BCGA 2000 Code of Practice CP 24

BCGA CODE OF PRACTICE CP24
Application of the Pressure Systems Safety

Regulations 2000 to Operational
Process Plant
Revision 1: 2004
BCGA CODE OF PRACTICE CP 24
Process Plant
Revision 1: 2004
Copyright © 2004 by British Compressed Gases

Association. First printed 1992. All rights reserved. No
part of this publication may be reproduced or transmitted
in any form or by any means, electronic or mechanical,
including photocopy, without permission from the
publisher:
BRITISH COMPRESSED GASES ASSOCIATION

6 St. Mary’s Street, Wallingford, OX10 0EL
Tel: 0044 (0)1491 825533 Fax: 0044 (0)1491 826689
Website: www.bcga.co.uk
E-mail: enquiries@bcga.co.uk
ISSN 0260-4809
BCGA CP24 Rev 1 © 2004

PREFACE
The various publications issued by the British Compressed Gases

Association have the objective of establishing consistency in
design, construction practices and user operational and
maintenance procedures, in order to establish high standards of
reliability and safety in the interests of employers, employees and
the general public.
The Association endeavours to compile these documents using

the best sources of information known at the date of issue. The
information is used in good faith and belief in its accuracy. The
publications are intended for use by technical competent persons
and their application does not, therefore, remove the need for
technical and managerial judgement in practical situations and
with due regard to local circumstances, nor do they confer any
immunity or exemption from relevant legal requirements,
including by-laws.
The onus of responsibility for their application lies with the user.
The Association, its officers, its members and individual members
of any Working Parties can accept no legal liability or
responsibility whatsoever, howsoever arising, for the
consequences of the use or misuse of the publications.
For the assistance of users, references are given, either in the text
or Appendices, to publications such as British, European, and
International Standards and Codes of Practice, and current
legislation that may be applicable. The intention of BCGA is that
this document should be read and used in the context of these
references where the subjects have a bearing on the local
application of the processes or operations carried out by the user.
BCGA’s publications are reviewed, and revised if necessary, at

three-yearly intervals. Readers are advised to check the list of
publications on the Association’s website www.bcga.co.uk to
ensure that the copy in their possession is the current version.

CONTENTS
Section Page
TERMONOLOGY AND DEFINITIONS 1
1 INTRODUCTION 3
2 SCOPE 4
3 SAFETY 4
4 DESIGN, CONSTRUCTION, INSTALLATION, MODIFICATION 5

AND REPAIR
5 PROVISION OF INFORMATION AND MARKING 6
6 WRITTEN SCHEME OF EXAMINATION 7
7 OPERATION, SAFE OPERATING LIMITS AND MAINTENANCE 7
8 KEEPING OF RECORDS 8
9 PRECAUTIONS TO PREVENT PRESSURISATION 9
10 THE COMPETENT PERSON 9
11 LIST OF REFERENCE DOCUMENTS 10
APPENDIX 1 11
APPENDIX 2 12
APPENDIX 3 13
APPENDIX 4 14
APPENDIX 5 15
APPENDIX 6 19
APPENDIX 7 20
APPENDIX 8 22
HISTORY AND OBJECTIVES OF BCGA 25

BCGA CODE OF PRACTICE CP 24
Process Plant
TERMINOLOGY AND DEFINITIONS
Shall Indicates a mandatory requirement for compliance with this Code of

Practice.
Should Indicates a preferred requirement, but is not mandatory for compliance

with this Code of Practice.
May Indicates an option available to the user of this Code of Practice.
Cryogenic Tank Indicates an assembly, complete with a piping system, of an inner vessel
and an outer jacket to contain insulation. The insulation space will
normally be subject to a vacuum.
Vessel Indicates a pressure vessel which may or may not be insulated.
Revalidation Indicates the endorsement of a cryogenic tank as fit for continued service
based upon a review of documentation for design, operation and
examinations.
Cryogenic liquid For the purpose of this document cryogenic liquid is liquid oxygen,
nitrogen, argon, hydrogen or helium.
Pressure system
Relevant fluid
Danger
Examination
Pipework
Pipeline
Installed system These terms are as defined in the Pressure
Mobile system Systems Safety Regulations 2000 (S1128)
Safe operating limits which will be referred to as the Regulations
User in this Code of Practice.
Transportable pressure
receptacle
Protective device
Competent person
Liquid cylinder Indicates a transportable pressure receptacle, containing a cryogenic

liquid or liquid CO2 below ambient temperatures.
BCGA CP24 Rev 1 © 2004 1

Gas cylinder Indicates a transportable pressure receptacle, containing a permanent or
liquefiable gas at ambient temperatures.
Operational process Equipment that is used for the manufacture, storage and
plant distribution of industrial gases in either gaseous or liquid form.
BCGA CP24 Rev 1 © 2004 2

