting organization and the user shall reach an agreement
on an inspection plan and prepare for the inspection and assign staff to
participate in and witness the inspection.
7.2. Inspection of the profile of
the equipment. Inspect the equipment profile and documents. The following
documents shall be inspected according to inspection regulations:
7.2.1. Regarding first inspection:
- Equipment profile/documents,
especially the following documents (under QCVN 07:2012/BLDTBXH):
+ Calculation of strength of
load-bearing parts (if any);
+ Drawing which specify all main
dimensions;
+ Guidelines for operation and
maintenance.
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+ Certificates of fabricated metal
and weld metal (under 3.1.2 of TCVN 4244 : 2005);
+ Results of inspection of quality
of weld joints (under 3.3.4 of TCVN 4244: 2005);
+ Factory acceptance record.
- Reports on results of and records
on inspection of insulation grounding, lightning protection and resistance of
the motor, protection devices (if any);
- Document on design and as-built
document on the foundation or anchoring parts (according to the manufacturer's
document or approved design).
- Installation documents;
- Certificate of conformity issued
by the designated organization as prescribed.
7.2.2. Regarding periodic
inspection:
- The previous profile, inspection
record and inspection result report;
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7.2.3. Regarding unscheduled
inspection:
- In case of renovation or repair:
documents on renovation or repair and commissioning record;
- In case of relocation: installation
documents;
- The inspection record issued by
competent authority (if any).
The document inspection result is
satisfactory if the documents are adequate and the regulations of QCVN
07:2012/BLDTBXH are observed. If the result is unsatisfactory, the user shall
take remedial actions.
7.3. Prepare suitable and adequate
equipment for inspection.
7.4. Develop measures for ensuring
safety and reach an agreement with the user before inspection. Provide adequate
personal protective equipment to ensure safety during the inspection.
8. INSPECTION PROCESS
An inspection shall be carried out
in the following order:
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8.1.1. Check the installation
location, electrical system, instruction manual, protective fences, ground,
distance and safety measures, notable obstacles during inspection; conformity
of parts and specifications of the equipment with those specified in the
profile/documents.
8.1.2. Check all mechanisms or
parts of the lifting equipment individually, pay particular attention to the
condition of the following parts:
- Metal structure of the equipment,
welds, riveted joints (if any), bolted joints of the metal structure, control
room, ladder, platform and covers;
8.1.2.1. Load wire rope inspection:
- Type and diameter of the wire
rope installed according to the equipment document;
- Wear and reduction in in the
cross section of the steel wire rope according to 6.3 of TCVN 6780-2: 2009;
- Rust or other damage to wire rope
according to Article 6.3.1 of TCVN 6780-2: 2009;
- Wire rope clamps and condition of
wire rope on drum: meeting the manufacturer’s requirements or according to the
Appendices 18C and 21 of TCVN 4244 : 2005, for the equipment used in
underground mining, complying with Article 7.6 of TCVN 6780-2: 2009;
- Hooks and parts of hook assembly
(Appendices 13A, 13B and 13C of TCVN 4244: 2005);
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8.1.2.4. Gearbox: inspected and
assessed according to 4.3.6 TCVN 6997: 2002.
8.1.2.5. Wire rope reel inspected
according to 1.5.3.1.1 TCVN 4244: 2005;
8.1.2.6. Protective earthing and
lightning protection system:
- Grounding resistance not
exceeding exceed 4.0Ω, insulation resistance not exceeding 0.5 MΩ (test voltage
500V);
- Result of measurement of the
lightning protection system according to TCXDVN 9385:2012.
8.1.2.7. Coupling between the motor
and the gearbox, between the gear box and the wire rope reel.
8.1.2.8. Rail (if any) (Appendix 5
of TCVN 4244: 2005). Safety devices (height limiter, etc.);
8.1.2.9. Brakes: inspected and
assessed according to 1.5.3.3 of TCVN 4244: 2005.
8.1.2.10. Safety brake (if any):
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The equipment passes the test if it
is installed according to the technical documents, no damage or defect is found
and the requirements in section 8.1 are met.
8.2. Technical inspection - No-load
test:
- Conduct no-load test of
structures and equipment, including all structures, electrical equipment,
safety devices, brakes, parking pawls, control equipment, lighting equipment,
signals.
