【Safety Management and Standardization of Special Equipment】What are the specific definitions for the installation, modification, and repair of these 8 types of special equipment, and what should be taken into consideration?
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This post was last edited by HaiChuanLaoYu on 2026-4-26 at 12:50. Ensure proper safety management of special equipment – standardization ensures safety! [Special Equipment Safety Management and Standardization] – Comprehensive thread! Constantly being updated – feel free to communicate! ! ! https://bbs.hcbbs.com/forum.php?mod=viewthread&tid=5718553 (Source: Haichuan Chemical Industry Forum (Hua Haichuan Liu hcbbs)). Everyone is welcome to participate in the discussions. --------------------------------------------------------- The safety of special equipment begins with compliance. And the first step toward compliance is to clarify the precise legal meanings of the terms “installation,” “modification,” and “repair.” Same device, different component – repair or modification? Change location — installation or relocation? For different devices, the criteria for judgment are completely different. Today, we will take eight categories of equipment – boilers, pressure vessels, pressure pipelines, elevators, lifting machinery, passenger cableways, large-scale amusement facilities, and special-purpose motor vehicles used within sites (factories) – and analyze the definitions provided in the latest regulations for each one. We will also examine the licensing requirements in conjunction with TSG 07-2019, the \"Rules for Licensing Special Equipment Production and Filling Units\". I. Boilers (Basis: TSG 11—2020 \"Technical Regulations for Boiler Safety\", including Amendment No. 1 of 2024) 1. Installation: There is no specific definition of installation provided in TSG 11—2020 \"Technical Regulations for Boiler Safety\". Note: No installation qualifications are required when an integrated boiler is placed in position, and no supervision or inspection is necessary during the installation process. An integrated boiler refers to a boiler in which the boiler body, along with its auxiliary equipment and systems, are assembled by the boiler manufacturer on a single chassis or frame. 2. Definition of modification: Boiler modification refers to the act of altering the pressure-bearing structure of the boiler itself or changing its combustion method. Note 1: The modification design shall be carried out by a boiler manufacturing unit with the appropriate qualifications. Note 2: Steam boilers can be converted into hot water boilers, but hot water boilers cannot be converted into steam boilers. Note 3: The rated operating pressure should not be increased after modification. 3. Major repairs to Class A boilers: (1) Replacement of the boiler drum, start-up (steam-water) separator and water storage tank, temperature reducer, and central downcomers, along with welding repairs to their longitudinal and circumferential joints; (the character “ apparatus” was added to correct the wording error). (2) Replacement of more than 50% of the total number of heating surface tubes (screens and fins). (3) Replacement of headers, pipes, and fittings with an outer diameter greater than 273 mm. (4) Welding repairs to the main welds of the large plate girders. (5) Replacement of liquid (gas) fuel burners. Major repairs for boilers of Class B and below: (1) Replacement or patching of the cylinder, head (tube sheet), furnace chamber, top of the furnace chamber, flashback chamber, lower ring girth, and header; (2) Replacement of heating surface tubes in quantities exceeding 10% of the total number of such tubes (including water wall, convection tube banks, superheater, economizer, flue tubes, etc.), with a minimum of 10 tubes; replacement of the entire set of heating surfaces in once-through and cross-flow boilers; (3) Replacement of liquid (gas) fuel burners. Summary: 1. Construction notification is required for installation, modification, and major repairs. 2. Boiler manufacturers may install the boilers they produce (except bulk boilers). 3. Boiler modifications and repairs should be carried out by units with the appropriate qualification for boiler installation or by units with the corresponding qualification for boiler manufacturing; no separate licensing is required. 4. The installation, modification, and major repairs of boilers shall be subject to supervision and inspection by special equipment inspection agencies. 5. The relocation of a boiler shall be regarded as installation; notification must be provided and supervision inspection shall be carried out, with an inspection to be conducted prior to the relocation.
II. Pressure Vessels (Basis: TSG 21—2016 \"Regulations on Safety Supervision of Fixed Pressure Vessels\" and Amendment No. 1) 1. Installation: There is no explicit definition of installation in TSG 21—2016 \"Regulations on Safety Supervision of Fixed Pressure Vessels\". 2. Definition of modification: The modification of a pressure vessel refers to changing the structure of its main pressure-bearing components, or altering the operating parameters of the vessel, the medium it contains, or its intended use. Main stressed components: tube sections (including tapered sections), shell plates, shell plates of non-circular vessels, end caps, end plates, expansion joints, equipment flanges, tube sheets and heat exchange tubes of heat exchangers, studs of M36 and above (including M36), as well as pipe connections and pipe flanges with a nominal diameter of 250 mm or more. 3. Major repairs: Definition of major repairs: Replacement, reshaping, or patching of the main pressure-bearing components, as well as rewelding of butt joints that meet the requirements specified in 3.2.2.1 of these regulations, or repairing the adhesive joints of non-metallic pressure vessels. 3.2.2.1 Shell joint design: For butt joints of pressure vessels of Classes A and B manufactured by welding (the classification of butt joints of pressure vessels of Classes A and B is in accordance with the provisions of GB 150), full-thickness penetration welding shall be adopted. Summary: 1. Construction notification is required for installation, modification, and major repairs; the plans for modification or major repairs must obtain written approval from the original design firm or a design firm with corresponding capabilities. 2. Installation of fixed pressure vessels does not require a separate permit. 3. The production qualifications required to engage in the installation of pressure vessels at corresponding levels are as follows: Boiler Installation License (excluding oxygen chambers), Pressure Vessel Manufacturing License (enabling the installation of pressure vessels within the scope of the corresponding manufacturing license), and Pressure Pipeline Installation License (excluding oxygen chambers). Boiler installation units or pressure pipeline installation units with installation qualifications at any level can carry out the installation of pressure vessels. 4. The modification and repair of pressure vessels shall be carried out by units that have obtained the corresponding level of manufacturing license ； Manufacturers of A2-class pressure vessels can repair and modify large A1-class high-pressure vessels. 5. No supervision and inspection is carried out during the installation of pressure vessels, but such inspections are conducted during renovation and major repairs. 6. Fixed-pressure vessels shall not be converted into mobile-pressure vessels.
