Pressure Vessel Operation Training
Thread Content
My workplace is about to conduct training on the operation of pressure vessels. Does any member here have the training outline that they could share? Thank you in advance!
Search on BAIDU yourself – there are many! The following is excerpted from the \"Measures for the Training, Assessment and Management of Pressure Vessel Operators in Shanghai\", for LZ’s reference! Article 14: The theoretical examination for pressure vessel operators shall consist of questions selected from the contents of the following examination syllabus. 1. Theoretical aspects of pressure vessel safety technology (1) Main process parameters of pressure vessels, classification of pressure vessel types ； (2) Materials, structure of pressure vessels, and their basic working principle ； (3) Names, functions, and basic working principles of the safety accessories for pressure vessels ； (4) Provisions on safe use in the technical regulations and standards for pressure vessels ； (5) Main contents of the safety operation procedures and regulations for pressure vessels ； (6) Basic knowledge of pressure vessel maintenance ； (7) Classification of highly toxic, toxic, and flammable media, main physicochemical properties of common gases, and their impact on safe use ； (8) Common internal and external defects of pressure vessels, general requirements for regular inspection and repair ； (9) Corrosion protection technology for pressure vessels ； (10) Rules for replacing pressure vessels and performing safe hot work ； (11) Types, causes, prevention, and handling of common accidents in pressure vessels ； (12) The uses and operational precautions for various common thermal instruments, automatic control, and interlock protection devices. 2. Theoretical aspects of cylinder safety technology: (1) Provisions related to safe use in cylinder technical regulations and standards, as well as the cylinder filling process and its associated equipment ； (2) Basic knowledge of gases, filling procedures for gas cylinders, and main contents of safety operating procedures ； (3) Methods of gas production ； (4) Cylinder classification, structural types, main technical parameters ； (5) Gas cylinder accessories and their functions ； (6) Color markings and steel stamp marks on gas cylinders ； (7) Common internal and external defects of gas cylinders, general requirements for periodic inspections ； (8) Types, causes, prevention, and handling of common accidents involving gas cylinders. Article 15: Methods and content of practical operation assessment 1. The practical assessment is conducted at a specially designated site, where certain unsafe issues and faults are intentionally created, and it is the responsibility of the person being assessed to identify and overcome them ； 2. The actual assessment should specify a set of operational tasks to be carried out on-site by the person being assessed, in order to check the correctness and proficiency of their procedures. For example, inspections before operating pressure vessels, preparations for startup, opening valves, powering on the system, adjusting operating conditions, normal operation, shutdown procedures, and handling of abnormal situations, etc ； 3. Inspection of safety accessories ； 4. The practical operation assessment should be completed within a specified time limit; those who exceed this time limit will have points deducted.
Let’s get one from Beijing. Training and Assessment Syllabus for Personnel Working with Pressure Vessels (Gas Cylinders) (Trial Version) I. Instructions (1) This syllabus is formulated in accordance with the provisions of the Regulations on the Safety Supervision of Special Equipment, taking into account the characteristics of Beijing ； (2) This outline is applicable to the assessment, training, and teaching of personnel working with pressure vessels (gas cylinders) within the jurisdiction of Beijing ； (3) Selection of training materials:
For pressure vessels: “Pressure Vessel Management and Operation”, written by Feng Suxia, Kuang Jiarui, and Hou Siming; published by China Pressure Vessel Safety Magazine (1998.7). “Use Management and Safe Operation of Pressure Vessels”, edited by Xie Yadong; published by Atomic Energy Press (1995.3). “Safe Operation Techniques for Pressure Vessels”, written by Shi Zhihao and Chen Xiancai; published by China Pressure Vessel Safety Magazine (1989.6).
For gas cylinders: “Safety Inspection Regulations for Gas Cylinders”. The following materials are selected based on the specific duties of the workers: “Safety Inspection Regulations for Acetylene Cylinders”, “Technology of Liquefied Petroleum Gas Storage and Distribution”, “Regulations for Filling Acetylene Cylinders”, “Regulations for Filling Liquefied Gas Cylinders”, “Regulations for Filling Inert Gas Cylinders”, “Warning Labels for Gas Cylinders”. There are also safety technical requirements for filling stations for inert gases, liquefied petroleum gas, liquefied gases, acetylene cylinders, as well as stations for filling compressed natural gas in vehicles.
II. Teaching arrangement:
Total training and assessment hours: 90–110. Of these, 50 hours are dedicated to teaching basic theories, while practical training is carried out according to the knowledge and skills required for the workers’ positions, with 30–50 hours allocated to this purpose. The examination consists of two parts: a theoretical exam taking 4 hours and a practical exam taking 6 hours, for a total of 10 hours. III. Assessment Method: The basic theory exam is conducted in the form of a closed-book written test, with a full score of 100 points; 70 points is considered a passing score ； The actual exam consists of two parts: basic knowledge related to the position and on-site practical operations. The total score is 100 points, with 70 points being the passing mark. Of this, basic job knowledge accounts for 60%, while practical operations account for 40%. A qualification certificate will be issued only to those who pass both the theoretical and practical exams. IV. Teaching Plan for Basic Theories
Chapter | Teaching Content | Class Hours
1 | Overview of Comprehensive Regulations | 4
2 | Introduction to the Regulations on the Safety Supervision of Special Equipment and Related Provisions | 4
Chapter | Class Hours for Pressure Vessels
Chapter | Class Hours for Gas Cylinders
3 | Basic Knowledge of Pressure Vessels | 5
3 | Basic Knowledge of Gas Cylinders | 5
4 | Regulatory Standards for Pressure Vessels | 3
4 | Regulatory Standards for Gas Cylinders | 3
5 | Materials Used in Pressure Vessels | 2
5 | Safety Technical Requirements and Job Responsibilities of Gas Filling Units | 4
6 | Stress on Pressure Vessels and Its Impact on Safety | 2
7 | Corrosion of Pressure Vessels and Anti-corrosion Measures | 4
6 | Gas Filling and Storage Equipment | 10
8 | Safety Accessories for Pressure Vessels | 6
9 | Use and Management of Pressure Vessels | 4
7 | Gas Filling Processes | 12
10 | Operation and Maintenance of Pressure Vessels | 8
11 | Regular Inspections of In-service Pressure Vessels | 4
12 | Inspection and Regular Testing of Gas Cylinders | 4
13 | Accidents Involving Pressure Vessels | 4
14 | Accidents Involving Gas Cylinders | 4
V. Teaching Section on Basic Theories
Chapter 1: Overview of Comprehensive Regulations (4)
(1) Teaching Content
Section 1: China’s System of Administrative Laws and Regulations
Section 2: China’s System of Administrative Regulations for Special Equipment
Section 3: Departmental Administrative Regulations and Relevant Standards for Pressure Vessels (Gas Cylinders)
(2) Teaching Requirements