- Conduct the abovementioned tests
at least 03 (three) times.
The equipment passes the test if
its mechanisms and safety devices operate according to their specifications and
design.
8.3. Load test - Test methods:
8.3.1. Static test:
- Test load: 125% of SWL (the safe
working load must not be greater than the design load)
- The test load is pulled to the
position with the greatest slope and held for 10 (ten) minutes.
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8.3.2. Dynamic test:
- Conduct a dynamic test at 110% of
SWL.
- Hoist and lower the load three
times and check operation of other structures bearing such load;
The equipment passes the test if
its structure and parts operate according to the design, the requirements
specified by the applicable technical regulations are met and no crack,
deformation or other damage is found.
8.3.3. Safety brake test (if any):
- Conduct a test load of safety
brake at 110% of SWL.
- Run the winch at rated speed,
apply the safety brake while the winch is operating.
The equipment passes the test if
its structure and parts operate according to the design, the requirements
specified by the applicable technical regulations are met and no crack,
deformation or other damage is found.
9. INSPECTION RESULT PROCESSING
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9.2. Approve the inspection record:
Mandatory participants in the
process of approving the inspection record:
- The representative of the user or
a person authorized by the user;
- A witness;
- The inspectors.
When the record is approved, the
inspector, the witness, and the representative of the user or a person
authorized by the user shall append their signatures and seals (if any) on the
record. The record shall be made into two (02) copies, each party shall keep
01.
9.3. Write the brief inspection
result to the profile of the equipment (including full names of the inspectors
and the date of inspection).
9.4. Put on the inspection stamp:
if the equipment passes the test, the inspector shall put an inspection stamp
on it at a noticeable position.
9.5. Issuance of certificate of
inspection results:
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9.5.2. If the equipment fails the
test, only the steps in 9.1 and 9.2 shall be taken and the inspection record
must specify the explanation for failed result, necessary remedial actions and
a deadline for taking such actions. The inspection record shall be sent to the
employment authority of the area where the equipment is installed and located.
10. INSPECTION INTERVAL
10.1. The equipment has to be
inspected every 02 years. For the equipment that has been used for more than 12
years, it has to be inspected every year.
10.2. In the case where a shorter
interval is demanded by the manufacturer or user, such interval shall apply.
10.3. If the inspection interval is
shortened, the inspector shall specify explanation in the inspection record.
10.4. If the inspection interval is
specified in national technical regulations, such regulations shall apply.
Appendix
01
SPECIMEN
OF ON-SITE RECORD
(INSPECTION OF TECHNICAL SAFETY OF ELECTRIC WINCH FOR PULLING LOAD ON INCLINED
PLANE)
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THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
…………..
[place], ………[date]
ON-SITE
RECORD
No.
...................
(written
by the inspector)
1- General information
Name of the equipment:
.…………….……………………….…………….……………………………………….
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Address (head office of the user):
.…………….……………………….…………….………………
Address (location) of the
equipment: .…………….……………………….…………….…………………………….
Content of the meeting with the
user:
- Representative: (information)
- Witness:
2- Basic specifications:
- Code:
.......................................
- Lifting speed: …………….……..
m/min
- Production number:
...................................
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- Production year:
..............................
- Design
load:..................... tonnes
- Manufacturer:
...................................
- Uses:
..............................................
3- Document inspection:
- Machine profile:
- Technical documents:
4- Code of measuring and testing
equipment:
5- Equipment inspection:
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+ Metal structure:
+ Hook and pulley assembly:…
+ Wire ropes and wire rope
fixation:…
+ Protective grounding:
+ Rail and rail fixation:
+ Brakes:…
+ Safety devices:
+ Electrical system:
b. Technical inspection:
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+ Brakes: ……
+ Metal structure:….
- 110% dynamic test:
+ Brakes (load holding)
+ Mechanisms and parts:
+ Metal structure:
6- Inspection of limiters, load
indicator, overload indicator.
7. Processing and evaluation of
inspection results.
8- Recommendations: (if any).
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WITNESS
(Signature and full name)
INSPECTOR
(Signature and full name)
Appendix
02
SPECIMEN
OF RECORD ON INSPECTION OF TECHNICAL SAFETY OF ELECTRIC WINCH FOR PULLING LOAD
ON INCLINED PLANE
(Name
of inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
…………..
