GUIDANCE DOCUMENT

REGISTRATION

INTERNATIONAL LABOR ORGANIZATION (ILO)

DEVELOPMENT OF A SYSTEM AND WORKFLOW FOR HEAVY DUTY

MACHINERY INSPECTION BY A THIRD PARTY

VOULME II –PART I

GUIDANCE DOCUMENT FOR REGISTERATION AND PERIODIC INSPECTION

OF BOILERS AND PRESSURE VESSELS
BY

ADDIS ABABA INSTITUTE OF TECHNOLOGY, AAU

AUGUST 2024
EXECUTIVE SUMMARY

As part of the consultancy service agreement between ILO and AAiT-AAU for the
Development of a System and Workflow for Heavy Duty Machineries Inspection by a Third
Party, Volume I of the project, which is Assessment of Heavy Duty Machinery Registration
and Inspection Practice at National and International Level was completed and submitted to
the ILO.

Volume II of the project, which focuses on preparing the Guidance Document and Workflow
for the Inspection, Reporting, and Certification of Heavy-Duty Machineries, is presented in
this document by the AAiT consultancy team.

The first section of this document, titled Guidance Document for Registration and Periodic
Inspection of Pressure Vessels, presents the types of pressure vessels that require registration
under the OSH Directives of MoLS, along with the duties and responsibilities of both owners
and authorized inspectors, benchmarked against Singapore's practices. Following this, annual
inspection procedures for heavy-duty machinery, including boilers and air receivers in
compressed air systems, have been developed based on AAiT's experience and international
best practices.

The documents provide brief introductions to the technical aspects of heavy-duty machinery,
including common hazard causes and associated safety devices. They detail inspection
procedures and offer guidance on form-filling, including verifying safety device compliance,
checking good housekeeping practices, and recording annual inspection results and
recommendations. Additionally, the detailed processes for inspecting heavy-duty machinery
are comprehensively outlined.".

Finally, pressure vessel registration forms, annual inspection forms for boilers, compressors
and air receivers, inspection certificate form, registration certificate form, pressure vessel
annual inspection certification are prepared and annexed.

The inspection forms capture essential information about the manufacturer and technical
specifications. They include checklists for verifying compliance with mandatory safety
requirements, adherence to good housekeeping practices, and documenting annual inspection
results. Additionally, the forms provide space for overall comments, recommendations, and
the validity period of the annual inspection.

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CONTENTS

EXECUTIVE SUMMARY ................................................................................................. ii

CONTENTS ....................................................................................................................... iii
ACRONYMS ...................................................................................................................... iv
LIST OF FORMS ................................................................................................................. v
1. INTRODUCTION............................................................................................................. 1
2. PRESSURE VESSELS ..................................................................................................... 1
3. REGISTRATION OF NEW PRESSURE VESSELS ........................................................ 2
4. RE-REGISTRATION OF EXISTING PRESSURE VESSEL ........................................... 3
5. PERIODIC INSPECTION OF PRESSURE VESSELS .................................................... 4
6. DUTIES AND RESPONSIBILITIES OF OWNERS ......................................................... 5
7. DUTIES AND RESPONSIBILITIES OF AUTHORISED INSPECTORS ........................ 6
8. REGISTRATION, RE-REGISTRATION, AND ANNUAL INSPECTION WORKFLOW
FOR HEAVY-DUTY MACHINERY ................................................................................... 7
ANNEX 1 – GLOSSARY OF TERMS ............................................................................... 13
ANNEX 2 ........................................................................................................................... 15
PRESSUE VESSEL REGISTERATION FORMS............................................................... 15
ANNEX 3 – BOILER ANNUAL INSPECTION PROCEDURE ......................................... 19
ANNEX 4 – AIR RECIEVER ANNUAL INSPECTION PROCEDURE ............................ 30

GUIDAN DOCUMENT

FREGISTRATION

OF BOILERS AND PRESSURE VESSELS IN WORKPLACES

iii
ACRONYMS

AI Authorized Inspector
ASME American Society of Mechanical Engineers
BPVC Boiler and Pressure Vessel Code
BSI British Standards Institution
DOSHS Directorate of Occupational Safety & Health Services
EN European Standard
FDRE Federal Democratic Republic of Ethiopia
MoLS Ministry of Labor and Skill
OSH Occupational Safety and Health
OSHA Occupational Safety and Health Administration
RLSB Regional government labor and skill bureau

RAF01 Registration or Re registration Application

IC01 Inspection Checklist for Boiler
IC02 Inspection checklist for Air receivers
RC01 Registration Certificate
RC02 Annual Inspection Certificate
AIF01 Annual Inspection Application Form (not prepared)
TDS Total Dissolved Solids

iv
LIST OF FORMS

Form 1 Pressure Vessel Registration Application Form (RAF01) ..............................................15

Form 2 Pressure Vessel Registration Certificate (RC01)............................................................ 16
Form 3 Pressure Vessel Periodic Inspection Application Form (RAF02) ...................................17
Form 4 Pressure Vessel Annual Inspection Certification (RC02) ...............................................18
Form 5 Boiler Annual Inspection Checklist (IC01) ...................................................................28
Form 6 Compressed Air Receivers Annual Inspection Checklist (IC02) .................................... 38

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1. INTRODUCTION

1.1 This Guideline for Registration and Periodic Inspection of Pressure Vessels in
Workplaces is intended for owners of pressure vessels who wish to have their pressure
vessels approved for use in workplaces in Ethiopia.

1.2 Under the OSH Directives of FDRE, pressure vessel owners are required to obtain
registration and approval of inspection from the Federal Ministry of Labor and Skill
(MoLS), Regional Labor and Skill Bureaus (RLSB), or their delegate branches to ensure
that inspection and tests specified in the OSH directives are carried out by an
Authorized Inspector before use and during use in a workplace.

1.3 This document provides guidance to owners and Authorized Inspectors on the
requirements for the use of pressure vessels in workplaces, through a registration and
periodic inspection system administered by the Occupational Safety and Health
Directorate or Unit of MoLS or RLSB.

2. PRESSURE VESSELS

2.1 A pressure vessel is a container or a vessel used for containing a substance under
pressure, and includes a steam boiler, steam receiver, steam container, air receiver,
refrigerating plant pressure receiver and gas cylinder.

2.2 If a pressure vessel fails while in use, it can cause fatal or serious body injuries to
persons in the vicinity or severe damage to equipment and properties. It is therefore
essential that the design, fabrication and use of pressure vessels are regulated to ensure
that they are of good construction, sound material, free from patent defects and safe for
intended use.

2.3 The types of pressure vessels which require registration with Federal Ministry of Labor
and Skill or Regional Labor and Skill Bureaus are:

(a) Air Receiver – any vessel containing air under pressure and connected with an air
compressor, which includes compressor air tanks and headers, as well as any
vessel which a liquid or solid substance is stored and forced by compressed air.

(b) Steam Boiler – any closed vessel in which steam is generated at a pressure
greater than atmospheric pressure, which includes autoclaves, steam generating
heat exchangers, economizers and superheaters.

(c) Steam Receiver – any vessel or apparatus (other than a steam boiler, steam
container, steam pipe or coil or part of a prime mover) used for containing steam
under pressure greater than atmospheric pressure.

(d) Refrigerating Plant Pressure Receiver – any vessel containing refrigerant under
pressure.

2.4 The following types of pressure vessels are not required to be registered.

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 (a) Pressure vessels that only process chemicals and other substances, not with air,
steam or water (when being used as a refrigerant).