Understand the framework of China’s legal system, including the constitution, laws, and administrative regulations; be familiar with the regulatory requirements related to pressure vessels and gas cylinders; and clarify the responsibilities and obligations of personnel working with special equipment. (III) Key points and difficulties: It is important to understand the relevant provisions in the comprehensive regulations, namely the Constitution of the People’s Republic of China, the Work Safety Law, the Product Quality Law, the **Standardization Law, the Metrology Law, and the Regulations on the Safety Supervision of Special Equipment, in order to clarify the respective legal responsibilities and obligations. Chapter 2 Introduction to the Regulations on the Safety of Special Equipment and Related Provisions (4) (I) Teaching Content Section 1 Introduction to the Regulations on the Supervision of the Safety of Special Equipment Section 2 Introduction to the Related Provisions of the Regulations on the Supervision of the Safety of Special Equipment (II) Teaching Requirements Understand the basic framework of the Regulations on the Supervision of the Safety of Special Equipment, and become familiar with the relevant requirements and contents of the accompanying laws, regulations, standards, and norms. (III) Key points and difficulties: It is essential to understand the basic requirements regarding the safety protection of special equipment operators, as stipulated in the \"Regulations on the Safety Supervision of Special Equipment\" and its accompanying rules, including the \"Technical Supervision Regulations for Pressure Vessels\", the \"Safety Supervision Regulations for Gas Cylinders\", the \"Rules for the Registration, Record-keeping, and Use Management of Special Equipment\", and the \"Regulations on the Handling of Accidents Involving Boilers, Pressure Vessels, Pressure Pipelines, and Other Special Equipment\". Chapter 3 of the Pressure Vessels section: Basic Knowledge of Pressure Vessels (5) (I) Teaching Content Section 1: Definition of Pressure Vessels Section 2: Structure and Manufacturing of Pressure Vessels Section 3: Basic Requirements for Pressure Vessels Section 4: Main Process Parameters of Pressure Vessels Section 5: Classification of Pressure Vessels (II) Teaching Objectives: Understand the definition, structure, and manufacturing of pressure vessels; be familiar with the basic requirements for their safe operation; understand the significance of the main process parameters of pressure vessels; and master the methods for classifying pressure vessels. (III) Key points and difficulties: Understanding the main process parameters of pressure vessels, as well as being familiar with the basic requirements for safe operation. Chapter 4 Regulations and Standards for Pressure Vessels (3) (I) Teaching Content Section 1: The regulatory and standard system for pressure vessels in China Section 2: The methods of expressing standards in China Section 3: Commonly used standards and specifications for pressure vessels in China (II) Teaching Requirements: Understand the regulatory and standard system for pressure vessels ； Master the notation methods for pressure vessel standards in our country, and be familiar with the common standards and specifications for pressure vessels. (III) Key points and difficulties: Gain a comprehensive understanding of the regulatory and standard system for pressure vessels, as well as the commonly used specifications and standards. Chapter 5 Materials for Pressure Vessels (2) (I) Teaching Content Section 1 Basic Knowledge of Steel and Requirements for Material Selection Section 2 Classification of Steel and Common Steel Grades Used in Pressure Vessels (II) Teaching Requirements It is essential to master the basic knowledge of steel used in pressure vessels, as well as to understand the classification of steel and the common steel plates utilized in such vessels. (III) Key points and difficulties: Principles for selecting steel for pressure vessels and requirements for their mechanical properties ； Common steel classification and grades for pressure vessel steel. Chapter 6: Effects of Stress on Pressure Vessels and Their Safety (2) (I) Teaching Content Section 1: Stress in Pressure Vessels Section 2: Impact of Stress on Safety (II) Teaching Requirements: Understand the concepts of stress and pressure in pressure vessels as well as the differences between them; understand the meanings of membrane stress, thermal stress, and local stress in pressure vessels; and grasp the impact of stress on the safety performance of pressure vessels. (III) Key points and difficulties: The concepts of stress and pressure in pressure vessels ； The influence of stress in pressure vessels on their safety performance. Chapter 7 Corrosion and Anti-corrosion of Pressure Vessels (4) (I) Teaching Content Section 1 Classification of Metal Corrosion Section 2 Main Factors Affecting Metal Corrosion Section 3 Prevention of Corrosion (II) Teaching Requirements Understand the classification of metal corrosion, as well as the concepts of chemical corrosion and electrochemical corrosion of metals, as well as high-temperature oxidation of metals ； Understand the impact of carburization, decarburization, and hydrogen corrosion on the mechanical properties of steel ； Understand the mechanism and hazards of hydrogen corrosion. (III) Key points and difficulties: Concepts of metal chemical corrosion, high-temperature corrosion, electrochemical corrosion, and high-temperature oxidation, as well as the mechanism of hydrogen corrosion ； Be familiar with the main factors affecting metal corrosion, and master the protective measures against various forms of corrosion damage. Chapter 8 Safety Accessories for Pressure Vessels (10) (I) Teaching Content Section 1 Requirements for Safety Accessories Section 2 Safety Valves Section 3 Burst Disc Devices Section 4 Combination of Safety Valves and Burst Disc Devices Section 5 Pressure Gauges Section 6 Level Gauges Section 7 Temperature Measurement Devices (II) Teaching Requirements Understand the main requirements that pressure vessels have regarding various safety accessories, master the basic structure and working principles of these accessories, and be familiar with the regulations regarding their use as well as the requirements for maintenance. (III) Key points and difficulties: The working principles of various safety accessories and their maintenance requirements. Chapter 9: Use and Management of Pressure Vessels (4) (I) Teaching Content Section 1: The Safety Status of Pressure Vessels in China Section 2: Measures Taken in China to Enhance the Safe Operation of Pressure Vessels Section 3: Safety Technical Management of Pressure Vessels Section 4: Registration Management for the Use of Pressure Vessels (II) Teaching Requirements: Understand the safety status of pressure vessels and the requirements for their safe operation, be aware of the regulations regarding safety technical management of pressure vessels in China, and clarify the responsibilities associated with ensuring safe operation. (III) Key points and difficulties: Requirements for the safe operation of pressure vessels and responsibilities for such operation. Chapter 10 Operation and Maintenance of Pressure Vessels (12) (I) Teaching Content Section 1: The Importance of Operating Pressure Vessels Section 2: Safe Operation Section 3: Maintenance of Pressure Vessels (II) Teaching Requirements: Master the basic requirements for the safe operation of pressure vessels, understand the basic contents of operational procedures, be familiar with the knowledge and skills necessary for pressure vessel operators, and comprehend the basic requirements for the maintenance of pressure vessels. (III) Key points and difficulties: The sense of responsibility of pressure vessel operators, as well as their knowledge and skills in safe operation. Chapter 11 Regular Inspections of In-Use Pressure Vessels (4) (I) Teaching Content Section 1 Classification of Regular Inspections for In-Use Pressure Vessels Section 2 Items for Regular Inspections of In-Use Pressure Vessels Section 3 Assessment of Safety Condition Grades (II) Teaching Requirements Understand the system for regular inspections of pressure vessels and the relevant inspection items, and master the requirements for assessing the safety condition grades of pressure vessels. (III) Key points and difficulties: Regular inspection items for pressure vessels. Chapter 12 Pressure Vessel Accidents (4) (I) Teaching Content Section 1 Accident Handling Section 2 Classification and Closure of Accidents (II) Teaching Requirements Understand the hazards associated with pressure vessel accidents, recognize the diversity of causes and the severity of consequences of pressure vessel explosions, be aware of the basic principles governing accident handling as well as the legal responsibilities of those responsible for accidents, and be familiar with the requirements regarding emergency plans for pressure vessel accidents. (III) Key points and difficulties: The diversity of causes of pressure vessel explosion accidents and the severity of their consequences. Chapter 3: Basic Knowledge of Gas Cylinders (5) (I) Teaching Content Section 1: State Parameters of Gases Section 2: Laws of Gas Changes Section 3: Classification and Applications of Gases Section 4: Classification of Gas Cylinders (II) Teaching Requirements: Students should be familiar with the basic properties, applications, and production methods of gases, as well as understand the classification, structure, accessories, and technical parameters of gas cylinders, including their paint color markings and stamp markings. (III) Key Points and Difficulties: Basic properties of gases, classification of gas cylinders, accessories, and technical parameters. Chapter 4: Regulatory Standards for Gas Cylinders (3) (I) Teaching Content Section 1: The regulatory standard system for gas cylinders in China Section 2: The methods of expressing standards in China Section 3: Commonly used standard specifications for gas cylinders in China (II) Teaching Requirements: Understand the regulatory standard system for gas cylinders ； Master the notation methods for gas cylinder standards in our country, and be familiar with the common standards and specifications for gas cylinders. (III) Key Points and Difficulties: A comprehensive understanding of the regulatory standards system for gas cylinders, as well as common norms and standards. Chapter 5: Safety Technical Requirements and Job Responsibilities for Gas Filling Units (4) (I) Teaching Content: Section 1: Safety Technical Requirements for Gas Filling Units; Section 2: Job Responsibilities. (II) Teaching Requirements: It is necessary to master the basic knowledge regarding the safety technical requirements for gas filling units, including fire prevention, explosion prevention, and anti-static measures, as well as various safety management systems and the use and maintenance of fire-fighting equipment. It is also important to understand the job responsibilities of relevant personnel and the legal responsibilities of operators, as well as to be familiar with the basic methods for emergency response and self-rescue. (III) Key points and difficulties: Master the basic knowledge of the safety technical requirements for gas filling units, and clarify the job responsibilities of relevant personnel as well as the legal responsibilities of operators. Chapter 6 Gas Filling Equipment and Storage and Distribution Equipment (10) (I) Teaching Content Section 1 Structure and Principles of Gas Filling Equipment Section 2 Safety Technical Requirements for Gas Filling Equipment and Storage and Distribution Equipment Section 3 Safety Accessories Used in Gas Filling Equipment and Storage and Distribution Equipment (II) Teaching Requirements Understand the safety technical requirements for gas filling equipment and storage and distribution equipment, and master the correct methods of using as well as maintaining the safety accessories employed in such equipment. (III) Key points and difficulties: The structure and principles of gas filling equipment, as well as the safety technical requirements for gas filling equipment and storage and distribution equipment. The attachment provides information on the basic structure and working principles of key accessories such as bottle valves, pressure relief valves, and fusible plugs, and outlines the regulations regarding their use as well as the requirements for maintenance. Chapter 7 Cylinder Filling Process and Safe Operation (12) (I) Teaching Content Section 1 Inspections and Preparations Before Filling Section 2 Filling Process Section 3 Regulations Regarding Cylinder Modifications Section 4 Filling Records Section 5 Safety Technical Requirements for Cylinder Filling Processes and Operating Procedures (II) Teaching Objectives To understand the safety technical requirements related to gas filling processes and operating procedures, to master the correct methods and key points of gas filling, and to be aware of the legal responsibilities and obligations of operators. (III) Key points and difficulties: The safety technical requirements for gas filling processes and operating procedures, as well as the correct methods and essentials for gas filling. Chapter 8 Inspection for Cylinder Filling and Periodic Inspections (4) (I) Teaching Content Section 1 Classification of Inspection for Cylinder Filling and Periodic Inspections Section 2 Items for Inspection of Cylinder Filling and Periodic Inspections of Cylinders Section 3 Assessment of Safety Conditions (II) Teaching Requirements Understand the systems for inspection of cylinder filling and periodic inspections, as well as the relevant inspection items, and master the requirements for assessing the safety conditions of cylinders. (III) Key points and difficulties: Inspection items for cylinder filling and periodic inspections, as well as requirements for assessing the safety status of cylinders. Chapter 9 Cylinder Accidents (4) (I) Teaching Content Section 1: Accident Handling Section 2: Classification and Resolution of Accidents (II) Teaching Requirements: Understand the hazards associated with cylinder accidents, recognize the diversity of causes and the severity of consequences resulting from cylinder leaks and explosions, be aware of the basic principles governing accident handling as well as the legal responsibilities of those responsible for accidents, and be familiar with the requirements regarding emergency plans for cylinder accidents. (III) Key points and difficulties: The diversity of causes and the severity of consequences of gas cylinder leakage and explosion accidents. Instructions for the practical operation section: 1. A practical operation assessment is required to evaluate the operator’s actual hands-on skills ； 2. The physical identification must be accurate, no steps in the procedure should be omitted, the order of operations must not be reversed, and responses on-site must be fluent and error-free ； 3. During the assessment, attention should be paid to the assessee’s understanding of the integrity of pressure vessels and gas cylinders, as well as the technical requirements for various components of these vessels and cylinders, their safety and technical characteristics, the working principles of instruments and meters, and the safety protection requirements ； 4. During the assessment, attention should be paid to the assessee’s understanding of the specific characteristics of the pressure vessels and gas cylinders being operated, their comprehension of the process operation procedures, and their willingness to follow these procedures. (1) Schedule of teaching hours for practical training of various types of operators: 1. Operators of ordinary pressure vessels (30); 2. Personnel in charge of transporting liquefied gas in vehicles and railway tank cars (40); 3. Workers involved in filling operations at liquefied petroleum gas filling stations (50) ； 4. Filling operators at various gas filling stations (40) ； 5. Operators of high-pressure, ultra-high-pressure, and low-temperature vessels in petroleum chemical plants (50) ； Training and assessment outlines for various types of workers (see attachment)
For pressure vessels: “Pressure Vessel Management and Operation”, written by Feng Suxia, Kuang Jiarui, and Hou Siming; published by China Pressure Vessel Safety Magazine (1998.7). “Use Management and Safe Operation of Pressure Vessels”, edited by Xie Yadong; published by Atomic Energy Press (1995.3). “Safe Operation Techniques for Pressure Vessels”, written by Shi Zhihao and Chen Xiancai; published by China Pressure Vessel Safety Magazine (1989.6).