[place], ………[date]
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RECORD
ON INSPECTION OF TECHNICAL SAFETY
(ELECTRIC WINCH FOR PULLING LOAD ON INCLINED PLANE)
No.
…………….
(According to the on-site record No. ………………..)
We are:
1. .…………….……………………… Inspector
number: .…………….………………………
2. .…………….……………………… Inspector
number: .…………….………………………
Inspecting organization: .…………….…………………….…………….…………………………….
Registration certificate No.
……………………………………….……………
Name of the inspected
equipment:……………………………. ………………………………
Name of the user:
….………………………………………………..………..…………
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Address (location) of the
equipment: ……………………………………………………………………….…………
Inspection procedure and standards
applied: …………………………………………………
Individuals
witnessing and approving the record:………………….………………… ………
1………………………………………
Position:………….…………………
2………………………………………
Position:………….…………………
I- BASIC SPECIFICATIONS
- Code:
............................................
- Design
load:.....................
tonnes
- Production number:
...................................
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- Production year:
...................................
- Pull speed:
............................... m
- Manufacturer:
...................................
- Greatest slope:
.................. degree
- Uses:
..............................................
II- FORMS OF INSPECTION
First
time □
Periodic □
Unscheduled □
Reason for unscheduled
inspection: .…………….………………………………………
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A-Technical document inspection:
- Comments:
…………………………………………………………………………...
- Result evaluation:
No.
Item
Passed
Failed
Note
1
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B- External inspection; no-load
test:
- Comments:
.…………….……………………….…………….…………………………………
- Result evaluation:
No.
Mechanism;
part
Passed
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Note
No.
Mechanism;
part
Passed
Failed
Note
1
Pull hook
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10
Load hoisting mechanism
2
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11
Load pulling brake
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Pulling wire rope
12
Whistle/bell
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4
Guide pulley
13
Grounding, lightning protection
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5
Balancing pulley
14
Protective fence
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6
Base
15
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7
Control system
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Guide pulley hanging mechanism
8
Pull limiter
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17
Guide pulley fixing mechanism
9
Safety brake
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C-Load test:
- Comments:
.…………….……………………….…………….……………………………………..
- Result evaluation:
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Load
pulling position and test result
Passed
Failed
Corresponding
pulling load
(tonnes)
Static
test load
(tonnes)
Dynamic
test load
(tonnes)
1
Carrying hook/equipment
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2
Stability
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No.
Result
evaluation
Passed
Failed
Note
No.
Result
evaluation
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Failed
Note
1
Base
6
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2
Anchor winch
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Control system
3
Load pulling brake
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8
Guide pulley hanging and fixing
mechanism
4
Load hoisting mechanism
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9
Pull limiter
5
Safety brake
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IV - CONCLUSIONS AND
RECOMMENDATIONS
1. Result: Passed
□ Failed □
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2. Inspection stamp No. ……………… At:
…………………………….…………
3. Recommendations:
.…………….………………………
Deadline for implementation of
recommendations: …………………..........
V-
INSPECTION INTERVAL
Date of next inspection:
Reasons for shortened interval (if
any):
The record is approved on:
At: .…………….………………………
The record is made into of ....
copies, each party holds.... copies./.
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EQUIPMENT
USER
(Full name and signature)
(Undertaking to fulfill recommendations in sufficient and timely manner)
WITNESS
(Signature and full name)
INSPECTOR
(Signature and full name)
PROCEDURES FOR TECHNICAL INSPECTION OF SAFETY OF HAND
WINCHES
QTKD: 16- 2016/BLDTBXH
Foreword
Procedures for inspection of
technical safety of hand winches are drafted by the Department of Work Safety
and promulgated together with the Circular No. 54/2016/TT-BLDTBXH dated
December 28, 2016 of the Ministry of Labour, Invalids and Social Affairs.
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1. SCOPE AND REGULATED ENTITIES
1.1. Scope
Such procedures shall be used for
first, periodic and unscheduled inspection of hand winches with a load capacity
of 1,000kg or more under state management of the Ministry of Labour, Invalids
and Social Affairs.