1 INTRODUCTION
The intention of the Pressure Systems Safety Regulations (PSSR) is to prevent the risk
of danger from the uncontrolled release of stored energy as a result of the failure of a
pressure system or any part of it.
It should be noted that the Regulations do not take into account the properties of the
fluid contained within the pressure system, with the exception of steam. Additional
precautions should be considered when hazardous, eg toxic, corrosive or flammable,
fluids are within pressure systems.
The Regulations (originally introduced in 1989 as the Pressure Systems and

Transportable Gas Containers Regulations) gave legal recognition to existing safe
practices.
There are requirements for:

• design and construction
• suppliers to provide information to users
• users to establish safe operating limits for installed systems
• Written Schemes of Examination and recorded Scheduled Maintenance Schemes
• the appointment of Competent Persons to prepare, implement and advise on the
scope of Written Schemes.
• Examination in accordance with the written scheme
• Operation
• Maintenance
• Modification and Repair
• Keeping of records
The primary responsibility for compliance with the Regulations lies with the user of an
installed system and it is his responsibility to enlist the assistance he requires to comply
with the Regulations.
This Code of Practice is designed to provide industry guidance for the benefit of
suppliers and users of Industrial Gas Pressure systems on their own or consumers’
premises. It will address the main points of the Regulations insofar as they affect these
typical installations.
It should be noted that other industrial Associations have their own Codes of Practice.
BCGA CP24 Rev 1 © 2004 3

2 SCOPE
This Code of Practice covers installed pressure systems, and systems open to
atmosphere at operational process plants in the industrial gases industry.
In principle, for a system to be a pressure system, it must contain a relevant fluid.

However, in general, water and hydraulic lines are excluded, as are systems below 0.5
bar unless they contain steam. All systems containing steam fall within the Regulations
irrespective of pressure.
A pressure system, as defined in this Code of Practice, will therefore include:
a) pressure vessels, storage tanks, heat exchangers, steam generating plant, pipework,
vaporisers and protective devices,
b) pipework and protective devices connected to gas or liquid cylinders.
c) a pipeline operating at 2 bar(g) and above and its protective devices.
Road tankers and transportable pressure receptacles, subject to the Carriage of

Dangerous Goods and Use of Transportable Pressure Equipment Regulations 2004, are
not included with the scope of this Code of Practice.
Since 30th May 2002 design & construction, provision of information & marking, and
modification of pressure equipment are, in most cases, covered by the Pressure
Equipment Regulations 1999 (PER). However, the Pressure Equipment Regulations do
not apply to the assembly of pressure equipment on the site(s) & under the
responsibility of the user, as in the case of industrial installations. In such cases, the in-
use regulations cover the assembly of pressure equipment on site.
The application of these Regulations to industrial and medical pressure systems installed
at consumer premises is addressed in another BCGA Code of Practice, CP23.
3 SAFETY
The objective of these Regulations is to prevent danger from the failure of a pressure
system whilst under pressure.
The appendices give guidelines on the content of Written Schemes of Examination for
various items of process plant and details of maximum intervals between examinations.
The outline Written Schemes of Examination set out in the appendices, with the
associated intervals, have been prepared with the objectives of the Regulations in mind.
Personnel involved in any way with the examination of pressure systems should follow
the guidelines given below:
• All personnel shall observe the Permit to Work system as administered by a

particular operational site.
• Entry into vessels, or other confined spaces, shall be in accordance with The
Confined Spaces Regulations 1997.
BCGA CP24 Rev 1 © 2004 4

• All vessel contents shall be disposed of by the safe draining/venting and checks
carried out to ensure atmospheric pressure is present prior to opening of any
manway.
• Before entry into a vessel, it shall be physically isolated (eg broken lines, spading)
and atmospheric sampling carried out.
4 DESIGN, CONSTRUCTION, INSTALLATION, MODIFICATION & REPAIR

(Reference Regulations 4, 6 and 13)
The design, construction and significant modification of the majority of pressure

equipment and assemblies are subject to the requirements of PER.
However the design, construction and modification requirements of the PSSR apply
under the following circumstances
• Assembly of pressure equipment on site and under the responsibility of the user.
• Steam systems under 0.5 barg
• Repair of pressure equipment
• Modification of pressure equipment which does not result in a substantial change of
use
• Second hand equipment
• Pipelines
Where PSSR are applicable the following shall apply
4.1 Design and construction
The pressure system shall be properly designed and properly constructed from suitable
material, so as to prevent danger, and that all necessary examinations can be effectively
and safely carried out.
The pressure system shall be provided with suitable protective devices.
4.2 Installation
The pressure system shall not be installed in such a way as to give rise to danger or
otherwise impairs the operation of any protective device or inspection facility.
4.3 Modification and repair
The pressure system shall not be modified or repaired in such a way as to give rise to
danger or impair the operation of any protective device or any inspection facility.
BCGA CP24 Rev 1 © 2004 5