For gas cylinders: “Safety Inspection Regulations for Gas Cylinders”. The following materials are selected based on the specific duties of the workers: “Safety Inspection Regulations for Acetylene Cylinders”, “Technology of Liquefied Petroleum Gas Storage and Distribution”, “Regulations for Filling Acetylene Cylinders”, “Regulations for Filling Liquefied Gas Cylinders”, “Regulations for Filling Inert Gas Cylinders”, “Warning Labels for Gas Cylinders”. There are also safety technical requirements for filling stations for inert gases, liquefied petroleum gas, liquefied gases, acetylene cylinders, as well as stations for filling compressed natural gas in vehicles.
II. Teaching arrangement:
Total training and assessment hours: 90–110. Of these, 50 hours are dedicated to teaching basic theories, while practical training is carried out according to the knowledge and skills required for the workers’ positions, with 30–50 hours allocated to this purpose. The examination consists of two parts: a theoretical exam taking 4 hours and a practical exam taking 6 hours, for a total of 10 hours. III. Assessment Method: The basic theory exam is conducted in the form of a closed-book written test, with a full score of 100 points; 70 points is considered a passing score ； The actual exam consists of two parts: basic knowledge related to the position and on-site practical operations. The total score is 100 points, with 70 points being the passing mark. Of this, basic job knowledge accounts for 60%, while practical operations account for 40%. A qualification certificate will be issued only to those who pass both the theoretical and practical exams. IV. Teaching Plan for Basic Theories
Chapter | Teaching Content | Class Hours
1 | Overview of Comprehensive Regulations | 4
2 | Introduction to the Regulations on the Safety Supervision of Special Equipment and Related Provisions | 4
Chapter | Class Hours for Pressure Vessels
Chapter | Class Hours for Gas Cylinders
3 | Basic Knowledge of Pressure Vessels | 5
3 | Basic Knowledge of Gas Cylinders | 5
4 | Regulatory Standards for Pressure Vessels | 3
4 | Regulatory Standards for Gas Cylinders | 3
5 | Materials Used in Pressure Vessels | 2
5 | Safety Technical Requirements and Job Responsibilities of Gas Filling Units | 4
6 | Stress on Pressure Vessels and Its Impact on Safety | 2
7 | Corrosion of Pressure Vessels and Anti-corrosion Measures | 4
6 | Gas Filling and Storage Equipment | 10
8 | Safety Accessories for Pressure Vessels | 6
9 | Use and Management of Pressure Vessels | 4
7 | Gas Filling Processes | 12
10 | Operation and Maintenance of Pressure Vessels | 8
11 | Regular Inspections of In-service Pressure Vessels | 4
12 | Inspection and Regular Testing of Gas Cylinders | 4
13 | Accidents Involving Pressure Vessels | 4
14 | Accidents Involving Gas Cylinders | 4
V. Teaching Section on Basic Theories
Chapter 1: Overview of Comprehensive Regulations (4)
(1) Teaching Content
Section 1: China’s System of Administrative Laws and Regulations
Section 2: China’s System of Administrative Regulations for Special Equipment
Section 3: Departmental Administrative Regulations and Relevant Standards for Pressure Vessels (Gas Cylinders)
(2) Teaching Requirements
Understand the framework of China’s legal system, including the constitution, laws, and administrative regulations; be familiar with the regulatory requirements related to pressure vessels and gas cylinders; and clarify the responsibilities and obligations of personnel working with special equipment. (III) Key points and difficulties: It is important to understand the relevant provisions in the comprehensive regulations, namely the Constitution of the People’s Republic of China, the Work Safety Law, the Product Quality Law, the **Standardization Law, the Metrology Law, and the Regulations on the Safety Supervision of Special Equipment, in order to clarify the respective legal responsibilities and obligations. Chapter 2 Introduction to the Regulations on the Safety of Special Equipment and Related Provisions (4) (I) Teaching Content Section 1 Introduction to the Regulations on the Supervision of the Safety of Special Equipment Section 2 Introduction to the Related Provisions of the Regulations on the Supervision of the Safety of Special Equipment (II) Teaching Requirements Understand the basic framework of the Regulations on the Supervision of the Safety of Special Equipment, and become familiar with the relevant requirements and contents of the accompanying laws, regulations, standards, and norms. (III) Key points and difficulties: It is essential to understand the basic requirements regarding the safety protection of special equipment operators, as stipulated in the \"Regulations on the Safety Supervision of Special Equipment\" and its accompanying rules, including the \"Technical Supervision Regulations for Pressure Vessels\", the \"Safety Supervision Regulations for Gas Cylinders\", the \"Rules for the Registration, Record-keeping, and Use Management of Special Equipment\", and the \"Regulations on the Handling of Accidents Involving Boilers, Pressure Vessels, Pressure Pipelines, and Other Special Equipment\". Chapter 3 of the Pressure Vessels section: Basic Knowledge of Pressure Vessels (5) (I) Teaching Content Section 1: Definition of Pressure Vessels Section 2: Structure and Manufacturing of Pressure Vessels Section 3: Basic Requirements for Pressure Vessels Section 4: Main Process Parameters of Pressure Vessels Section 5: Classification of Pressure Vessels (II) Teaching Objectives: Understand the definition, structure, and manufacturing of pressure vessels; be familiar with the basic requirements for their safe operation; understand the significance of the main process parameters of pressure vessels; and master the methods for classifying pressure vessels. (III) Key points and difficulties: Understanding the main process parameters of pressure vessels, as well as being familiar with the basic requirements for safe operation. Chapter 4 Regulations and Standards for Pressure Vessels (3) (I) Teaching Content Section 1: The regulatory and standard system for pressure vessels in China Section 2: The methods of expressing standards in China Section 3: Commonly used standards and specifications for pressure vessels in China (II) Teaching Requirements: Understand the regulatory and standard system for pressure vessels ； Master the notation methods for pressure vessel standards in our country, and be familiar with the common standards and specifications for pressure vessels. (III) Key points and difficulties: Gain a comprehensive understanding of the regulatory and standard system for pressure vessels, as well as the commonly used specifications and standards. Chapter 5 Materials for Pressure Vessels (2) (I) Teaching Content Section 1 Basic Knowledge of Steel and Requirements for Material Selection Section 2 Classification of Steel and Common Steel Grades Used in Pressure Vessels (II) Teaching Requirements It is essential to master the basic knowledge of steel used in