(b) Pressure vessels that operate under vacuum or negative pressure;

(c) Air receivers, steam receivers or refrigerating plant pressure receivers where the
safe working pressure does not exceed 1.5 bar, or the product of its safe working
pressure and volume does not exceed 100 bar-litre; or

(d) Steam boilers where the maximum permissible working pressure does not exceed
1.5 bar.

2.5 It shall be noted that although these pressure vessels do not require registration, they are
required to comply with relevant requirements under the OSH directives and its
subsidiary legislation.

3. REGISTRATION OF NEW PRESSURE VESSELS

3.1 The owner of a pressure vessel who wishes to register shall submit an application for
registration with proposed inspector to the OSH Directorate/Unit of MoLS or the
Regional Labor and Skills Bureau (RLSB) through the proposed inspector.

3.2 Upon the approval of the application for registrations, the owner shall provide the
following documents for review by the authorized inspector.

(a) Drawings of the pressure vessel.

(b) Certification in accordance with ASME BPVC, EN 13445, or equivalent

standard.

(c) Layout plan of the equipment room

(d) Steam or other piping diagrams.

(e) Fuel supply system layout, if applicable

(f) Supporting documents to prove ownership (e.g. Invoice, Delivery Order)

3.3 The Authorized Inspector shall ensure that all of the following necessary inspection and
tests are conducted to his/her satisfaction before he/she recommends registration of the
pressure vessel to MoLS or RLSB.

Steam Air Other Pressure

Boiler Receiver vessels

Hydrostatic pressure at 1.5 X   

working pressure

Visual Inspection   

Operational (Running)Test   

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 The Authorized Inspector may also conduct additional tests as deemed necessary to
ensure the overall integrity of the pressure vessel.

3.4 The owner shall submit the test report of the inspector, one original and one copy to the
OSH Directorate/ Unit for registration. Upon successful completion of the registration
process, the OSH unit will issue the registration certificate.

3.5 The owner shall retain the necessary documents to facilitate any future repair or
modification works on the pressure vessel until the vessel is no longer in use.

4. RE-REGISTRATION OF EXISTING PRESSURE VESSEL

4.1 An existing pressure vessel which was previously registered for use in a workplace is
required to be re-registered when:

(a) There is change in pressure vessel ownership, or

(b) The pressure vessel (non-mobile units) has been moved to a different workplace

4.2 For an existing pressure vessel to be re-registered an application form with the following
documents and proposed AI has to be submitted to MoLS or RLSB

(a) The previous inspection report of the pressure vessel issued by an AI and

(b) Past registration documentation.

4.3 The Authorized Inspector shall ensure that all the necessary inspection and tests, as
specified below are conducted to his/her satisfaction before he/she recommends
registration of the pressure vessel to MoLS or RLSB.

Steam Air Other

Boiler Receiver Pressure
vessels

Ultrasonic thickness measurement when   

life is above 10 years only

Hydrostatic pressure at 1.5 x working   

pressure

Visual Inspection   

Operational (running) Test   

The Authorized Inspector may also conduct further examinations or tests as deemed
necessary to ensure the overall integrity of the pressure vessel before recommending the
pressure vessel for registration.

4.4 A new owner buying or taking over a previously registered pressure vessel shall ensure
that the vessel has been de-registered by the previous owner before doing so.

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5. PERIODIC INSPECTION OF PRESSURE VESSELS

Neglecting inspections can lead to severe failures, resulting in injuries, environmental harm, and
financial losses. Regular inspections are crucial to prevent these risks.

5.1 The owner of a pressure vessel shall apply for inspection by submitting the following
documents and proposed inspector to the OSH Unit of MoLS or RLSB:

(a) Previous inspection report by AI or Registration document for new equipment

(b) Approval letter or certificate.

5.2 As shown in the table below, inspection has to be conducted for different types of pressure
vessels to ensure that explosions do not occur in the workplace.

Type of vessel Inspection Type of inspection

interval

Steam boiler Every year Visual inspection and running tests.

Air receiver Every 2 years Visual inspection and running tests.

steam receiver

Autoclaves Every 2 years Visual inspection and running tests.

Autoclaves Every 6 years Visual examination on the surface of the

external shell. The insulation must be
removed completely.

All types as listed Every 10 At least one hydrostatic test and thickness
above years gauging must be conducted to ensure the
integrity of the Pressure Vessel.

A Steam boiler is defined as an Autoclave if it meets all of the following criteria:

 It uses electricity as the only form of power.

 It has a maximum steam volume of 40 liter.

 It has a safe working pressure of maximum 4 bars.

5.3 Based on the documents provided, the Authorized Inspector shall ensure that all
necessary inspection and tests are conducted to his/her satisfaction before he/she
recommends registration of the pressure vessel by MoLS or RLSB.

5.4 If major shortcomings that affect the safety of the equipment are identified, the
authorized inspector shall instruct the owner to rectify the shortcomings as soon as
possible and request for reinspection.

5.5 If the remarks are minor or none, the authorized inspector shall sign on the inspection
report, and provide comments noting that any minor issues to be rectified up to next
inspection

4
 5.6 The owner shall make the report approved in original and one copy by MoLS or RLSB
and retain the original report and approval letter/ certificate for next inspection.

6. DUTIES AND RESPONSIBILITIES OF OWNERS

6.1 Owners and Authorized Inspectors shall collaborate to ensure that the pressure vessel is
inspected and tested in accordance with accepted standards or codes.

6.2 The owner of a pressure vessel shall ensure that the pressure vessel is designed,
fabricated and tested in accordance with standards such ASME boiler and pressure
vessel code or equivalent.

6.3 The owner shall ensure adherence to the above guidance for both registration and re-
registration of pressure vessels.

6.4 For pressure vessels fabricated overseas, the pressure vessel must carry ASME BPV
certification or equivalent. .

6.5 For pressure vessels fabricated locally, each pressure vessel must be inspected by an
accredited inspection agency, and a certificate of compliance with the ASME BPV
code shall be issued.

6.6 The owner shall ensure that the pressure vessel is examined and tested by an Authorized
Inspectors or a MoLS inspector in accordance with the requirements of the OSH
directives and its subsidiary legislation, and a Report of Inspection and Test is issued by
the Authorized Inspector and approved by MoLS or RLSB.

6.7 The owner shall retain the documents as specified and produce them for verification
upon request by MoLS, RLSB, or an Authorized Inspector.

6.8 The owner shall notify and seek approval from MoLS or RLSB before carrying out
major repair or modification work on any pressure vessel.

6.9 The owner shall de-register the pressure vessel once it is no longer in use.

5
7. DUTIES AND RESPONSIBILITIES OF AUTHORISED INSPECTORS

7.1 The authorized Inspector shall possess a relevant engineering education background and
sufficient experience in inspection, installation and commissioning of boilers and
pressure vessels. Additionally, the inspector should hold a permit from MoLS for
certification in Boiler and pressure vessel inspection.

7.2 The Authorized Inspector shall review the documents and ensure that they are in order
and to his/her satisfaction, for the purpose of registration or re-registration of the
pressure vessel.

7.3 For pressure vessels manufactured overseas, the Authorized Inspectors shall verify that
the pressure vessel has proper certification during registration.

7.4 By determining and conducting the necessary tests in accordance with this guideline, the
AI is deemed to have verified and confirmed that the documents meet the acceptance
criteria for registration or periodic inspection.