1.2. Regulated entities
- Organizations carrying out
occupational safety inspection;
- Occupational safety inspectors.
2. NORMATIVE REFERENCES
- TCVN 4244:2005, Lifting
appliances - Design construction and survey.
- TCVN 5207:1990, Loading crane -
Safety requirements.
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- TCVN 9385:2012, Protection of
structures against lightning - Guide for design, inspection and maintenance.
- QCVN 7: 2012/BLDTBXH, National
technical regulation on safe work of lift appliances;
In the cases where the
abovementioned normative references are amended or replaced, regulations of the
latest references shall apply.
Other standards may be applied to
hand winches at the request of their user or manufacturer if such standards
contain the same or higher safety criteria than those in the national standards
referred to in this document.
3. TERMS AND DEFINITIONS
For the purposes of this document,
the terms and definitions given in the abovementioned normative references and
the following shall apply:
3.1. “hand winch” means a
hand-operated lifting mechanism, consisting of a drum or chain wheel drive
transmission used to lift or pull loads. The winch can be operated as
stand-alone equipment or as a part of other complex lifting equipment.
3.2. “first safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after its installation and
before its first use.
3.3. “periodic safety inspection”
means the inspection of technical safety of equipment according to national
technical standards and technical safety standards after expiration of the last
safety inspection result.
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- after a repair, upgrade or
renovation that affects the safety of equipment;
- after change of the location of
installation;
- at the request of the user or a
competent authority.
4. INSPECTION STEPS
Safety inspection shall be carried
out in the following order:
- Inspection of the equipment
profile/documents;
- External inspection;
- Technical inspection - No-load
test;
- Load test - Test methods;
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Note: Only take the next step if
the equipment passes the test in the previous step. The result of each step
shall be documented according to the form in the Appendix 01 and retained by
the inspecting organization.
5. INSPECTION EQUIPMENT
Inspection equipment shall be
inspected and calibrated in accordance with regulations. Inspection equipment
includes:
- Altimeter (speedometer);
- Distance measuring equipment;
- Geometric inspection equipment;
- Dynamometer or hanging scale.
6. CONDITIONS FOR INSPECTION
The inspection must not be carried
out unless the following conditions are met:
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6.2. Documents about the equipment
are adequate.
6.3. The inspection is not affected
by environment or weather.
6.4. Requirements concerning
occupational safety and health are met.
7. PREPARATION FOR INSPECTION
7.1. Before carrying out the
inspection, the inspecting organization and the user shall reach an agreement
on an inspection plan and prepare for the inspection and assign staff to
participate in and witness the inspection.
7.2. Inspect the equipment profile
and documents. The following documents shall be inspected according to
inspection regulations:
7.2.1. Regarding first inspection:
- Equipment profile/documents,
especially the following documents (under QCVN 07:2012/BLDTBXH):
+ Calculation of strength of
load-bearing parts (if any);
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+ Guidelines for operation and
maintenance.
+ Certificates of fabricated metal
and weld metal (under 3.1.2 of TCVN 4244 : 2005);
+ Results of inspection of quality
of weld joints (under 3.3.4 of TCVN 4244: 2005);
+ Factory acceptance test results.
- Reports on results of and records
on inspection of lightning protection (if any);
- Installation documents;
7.2.2. Regarding periodic
inspection:
- The previous profile, inspection
record and inspection result report;
- Documents on the use, operation
and maintenance of the equipment; inspection record (if any).
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- In case of renovation or repair:
documents on renovation or repair and commissioning record;
- In case of relocation:
installation documents;
- The inspection record issued by
competent authority (if any).
The document inspection result is
satisfactory if the documents are adequate and the regulations of QCVN
07:2012/BLDTBXH are observed. If the result is unsatisfactory, the user shall
take remedial actions.
7.3. Prepare suitable and adequate
equipment for inspection.
7.4. Develop measures for ensuring
safety and reach an agreement with the user before inspection. Provide adequate
personal protective equipment to ensure safety during the inspection.