pressure vessels, as well as to understand the classification of steel and the common steel plates utilized in such vessels. (III) Key points and difficulties: Principles for selecting steel for pressure vessels and requirements for their mechanical properties ； Common steel classification and grades for pressure vessel steel. Chapter 6: Effects of Stress on Pressure Vessels and Their Safety (2) (I) Teaching Content Section 1: Stress in Pressure Vessels Section 2: Impact of Stress on Safety (II) Teaching Requirements: Understand the concepts of stress and pressure in pressure vessels as well as the differences between them; understand the meanings of membrane stress, thermal stress, and local stress in pressure vessels; and grasp the impact of stress on the safety performance of pressure vessels. (III) Key points and difficulties: The concepts of stress and pressure in pressure vessels ； The influence of stress in pressure vessels on their safety performance. Chapter 7 Corrosion and Anti-corrosion of Pressure Vessels (4) (I) Teaching Content Section 1 Classification of Metal Corrosion Section 2 Main Factors Affecting Metal Corrosion Section 3 Prevention of Corrosion (II) Teaching Requirements Understand the classification of metal corrosion, as well as the concepts of chemical corrosion and electrochemical corrosion of metals, as well as high-temperature oxidation of metals ； Understand the impact of carburization, decarburization, and hydrogen corrosion on the mechanical properties of steel ； Understand the mechanism and hazards of hydrogen corrosion. (III) Key points and difficulties: Concepts of metal chemical corrosion, high-temperature corrosion, electrochemical corrosion, and high-temperature oxidation, as well as the mechanism of hydrogen corrosion ； Be familiar with the main factors affecting metal corrosion, and master the protective measures against various forms of corrosion damage. Chapter 8 Safety Accessories for Pressure Vessels (10) (I) Teaching Content Section 1 Requirements for Safety Accessories Section 2 Safety Valves Section 3 Burst Disc Devices Section 4 Combination of Safety Valves and Burst Disc Devices Section 5 Pressure Gauges Section 6 Level Gauges Section 7 Temperature Measurement Devices (II) Teaching Requirements Understand the main requirements that pressure vessels have regarding various safety accessories, master the basic structure and working principles of these accessories, and be familiar with the regulations regarding their use as well as the requirements for maintenance. (III) Key points and difficulties: The working principles of various safety accessories and their maintenance requirements. Chapter 9: Use and Management of Pressure Vessels (4) (I) Teaching Content Section 1: The Safety Status of Pressure Vessels in China Section 2: Measures Taken in China to Enhance the Safe Operation of Pressure Vessels Section 3: Safety Technical Management of Pressure Vessels Section 4: Registration Management for the Use of Pressure Vessels (II) Teaching Requirements: Understand the safety status of pressure vessels and the requirements for their safe operation, be aware of the regulations regarding safety technical management of pressure vessels in China, and clarify the responsibilities associated with ensuring safe operation. (III) Key points and difficulties: Requirements for the safe operation of pressure vessels and responsibilities for such operation. Chapter 10 Operation and Maintenance of Pressure Vessels (12) (I) Teaching Content Section 1: The Importance of Operating Pressure Vessels Section 2: Safe Operation Section 3: Maintenance of Pressure Vessels (II) Teaching Requirements: Master the basic requirements for the safe operation of pressure vessels, understand the basic contents of operational procedures, be familiar with the knowledge and skills necessary for pressure vessel operators, and comprehend the basic requirements for the maintenance of pressure vessels. (III) Key points and difficulties: The sense of responsibility of pressure vessel operators, as well as their knowledge and skills in safe operation. Chapter 11 Regular Inspections of In-Use Pressure Vessels (4) (I) Teaching Content Section 1 Classification of Regular Inspections for In-Use Pressure Vessels Section 2 Items for Regular Inspections of In-Use Pressure Vessels Section 3 Assessment of Safety Condition Grades (II) Teaching Requirements Understand the system for regular inspections of pressure vessels and the relevant inspection items, and master the requirements for assessing the safety condition grades of pressure vessels. (III) Key points and difficulties: Regular inspection items for pressure vessels. Chapter 12 Pressure Vessel Accidents (4) (I) Teaching Content Section 1 Accident Handling Section 2 Classification and Closure of Accidents (II) Teaching Requirements Understand the hazards associated with pressure vessel accidents, recognize the diversity of causes and the severity of consequences of pressure vessel explosions, be aware of the basic principles governing accident handling as well as the legal responsibilities of those responsible for accidents, and be familiar with the requirements regarding emergency plans for pressure vessel accidents. (III) Key points and difficulties: The diversity of causes of pressure vessel explosion accidents and the severity of their consequences. Chapter 3: Basic Knowledge of Gas Cylinders (5) (I) Teaching Content Section 1: State Parameters of Gases Section 2: Laws of Gas Changes Section 3: Classification and Applications of Gases Section 4: Classification of Gas Cylinders (II) Teaching Requirements: Students should be familiar with the basic properties, applications, and production methods of gases, as well as understand the classification, structure, accessories, and technical parameters of gas cylinders, including their paint color markings and stamp markings. (III) Key Points and Difficulties: Basic properties of gases, classification of gas cylinders, accessories, and technical parameters. Chapter 4: Regulatory Standards for Gas Cylinders (3) (I) Teaching Content Section 1: The regulatory standard system for gas cylinders in China Section 2: The methods of expressing standards in China Section 3: Commonly used standard specifications for gas cylinders in China (II) Teaching Requirements: Understand the regulatory standard system for gas cylinders ； Master the notation methods for gas cylinder standards in our country, and be familiar with the common standards and specifications for gas cylinders. (III) Key Points and Difficulties: A comprehensive understanding of the regulatory standards system for gas cylinders, as well as common norms and standards. Chapter 5: Safety Technical Requirements and Job Responsibilities for Gas Filling Units (4) (I) Teaching Content: Section 1: Safety Technical Requirements for Gas Filling Units; Section 2: Job Responsibilities. (II) Teaching Requirements: It is necessary to master the basic knowledge regarding the safety technical requirements for