Why comply with the Pressure system Safety Regulations 2000 ?
If pressure equipment fails in use, it can seriously injure or kill people nearby and cause serious damage to property. Each year in Great Britain, there are about 150 dangerous occurrences involving such unintentional releases. Around six of these result in fatal or serious injury.
This text advises you on how to minimise the risks when working with pressure systems or pressure equipment which contain a liquid or gas under pressure. It does not cover gas cylinders (now called transportable pressure receptacles or transportable pressure vessels), or tanks and tank containers.
As an employer or self-employed person, you have a duty to provide a safe workplace and safe work equipment. Designers, manufacturers, suppliers, installers, users and owners also have duties. The main regulations covering pressure equipment and pressure systems are the Pressure Equipment Regulations 1999 and the Pressure Systems Safety Regulations 2000. Employers have a further duty to consult any safety or employee representatives on health and safety matters. Where none are appointed, employers should consult the workforce direct.
Examples of pressure systems and equipment are:
pressure cookers, autoclaves and retorts pressurised process plant and piping compressed air systems/air compressors (fixed and portable) heat exchangers and refrigeration plant valves, steam traps and filters boilers and steam heating systems pipe work and hoses.
Principal causes of incidents are:
poor maintenance of equipment, an unsafe system of work, poor equipment and/or system design, poor installation, inadequate repairs or modifications, operator error and poor training/supervision
The main hazards are:
impact from the blast of an explosion or release of compressed liquid or gas;
impact from parts of equipment that fail or any fragmented part or debris;
contact with the released liquid or gas, such as steam; and
fire resulting from the escape of flammable liquids or gases.
Pressure Systems - Reduce the risk of failure
The level of risk from the failure of pressure systems and equipment depends on a number of factors including:
the pressure in the system;
the complexity and control of its operation;
the suitability of the equipment and pipe work that contains it;
the type of liquid or gas and its properties;
the age and condition of the equipment;
the prevailing conditions (e.g. a process carried out at high temperature); and
the skills and knowledge of the people who design, manufacture, install, maintain, test and operate the pressure equipment and systems.
To reduce the risks you need to know (and act on) some basic precautions, some of which are contained in the Pressure Systems Safety Regulations 2000 and the Pressure Equipment Regulations 1999.
Pressure systems - Provide safe and suitable equipment
When installing new equipment, ensure that it is suitable for its intended purpose and that it is installed correctly. This requirement can normally be met by using the appropriate design, construction and installation standards and/or codes of practice. From 30 May 2002, most pressure equipment placed on the market must meet the requirements of the Pressure Equipment Regulations 1999. For pressure equipment not covered by the Pressure Equipment Regulations 1999, the more general requirements of the Pressure Systems Safety Regulations 2000 apply.
Be careful when repairing or modifying a pressure system. Following a major repair and/or modification, you may need to have the whole system re-examined before allowing the system to come back into use.
The pressure system should be designed and manufactured from suitable materials. You should make sure that the vessel, pipes and valves have been made of suitable materials for the liquids or gases they will contain.
Pressure Systems - Know the operating conditions
Know what liquid or gas is being contained, stored or processed (e.g. is it toxic/flammable?).
Know the safe operating limits of the system and any equipment directly linked to it or affected by it.
Know the process conditions, such as the pressures and temperatures.
Ensure that appropriate employees have access to these instructions, and are properly trained in the operation and use of the equipment or system (see the section on training).
Ensure there is a set of operating instructions for all the equipment and for the control of the whole system including emergencies.
ISI can offer free advice on all statutory inspections of these Pressure System Safety Regulations 2000 , please call 01675 481779
Pressure Systems - Fit suitable protective devices and ensure they function properly
Ensure suitable protective devices are fitted to the vessels, or pipe work (e.g. safety valves and any electronic devices which cause shutdown when the pressure, temperature or liquid or gas level exceed permissible limits).
Ensure the protective devices have been adjusted to the correct settings.
If warning devices are fitted, ensure they are noticeable, either by sight or sound.
Ensure protective devices are kept in good working order.
Ensure that, where fitted, protective devices such as safety valves and bursting discs discharge to a safe place.
Ensure that, once set, protective devices cannot be altered except by an authorised person.