5 PROVISION OF INFORMATION AND MARKING
(Reference Regulation 5)
Sufficient written information shall be supplied to enable the pressure system to be

installed, operated, maintained, and examined safely. Such information shall include
data to enable the user to determine the safe operating limits.
Information may include the following:
• maximum and minimum design pressure

• maximum and minimum design temperature
• maximum flow at design pressure
• operating instructions
• maintenance instructions
• test certificates
• system schematic or flowsheet
• schedule of protective devices and their function.
The above information may be included in the handover documentation and operating
instructions supplied to the user.
Equipment supplied in accordance with the PER should have sufficient information and
marking to satisfy the above requirements, however additional information to enable
complex examination and/or repairs may be required. The user should ensure that
information requirements are specified at the time of order.
Pressure vessels, not subject to PER, over 250 bar litre capacity shall be marked by the
manufacturer with the information contained in Schedule 3 of the Regulations.
BCGA CP24 Rev 1 © 2004 6

6 WRITTEN SCHEME OF EXAMINATION
(Reference Regulations 8, 9 & 10)
A pressure system shall not be operated without a written scheme of examination for the
following parts of the system :
a) all primary protective devices

b) all vessels (over 250 bar litre capacity) and all pipelines in which a defect may give
rise to danger
c) those parts of the pipework in which a defect may give rise to danger.
The written scheme shall be certified by a Competent Person.
Appendices 1 to 8 give guidelines on the content of the Written Schemes of

Examination for various items of process plant.
The examination intervals stated in the appendices are the maximum that shall be
considered, based on current industry practice. Where users wish to extend examination
intervals beyond their existing practices, they must have sufficient data to demonstrate
that the new intervals will not give rise to danger. The extension of examination
intervals must be endorsed by the Competent Person.
Under some circumstances, it may be necessary to reduce examination intervals as

required by the Competent Person.
The Competent Person must carry out the required examination in accordance with the
Written Scheme of Examination and submit a report accordingly. If, for any reason, an
examination is postponed, then this must be by prior written notification to the
enforcing authority for the premises at which the pressure system is situated.
If the Competent Person carrying out an examination is of the opinion that the pressure
system will give rise to imminent danger without modification, repair or change in
operating conditions, then it must not be operated until the required changes have been
made. The Competent Person must also advise the enforcing authority in writing of this
action.
7 OPERATION, SAFE OPERATING LIMITS AND MAINTENANCE

(Reference Regulations 7, 11 and 12)
7.1 Operation
The user of a pressure system shall provide any person operating the system with
suitable instructions and appropriate training for the safe operation of the system and the
action that needs to be taken in the event of an emergency.
It is good practice for the user to have a schematic or flow diagram for the system which
indicates the necessary valves and controls to operate the system safely.
BCGA CP24 Rev 1 © 2004 7

7.2 Safe operating limits
The user of a pressure system must not allow it to be operated unless he has established
the safe operating limits of that system.
It is the responsibility of the user to set the safe operating limits of all pressure systems
connected to that equipment.
7.3 Maintenance
Maintenance is required under the Regulations to ensure equipment remains in a safe

condition. It is the responsibility of the user to ensure that this is carried out.
The following points should be noted:
7.3.1 Equipment out of service should be checked thoroughly prior to being returned
to service.
7.3.2 Precautions are required to ensure that vessels are not subject to over or under-
pressure at anytime. It shall not be permitted to isolate pressure/vacuum relief
devices unless adequate precautions have been taken to prevent the possibility of
unacceptable pressure conditions occurring.
8 KEEPING OF RECORDS
The following records shall be kept by the user, or the owner in the case where he has
undertaken to examine and maintain the system:
8.1 The Written Scheme of Examination.
8.2 The last report, in accordance with the Written Scheme of Examination.
8.3 Any previous reports if they assist in assessing whether the system is safe to operate.
8.4 Records of any repairs or modifications carried out.
8.5 Documents supplied under Section 5.
8.6 Agreement to postpone an examination and advice to enforcing authority.
8.7 Tank revalidation report, where appropriate.
8.8 Records of any out-of-service period and storage conditions, where appropriate.
These records shall either be kept at the premises where the equipment is installed, or at
the office of the user or owner, when applicable. The records may be kept within a
computer system as long as the records are protected from unauthorised alteration, and a
printed copy can be produced when required.
BCGA CP24 Rev 1 © 2004 8

9 PRECAUTIONS TO PREVENT PRESSURISATION
The user of a vessel which is constructed with a permanent outlet to the atmosphere,
shall ensure that the outlet is not obstructed when the vessel is in use.
10 THE COMPETENT PERSON
The Regulations define duties for the Competent Person in two distinct functions:
• certifying Written Schemes of Examination