gas filling units, including fire prevention, explosion prevention, and anti-static measures, as well as various safety management systems and the use and maintenance of fire-fighting equipment. It is also important to understand the job responsibilities of relevant personnel and the legal responsibilities of operators, as well as to be familiar with the basic methods for emergency response and self-rescue. (III) Key points and difficulties: Master the basic knowledge of the safety technical requirements for gas filling units, and clarify the job responsibilities of relevant personnel as well as the legal responsibilities of operators. Chapter 6 Gas Filling Equipment and Storage and Distribution Equipment (10) (I) Teaching Content Section 1 Structure and Principles of Gas Filling Equipment Section 2 Safety Technical Requirements for Gas Filling Equipment and Storage and Distribution Equipment Section 3 Safety Accessories Used in Gas Filling Equipment and Storage and Distribution Equipment (II) Teaching Requirements Understand the safety technical requirements for gas filling equipment and storage and distribution equipment, and master the correct methods of using as well as maintaining the safety accessories employed in such equipment. (III) Key points and difficulties: The structure and principles of gas filling equipment, as well as the safety technical requirements for gas filling equipment and storage and distribution equipment. The attachment provides information on the basic structure and working principles of key accessories such as bottle valves, pressure relief valves, and fusible plugs, and outlines the regulations regarding their use as well as the requirements for maintenance. Chapter 7 Cylinder Filling Process and Safe Operation (12) (I) Teaching Content Section 1 Inspections and Preparations Before Filling Section 2 Filling Process Section 3 Regulations Regarding Cylinder Modifications Section 4 Filling Records Section 5 Safety Technical Requirements for Cylinder Filling Processes and Operating Procedures (II) Teaching Objectives To understand the safety technical requirements related to gas filling processes and operating procedures, to master the correct methods and key points of gas filling, and to be aware of the legal responsibilities and obligations of operators. (III) Key points and difficulties: The safety technical requirements for gas filling processes and operating procedures, as well as the correct methods and essentials for gas filling. Chapter 8 Inspection for Cylinder Filling and Periodic Inspections (4) (I) Teaching Content Section 1 Classification of Inspection for Cylinder Filling and Periodic Inspections Section 2 Items for Inspection of Cylinder Filling and Periodic Inspections of Cylinders Section 3 Assessment of Safety Conditions (II) Teaching Requirements Understand the systems for inspection of cylinder filling and periodic inspections, as well as the relevant inspection items, and master the requirements for assessing the safety conditions of cylinders. (III) Key points and difficulties: Inspection items for cylinder filling and periodic inspections, as well as requirements for assessing the safety status of cylinders. Chapter 9 Cylinder Accidents (4) (I) Teaching Content Section 1: Accident Handling Section 2: Classification and Resolution of Accidents (II) Teaching Requirements: Understand the hazards associated with cylinder accidents, recognize the diversity of causes and the severity of consequences resulting from cylinder leaks and explosions, be aware of the basic principles governing accident handling as well as the legal responsibilities of those responsible for accidents, and be familiar with the requirements regarding emergency plans for cylinder accidents. (III) Key points and difficulties: The diversity of causes and the severity of consequences of gas cylinder leakage and explosion accidents. Instructions for the practical operation section: 1. A practical operation assessment is required to evaluate the operator’s actual hands-on skills ； 2. The physical identification must be accurate, no steps in the procedure should be omitted, the order of operations must not be reversed, and responses on-site must be fluent and error-free ； 3. During the assessment, attention should be paid to the assessee’s understanding of the integrity of pressure vessels and gas cylinders, as well as the technical requirements for various components of these vessels and cylinders, their safety and technical characteristics, the working principles of instruments and meters, and the safety protection requirements ； 4. During the assessment, attention should be paid to the assessee’s understanding of the specific characteristics of the pressure vessels and gas cylinders being operated, their comprehension of the process operation procedures, and their willingness to follow these procedures. (1) Schedule of teaching hours for practical training of various types of operators: 1. Operators of ordinary pressure vessels (30); 2. Personnel in charge of transporting liquefied gas in vehicles and railway tank cars (40); 3. Workers involved in filling operations at liquefied petroleum gas filling stations (50) ； 4. Filling operators at various gas filling stations (40) ； 5. Operators of high-pressure, ultra-high-pressure, and low-temperature vessels in petroleum chemical plants (50) ； Training and assessment outlines for various types of workers (see attachment)
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The importance of safety management in pressure vessels l What are pressure vessels? Any closed container in which there is a certain pressure difference on both sides of its walls can be referred to as a pressure vessel, or a pressurized container. This is the meaning in a broad sense, and it is widely applied in various aspects of production and daily life. A pressure difference existing on either side of the wall of a pressure vessel indicates that the vessel wall is under pressure load. This pressure load results from the intentional elevation and accumulation of energy, which gives the vessel the potential and risk of releasing that energy at any time, leading to leaks or explosions. Such risks and possibilities are related to the volume of the container, the working medium, as well as pressure loads, structure, and purpose; it is not the case that all pressure vessels will experience accidents. In fact, only a certain portion of pressure vessels are prone to accidents and pose significant hazards; these vessels are classified as special equipment for management, which is what we commonly refer to as pressure vessels. Therefore, the definition of pressure vessels must take into account the likelihood of accidents occurring and the severity of the potential harm from such accidents. Working medium: refers to the substances contained within a container or those that participate in reactions within it. For pressure vessels filled with liquid media, due to the low compressibility of liquids, the expansion