7.5 Authorized Inspectors Certification Criteria for Heavy Duty Machineries

7.5.1 Inspectors for heavy duty machineries such as boiler, pressure vessels and generators,
shall be mainly Mechanical engineers due to the proximity to the academic training at
BSc and MSc programs of Mechanical engineering. A Mechanical Engineer registered
as professional or practicing Mechanical Engineer in Ethiopia or similar equivalency
from international institute can be qualified to the inspection of heavy duty
machineries and must fulfill one of the following aside from registration:

a) A Mechanical Engineering professional or related, and certified as Professional

Engineer, with five years of industry experience in process industries ( such as
Sugar, Breweries, tanneries etc),or Service Industry (such as hotels and hospitals),
and specifically working with boiler and steam distribution systems, pressure tanks
in compressed air systems and generator sets.

b) A Mechanical Engineer or related professional with experience in the installation

and inspection of boiler and steam distribution system, pressure tanks in
compressed air systems, and generator sets, and certified as Professional Engineer.

7.5.2 The candidate must provide authentic academic and professional experience credentials.

7.5.3 The candidate might be required to pass certification test, which will be prepared in
collaboration with Ethiopian Society of Mechanical Engineers (ESME).

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 8. REGISTRATION, RE-REGISTRATION, AND ANNUAL INSPECTION
WORKFLOW FOR HEAVY-DUTY MACHINERY

The importance of a standardized workflow for the registration, re-registration, and inspection of
heavy-duty hazardous equipment is well established to ensure consistency of activities. Such a
workflow provides a structured framework that promotes consistency, efficiency, and
compliance with safety regulations set by national regulations and enforced by MoLS/RLSBs.
By outlining specific steps and procedures, it helps to prevent errors, omissions, and delays in
the process. This, in turn, reduces the risk of accidents and incidents that could have serious
consequences in industries.
A well-defined workflow is designed to enhance the transparency and accountability of each
stakeholder in the nation's OSH Directive. It clearly defines the roles and responsibilities of all
involved, from equipment owners to authorized inspectors and regulatory authorities. This helps
to foster trust and cooperation, as it ensures that everyone is working towards the same goal: the
safe and responsible operation of hazardous equipment. Additionally, a standardized workflow
facilitates data collection and analysis, enabling authorities to identify trends, assess risks, and
implement targeted safety measures.
This section presents the workflow to be followed for the three key regulatory activities.

8.1 Registration process

As presented in Section 3, the registration process of pressure vessels shall follow the workflow
shown in Figure 8.1.

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 Owner Identifies
Authorized Inspector

Owner Registration
Application
(Application Form)

No

Approved?
Provide Registration
Certificate to Owner
Yes
Acceptable
Owner Provides
Authorized Inspector
documents for review
Report Evaluation Unacceptable

Inspector Review
Documentations and
Owner Presents
Conduct Appropriate Return Report for
Inspection and Tests
Tests Correction
Report to RLSB

Provide Inspection Make necessary

Pass or Fail? Pass
Report to Owner amendments

Fail

Provide Corrective
NO
Measures to be taken
Yes

Evaluate Corrective
Corrected?
Action by Owner

Figure 8.1: Workflow for registration of heavy-duty hazardous equipment

Registration Remarks:
 List of Authorized Inspectors (AI) shall be developed and made public by MoLS/RSLB.
AI qualification and certification shall be conducted following Section 7.5 of this
guideline
 Registration Application Form RAF01shall be used to initiate the registration process.
The application form is attached in Annex 2

8
  Once the AI receives the accepted registration application form for the pressure vessel(s)
from the owner, a review of documentation and appropriate testing shall be done
following the checklist IC01 for boilers, IC02 for compressors and air receivers.
 Registration inspection report shall include the filled inspection checklist along with a
summary form of the inspection result. Additional contents may be added that are
deemed important by the AI based on the inspection results.
 Report evaluation by MoLS and regional bureaus shall check that all forms are filled
properly, and registration inspection results are indicated as ‘Pass’ or ‘Pass with
Comments’ as per Annex 3.4.6 & 4.4.6 of this guideline
 Certification provided for heavy-duty equipment acceptable for registration shall follow
the certification form RC01 as indicated in Annex 2.

8.2 Re-registration process

Owners seeking to re-register their pressure vessel(s) due to major changes in the equipment or if
the equipment has been moved shall follow the workflow presented in Figure 8.2.

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 Equipment Moved or
any Change?

Yes No End

Yes

Fill Re-registration form Provide Re-registration

with RLSB Certificate to Owner

Authorized Inspector Owner Presents

Conducts inspection and Inspection and Tests
Tests Report to RLSB

Provide Inspection
Pass or Fail? Pass
Report to Owner

Fail

Provide Corrective
NO
Measures to be taken
Yes

Evaluate Corrective
Corrected?
Action by Owner

Figure 8.2: Workflow for re-registration of heavy-duty equipment

Re-registration Remarks

 Re-registration Application Form RAF01 must be used to initiate the registration process.
The application form is attached in Annex 2.
 Accepted applications for pressure vessel(s) re-registration inspection and testing shall be
made by following the checklists IC01 for boilers, and IC02 for compressors and air
receivers.

10
  Re-Registration Inspection report shall include the filled inspection checklist along with a
summary of results. Additional contents regarding the changes made or pressure vessel(s)
moved may be added that are deemed important by the AI based on the inspection results.
 For accepted re-registration applications, a certificate with the same content as the initial
registration will be issued indicating the re-registration

8.3 Annual Inspection Process

The annual inspection of heavy-duty equipment, based on the equipment type and inspection
interval, shall be managed as per the workflow shown in Figure 8.3.

Owner Identifies
Authorized Inspector

Owner Applies for

Periodic Inspection as
per Inspection Intervals
No

Approved?

Yes

Provide Annual
Provide Documents for Inspection Certificate
review by Authorized
Inspector

Owner Presents
Inspector Review Inspection and Tests
Documentations and Report to RLSB
Conduct Appropriate
Tests

Provide Inspection
Pass or Fail? Pass
Report to Owner

Fail

Provide Corrective
NO
Measures to be taken
Yes

Evaluate Corrective
Corrected?
Action by Owner

Figure 8.3: Workflow for annual inspection of heavy-duty equipment

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Remarks:
 Authorized Inspectors (AI) list shall be developed and made public by MoLS/RSLB. AI
qualification and certification shall be conducted following Section 7.5 of this guideline
 Annual Inspection Application Form RAF02 must be used to initiate the annual
inspection process. The application form is attached in Annex 2
 Once AI receives the accepted annual inspection application form for the heavy-duty
equipment from the owner, a review of documentation and appropriate testing shall be
done following the checklist IC01 for boilers and IC02 for compressors and air revivers.
 Registration inspection report shall include the filled inspection checklist along with the
summary of all pressure vessels inspection result in the periodic inspection. Additional
contents may be added that are deemed important by the AI based on the inspection
results.
 Report evaluation by MoLS and regional bureaus shall check that all forms are filled
properly, and annual inspection results are indicated as ‘Pass’ or ‘Pass with Comments’
as per Annex 3.4.6 & 4.4.6 of this guideline
 Annual Inspection Certification provided for heavy-duty hazardous equipment that are
acceptable for operation shall follow the certification from RC02 as indicated in Annex 2.

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ANNEX 1 – GLOSSARY OF TERMS

1.1 Authorized Inspector (AI)” – Shall be certified by MoLS in Collaboration with the most
relevant professional Association based on relevant educational background, experience
in boiler and pressure vessel inspection or installation and commissioning. Passing
certification test shall be also are requirement in the near future,

1.2 Hydrostatic Test – Hydrostatic test conducted at a test pressure (Usually 1.5 X working
pressure) and duration in accordance with the accepted standards or codes to confirm the
overall integrity of the pressure vessel.