• carrying out examinations under the Scheme.
The Competent Person may be either:
• a user company with its own in-house inspection department

• an inspection organisation providing such services
• a self-employed person.
The Approved Code of Practice, Safety of Pressure Systems L122, defines the level of
corporate membership, experience, specialist services and organisations required for the
Competent Person certifying Written Schemes of Examination for minor, intermediate
and major systems, and gives guidance on accreditation to EN45004.
BCGA CP24 Rev 1 © 2004 9

11 LIST OF REFERENCE DOCUMENTS
(1) SI 128 The Pressure Systems Safety Regulations 2000.
(2) HSC L122 Health and Safety Commission Approved Code of Practice,
“Safety of Pressure Systems”.
(3) HSE GS4 Guidance Note from the Health and Safety Executive,
“Safety in Pressure Testing” 1998.
(4) SI 1713 The Confined Spaces Regulations 1997
(5) LPGA “Installation and Maintenance of Bulk LPG Storage at

Code of Practice Consumers’ Premises – Part 3: Periodic Inspection and
1 Pt 3 Testing”.
(6) BCGA “Application of the Pressure Systems Safety Regulations

Code of Practice 2000 to Industrial and Medical Pressure Systems Installed at
CP23 Consumer Premises”
(7) BCGA “Revalidation of Bulk Liquid Oxygen, Nitrogen, Argon and

Code of Practice Hydrogen Cryogenic Storage Tanks”
CP25
(8) SI 2001 The Pressure Equipment Regulations 1999
(9) AOTC GN3 Guidelines for the measurement of Peaking and Calculation
of Ultrasonic Inspection Intervals
(10) SAFed GN4 Guidelines for the Examination of Boiler Shell-to-Endplate

and Furnace-to-Endplate Welded Joints
(11) BS EN 45004 General criteria for the operation of various types of bodies
performing inspection
(12) SI 825 The Pipelines Safety Regulations 1996
(13) SI The Carriage of Dangerous Goods and Use of Transportable

Pressure Equipment Regulations 2004
BCGA CP24 Rev 1 © 2004 10

APPENDIX 1
Sheet 1 of 1
OUTLINE WRITTEN SCHEME OF EXAMINATION FOR HEAT EXCHANGERS
Plant/equipment Examination interval Guidelines for Written Scheme of Examination

1 Generally no requirement for regular a) Scope of examination to be determined by the Competent Person
Heat exchangers periodic examinations
~ cryogenic duty
2 12-years The following examinations will be undertaken on the part(s) of the heat
Heat exchangers exchanger containing the relevant fluids.
~ non-corrosive a) Visual, external and internal examination or visual, external
~ non-erosive examination and NDT when specified by the Competent Person, or
~ non-fatigue duty strength test at a pressure defined by the Competent Person.
b) Check nameplate(s) are attached and the heat exchanger is operating
with its design limits.
c) Record all details of examination.
2 Examination intervals to be determined The following examinations will be undertaken on the part(s) of the heat
Heat exchangers by local operating conditions. exchanger containing the relevant fluids.
~ corrosive/fatigue duty Maximum period : 8-years a) Visual, external and internal examination or visual, external
examination and NDT when specified by the Competent Person, or
strength test at a pressure defined by the Competent Person.
b) Check nameplate(s) are attached and the heat exchanger is operating
with its design limits.
BCGA CP24 Rev 1 © 2004 11

APPENDIX 2
Sheet 1 of 1
OUTLINE WRITTEN SCHEME OF EXAMINATION FOR HOSES

1 Examination periods to be a) Hoses to be examined and re-certified for further use, or
Hoses determined by local operating b) Replaced on a time-expired basis
Cylinder filling conditions. c) Record all details of examination.
2 1-year a) Visual examination.

Hoses b) Check couplings for wear.
Liquid transfer c) Fit new seals where applicable.
d) Pressure test when specified by the Competent Person.
e) Record all details of examination.
3 Examination periods to be d) Hoses to be examined and re-certified for further use, or

Hoses determined by local operating e) Replaced on a time-expired basis
Tube trailer filling conditions. f) Record all details of examination.
4
Hoses 1 year a) Visual external examination to check for cracking, bulging, distortion, or
Hydrogen Reformer Tube inlet damage
6 years Mandatory replacement
BCGA CP24 Rev 1 © 2004 12

APPENDIX 3
Sheet 1 of 1
OUTLINE WRITTEN SCHEME OF EXAMINATION FOR PIPELINES

1 First examination, 15-years a) Visual examination of exposed sections.
Pipelines after pipeline was first b) Diagnostic check of underground sections.
All duties passed for service. c) Pressure test when specified by the Competent Person
d) Competent Person to determine date of the next examination.
Future examinations to be e) Record all details of examination
determined by the
Competent Person
BCGA CP24 Rev 1 © 2004 13

