PRESSURE EQUIPMENT DIRECTIVE - TiscaliNews

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PRESSURE EQUIPMENT DIRECTIVE

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La Nuova Direttiva PED: quale impatto sullastrumentazione?

AIS - Sezione di Roma


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S U M M A R Y

− New approach Directives− Pressure Equipment Directive (PED)

−Scope of Pressure Equipment Directive−Notified Bodies−Fluids−Equipment Classification−Modules−Materials−Permantent Joints

− Instrument & Automation Involvement(Engineers and Manufacturers)

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Following Principles !!!! Essential Safety Requirements (E.S.R.)

Free Movement

NEW APPROACH DIRECTIVES

Harmonized Standards

Are presumed to be in conformity with E.S.R

Standards are not mandatory

Manufacturer is free to choose any technical solution

Manufacturers may choose between different Conformity Assessment Procedures MODULES


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SCOPEE.S.R

FREEMOVEMENT

ADMINISTRATIVECOOPERATION

PRESUMPTIONOF CONFORMITY

SURVEILLANCEOF MARKET

CONFORMITYASSESSMENT

NOTIFIEDBODIES

TRANSPOSITION

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3

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NEW APPROACH DIRECTIVES

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SCOPE

• Vessels manufactured in batch series intended to contain air or nitrogen

• Welded steel vessels (non alloy carbon and aluminium or aluminium alloy)

• Pressure from 0.5 bar to 30 bar

• Product Pressure* Volume between 50 up to 10000 barl

• Simple shape

• In force since 1st July 1992

1st Pressure VesselNew Approach Directive

87/404/EEC - Simple Pressure Vessels


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The Products

- Boilers

- Vessels

- Piping

- Accessories

- Safety Devices

MWP(=PS) > 0.5 Barg

Whatever the capacity !!!

Pressure Equipment Directive 97/23/EC

Mandatoryfrom

May 29th 2002

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Example of Pressure Equipment Submitted to PED

Lighters

Gauges

Safety Valves

Fire Extinguishers

Globe ValvesControl Valves

Bulk Containers



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GASVESSELS

PIPING

STEAMEQUIPMENT

Example of Pressure Equipment Submitted to PED

Pressure Equipment Directive 97/23/EEC

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Items Excluded From PED

Steam Waterways,Penstocks,Nuclear Use, Military Use,

Vessels designedfor the transport and distribution ofdrinks having :- PS*V < 500 Bar.L- PS < 7 Bar

Equipmentcoveredby aerosoldispensersDirective

Bottles and cansfor drinks

Tyres,Ballsfor playground


Pressure Equipmentcovered by otherdirectives

- 84/525/EEC,- 84/526/EEC,- 84/527/EEC

- 87/404/EEC


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Items Excluded From PED

Turbines

Steamengines

Internalcombustionengines

Exhaust and inletsilencers

Vessels designed tocontain liquids witha gas pressure abovethe liquid of not morethan 0.5 bar


Enclosures for high-voltage elect.Equip. (control gear, transformers, rotating machines)

Pressurized pipes for the containment oftransmission systems (elect. Tele.)

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Why it ’s a BIG CHANGE ?

National AuthoritiesNOTIFIED BODIES


•Technical Competence•Insurance•Third Party•Link with Nat/Eup Org.•Wide Representation•Professional Integrity


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NOTIFICATIONS

European approval for materials N.B. 1

Qualification of Operating Procedures N.B./R.T.P.

Approval of Personnel for joining parts. N.B./R.T.P.

Qualification of Personnel for N.D.T. N.B./R.T.P.

Application of Modules N.B. 2/U.I.

N.B. : Notified Body R.T.P. : Recognized Third Party organisationU.I. : User Inspectorate


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USER INSPECTORATES

u Second Party inspection bodyu Property of Groups (Oil Companies, etc)u Applicable modules are A1, C1, F and Gu Designation by Member Statesu No CE markingu Pressure Equipment used only in factories

operated by the same Groupu No free movement of equipment



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ESSENTIAL SAFETY REQUIREMENTS

SPECIFICREQUIREMENTS

GENERALREQUIREMENTS

Design (parameters)

Manufacturing

Materials

Fired or otherwise heated pressureequipment with a risk of overheating

Piping

Specific quantitative requirements


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PED ClassificationDIRECTIVE "67/548/EEC"

FLUIDS


GROUP 1

Dangerous Fluids

- Explosive- Oxidizing- Extremely flammable- Highly flammable- Flammable- Very toxic- Toxic

- Harmful- Corrosive- Irritant- Sensitizing- Carcinogenic- Mutagenic- Toxic for reproduction- Dangerous for environment

GROUP 2

Fluids not referredin Group 1

EOF +FR 10T+T

XnCXiR 42 and/or R 43Carc. Cat.Mut. Cat.Repr. Cat.N and/or R 52,R 53, R 59


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CLASSIFICATION OF EQUIPMENTSBased on

- Type of Equipment ------> Vessel, Piping, Accessories- Nature of fluid ------> Gas, Liquid,Steam- Fluids ’ Danger ------> Dangerous and Other- Maximum working pressure Ps- Volume or nominal dimension V or DN

9 TABLES =4 Hazard Categories


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Products Vessels Piping Fluids

Gases, liquefied gases, gases dissolved underpressure, vapours and also those liquidswhose vapour pressure at the maximumallowable temperature is greater than 0,5 barabove normal atmospheric pressure, (1013mbar)

Liquids having a vapour pressure at themaximum allowable temperature of not morethan 0,5 bar above normal atmosphericpressure (1013 mbar)