8. INSPECTION PROCESS
An inspection shall be carried out
in the following order:
8.1. External inspection:
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8.1.2. Check all mechanisms or
parts of the lifting equipment individually, pay particular attention to the
condition of the following parts:
- Connection between the hand winch
and the winch location (according to the manufacturer’s instructions);
- Metal structure and crank of the
winch, welds, riveted joints (if any), bolted joints of the metal structure,
platform and covers; (according to the Appendices 1, 2 and 6 of TCVN 4244:
2005);
- Hooks and parts of hooks
(Appendices 13A, 13B and 13C of TCVN 4244: 2005);
- Wire ropes and parts used to fix
wire ropes (meeting the manufacturer's requirements or refer to Appendices 18C
and 21 of TCVN 4244: 2005);
- Pulleys, shafts and pulley shaft
fixing parts (Appendices 19A, 20A and 20B of TCVN 4244: 2005);
- Drum inspected and assessed
according to 1.5.3.1.1 of TCVN 4244: 2005;
- Brakes (parking pawls or
automatic braking mechanism);
- Chain and chain wheel (3,4 of
TCVN 5864:1995).
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8.2. Technical inspection - No-load
test:
- Conduct no-load tests of all
structures, safety devices, brakes, clips;
- Conduct the abovementioned tests
at least 03 (three) times.
The equipment passes the test if
its mechanisms and safety devices operate according to their specifications and
design and satisfy the regulations set out in 8.2.
8.3. Load test - Test methods:
8.3.1. Static test:
- Test load: 125% of SWL (the safe
working load must not be greater than the design load)
- Conduct the static test according
to 4.3.2 of TCVN 4244: 2005.
The equipment passes the test if
the load remains constant while it is being held for 10 (ten) minutes and after
the load is lowered, the structures and parts of equipment have no crack,
deformation or other damage (according to 4.3.2 of TCVN 4244-2005).
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- Conduct a dynamic test at 110% of
SWL. Hoist and lower the load three times and check operation of other
structures bearing such load;
- Conduct the dynamic load test
according to the type of equipment and 4.3.2 of TCVN 4244: 2005.
The equipment passes the test if
its structure and parts operate according to the design, the requirements specified
by the applicable technical regulations are met and no crack, deformation or
other damage is found.
9. INSPECTION RESULT PROCESSING
9.1. Prepare an inspection record
which contains sufficient information according to the form in the Appendix 02
enclosed herewith.
9.2. Approve the inspection record:
Mandatory participants in the
process of approving the inspection record:
- The representative of the user or
a person authorized by the user;
- A witness;
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When the record is approved, the
inspector, the witness, and the representative of the user or a person
authorized by the user shall append their signatures and seals (if any) on the
record. The record shall be made into two (02) copies, each party shall keep
01.
9.3. Write the brief inspection
result to the profile of the equipment (including full names of the inspectors
and the date of inspection).
9.4. Put on the inspection stamp:
if the equipment passes the test, the inspector shall put an inspection stamp
on it at a noticeable position.
9.5. Issuance of certificate of
inspection results:
9.5.1. If the hand winch passes the
test, the inspecting organization shall issue the certificate of inspection
result to the equipment within 05 working days from the date on which the
inspection record is approved.
9.5.2. If the hand winch fails the
test, only the steps in 9.1 and 9.2 shall be taken and the inspection record
must specify the explanation for failed result, necessary remedial actions and
a deadline for taking such actions. The inspection record shall be sent to the
employment authority of the area where the hand winch is installed and located.
10. INSPECTION INTERVAL
10.1. An hand winch has to be
inspected every 02 years. For the hand winch that has been used for more than
12 years, it has to be inspected every year.
Regarding a mobile hand winch, it
has to be inspected every year.
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10.3. If the inspection interval is
shortened, the inspector shall specify explanation in the inspection record.
10.4. If the inspection interval is
specified in national technical regulations, such regulations shall apply.
Appendix
01
SPECIMEN
OF ON-SITE RECORD
(INSPECTION OF TECHNICAL SAFETY OF HAND WINCH)
(Name
of inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
---------------
…………..
[place], ………[date]
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ON-SITE
RECORD
No.
...................
(written
by the inspector)
1- General information
Name of the equipment:
.…………….……………………….…………….……………………………………….
Name of the user:
.…………….……………………….…………….………………….
Address (head office of the user):
.…………….……………………….…………….………
Address (location) of the equipment:
.…………….……………………….…………….…………………………….