APPENDIX 4
Sheet 1 of 1
OUTLINE WRITTEN SCHEME OF EXAMINATION FOR PIPEWORK

1 Examination intervals to be a) Visual, external examination.
Pipework set by local operating b) Check insulation for damage or water ingress.
Pipework in the following conditions. c) NDT when specified by the Competent Person.
duties needs to be considered: d) Pressure test as required by the Competent Person.
~ steam/condensate e) Record all details of examination.
~ subject to mechanical damage
~ subject to erosion
~ subject to corrosion
~ where a defect may give rise
to danger
2 Examination intervals to be a) Visual external examination
Pipework at elevated set by local operating b) Dye-penetrant check of a sample of welds
temperature conditions, subject to c) Dye penetrant check of external surfaces at inside and outside of bends
(under creep conditions) maximum interval of 6 d) Measurement of external diameter at hot end
years
3
Reformer Systems Examination intervals to be
Reformer tubes set by local operating a) Visual external examination to check for straightness and lack of bowing or bulging
conditions, subject to b) Measurement of tube external diameter at reference locations
maximum interval of 6 c) Check tube surfaces for glazing
years Check setting and freedom of movement of tube tensioning devices (where fitted)
BCGA CP24 Rev 1 © 2004 14

APPENDIX 5
Sheet 1 of 4
OUTLINE WRITTEN SCHEME OF EXAMINATION FOR PROTECTIVE DEVICES

1 In line with the examination of a) Visual, external examination including vent pipe supports. In-situ test with calibrated
Relief valves associated equipment equipment. Attach tag with valve number, test pressure and test date. Record all details of
Air examination, or
b) As appropriate complete “As found lift pressure” test and record result Replace with new or
refurbished valve. Attach tag with valve number, test pressure and test date. Record all
details of examination, or
c) Visual, external examination including vent pipe and supports. Complete “As found lift
pressure” test and record result Dismantle and check all moving parts for damage, wear and
freedom of movement. Re-assemble. Re-set valve to the required pressure. Attach tag with
valve number, test pressure and test date. Record all details of examination.
2 2-years a) Visual, external examination including vent pipe supports. In-situ test with calibrated
Relief valves equipment. Attach tag with valve number, test pressure and test date. Record all details of
Carbon dioxide storage examination, or
3 a) Visual, external examination including vent pipe supports. In-situ test with calibrated
Cryogenic liquid storage examination, or
~ non-vacuum insulated 3-years refurbished valve. Attach tag with valve number, test pressure and test date. Record all
~ vacuum insulated 3-years details of examination, or
~ vacuum insulated fitting with 5-years c) Visual, external examination including vent pipe and supports. Complete “As found lift
bursting discs pressure” test and record result Dismantle and check all moving parts for damage, wear and
BCGA CP24 Rev 1 © 2004 15

APPENDIX 5
Sheet 2 of 4
Cryogenic process plant examination, or
Cylinder filling examination, or
Hydrogen/carbon monoxide examination, or
Process & storage b) As appropriate complete “As found lift pressure” test and record result Replace with new or
BCGA CP24 Rev 1 © 2004 16

APPENDIX 5
Sheet 3 of 4
7 10-years a) Visual, external examination including vent pipe supports.
Relief valves b) Check drain-holes are clear.
Hydrostatic/thermal relief for c) Replace with new or refurbished unit.
pipework protection d) Record all details of examination.
8 5-years replacement a) Replace valve with new or refurbished unit with correct set pressure.
Relief valves b) Check pressure setting and test-date stamping on body.
LPG Valve to be replaced during c) Check vent stacks for corrosion.
the 5 or 10 year d) Record all details of examination.
examination of the vessel to
which it is fitted. (LPGA
CoP (1) Part 3)
9 In line with the examination a) Visual, external examination including vent pipe supports. In-situ test with
Relief valves of the associated calibrated equipment. Attach tag with valve number, test pressure and test date.
Steam equipment, subject to a Record all details of examination, or
maximum interval of 4 b) As appropriate complete “As found lift pressure” test and record result Replace with
years. new or refurbished valve. Attach tag with valve number, test pressure and test date.
Record all details of examination, or
c) Visual, external examination including vent pipe and supports. Complete “As found
lift pressure” test and record result Dismantle and check all moving parts for
damage, wear and freedom of movement. Re-assemble. Re-set valve to the
required pressure. Attach tag with valve number, test pressure and test date.
Record all details of examination.
10 Examination intervals to be a) Visual, external examination including vent pipe supports. In-situ test with
Relief valves set by local operating calibrated equipment. Attach tag with valve number, test pressure and test date.
Other duties conditions. Record all details of examination, or
b) As appropriate complete “As found lift pressure” test and record result Replace with
new or refurbished valve. Attach tag with valve number, test pressure and test date.
Record all details of examination, or
Visual, external examination including vent pipe and supports. Complete “As found lift
pressure” test and record result Dismantle and check all moving parts for damage, wear
and freedom of movement. Re-assemble. Re-set valve to the required pressure. Attach
tag with valve number, test pressure and test date. Record all details of examination.
BCGA CP24 Rev 1 © 2004 17