1.3 Radiography – Conducted by digital or conventional means to check for inherent defects
on welding joints and seams of the pressure vessel using appropriate radiography
equipment.

1.4 Running Test – Test of safety valves and other safety devices ( sight glass, pressure
gauge, level controller, stop valve, blow down valve/ drain valve) installed on the
pressure vessel to ensure that they are of adequate design, set at the correct settings and
operating as intended or designed for.

1.5 Ultrasonic Test –Test to ensure that the thicknesses of various parts of the pressure
vessel conform to the minimum thickness specified in the design.

1.6 Visual Inspection – A type of inspection to ensure that there are no physical defects on
the visually accessible parts of the boiler and pressure vessel. Accessories or ancillary
equipment should not be attached to the pressure vessel to facilitate this inspection. The
AI shall also confirm the minimum safety devices as required under the OSH Directives
are installed or supplied with the pressure vessel.

1.7 EN 13445 -This European standard governs the design and construction of pressure
vessels. It also outlines the requirements for inspection, testing, and documentation.

1.8 ASME BPVC (Boiler and Pressure Vessel Code) - Widely recognized in North America
and many other parts of the world, this code sets the standards for the design,
construction, and inspection of pressure vessels.

1.9 Air Compressor: A machine that converts power into potential energy stored in
compressed air, which is then used to power pneumatic tools, machinery, and other
devices.

1.10 Air Receiver Tank: A storage tank that holds compressed air from the compressor,
allowing for a steady supply of air and helping to reduce pressure fluctuations in the
system.

1.11 Maximum Allowable Working Pressure (MAWP): The maximum pressure at which
the air receiver tank is designed to operate safely.

1.12 Pressure Relief Valve (Safety Valve): A valve designed to release excess pressure from
the air receiver tank to prevent it from exceeding the MAWP.

1.13 Blow-Down Valve / Drain Valve: A valve used to remove accumulated moisture,
condensate, and debris from the bottom of the air receiver tank.

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1.14 Condensate: The water that forms in the air receiver tank as a result of compressing air,
which increases moisture content.

1.15 Dew Point: The temperature at which air becomes saturated with moisture and water
begins to condense out of the air.

1.16 Overpressure: A condition where the pressure in the air receiver tank exceeds the
MAWP, potentially leading to equipment failure or safety hazards.

1.17 Moisture Separator: A device that removes moisture from the compressed air before it
enters the air receiver tank or downstream equipment.

1.18 Refrigerator Dryer: A device that cools compressed air to condense and remove moisture,
ensuring dry air for industrial applications and protecting equipment from moisture-
related damage.

1.19 Filter: A component that removes contaminants such as dust, oil, and dirt from the
compressed air to protect the system and improve air quality.

1.20 Oil Carryover: The unintended presence of oil in the compressed air, which can result
from oil-lubricated compressors and cause contamination or corrosion in the system.

1.21 Corrosion: The gradual destruction or weakening of the air receiver tank’s metal due to
chemical reactions, often caused by moisture inside the tank.

1.22 Pressure Drop: The reduction in air pressure as it moves through the system, which can
be caused by blockages, leaks, or undersized piping.

1.23 Automatic Drain Valve: A valve that automatically expels condensate from the air
receiver tank at regular intervals or when a certain level of moisture is detected.

1.24 Capacity (of Air Receiver): The volume of air the receiver tank can hold at a given
pressure, typically measured in gallons or liters.

1.25 Check Valve: A valve that allows air to flow in one direction only, preventing backflow
and ensuring air is stored in the receiver tank.

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ANNEX 2

PRESSUE VESSEL REGISTERATION FORMS

Federal Democratic Republic of Ethiopia

Ministry of Labor and Skill
Form 1 Pressure Vessel Registration Application Form (RAF01)
Date_____________

Applying Enterprise________________________________________________________
Approving Labor and Skill Bureau ____________________________________________
Proposed Authorized Inspecting agency or Inspector______________________________
Application type: New registration Re registration
Tick
Vessel Type Boiler Capacity
Air receiver Working Pressure
Gas Tank Year of Manufacturing
Other _________ Owner
Manufacturer Location
Model City
Serial No Region

_________________________________________

Name and Signature of Enterprise representative

The ___________________________________ Labor and Skill Bureau authorizes the

Inspection and Testing of the above list of pressure vessels to check that they meet the
requirements for registration.
_________________________________________ _________________

Name and Signature of Approving Officer Date

15
 Federal Democratic Republic of Ethiopia
Ministry of Labor and Skill
Form 2 Pressure Vessel Registration Certificate (RC01)
Date__________
Enterprise________________________________________________________

Tick
Vessel Type Boiler Capacity
Air receiver Working Pressure
Gas Tank Year of Manufacturing
Other _________ Identification No
Manufacturer Location
Model City
Serial No Region

I, ___________________________________ (Name) recommend the registration of the above-

mentioned pressure vessel as the following criteria were met.
a) The pressure vessel is designed to the code as ticked () :
[ ] ASME Boiler & Pressure Vessel Code
[ ] European Standards and Code (EN)
[ ] Japan Industrial Standards (JIS)
[ ] Other equivalent _________________
b) Visual test indicate that the pressure vessel meets the relevant requirements stipulated in
OSH Directives with regard to devices and other ancillary equipment
c) Room lay-out with sufficient circulation space.
d) Pressure test at 1.5xWorking pressure was successful
e) Run Test shows all safety and other operational requirements are met
f) Any other comments:___________________________________________________
________________________________________________________________________

___________________________
Signature of Authorized Inspector

The ___________________________________ Labor and Skill Bureau approves registration of

the pressure vessel.

_________________________________________ _________________
Name and Signature of Approving Officer Date

Annex: Test Report

16
 PRESSUE VESSEL INSPECTON FORMS

Federal Democratic Republic of Ethiopia

Ministry of Labor and Skill
Form 3 Pressure Vessel Periodic Inspection Application Form (RAF02)
Date_____________

Applying Enterprise________________________________________________________
Address: Region _____________________ City_________________________________

Approving Labor and Skill Bureau ____________________________________________

Proposed Authorized Inspecting agency or Inspector______________________________

S.No. Type of Brand and Serial No Last date of Inspection Location of

Equipment Model inspection interval Equipment

_________________________________________

Name and Signature of Enterprise representative

The ___________________________________ Labor I and Skill Bureau authorizes the

Inspection and Testing of the above list of pressure vessels.

_________________________________________ _________________

Name and Signature of Approving Officer Date

17
 Federal Democratic Republic of Ethiopia
Ministry of Labor and Skill
Form 4 Pressure Vessel Annual Inspection Certification (RC02)
Date_____________

Applying Enterprise________________________________________________________
Approving Labor and Skill Bureau ____________________________________________
Proposed Authorized Inspecting Agency or Inspector______________________________

Type of Equipment Brand and Model Serial No Last date of

inspection

I, ___________________________________ (Name) recommend the approval of the annual

inspection of the above listed pressure vessels as per the annexed test reports.

_________________________________________ _________________

Name and Signature of Enterprise Representative Date

The ___________________________________ Labor and Skill Bureau authorizes the periodic

inspection of the above listed pressure vessels.

_________________________________________ _________________

Name and Signature of Approving Officer Date

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ANNEX 3 – BOILER ANNUAL INSPECTION PROCEDURE

3.1 Introduction

The purpose of a boiler inspection is to provide assurance of equipment integrity to minimize

safety issues with operating a pressure vessel.

The objectives of a boiler are:

 To release the energy in the fuel or electricity as efficiently as possible.