III. Pressure pipelines (Basis: TSGD 7006—2020 \"Rules for Supervision and Inspection of Pressure Pipelines\") 1. Installation: There is no specific definition for installation provided in TSG 31—2025 \"Safety Technical Regulations for Industrial Pipelines\". 2. Definition of modification: Activities that involve changing the specifications, material, or structural layout of pipes, or altering working parameters such as the medium, pressure, and temperature within the pipes, thereby causing changes in the performance parameters or structure of the pipes. 3. Definition of major repairs: Replacing pipe sections using welding methods on pipelines, as well as valve and pipe straightening, welding repairs to pressure-bearing components, sealing under pressure, and plugging under pressure. Replacing pipes of the same medium in one go over a total length of 100 meters falls under the category of major repairs. Length threshold: For the same medium, if the total length of pipes to be replaced at one time is >100 meters → major repair. General repairs: replacement for lengths of 100 meters or less, or repair using non-welding methods. Summary: 1. Construction notification is required for installation, modification, and major repairs. 2. The definitions of renovation and major repair are taken from TSG D7006-2020 \"Rules for Supervision and Inspection of Pressure Pipelines\". 3. The production qualifications required to carry out the installation of pressure pipelines at corresponding levels are as follows: Boiler Installation License (allows for the installation of pressure pipelines directly connected to the boilers being installed), Pressure Vessel Manufacturing License (allows for the installation of pressure pipelines directly connected to the pressure vessels being installed), and Pressure Pipeline Installation License (allows for the installation of pressure pipelines within the scope specified by the license). 4. The renovation and major repairs of utility pipelines and industrial pipelines shall be carried out by units with installation permits at the corresponding level, and no separate permit is required. 5. Supervised inspection is required throughout the installation, modification, and repair of pressure pipelines. However, for modifications or major repairs (except for emergency repair work on pipelines), supervised inspection is necessary when the total length of pipelines replaced at one time with the same medium exceeds 100 meters.
IV. Elevators (Basis: State Administration for Market Regulation’s Special Letter No. [2019] 64, “Table of Classification for Elevator Construction Categories”) 1. Definition of installation: The process of combining elevator components into a functional elevator unit through various operations such as assembly, fixation, and debugging； Including relocation. 2. Modifications fall into three categories: (1) Changing the rated speed, rated load capacity, lifting height, car weight (with the exception of the decorative weight specified by the manufacturer, or any cumulative increase or decrease in weight that does not exceed 5% of the rated load capacity), explosion protection rating, drive method, suspension method, speed control method, or control system. (2) Change the type of elevator doors, or add or remove them. (3) Change the load-bearing structure of the car frame, replace the car frame, or replace it with a car frameless elevator car. 3. Major repairs (5 categories of situations) (1) Installation or replacement of drive machines of different specifications or their main components, control cabinets or their control motherboards/speed control devices, speed limiters, safety gears, buffers, door locking devices, car upward overspeed protection devices, car unintended movement protection devices, safety circuits containing electronic components, programmable electronic safety-related systems, clamping devices, pawl devices, speed-limiting cut-off valves, hydraulic cylinders, steps, treads, handrails, and auxiliary brakes. (2) Replace suspension and termination devices, high-pressure hoses, and explosion-proof electrical components of different specifications. (3) Change the type of floor door or add more floor doors. (4) Install automatic rescue operation (automatic leveling in case of power outage) devices, energy recovery and energy-saving devices, etc., to modify the elevator’s original control circuit. (5) Adopt identity verification methods such as an elevator IC card system, installed in a manner other than through the external wiring of the elevator car control panel, floor call box, or their buttons. 4. General repairs (5 categories)(1) Repairing or replacing door lock devices of the same specification but different models, the control motherboard of the control cabinet, or the speed control device. (2) Repairing or replacing drive units of the same specifications or their main components, speed limiters, safety brakes, suspension systems, upper-speed protection devices for the car, devices to prevent accidental movement of the car, safety circuits containing electronic components, programmable electronic safety-related systems, clamping devices, speed-limiting cut-off valves, hydraulic cylinders, high-pressure hoses, explosion-proof electrical components, additional brakes, etc. (3) Replace the seal ring at the cable entry point of the explosion-proof elevator. (4) Reduce the number of floor doors. (5) The elevator IC card system is installed merely by adding external wiring to the elevator car control panel, the floor call box, or their buttons. 5. Maintenance (1) Activities such as cleaning, lubricating, adjusting, inspecting, and replacing wear-prone parts, including cutting and adjusting steel cables. (2) Tasks such as replacing door lock devices of the same specification and model, the control motherboard or speed control device in the control cabinet, repairing or replacing buffers of the same specification, stairs, pedals, handrails, and repairing or replacing apron panels are considered maintenance work. Summary: 1. For the installation, renovation, and major repairs of elevators, the construction party must provide a written notice prior to commencing work. 2. Entities that may engage in elevator installation and repair include: manufacturing entities that have obtained a license for elevator manufacturing (including installation, repair, and modification) ； A unit that has obtained a license for elevator installation (including repair) and is authorized by the corresponding elevator manufacturer. Elevator renovation work shall be carried out by the elevator manufacturer or a unit entrusted by it that holds the corresponding permits. 3. The installation, modification, and major repairs of elevators must all be subject to supervision and inspection by specialized equipment inspection agencies ；