APPENDIX 5
Sheet 4 of 4

11 a) Visual, external examination.
Bursting discs b) Replacement with new disc.
Carbon dioxide 2-years c) Record all details of examination.
Note
Bursting discs should be replace in this function by pressure-relief valves at the earliest
opportunity due to the hazards of uncontrolled release of CO2 (solidification of
contents).
Other duties In line with the examination a) Visual, external examination.

of associated relief-valve.
12 4 years a) Visual external examination

Non Return valves b) Where possible, remove from plant, complete “as found” reverse flow leak test and
(when acting as a primary record results
protective device) c) Disassemble and inspect all components, rectify or replace as necessary
d) Reassemble, complete functional test and record results
13 6 years a) Functional check to verify operation of device
Low Temperature Protective b) Recalibrate/adjust set point to the correct operating temperature
Devices c) Where possible, dismantle and check all moving parts for damage, wear and freedom of
movement, Re-assemble and reset valve to set point
d) Record all details of examination
14
Overflow devices
Cryogenic liquid storage
~ non-vacuum insulated 3 years Visual external examination and functional test.

15 No requirement for regular Recalibration and functional checks to be carried out during planned maintenance periods or
Other protective devices periodic examination main plant overhaul.
Instrumentation/control
equipment
BCGA CP24 Rev 1 © 2004 18

APPENDIX 6
Sheet 1 of 1
OUTLINE WRITTEN SCHEME OF EXAMINATION FOR STEAM-RAISING PLANT

Steam-raising plant b) Visual, internal examination.
Direct-fired heater 14-months c) NDT in accordance with SAFed GN4
d) Peaking check in accordance with AOTC GN3
e) Confirm nameplate is attached and check that equipment is working within design
limits.
f) Carry out function check on all controls.
g) Record all details of examination.
2 The first thorough and in- a) Visual, external examination.
Steam-raising plant service examinations are b) Visual, internal examination.
Economisers/waste heat required within 2 years of c) NDT when specified by Competent Person.
boilers/super-heaters service, after which the d) Confirm nameplate is attached and check that equipment is working within design
Competent Person may limits.
extend the period up to a e) Carry out function check on all controls.
maximum of 4-years. f) Record all details of examination.
3 a) Visual external examination
Blowdown vessels In Phase with associated b) Visual internal examination (as accessible)
boiler c) NDT when required by competent person
4 a) Visual external examination
Deaerators Maximum interval 4 years b) Visual internal examination (as accessible)
c) Mandatory internal crack detection after 5 years service
BCGA CP24 Rev 1 © 2004 19

APPENDIX 7
Sheet 1 of 2
OUTLINE WRITTEN SCHEME OF EXAMINATION FOR VAPORISERS

Vaporisers set by local operating b) NDT when specified by Competent Person.
Ambient-air heaters (all duties) conditions c) Pressure test as required by the Competent Person.
d) Record all details of examination.

Vaporisers set by local operating b) Check insulation for damage or water ingress.
Carbon dioxide (electrically conditions c) NDT when specified by Competent Person.
heated) d) Pressure test as required by the Competent Person.

Vaporisers 1-year for direct fired b) Leak test
LPG duty 5 years for non-direct fired c) Check operation of control equipment
d) For direct-fired types only – hydraulic test and check flame impingement areas.
e) Check vaporiser identity and nameplate marking.
f) Check that relief valves are of the correct type and are in test.
g) Record all details of examination.
4 The first thorough and in- a) Visual, external examination.

Vaporisers service examinations are b) Visual, internal examination.
Steam/hot-water required within 2 years of c) NDT when specified by Competent Person.
(Closed systems, all duties) service, after which the d) Confirm nameplate is attached and check that vaporiser is working within design
Competent Person may limits.
extend the period up to a e) Carry out function check on all controls.
maximum of 4-years. f) Record all details of examination.
BCGA CP24 Rev 1 © 2004 20

APPENDIX 7
Sheet 2 of 2
OUTLINE WRITTEN SCHEME OF EXAMINATION FOR VAPORISERS

5 1 and 12-years Every year
Vaporisers
Steam a) Check discharge vents for blockage
(Open system – all duties) b) Check maintenance of correct water level
Note: It is recommended that where stainless steel coils are fitted the chloride
content of the water should be checked at the first examination
Every 12-years
a) Visual, internal examination to check condition of steam sparge manifold,

vaporiser coils and support structure
b) NDT when specified by the competent person
BCGA CP24 Rev 1 © 2004 21