 To transfer the released heat to the water and to generate steam as efficiently as possible.
 To separate the steam from the water ready for transfer to the plant, where the energy in
the steam will be used for different processes.

A number of different boiler types have been developed to suit the various steam applications.

Steam boilers are required in manufacturing, power and service industry for supplying steam for
different process as well as electric power production with steam generators. Steam boilers are
classified into water tube and fire tube boilers. The application of these boilers in Ethiopia is as
follows.

a) Water tube boiler of large capacity:- They are used for generating steam for power
production and process heat. Such type of boiler that fire bagasse (fiber left after
extraction of juice) in all sugar factories in Ethiopia for cogeneration of heat and power.

b) Packaged fire tube boiler:- These boilers, designed to burn fuel oil, are widely employed
in Ethiopia's manufacturing and service subsectors. Their compact design makes them
suitable for smaller industrial operations, where space and efficiency are crucial. These
boilers are commonly used in industries such as food processing, textile production, and
hospitality services, providing reliable steam generation for heating, sterilization, and
other critical processes. Due to the skyrocketing fuel prices, there has been a noticeable
shift in newer boiler installations from fuel-fired packaged boilers to electric boilers. As a
result, the majority of recent installations now utilize electric heating. For example, all
boilers in Bole Lemi Industrial Park are electric, reflecting this growing preference for
more cost-effective and sustainable heating solutions in industrial applications. The
purpose of a boiler inspection is to ensure the integrity of the equipment, thereby
minimizing safety risks associated with operating a pressure vessel.

3.2 Causes of Boiler Explosion

3.2.1 Low Water level

Water acts as a cooling layer to protect the steel shell/ walls of the boiler from high temperatures
during its operation. When the water level falls below the minimum level, the boiler fire chamber
or walls come into direct contact with extremely high temperatures, causing them to melt and
deform. In addition the tubes can crack and loosen, causing water leakage.

19
Therefore, maintaining an adequate water level in the boiler is crucial to ensuring safe operation.
Several factors can contribute to low water levels in the boiler, including:

 A malfunctioning feed water pump or water level control device, which can lead to an
inadequate water supply to the boiler.
 Insufficient water in the feed water tank, resulting in an inadequate amount of water
available for boiler replenishment.

Therefore, maintaining an adequate water level in the boiler is crucial to ensure safety during
operation. There are several factors contribute to low water levels in the boiler:

Malfunctioning feed water pump or water level control device can lead to inadequate water
supply to the boiler.
Insufficient water in the feed water tank results in an inadequate amount of water available for
boiler replenishment.

3.2.2 Lack of proper supervision

Water levels in steam boilers

To prevent such situations, low water cutoff device installed in steam boiler to prevent any
significant damage. The devices operate to detect the low water condition and shut down the
boiler system. The burner remains off till the water returns for the burner to fire normally.

3.2.3 Overpressure
Controlling pressure ensures that the boiler operates efficiently without encountering issues such
as overheating, overpressure, or the risk of explosion. Overpressure occurs when the pressure
inside the boiler exceeds the design pressure, when the pressure controller is not functioning, At
this point; the likelihood of an explosion is very high. The safety valve is designed to release
steam when the pressure exceeds the set limit. If, for some reason, the safety valve fails to
function, the pressure inside the boiler surpasses the tolerable pressure of pipes, metal walls, or
weld joints. This can lead to swelling, cracking of pipes, leakage at weld joints, and, in severe
cases, result in an explosion.
To prevent overpressure in the boiler, it is advisable to use a pressure safety valve to reduce the
outlet pressure when it exceeds the safety limit. Additionally, regular checks of boiler
components such as safety valves, , and pressure control systems should be conducted to ensure
their proper functioning.

Installation of a warning system, such as pressure sensors that monitors the pressure level in
the boiler and gives early alerts on any sudden pressure increases can ensure that accident will
not happen.

3.2.4 Overheating

Heat is required to generate steam by burning fuel. Overheating is a condition where the
temperature inside the boiler exceeds safe limits, which might be caused by overheating of the
superheated steam(applicable to power plants and cogeneration plants).

A common cause of overheating is the local deviation of flue gas flow; leading to certain tube
groups becoming overheated, experiencing excessive temperatures, and potentially exploding.

• Tube fouling: Deposits of scale on tube wall that reduces heat transfer, causing an
increase in the temperature of the tube wall.

• Excessive tube overheating due to poorly controlled combustion in the combustion

chamber.

• Thermal shock: If the boiler water level falls, parts of the boiler tubes may overheat or
dry out. When water is reintroduced, the sudden cooling can cause significant thermal
stress, leading to severe damage, even potential tube explosion.

To prevent overheating in the boiler, it is necessary to:

• Ensure that the boiler feed water hardness is treated and total dissolved solid and oxygen
concentration in the boiler water are reduced to minimize corrosion and scale deposition.

• Guard against water level fall incidents.

• Prevent external tube damage; optimize combustion in the combustion chamber.

3.3 Safety Devices of Steam Boiler

21
Every steam boiler, shall have the following component that function properly

a) Flame sensors (only for fuel firing burner):- Flame sensors or detectors, which are
responsible for monitoring the presence of a flame within the combustion chamber. They
utilize ultraviolet (UV), infrared (IR), or flame rectification technologies to detect the
flame's existence. If the sensor fails to detect a flame within short period, it can send
signals to the combustion control system to initiate safety shutdown procedures. This
prevents the accumulation of unburned fuel which can lead to explosions.

b) The Steam pressure control device shall be set to a pressure that is at or below the
maximum permissible working pressure of the boiler. This device must turn off or
modulate the fuel supply or electricity to the boiler, depending on whether it is a fuel-fired
or electric boiler. Additionally, a safety valve should be adjusted to prevent the boiler from
exceeding the safe working pressure and must be fixed directly to the boiler.

c) Boiler shall have a control panel equipped with start, stop, and emergency stop switches,
along with indicator lights,

d) Stop-valve connecting the boiler to the steam pipe.

e) Steam pressure gauge connected to the steam space and easily visible by the boiler
attendant.

f) Safety valve: an important boiler fitting is the safety valve. Its function is to protect the
boiler shell from over pressure and subsequent explosion
g) Water gauge or sight glass that shows the water level in the boiler;

h) Water level control system: a control system that turns pump on before lower level so that
the boiler cannot run out of water and over heats and turns off pump at maximum level to
prevent carryover of water droplet with steam to prevent water hammer.

i) Blow-down valve that open manually or automatically to discharge boiler water to prevent
it becoming concentrated with salts the steam evaporates and keep TDS constant to prevent
formation of sludge and priming.
 j) Every steam boiler shall have water treatment unit which reduces hardness and TDS to
allowable value.

k) Steam, condensate, feed water as well as fuel piping shall be leak free.

l) Steam and condensate lines shall be insulated.

3.4 How to fill the Inspection Checklist

The Inspection checklist (IC01) at the end of this section has to be filled as follows.

3.4.1 Inspection data

Fill from inspection request communication and previous inspection report inspection data.

3.4.2 Technical data

Fill by reading from nameplate and visual inspection.

a) Record number of sight glasses

b) Record number of safety valves

 c) Record number of feed pumps

d) Ask for missing data from boiler manual or check online

3.4.3 Boiler Integrity test

(Every 10 year or after every major repair)

 Stop and drain the boiler and remove insulation and open man and hand hole
 Conduct Visual inspection of internal boiler waterside indicate that there is no major
surface and pipe damage by overheating, scale and corrosion
 Conduct ultrasonic test to see thinning of boiler wall by corrosion.
 If major repair by welding is not required reassemble the boiler and conduct
hydrostatic test 1.5 x working pressure for 30 minutes checking for leakage.