of the medium when pressure is released is minimal; as a result, the energy released in the event of a vessel explosion is also small. A pressure vessel for gaseous working media: due to the high compressibility of gases, when the vessel ruptures, the gas is released instantaneously, expanding and doing work, which results in a large amount of energy being released. For containers with the same pressure and volume, the blasting energy of a gas as a working medium is hundreds or even tens of thousands of times greater than that of a liquid. Therefore, if the medium is a liquid, even if the container bursts, the level of destruction is minimal. The liquids referred to here are those at room temperature, and do not include saturated liquids at temperatures higher than their normal boiling point (such as the high-temperature saturated water in boiler drums), nor liquefied gases with a boiling point lower than room temperature (such as liquid chlorine and liquid ammonia). Because these media remain in a liquid state inside the container only due to high pressure (in fact, a two-phase gas-liquid mixture exists); if the container ruptures, the pressure inside drops rapidly, and the saturated liquid becomes superheated, instantly evaporating and expanding greatly in volume, which poses a significant hazard. The higher the work pressure and the larger the container, the greater the energy released, and the more severe the hazards. However, P and V are not as easy to define and delimit as the working medium; generally, a relatively appropriate lower limit value is artificially specified. Based on this, the \"Regulations on Safety Inspection of Pressure Vessels\" define pressure vessels as follows: 1. Pressure vessels that fall entirely within the scope of application of these regulations, as specified in Article 2, Paragraph 1, item (1): the maximum operating pressure (Pw) (Note 1) is greater than or equal to 0.1 MPa (excluding hydrostatic pressure; the same applies hereafter) ； (2) The inner diameter (for non-circular cross-sections, this refers to the largest dimension) is 0.15 m or more, and the volume (V) (Note 2) is 0.025 m3 or more ； (3) The medium contained is a gas, a liquefied gas, or a liquid whose maximum operating temperature is equal to or higher than its standard boiling point. (Note 3) 2. Pressure vessels partially covered by the scope of application of the Code for Pressure Vessels: (1) Storage tanks integrated with mobile compressors and not being independent, with a volume of 0.15 m3 or less, as well as cylinder banks in boiler rooms ； (2) High-pressure vessels with a volume of less than 0.025 m3 ； (3) Non-independent pressure vessels in cryogenic units, pressure vessels in direct-fired absorption refrigeration units, and cryogenic tanks in air separation equipment ； (4) Spiral plate heat exchanger ； (5) Pressure tanks in hydraulic automatic air-supplementing pressure water supply systems (towerless water supply), and gas or pressure water (foam) pressure tanks in fire protection systems ； (6) Pressure vessels for ion exchange or filtration in water treatment equipment, expansion tanks for hot water boilers ； (7) Fully enclosed combined electrical apparatus (capacitor pressure vessel) dedicated for the power industry ； (8) Tire vulcanizing machines and pressure-resistant rubber molds used in the rubber industry. 3. These regulations apply to the safety accessories used in the aforementioned pressure vessels, such as safety valves, rupture disc devices, emergency shut-off devices, safety interlock devices, pressure gauges, level gauges, and temperature measuring instruments. 4. The pressure vessels to which these regulations apply shall include, in addition to the vessel body itself: (1) the welding groove of the first circumferential weld connecting the pressure vessel to external pipes or devices, the first threaded joint in threaded connections, the first flange sealing surface in flanged connections, and the first sealing surface in connections using special fittings or pipe fittings ； (2) Pressure cover for the opening part of the pressure vessel and its fasteners ； (3) Weld joints connecting non-compressed components to the pressure vessel body. 5. Nuclear pressure vessels, auxiliary pressure vessels on ships and rail locomotives, pressure vessels used for defense or **equipment, pressure vessels operating under vacuum, and devices directly heated by flames within the scope of the Boiler Code. 6. Pressure vessels that operate normally at a maximum working pressure of less than 0.1 MPa. 7. Non-independent pressure-bearing components on the machine. 8. Shellless coil exchangers, corrugated plate exchangers, air-cooled exchangers, and cooling coils. l Pressure vessels that meet the three conditions are managed in accordance with the requirements of the Pressure Vessel Regulations. Pressure vessels that do not fully meet the three conditions are managed in accordance with the requirements of the Regulations. The pressure source for pressure vessels comes mainly from two sources: inside and outside the vessel. 1. When pressure is generated outside the vessel, the pressure source is usually a gas compressor or a steam boiler. 2. When pressure is generated inside the vessel — the reasons include: a change in the pumping condition of the medium within the vessel ； The gas is heated inside the vessel, causing its temperature to rise sharply ； A chemical reaction that causes the medium to increase in volume takes place inside the vessel. The sources of stress mostly come from outside the device ； There are few of them inside the device, but they are highly hazardous and require stricter pressure control. l Process parameters of pressure vessels — mainly pressure and temperature. l Classification of pressure vessels — different categories of pressure vessels pose varying levels of risk; adopting different management approaches and measures not only helps to reduce management costs but also ensures the safety of these vessels. General classification: Based on the usage characteristics of pressure vessels, they are divided into fixed and mobile types. 1. The design pressure of pressure vessels is divided into four pressure categories: low pressure, medium pressure, high pressure, and ultra-high pressure. 2. Based on the principle of operation in the production process, pressure vessels can be classified according to reactions. Classified by important safety procedures: The significance of pressure vessel safety depends on the level of operating pressure, the hazard level of the medium, and its role in the production process. 