APPENDIX 8
Sheet 1 of 3
OUTLINE WRITTEN SCHEME OF EXAMINATION FOR VESSELS

1 See guidelines The first thorough examination is required within 2-years of service, after which the Competent
Vessels Person may extend the period up to a maximum of 4-years; except that, in appropriate cases, where
Air receivers there is not liable to be significant corrosion, or where there is no significant pressure cycling and the
arrangements for maintaining the safety of the system are to a high standard, the period may be
extended to 6-years.
a) Visual, external examination.

b) Visual, internal examination.
c) NDT when specified by Competent Person.
d) Confirm nameplate is attached and check that equipment is working within design limits.
e) Carry out function check on all controls.
f) Record all details of examination.
2 The first thorough a) Visual, external examination

Vessels examination is required within b) Visual, internal examination
Steam receivers 2-years of service, after which c) Confirm vessel nameplate is attached and that the vessel is operating within design limits
the Competent Person may d) NDT when specified by the Competent Person
extend this period to a e) Record all details of examination
maximum of 4-years.
3 1-year a) Visual, external examination including foundations.
Vessels b) Check operation of purge systems.
Bulk cryogenic storage tanks c) Confirm nameplate is attached and check that equipment is working within design limits.
d) Record all details of examination.
Refer to BCGA CP 25 “Revalidation of Bulk Liquid Oxygen, Nitrogen, Argon and Hydrogen
20 year revalidation Cryogenic Storage Tanks”
4 The first thorough a) Visual, external examination.
Vessels examinations is required b) Check integrity of insulation.
Carbon dioxide and Nitrous oxide within 5-years of service, after c) Visual internal examination.
which the Competent Person d) NDT when specified by the Competent Person.
may extend the period up to a e) Ensure nameplate is fitted and visible.
maximum of 10-years. f) Survey vessel supports & civil foundations
g) Replica test of knuckle area if required
h) Record all details of examination.
BCGA CP24 Rev 1 © 2004 22

APPENDIX 8
Sheet 2 of 3

5 Generally no requirements Scope of examination to be determined by the Competent Person.
Vessels for regular periodic
Cryogenic process vessels examinations.
Maximum period: 8 years
(or 50% theoretical fatigue
life, whichever is shorter).
6 5 and 10-years Above-ground vessels – Every 5-years
Vessels a) Visual, external examination
LPG storage b) NDT when specified by the Competent Person.
c) Examination of vessel fittings.
d) Confirm vessel identity and nameplate markings.
Every 10 years
All actions listed above, plus
f) Visual, internal inspection or wall-thickness tests or hydraulic test.
Mounded Vessels
Every 5 years
a) Full internal examination plus either wall thickness tests or hydraulic test,
or
Expose sections of vessel external surface for visual examination, plus either full
internal examination or wall thickness tests or hydraulic test
b) Examination of vessel fittings
c) Check that relief valves have been replaced with correct type
d) Confirm vessel identity and nameplate markings
e) Record all details of examination
NOTE: If cathodic protection is fitted it must be checked for effective operation at

intervals specified by a Competent Person
BCGA CP24 Rev 1 © 2004 23

APPENDIX 8
Sheet 3 of 3

7 5-years a) Visual external examination including vessel foundations.
Vessels b) Confirm vessel nameplate is attached and check that vessel is operating within
Vacuum insulated design limits
c) Check if relief valve is in-test, if not replace with new or refurbished unit
d) Record all details of examination
20 year revalidation Refer to BCGA CP 25 “Revalidation of Bulk Liquid Oxygen, Nitrogen, Argon and
Hydrogen Cryogenic Storage Tanks”
8 In accordance with procedures issued by the Competent person responsible for transportable pressure receptacles
Buffer storage systems
comprising HP gas cylinders
9 Maximum period 6 years Competent Person to review failure mechanisms and determine scope of examination
Vessels
High temperature
10 4 years Scope of examination to be determined by the Competent Person, taking account of the
Vessels following factors:
Refrigeration system Vessels lagged or unlagged
Duty permanently below zero deg C, or cyclic
Ammonia system is/is not oil free
11 Examination intervals to be a) Visual external examination
Vessels determined by local b) Visual internal examination or wall thickness checks
Corrosive operating conditions. c) NDT when specified by Competent Person
Erosive d) Hydrostatic test to be carried out if required
Fatigue Maximum period 8-years e) Confirm vessel nameplate is attached and check that vessel is operating within
(or 50% theoretical fatigue design limits
life, whichever is shorter). f) Record all details of examination
12 12-years a) Visual external examination
Vessels b) Visual internal examination or wall thickness checks
Non-corrosive c) NDT when specified by Competent Person
Non-erosive d) Hydrostatic test to be carried out if required
Non-fatigue e) Confirm vessel nameplate is attached and check that vessel is operating within
design limits
f) Record all details of examination
BCGA CP24 Rev 1 © 2004 24