If the boiler passed hydrostatic pressure conduct running test as follows.

3.4.4 Safety device compliance checking by starting boiler

a) Check start/ stop and emergency shutdown buttons in control panel are operating
properly.

b) Verify that around control panel and boiler presence of loose electrical connection

c) Check sight glass level indication and marks. The water level must be between top
and bottom mark while the boiler operate. The sight has to be checked by draining.
The pump must turn on at lower level and turn off at upper level.

d) Check starting of pump at lower sight glass level and stopping at higher level.

e) Open blow down and check presence of sludge in the drain of blow down. The white
sludge must be insignificant. If the sludge is considerable, water treatment plant has
to be regenerated or replaced by new.

f) Check opening and closing of steam stop valve.

g) Check pressure limit switch operation: Lower set pressure of the boiler and see the
boiler pressures dropping to set value which indicates that the limit switch cuts off the
burner or the electrical heating element

h) Safety valve opening checking: Set the pressure limit value to slightly above safety
valve opening causing burner/heating element operation to operate up to this pressure.
When the safety valve opens, stop the boiler and reset the set pressure to actual
operating pressure.

3.4.5 Leakage and energy loss assessment in boiler room and steam condensate loop

a) Inspect for leakage in the following pipes:

 Steam
 Condensate
 Feed water
 Make-up water
 fuel
26
 b) Inspect the condition of insulation on the boiler shell, as well as on steam and
condensate piping.
c) Estimate the percentage of condensate returned to the feed water tank.

3.4.6 Annual Inspection Results

a) Passed

 If the boiler meets all safety device checklist requirements and adheres to good
housekeeping practices without major issues.

b) Passed with Comment

 If the boiler meets the safety device checklist requirements but has minor issues related to
housekeeping practices that need attention.

c) Failed

 If one or more safety devices are found to be non-operational or if the boiler fails the
integrity test, if applicable.

3.4.7 Recommendation

Expected improvements to be completed by the next inspection include:

 Addressing minor issues in water treatment.

 Rectifying any detected leaks.
 Reinsulating piping where necessary.
 Enhancing drainage and blow-off systems.

27
 MINISTRY OF LABOR AND SKILL
LABOR AND SKILL BUREAU

Form 5 Boiler Annual Inspection Checklist (IC01)

1. Inspection data
Factory/ Enterprise
Inspection Service provider
Inspection Engineer Name & Sign.
Inspection Date
Registration No (if available)
Last inspection date (if applicable)
2. Boiler Technical Data
Identification No:
Type Electric
Fuel Firing Fire Tube
Fuel Firing water tube
Manufacturer’s name:
Model
Serial no
Manufacturing year:
Boiler capacity kg/h
Hydrostatic test pressure (bar)
Design operating pressure (bar)
Actual operating pressure (bar)
Hydrostatic test pressure (bar)
Maximum temp (oC)
No of sight glasses:
No of safety valves
No of feed water pumps
Pressure gage range (bar)
Boiler Room is separate?
Is there 1 m clearance around boiler?

3. Compliance to Safety Requirements (Mandatory )

Compliance
Yes No NA
Burner flame/ignition senor does not malfunction.
Operation of on/off switch and indicators
Operation of emergency sop switch and indicators
No loose electrical connection:
Sight glass level indication and marks
Highest permissible water level marking:
Lowest permissible water level marking:
Operating switch does not start boiler at low water level
Blow down valve opening and closing:
Insignificant f sludge in the blow down water
Pressure limit switch operation
Turns off heating elements at maximum pressure:
Feed water Pumps operation
Starts at low water level:
Stops at highest water level :
Gives alarm below low water level :

28
Safety valve opening and closing :
Steam stop valve opening and closing
Feed Water valves opening and closing
Blow down valve opening and closing:
4. Compliance of good housekeeping practice
Compliance
Yes No NA
Water leakage in feed water line:
Steam leakage in steam header and steam line:
Condensate leakage in return line
Leakage in Blow down piping
Leakage in Blow off piping:
Leakage in Steam Header and valves:
Water treatment system operated
Water treatment quality is good
Steam pipe insulation good status
Condensate line insulation good status
High percentage of condenser is returned
5. Hydrostatic and thickness Test results (if applicable)
Compliance
Yes No NA
Visual inspection of internal boiler waterside indicate that
there is no major surface and pipe damage by overheating,
scale and corrosion
Boiler passed hydrostatic Pressure
Boiler shell and fire chamber thickness is acceptable
6. Annual Inspection Result
Compliance
Good Acceptable Poor
Boiler Status
Pass Pass with Fail
comment
Annual Inspection Result
7. Comments

8. Recommendation

Validity of the annual Inspection

29
ANNEX 4 – AIR RECIEVER ANNUAL INSPECTION PROCEDURE

4.1 Introduction

An annual inspection of an air compressor and its receiver tank is a critical maintenance task that
ensures the safe and efficient operation of the equipment. Regular inspections help identify
potential issues before they lead to equipment failure, thereby minimizing downtime and
extending the lifespan of the air compressor system. By following a structured inspection
procedure, operators can maintain optimal performance, comply with safety regulations, and
prevent costly repairs.

4.2 Objectives of Air Receiver Tank Inspection

The primary objectives of inspecting a compressor and air receiver tank are to ensure safe
operation, maintain efficiency, comply with regulations, and extend equipment lifespan. These
objectives are crucial for the reliable and economical operation of air compressor systems. Below
are the detailed objectives:

4.2.1 Ensure Safety

 Identify and Mitigate Hazards: Detect potential safety risks such as leaks, cracks, or
corrosion that could lead to equipment failure or hazardous situations.
 Check Safety Devices: Ensure that all safety devices, including pressure relief valves and
safety switches, are functioning correctly to prevent over-pressurization and accidents.
 Verify Structural Integrity: Inspect the physical condition of the tank and compressor to
ensure they can safely handle operational pressures.

4.2.2 Maintain Efficiency

 Optimize Performance: Identify issues that may reduce the efficiency of the compressor,
such as dirty filters, worn-out parts, or improper lubrication.
 Ensure Proper Operation: Verify that the compressor and air receiver are operating
within the manufacturer’s specifications for optimal performance.
 Reduce Energy Consumption: Ensure that the system is running efficiently to minimize
energy consumption and operational costs.

4.2.3 Comply with Regulations

 Adhere to Safety Standards: Comply with industry and governmental safety standards
and regulations to avoid legal penalties and ensure a safe working environment.
 Document Compliance: Maintain detailed records of inspections and maintenance to
demonstrate compliance with relevant safety and environmental regulations.

4.2.4 Extend Equipment Lifespan

 Preventive Maintenance: Conduct regular inspections to identify and address potential

issues before they lead to significant damage or failure, thus extending the life of the
equipment.
 Reduce Downtime: By preventing unexpected breakdowns, regular inspections help
minimize downtime and maintain consistent productivity.

30
  Maintain Warranty Conditions: Ensure that maintenance and inspections are conducted
as per manufacturer’s recommendations to keep warranties valid.

4.2.5 Improve Reliability

 Consistent Operation: Ensure that the compressor and air receiver are reliable and
capable of delivering consistent air pressure as required by the application.
 Minimize Repairs: Identify minor issues early and perform corrective actions to prevent
major repairs or replacements.