V. Lifting machinery (Basis: TSG 51—2023 \"Safety Technical Regulations for Lifting Machinery\") 1. Installation: There is no specific definition of installation provided in TSG 51—2023 \"Safety Technical Regulations for Lifting Machinery\". 2. Definition of modification: Changing the structural form of the main load-bearing components of the existing lifting machinery, or the configuration of its main mechanisms, or the variability of its key parameters. 3. Repair and major repair: Replace the original main components and safety devices, adjust the control system, without changing the main parameters. Major repair: Replace the main load-bearing structural components, main mechanisms, and control systems of the existing lifting equipment, without changing the main parameters. Key distinction: Modifications can change the main parameters, while major repairs cannot. Summary: 1. For the installation, modification, and major repairs of lifting machinery, the construction party must submit a written notification prior to commencement of work. 2. Units that may engage in the installation and repair of lifting machinery include: manufacturing units that have obtained a license for the manufacture of lifting machinery (including installation, repair, and modification) ； Entities that have obtained a license for the installation (including repair) of lifting machinery ； 3. The modification unit must be the manufacturing unit (not limited to the original manufacturer, but must have a manufacturing license). 4. The installation, modification, and major repairs of lifting machinery must all be subject to supervision and inspection by specialized equipment inspection agencies ； 5. The modified lifting machinery shall undergo supervision inspections by Class A inspection agencies of level A1 or A2 in accordance with the specified supervision inspection items, and no type tests are required. 6. The main parameters are different from the primary parameters; for lifting machinery, the main parameters are those specified in clause 7.1.8. For the main parameters of different lifting machines, refer to note ca-5 in the regulations.
Special motor vehicles used within premises (factories) (Reference: TSG 81—2022 \"Safety Technical Regulations for Special Motor Vehicles Used within Premises (Factories)\") 1. There is no separate definition of \"installation\" for such vehicles, as they are delivered as complete units from the factory and require no installation on-site. 2. Transformation definition: Activities that involve changing the power system, transmission method, frame structure, or driving mechanism of the original forklift, as well as the power system and transmission method of sightseeing vehicles, or altering the original parameters or load curves of such vehicles. 3. Repair definition: Refers to the activity of replacing the power unit, steering system, transmission system, drop protection components, and frame components of the original forklift, or replacing the power unit, body components, and transmission system of the sightseeing vehicle, without altering the original parameters or load curve of the vehicle. “What does “primary parameter” mean? The main parameters of a forklift refer to its rated lifting capacity and explosion-proof rating ； The main parameters of tourist vehicles refer to the rated passenger capacity and maximum operating speed, with each of these parameters having corresponding lower limits. “What does a “load curve” refer to? The random document should contain a load curve or load table indicating the forklift’s rated lifting capacity and actual lifting capacity, and a clear and permanent load curve or load table must be affixed in a prominent location on the forklift. Summary: 1. Notification should be given before modifying and constructing specialized motor vehicles used on the site (factory). 2. The modification shall be carried out by a unit that holds the corresponding manufacturing license. After the modification, the original nameplate is retained, while a new nameplate for the mobile vehicle is added, indicating the unit that carried out the modification, the date of modification, and the license number. If the modification involves main parameters, add information about these modified parameters to the nameplate. In cases involving changes to the original forklift load curve, the modifying party shall issue a new load curve diagram or load table indicating the forklift’s rated load capacity and actual lifting capacity. 3. Initial inspection: After the modification, it must pass an initial inspection, and use is permitted only after the change in usage registration is completed. 4. Units that may engage in the repair of special motor vehicles used within premises (factories) include: manufacturing units that hold a license for the manufacture (including repair and modification) of such special motor vehicles ； Entities that have obtained a license to repair specialized motor vehicles used on site (in factories) ； The modification of specialized motor vehicles used on site (factory) should be carried out by units that have obtained the corresponding manufacturing permits.
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