1. Degree of hazard of the medium: In accordance with the provisions of GB5044 \"Classification of Hazards from Occupational Exposure to Toxic Substances\", it is divided into the following four grades based on the maximum allowable concentration: (1) Extremely hazardous (Grade I) – maximum allowable concentration less than 0.1 mg/m3; (2) Highly hazardous (Grade II) – maximum allowable concentration between 0.1 and 1.0 mg/m3; (3) Moderately hazardous (Grade III) – maximum allowable concentration between 1.0 and 10 mg/m3; (4) Slightly hazardous (Grade IV) – maximum allowable concentration equal to or greater than 10 mg/m3. The classification of the toxicity level of media used in pressure vessels is also determined according to the criteria of Grades I to IV outlined in the above regulations. (1) Media with toxicity levels of I or II: such as fluorine, hydrofluoric acid, hydrogen fluoride, chlorine, etc. (2) Media with toxicity level III: such as SO2, NH3, CO, vinyl chloride, methanol, carbon disulfide, acetylene, hydrogen sulfide, etc. (3) Media with toxicity level IV: such as NaOH, tetrafluoroethylene, propylene, etc. 2. Classification method according to the Regulations on Pressure Vessels: Pressure vessels within the scope of application of Article 2 of these regulations are classified into three categories (for the pressure grades, types of pressure vessels, toxicity levels of media, and classification of flammable media, see Annex 1): 1. Pressure vessels fall under Category III in any of the following situations: (1) High-pressure vessels ； (2) Medium-pressure vessels (only for media with extremely high and high toxicity) ； (3) Medium-pressure storage vessels (only for flammable or moderately hazardous media with a PV product of 10 MPa·m3 or greater) ； (Note 2) (4) Medium-pressure reaction vessel (only for media that are flammable or have moderate toxicity, and whose PV product is greater than or equal to 0.5 MPa·m3) ； (5) Low-pressure reaction vessel (only for media with extremely high or high toxicity, and a PV product of 0.2 MPa·m3 or greater) ； (6) High-pressure and medium-pressure shell-and-tube waste heat boilers ； (Note 4) (7) Medium-pressure glass-lined pressure vessels ； (8) Pressure vessels manufactured from materials with a high strength level (meaning that the minimum specified value for tensile strength in the relevant standards is 540 MPa or higher) ； (9) Mobile pressure vessels, including railway tank cars (with liquefied gases or cryogenic liquids as the medium), tank trucks, and tank containers (with liquefied or cryogenic liquids as the medium), etc ； (10) Spherical storage tanks (volume greater than or equal to 50 m3) ； (11) Low-temperature liquid storage containers (volume greater than 5 m3). 2. A pressure vessel falls under Category II in one of the following situations (except as specified in Paragraph 1 of this article): (1) Medium-pressure vessels ； (2) Low-pressure vessels (only for media with extremely high and high toxicity) ； (3) Low-pressure reaction vessels and low-pressure storage vessels (only for flammable media or media with moderate toxicity) ； (4) Low-pressure shell-and-tube waste heat boiler ； (5) Low-pressure glass-lined pressure vessels: 3. Low-pressure vessels are classified as Category I pressure vessels (except as specified in paragraphs 1 and 2 of this article). The structure of pressure vessels, as a closed space that provides for heat and mass transfer, storage, chemical reactions, and separation, is generally quite simple. I. Basic structure of medium and low pressure vessels Although there are various structural types for pressure vessel bodies, the most common ones are cylindrical and spherical. 1. A spherical vessel consists of a spherical shell, which is usually of welded construction. Due to their relatively large diameter, it is difficult to press them into shape entirely or in a semi-integral manner; therefore, they are mostly assembled by welding pre-pressed spherical shells together. Advantages: Optimal stress distribution and material savings. Disadvantages: Difficult to manufacture, high cost; generally used only as storage containers. 2. Cylindrical vessels: For medium and low pressure vessels, they are mainly composed of a cylinder body (shell), end caps, flanges, openings for pipes, sealing and temperature compensation elements, supports, and other components. 2.1 Cylinder – the main component of pressure vessels. It constitutes the majority of the pressure vessels required for storing materials and carrying out chemical reactions. Therefore, the size of the volume (D, L) is usually determined based on the process conditions. Cylinders with a small diameter can be manufactured using seamless steel pipes, which have no longitudinal welds and thus offer better safety. 2.2 Heads – classified by shape into convex, conical, and flat types. Convex shapes are the most widely used, and end caps have been standardized in all forms. It is divided into four types: hemispherical, oval, butterfly-shaped, and edgeless spherical. Tapered types come in folded and unfolded versions, while flat types are commonly used for manholes and flange covers. JB/T4746-2002。 2.3 Flanges – important components for connecting containers and pipes. They are divided into pipe flanges and vessel flanges. TB/T4700-4708 2.4 Holes – Due to process requirements and maintenance needs, it is often necessary to create various holes in the cylinder or head, or to install nozzles. Such as manholes, handholes, sight glasses, material inlet pipes, and interfaces for safety accessories. Holes represent a major weak point in containers and have a significant impact on their fatigue life; therefore, the number of holes should be minimized, large holes should be avoided, and it is prohibited to create holes in the container cylinder that are larger than half of its diameter. When creating an elliptical hole, the short axis of the ellipse should be parallel to the cylinder axis. Minimum number and minimum size of inspection holes: Inner diameter Di (mm), Minimum number of inspection holes, Minimum size of inspection holes (mm), Remarks. Manhole/Access hole: 300
There are hundreds of threads on topics related to pressure vessels on HaiChuan: http://bbs.hcbbs.com/viewthread.php?tid=139131 http://bbs.hcbbs.com/viewthread.php?tid=208885 http://bbs.hcbbs.com/viewthread.php?tid=24075 http://bbs.hcbbs.com/viewthread.php?tid=418518
http://bbs.hcbbs.com/viewthread.php?tid=444268&extra=page%3D1&frombbs=1 or search on the forum for “safe use of pressure vessels””
I previously posted a PPT file on a forum regarding training on the safety management of pressure vessels in enterprises: http://bbs.hcbbs.com/thread-184096-1-1.html. 1. It is recommended that the original poster prepare training materials based on the situation of the pressure vessels in the enterprise, taking into account the specific requirements outlined in TSG R6001-2008 \"Outline for the Assessment of Safety Managers and Operators of Pressure Vessels\". 2. Consult the local special equipment training and assessment center and ask them to provide teaching materials and instructors ； Assessments are conducted in accordance with their requirements, and upon passing the exams, one can obtain the corresponding \"Qualification Certificate for Special Equipment Operators\", allowing them to work independently. For reference! This post was last edited by clguan on 2009-4-15 15:52.]