4.3 Causes of Air Receiver Tank Hazard

Air receiver tank failures in compressed air systems can be caused by various factors, which can
lead to significant safety risks and operational disruptions. Understanding these causes is critical
for preventive maintenance and ensuring reliable the common causes include:
i. Defective safety valve: Air receivers are designed to operate within specific parameters.
A defective safety valve can result in the over-pressurization and the potential for
significant damage to the air receiver and injury to those in its vicinity.
ii. Failure of refrigerator drier and filter: In a compressed air system, the presence of
excessive moisture is a critical issue that can lead to rust and corrosion in the air receiver
tank. The refrigerator dryer and filter play essential roles in removing moisture and
contaminants from the compressed air. Failure of these components can directly cause an
increase in humidity within the system, which subsequently leads to rusting of the air
receiver tank.
iii. Fatigue and Stress: Repeated pressurization and depressurization cycles can cause metal
fatigue in the tank, leading to cracks or fractures. Stress concentrations, particularly
around welded joints or connections, can also lead to failure.
iv. Blocked blow down / drain valve – This will prevent the air receiver from being blown
down daily as required. The blow-down or drain valve is designed to periodically release
moisture, condensate, and other contaminants that accumulate at the bottom of the air
receiver tank. With the drain valve blocked, moisture that would normally be expelled
from the tank accumulates at the bottom. This stagnant water causes internal corrosion
and rust, which weakens the tank over time. Rust can also flake off and contribute to
further blockage of the valve.
v. Contaminants: Oil, dirt, and other contaminants in the compressed air can accumulate
and cause blockages or damage the tank's interior, leading to localized stress and
potential failure.
vi. Oil Carryover: In oil-lubricated compressors, some amount of oil can carry over into the
compressed air. This is usually controlled by filters and separators, but if these
components fail or if the compressor is poorly maintained, excessive oil can pass into the
system. Oil in the air receiver tank can mix with moisture, leading to the formation of
acidic compounds that accelerate internal corrosion. Oil buildup can also clog drains and
create an environment that encourages rust formation. In severe cases, the tank can fail
due to internal corrosion.
vii. Overpressure: Operating the tank at pressures higher than its design limits can cause it to
fail. Overpressure can result from malfunctioning pressure regulators, relief valves, or
safety devices that fail to activate when needed.
viii. Poor Maintenance: Inadequate maintenance, such as failing to inspect and clean the tank
regularly, can allow small issues like corrosion or minor leaks to develop into major

31
 problems. Neglecting to drain accumulated moisture is a common oversight that
accelerates internal corrosion.
ix. Improper Installation: Incorrect installation, such as improper anchoring, can result in
excessive vibration, leading to stress and potential failure. Improper alignment of piping
can also introduce undue stress on the tank connections.
x. Compressor Fails to Stop: When the air receiver tank reaches its cut-off pressure, the
compressor should cease operation. If the compressor fails to stop, this can indicate an
issue that needs immediate attention as it can be a cause of over pressure of air receiver.
If the relief valve of air receiver stacks it can cause explosion. Here are the common
causes and solutions:

a) Power Switch Issues

o Faulty Power Switch: A malfunctioning power switch may fail to shut off the
compressor. Inspect and, if necessary, replace the power switch to ensure it
operates correctly.

b) Pressure Release Valve Problems

o Improper Pressure Release: If the pressure release valve is not functioning
correctly, the compressor may become over-pressurized. This can lead to potential
damage and safety hazards.
o Valve Replacement: If the pressure release valve is faulty, cutting power to the
compressor and replacing the valve is advisable. Ensure the new valve is properly
installed and functioning to maintain safe pressure levels.

4.4 How to fill the Inspection Checklist

The Inspection Form at the end of this section has to be filled as follows:

4.4.1 Inspection data

Fill from inspection request communication and previous inspection report inspection
data.

4.4.2 Technical data

a) Fill by reading from nameplate and visual inspection

b) Record maximum operating pressure of compressor and receiver tanks
 d) Record number of safety valves
e) Record number of air filters
f) Ask for missing data from compressor and receiver tank manual or check online

4.4.3 Air Receiver Tank Integrity Test

(Every 10 year or after every major repair)

a) Preparation
 Isolate the Tank: Shut down the compressor and isolate the receiver tank from the
system.
 Drain the Tank: Release any compressed air and drain condensate and sludge
from the receiver tank.
b) Disassembly and Inspection
 Open Inspection Ports: Remove any covers, inspection ports, or manholes for
internal access.
 Visual Inspection: Conduct a visual inspection of the internal surfaces of the
tank. Look for signs of corrosion, scale buildup, cracks, or other damage. Ensure
that welds and joints are intact.
c) Ultrasonic Testing
 Measure Wall Thickness: Perform ultrasonic testing to measure the wall
thickness of the receiver tank. Identify any thinning or erosion that could
compromise structural integrity.
d) Reassembly and Pressure Testing
 Reassemble the Tank: If no major repairs are necessary or if repairs have been
made, reassemble the tank and ensure all connections and fittings are secure.
 Conduct Hydrostatic Test: Perform a hydrostatic test at 1.5 times the working
pressure for 30 minutes. Check for leaks and ensure there are no signs of failure.
e) Running Test
 Operational Check: Reconnect the receiver tank to the system and start the
compressor. Monitor the tank for normal operating conditions and check for any
unusual vibrations, noises, or pressure fluctuations.

4.4.4 Safety Device Compliance Checking for Air Compressor and Receiver Tank
4.4.1 Safety Device Compliance Checking for Air Compressor

a) Control Panel and Emergency Shutdown

 Check Start/Stop and Emergency Shutdown Buttons: Ensure that the start/stop
buttons and emergency shutdown buttons on the control panel are functioning
correctly. The buttons should respond immediately and as intended.
b) Electrical Connections
 Inspect Electrical Connections: Examine the control panel and compressor for
any loose or damaged electrical connections. Ensure all connections are secure
and properly insulated.
c) Pressure Gauge and Indicator Marks
 Check Pressure Gauges: Verify that the pressure gauges are functioning correctly
and displaying accurate readings. The pressure should be within the operating
range specified for the compressor. Regularly calibrate gauges as needed.
d) Compressor Operation

33
  Test Compressor Starting and Stopping: Ensure the compressor starts and stops
according to the set pressure levels. The compressor should turn on at the lower
pressure threshold and turn off at the upper pressure threshold.
e) Drainage and Condensate Management
 Inspect Condensate Drains: Open the condensate drains and check for the
presence of water and sludge. There should be minimal sludge. Effective
drainage and condensate management are essential for maintaining the
efficiency, safety, and longevity of air compressors. Condensate, a byproduct of
compressed air, typically contains water, oil, and other contaminants, and must
be properly managed to prevent damage and ensure compliance with
environmental regulations.
f) Inspect Air Filters:
 Ensure that air filters are clean and free of obstructions. Replace filters if they are
dirty or clogged.
g) Pressure Relief Valve Operation
 Test Pressure Relief Valve: Set the pressure relief valve to slightly above the
normal operating pressure. Run the compressor until the relief valve opens to
ensure it functions correctly. Reset the pressure relief valve to the standard
operating pressure.
h) Safety Shutdown Systems
 Check Safety Shutdown Mechanisms: Verify that safety shutdown systems (e.g.,
for high temperature or high pressure) are operational. Ensure that these systems
activate correctly and shut down the compressor when necessary.