Pressure systems - Carry out suitable maintenance
All pressure equipment and systems should be properly maintained. There should be a maintenance programme for the system as a whole. It should take into account the system and equipment age, its uses and the environment.
Systems should be depressurised before maintenance work is carried out.
Ensure there is a safe system of work, so that maintenance work is carried out properly and under suitable supervision.
Further guidance on regulation 11 (Operation) and regulation 12 (Maintenance) of the Pressure Systems Safety Regulations 2000 is given in the Approved Code of Practice Safety of pressure systems. (See ‘Further reading’.)
Pressure systems - Have the equipment examined
Under the Pressure Systems Safety Regulations 2000, a written scheme of examination is required for most pressure systems , together with a statutory thorough examination and test . Exempted systems are listed in the Regulations. Generally speaking, only very small systems are exempted, i.e. those systems operating below 250 bar litres capacity ( to work this out multiply the capacity of the pressure vessel in litres and multiply by the pressure the system operates at in Bar units )
The ISI Pressure Systems inspection team can assist you with identifying statutory pressure system and pressure vessel, please call ISI for FREE advice on T: 01675 481779
Pressure systems - Written Scheme of Examination and Yearly Safety Inspection
The written scheme of examination should be drawn up (or certified as suitable) by a competent person. It is the duty of the user of an installed pressure system and the owner of a mobile pressure system to ensure that the written scheme of examination has been drawn up. You must not allow your pressure system to be operated (or hired out) until you have a written scheme of examination and ensured that the pressure system has been thoroughly examined and /or Inspected.
The written scheme of examination must cover all protective devices. It must also include every pressure vessel and those parts of pipelines and pipe work which, if they fail, may give rise to danger.
The written scheme of examination must specify the nature and frequency of thorough examinations, and include any special measures that may be needed to prepare a pressure system for a safe thorough examination.
The pressure system must undergo a thorough examination in accordance with the written scheme of examination by a competent person.
For fired (heated) pressure systems, such as steam boilers, the written scheme of examination should include an thorough examination of the system when it is cold and stripped down and when it is running under normal conditions.
The key steps are:
Decide what items of equipment, pressure vessels and parts of the pressure plant should be included in the written scheme of examination. These are items that require statutory inspection and thorough examination. It must include all protective devices. It must also include pressure vessels, and parts of pipe work which, if they failed, could give rise to danger.
The written scheme of examination must be drawn up (or certified as suitable) by a competent person. It must specify whether the thorough examination is in-service or out-of service and how often the system is to be thoroughly examined.
The system must be thoroughly examined/ inspected by a competent person or inspection company such as ISI, in accordance with that scheme.
Remember, a thorough examination undertaken in accordance with a written scheme of examination is like an MOT for your car. It is a statutory examination that is designed to ensure that your pressure system is ‘roadworthy’. It is not a substitute for regular and routine maintenance.
Pressure systems - Sources of advice
Professional advice is available from the following:
ISI Head office - Pressure Systems inspection team can offer free advice on how you can comply with these regulations and can provide written schemes of examination, together with statutory safety inspections and thorough examination of pressure vessels. Please contact the team on 01675 481779, or via email info@isisafety.com
Your local HSE office - the number can be obtained from directory enquiries or the phone book - under Health and Safety Executive, or from the HSE website www.hse.gov.uk.
For premises covered by the local authority, eg offices and shops, contact the Local Authority Unit enquiry point Tel: 020 7717 6442 Fax: 020 7717 6418.
Pressure systems - Further reading
This text can tell you only a few of the main facts about the dangers associated with pressure equipment, and about your responsibilities under the Pressure Systems Safety Regulations 2000. Further practical advice is available as follows:
Safety of pressure systems. Pressure Systems Safety Regulations 2000. Approved Code of Practice
L122 HSE Books 2000 ISBN 978 0 7176 1767 8
Pressure Systems Safety Regulations 2000 (SI 2000 No 128) The Stationery Office Tel: +44 (0)1603 622211
For information about health and safety ring HSE’s Infoline Tel: 0845 345 0055 Fax: 0845 408 9566 Textphone: 0845 408 9577 e-mail: hse.infoline@natbrit.com or write to HSE Information Services, Caerphilly Business Park, Caerphilly CF83 3GG.
ISI can offer free advice on all aspects of these Pressure System Safety Regulations (PSSR) 2000 , please call 01675 481779
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