HISTORY AND OBJECTIVES OF BCGA
The British Compressed Gases Association was established in August l971

as the successor to the British Acetylene Association, formed in l901. Its
Members consist of producers, suppliers of gases equipment and container
manufacturers and users operating in the compressed gas field.
The main objective of the Association is the advancement of technology and

safe practice in the manufacture, handling and use of all gases and the design
and manufacture of all containers, apparatus, appliances, plant, etc. BCGA
also provides advice and makes representations, insofar as these relate to
particular problems of the compressed gases industry, on behalf of its
Members to all regulatory bodies, including the UK Government, concerning
legislation both existing and proposed.
Policy is determined by a Council elected from Member Companies, with

detailed technical studies being undertaken by a Technical Committee and its
specialist Sub-Committees appointed for this purpose.
Further details of the Association may be obtained from:
BRITISH COMPRESSED GASES ASSOCIATION

6 St. Mary’s Street, Wallingford, OX10 0EL
Tel: 0044 (0)1491 825533 Fax: 0044 (0)1491 826689
Website: www.bcga.co.uk
E-mail: enquiries@bcga.co.uk
BCGA CP24 Rev 1 © 2004 25

British Compressed Gases Association, 6 St. Mary’s Street, Wallingford, OX10 0EL

BCGA 2000 Code of Practice CP 24

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BCGA CODE OF PRACTICE CP24

Application of the Pressure Systems Safety

Copyright © 2004 by British Compressed Gases

BRITISH COMPRESSED GASES ASSOCIATION

BCGA CP24 Rev 1 © 2004

The various publications issued by the British Compressed Gases

The Association endeavours to compile these documents using

BCGA’s publications are reviewed, and revised if necessary, at

BCGA CP24 Rev 1 © 2004

TERMONOLOGY AND DEFINITIONS 1

4 DESIGN, CONSTRUCTION, INSTALLATION, MODIFICATION 5

5 PROVISION OF INFORMATION AND MARKING 6

6 WRITTEN SCHEME OF EXAMINATION 7

7 OPERATION, SAFE OPERATING LIMITS AND MAINTENANCE 7

9 PRECAUTIONS TO PREVENT PRESSURISATION 9

10 THE COMPETENT PERSON 9

11 LIST OF REFERENCE DOCUMENTS 10

HISTORY AND OBJECTIVES OF BCGA 25

BCGA CP24 Rev 1 © 2004

TERMINOLOGY AND DEFINITIONS

Shall Indicates a mandatory requirement for compliance with this Code of

Should Indicates a preferred requirement, but is not mandatory for compliance

May Indicates an option available to the user of this Code of Practice.

Vessel Indicates a pressure vessel which may or may not be insulated.

Liquid cylinder Indicates a transportable pressure receptacle, containing a cryogenic

BCGA CP24 Rev 1 © 2004 1

BCGA CP24 Rev 1 © 2004 2

The Regulations (originally introduced in 1989 as the Pressure Systems and

There are requirements for:

BCGA CP24 Rev 1 © 2004 3

In principle, for a system to be a pressure system, it must contain a relevant fluid.

A pressure system, as defined in this Code of Practice, will therefore include:

b) pipework and protective devices connected to gas or liquid cylinders.

c) a pipeline operating at 2 bar(g) and above and its protective devices.

Road tankers and transportable pressure receptacles, subject to the Carriage of

• All personnel shall observe the Permit to Work system as administered by a

BCGA CP24 Rev 1 © 2004 4

4 DESIGN, CONSTRUCTION, INSTALLATION, MODIFICATION & REPAIR

The design, construction and significant modification of the majority of pressure

Where PSSR are applicable the following shall apply

4.1 Design and construction

4.3 Modification and repair

BCGA CP24 Rev 1 © 2004 5

Sufficient written information shall be supplied to enable the pressure system to be

Information may include the following:

• maximum and minimum design pressure

BCGA CP24 Rev 1 © 2004 6

(Reference Regulations 8, 9 & 10)

a) all primary protective devices

The written scheme shall be certified by a Competent Person.

Appendices 1 to 8 give guidelines on the content of the Written Schemes of

Under some circumstances, it may be necessary to reduce examination intervals as

7 OPERATION, SAFE OPERATING LIMITS AND MAINTENANCE

BCGA CP24 Rev 1 © 2004 7

Maintenance is required under the Regulations to ensure equipment remains in a safe

The following points should be noted:

8.1 The Written Scheme of Examination.

8.4 Records of any repairs or modifications carried out.

8.5 Documents supplied under Section 5.