4.4.2 Safety Device Compliance Checking for Air Receiver Tank

a) Pressure Gauge and Indicator Marks

 Check Pressure Gauges: Ensure pressure gauges on the receiver tank are accurate
and operational. The pressure should be within the safe operating range. Regularly
calibrate gauges as needed.
b) Pressure Relief Valve Operation
 Test Pressure Relief Valve: Set the pressure relief valve to slightly above the
normal operating pressure. Verify that the valve opens at the set pressure and resets
properly after opening.
c) Drainage and Condensate Management
 Inspect Drain Valves: Open the drain valves and check for water and sludge. The
sludge should be minimal. If significant sludge is present, consider servicing or
replacing the water treatment components.
d) Visual Inspection
 Check for Leaks and Damage: Inspect the receiver tank for any signs of leaks,
corrosion, or physical damage. Ensure that all connections and fittings are secure
and in good condition.
e) Test Emergency Shutdown
 Check Emergency Shutdown Systems: Test the emergency shutdown systems to
ensure they activate correctly in response to high pressure or other safety triggers.
The system should shut down the compressor and stop any further operations.

f) Check Alarms and Indicators

34
  Verify Alarm Systems: Ensure that alarm systems for high pressure, low pressure,
or other critical conditions are functioning correctly and that alarms are audible
and visible.
g) Inspect Safety Valves
 Check Safety Valves: Inspect safety valves for proper operation and cleanliness.
Ensure they are free from obstructions and functioning as intended.
h) Maintenance Records
 Review Maintenance Records: Check that all maintenance and inspection records
are up to date. Ensure that any issues identified during previous inspections have
been addressed.

4.4.5 Leakage and Energy Loss in Air Compressor Room and Air Receiver Tank System

Leakage and Energy Loss Check for Air Compressor Room and Piping
a) Check for Leakage in the Following Pipes:
 Compressed Air Lines:
 Condensate Drain Lines:
 Intake Lines:
 Cooling Water Lines (if applicable):
 Lubricant Lines:
b) Check Condition of Insulation of Compressor and Piping:
 Compressor Insulation:
 Piping Insulation:
c) Check the Efficiency of the Compressed Air System:
 System Pressure:
 Compressor Load/Unload Cycles:
 Air Receiver Tank Efficiency:
d) Check for Energy Loss:
 Vibration and Noise:
 Temperature:
 Filter Conditions:
Leakage and Energy Loss Check for Air Receiver Tank and Associated Piping

a) Check for Leakage in the Following Pipes:

 Receiver Tank Inlet/Outlet Lines:
 Drain Lines:
b) Check Condition of Insulation on the Air Receiver Tank and Piping:
 Receiver Tank Insulation:
 Piping Insulation:
c) Check the Efficiency of the Air Receiver Tank System:
 Condensate Return Efficiency: Measure the percentage of condensate
being properly drained and managed. Excess condensate can lead to
corrosion and reduce system efficiency.
 Tank Pressure: Monitor the pressure within the receiver tank to ensure it is
maintaining the desired level without excessive fluctuations.
 Automatic Drains: Verify that automatic drain valves are functioning
correctly and not allowing air leaks while removing condensate.

35
 4.4.6 Annual Inspection Results

a) Passed
Criteria:
o The air compressor and receiver tank comply with all safety device checklists.
o No major comments on good housekeeping practices.
Result:
o The air compressor and receiver tank are deemed safe and operational.
o Continue with regular maintenance and monitoring.
b) Passed with Comment
Criteria:
o The air compressor and receiver tank comply with all safety device checklists.
o Some non-compliance with good housekeeping practices (e.g., minor issues with
cleanliness, organization, or minor leaks that do not affect safety).
Result:
o The air compressor and receiver tank are safe to operate but require attention to
housekeeping practices.
o Address comments promptly and improve housekeeping standards.
c) Fail
Criteria:
o One or more safety devices are not operating satisfactorily.
o The air compressor or receiver tank fails the integrity test (e.g., significant leaks,
structural damage, or failed pressure test).
Result:
o The air compressor and/or receiver tank are not safe to operate.
o Immediate corrective action is required:
 Repair or replace faulty safety devices.
 Address integrity issues through repairs or replacement of the affected
components.
o Re-inspection is necessary after corrective actions are completed.

4.5 Recommendations

Air Receiver Tank

Expected improvements up to the next inspection will be given:
 Minor comments on improvement in air intake filtration and lubrication:
o Regularly replace or clean air intake filters to ensure optimal airflow and prevent
contaminants from entering the system.
o Ensure proper lubrication of all moving parts to reduce wear and tear and
maintain efficient operation.
 Rectification of leakage:
o Identify and repair any leaks in the compressed air lines, condensate drain lines,
intake lines, cooling water lines, and lubricant lines.
o Use leak detection solutions or ultrasonic leak detectors to pinpoint and address
even small leaks.

36
 Improvement in condensate drainage and management:
o Ensure all condensate drain systems, including automatic and manual drains, are
functioning correctly and efficiently.
o Regularly check and maintain condensate traps to prevent blockages and ensure
effective condensate removal.
o Implement or improve oil/water separation for proper disposal of condensate
containing oil.

37
 MINISTRY OF LABOR AND SKILL
LABOR AND SKILL BUREAU

Form 6 Compressed Air Receivers Annual Inspection Checklist (IC02)

Inspection data
Factory/ Enterprise
Inspection Service provider
Inspection Engineer Name & Sign.
Inspection Date
Registration No (if available)
Last inspection date (if applicable)
Compressor and Air Receiver Tank Technical Data

Compressor
Identification No:
Type Rotary Screw
Reciprocating
Centrifugal
Manufacturer’s name:
Model
Serial Number
Manufacturing year:
Compressor Power (kW)
Compressor Capacity (cfm/m³/h)
Maximum Pressure (bar)
Controller
Design operating pressure (bar)
Actual operating pressure (bar)
Number of Safety Valves
Number of Pressure Gauges
Number of air filters
Air Receiver
Manufacturer’s name:
Model
Serial Number
Manufacturing year:
Air Receiver Tank Capacity (L)
Hydrostatic Test Pressure (bar)
Maximum Working Pressure (bar)
Safety valve opening and closing (bar)
Number of safety valves

Compliance to Safety Requirements (Mandatory)

Compliance
Yes No NA
Functioning of Start/Stop and Emergency Shutdown
Buttons
No Loose Electrical Connections
Pressure Gauge Operation
Safety Valve Operation
Proper Functioning of Condensate Drains
Is the safety valve's total relieving capacity sufficient to
prevent the receiver's compressed air pressure from
38
exceeding the maximum allowable working pressure?
Proper Lubrication of Moving Parts
Operation of Cooling System (if applicable)
Air Filter Condition
Automatic Drain Valve Operation
Safety Shutdown System Operation
Pressure Relief Valve Operation
Compliance of good housekeeping practice

Compliance
Yes No NA
Cleanliness of Compressor Room
Compressed air receivers are periodically drained?
Are safety valves tested regularly to ensure they are in
good working condition?
Is the inlet of air receivers and piping systems kept free
of accumulated oil and carbonaceous materials?
Proper Insulation of Piping
Air Leaks in Compressed Air Lines
Water Leaks in Cooling Lines (if applicable)
Oil Leaks in Lubrication Lines
Proper Management of Condensate
Condition of Automatic Drains
Maintenance of Air Filters
Proper Organization of Tools and Equipment
Clear Access to Compressor and Receiver Tank
Hydrostatic and thickness Test results (if applicable)

Compliance
Yes No NA
Visual Inspection of Compressor and Receiver Tank
Indicate No Major Surface Damage or Corrosion
Compressor and Receiver Tank Passed Hydrostatic
Pressure Test
Shell and Wall Thickness of Receiver Tank is Acceptable
Annual Inspection Result

Compliance
Good Acceptable Poor
Air Receiver Tank Status
Pass Pass with Fail
comment
Annual Inspection Result
Comments

Recommendation

Validity of the annual Inspection

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