Content of the meeting with the
user:
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- Witness:
2- Basic specifications:
- Code:
............................................
- Design
load:.....................
tonnes
- Production number:
...................................
- Lifting (lowering) height of
hooks:................... m
- Production year:
...................................
- Uses: ..............................................
- Manufacturer:
...................................
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3- Document inspection:
- Machine profile:
- Technical documents:
4- Code of measuring and testing
equipment:
5- Equipment inspection:
a. External inspection:
+ Metal structure:
+ Hook and pulley (Chain wheel)
assembly:...
+ Wire ropes (chain) and wire rope
fixation:…
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+ Drum
b. Technical inspection:
- 125% load test: (10-minute hold)
+ Brakes, retaining clips:
+ Metal structure:….
- 110% dynamic test:
+ Brakes, retaining clips:
+ Mechanisms and parts:
+ Metal structure:
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7- Recommendations:
WITNESS
(Signature and full name)
INSPECTOR
(Signature and full name)
Appendix
02
SPECIMEN
OF RECORD ON INSPECTION OF TECHNICAL SAFETY OF HAND WINCH
(Name
of inspecting organization)
-------
THE
SOCIALIST REPUBLIC OF VIETNAM
Independence - Freedom - Happiness
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…………..
[place], ………[date]
RECORD
ON INSPECTION OF TECHNICAL SAFETY OF HAND WINCH
No.
…………….
(According to the on-site record No. ………………..)
We are:
1. .…………….……………………… Inspector
number: .…………….………………………
2. .…………….……………………… Inspector
number: .…………….………………………
Inspecting organization:
.…………….…………………….…………….………………………
Registration certificate No.
……………………………………….……………
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Name of the user:
….………………………………………………..………..…………
Address (head office of the user):
.…………….……………………….…………….…………
Address (location) of the
equipment: ……………………………………………………………………….…………
Inspection procedure and standards
applied: …………………………………………………
Individuals
witnessing and approving the record:………………….………………… ………
1………………………………………
Position:………….…………………
2………………………………………
Position:………….…………………
I- BASIC SPECIFICATIONS
- Code:
............................................
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- Production number:
...................................
- Lifting (lowering) height of
hooks:................... m
- Production year:
...................................
- Uses:
..............................................
- Manufacturer:
...................................
II-
FORMS OF INSPECTION
First
time □
Periodic □
Unscheduled □
Reason for unscheduled inspection:
.…………….………………………………………
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A-Technical document inspection:
- Comments:
.…………….……………………….…………….……………………………………..
- Result evaluation:
No.
Item
Passed
Failed
Note
1
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2
Technical documents
B- External inspection; no-load
test:
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- Result evaluation:
No.
Mechanism;
part
Passed
Failed
Note
No.
Mechanism;
part
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Failed
Note
1
Hook
5
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2
Pulley (chain reel) assembly
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Brake (retaining clip)
3
Load rope (chain)
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7
Drum
4
Metal structure; connection with
the building
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8
Grounding, lightning protection
C-Load test:
- Comments:
.…………….……………………….…………….…………………………………
- Result evaluation:
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Load
holding position and test result
Passed
Failed
Corresponding
load
(tonnes)
Static
test load
(tonnes)
Dynamic
test load
(tonnes)
1
On the hook
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2
Stability
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Result
evaluation
Passed
Failed
Note
No.
Result
evaluation
Passed
Failed
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1
Metal structure
3
Brake (retaining clip)
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2
Load rope (chain)
4
Hoisting mechanism
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IV
- CONCLUSIONS AND RECOMMENDATIONS
1. Result: Passed
□ Failed □
Maximum load: ...........
tonnes.
2. Inspection stamp No. :………… At:
.…………….………………………
3. Recommendations: ……………
Deadline for implementation of
recommendations:
V-
INSPECTION INTERVAL
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Reasons for shortened interval (if
any):
The record is approved on:
At: …………………………….
The record is made into of ....
copies, each party holds.... copies./.
EQUIPMENT
USER
(Full name and signature)
(Undertaking to fulfill recommendations in sufficient and timely manner)
WITNESS
(Signature and full name)
INSPECTOR
(Signature and full name)
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