The demarcation lines in the conformity assessment tables indicate the upper limit

for each category

Fired or otherwise heated pressureequipment with the risk of overheatingintended for the generation of steam orsuper-heated water at temperatureshigher than 110°C having a volumgreater than 2 l, and all pressure cookers

* All portable extinguishers and bottles for breathing apparatus are in the scope of Table 2

Group 1

Group 1

Group 2

Group 2

TABLE 1

TABLE 2 *

TABLE 3

TABLE 4

TABLE 6

TABLE 7

TABLE 8

TABLE 9

TABLE 5

TECHNICAL REQUIREMENTS



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Table 1Vessels referred to in Article 3, Section 1.1 (a), first indent (Vessels, Gas, Group 1)

0,1

1

10

100

1000

10000

0,1 1 10 100 1000 10000 100000V (l)

PS (bar)

PS =0,5 0,5

V =

1 l

PS = 1000

PS = 200

Article 3, paragraph 3

PS*V = 1000

PS*V = 200

PS*V = 50

PS*V = 25

I II III IV

Exceptionally, vessels intended to contain an unstable gas andfalling within categories I or II on the basis of table 1 must be classified in category III.


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Table 6Piping referred to in Article 3, Section 1,3 (a), first indent

0,1

1

10

100

1000

10000

0,1 1 10 100 1000 10000DN

PS (bar)

PS = 0,5

DN

= 2

5

Art

icle

3, p

arag

rah

3

PS*DN = 3500

I

II

DN

= 1

00

PS*DN = 1000

III

DN

= 1

00

DN

= 3

50Exceptionally, piping intended for unstable gases and falling within categories I or II on thebasis of Table 6 must be classified in category III.



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Table 7Piping referred to in Article 3, Section 1.3 (a), second indent

0,1

1

10

100

1000

10000

0,1 1 10 100 1000 10000 100000DN

PS (bar)

PS = 0,5


PS*DN = 3500

I II

DN

= 1

00

PS*DN = 1000

III

DN

= 2

50

PS*DN = 5000


Exceptionally, all piping containing fluids at a temperature greater than 350°C and fallingwithin category II on the basis of Table 7 must be classified in category III

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Table 8Piping referred to in Article 3, Section 1.3 (b), first indent

0,1

1

10

100

1000

10000

0,1 1 10 100 1000 10000 100000DN

PS (bar)

PS = 0,5

DN

= 2

5


I

II

PS*DN = 2000

III

PS = 10

PS = 500



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Table 9Piping referred to in Article 3, Section 1.3 (b), second indent

0,1

1

10

100

1000

10000

0,1 1 10 100 1000 10000 100000

DN

PS (bar)

PS = 0,5

DN

= 2

00


I

PS*DN = 5000

II

PS = 10

PS = 500


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PARTICULAR CASEEquipment Article 3 § 3

ü Must be designed and manufactured in accordance with the sound engineering practice

ü Are not submitted to E.S.R.

ü Are not submitted to C.A.P. (Conformity Assessment Procedure)

ü Must not bear the CE marking

ü Has the benefit of free movement



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CONFORMITY ASSESSMENT PROCEDURE = MODULES

Numbering A to H

Modules with or without QA

Modules for Design and Production

Modules with or without Notified Bodies

Choice depending on the Equipment Category


Define the activities necessary to preformthe Conformity AssessmentDefine the responsibilities and the activitiesfor both Manufacturer and Notified Body.

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MODULES - Examples


Module F(Product Verification)

ð Compliance of Manufacturing Processes with the Design Examination Cert. (M)

ð CE Mark the Equipment. (M)ð Verify that personnell performing the

Permanent Joint are qualified. (NB)ð Verify that Material Certificates are in

compliance with PED (Annex I sect.4.3) (NB)

ð Perform the final inspection and ProofTest (Annex I sect. 3.2) (NB)

ð Affix the NB identificatiion Number (NB)

Module B1(Design EC examination)

ð Application content (M)ð Description of the Equipment

and Technical Documentation(M)ð Review of Technical

Documentation by NBð Verify if the E.S.R. are fullifilled

(NB)ð Assess the material selection if

not covered by Harmodized Std.or European Approval. (NB)

ð Issue the EC Design Examination Certificate (NB)


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Simplified Flowchart MODULESProduction Phase


Design Phase

Man

ufa

ctu

rer

Module A (Internal Control of Production)

Module G (Unit verification)

Module H1 ( Full Quality Assurance with Design Examination and Special Survelliance of Final Assessment)

Module C1(conformity to type)

Module D (Production QA - ISO 9002)

Module E(Product QA - ISO 9003)

Module F (Product Verification)

Module B (Type Examination)

Module B1 (Design Examination)

Module H (Full Quality Assurance)

Module A1 (Int. Control of Prod. with monitoring of Final Assessment)

Module D1 (Production QA - ISO 9003)

Module E1 (Product QA - ISO 9002)

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Basic MODULES

Number Definition Design phase Production phase Notified Body Q/A

A Internal control of production YES YES NO NA

A1 Internal control of production YES YES NO NA

B Type-examination YES NO YES NA

B1 Type-examination YES NO YES NA

D Production quality assurance NO YES + Mod. B or B1 YESYES

(ISO 9002)

D1 Production quality assurance NO YES YESYES

(ISO 9002)

E Product quality assurance NO YES + Mod. B YESYES

(ISO 9003)

E1 Product quality assurance NO YES YES YES (ISO 9003)

F Product verification NO YES + Mod. B or B1 YES NA

G Unit verification YES YES YES NA

H Full quality assurance YES YES YESYES (ISO

9001)

H1 Full quality assurance (with special Survelliance)

YES YES YESYES

(ISO 9001)



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F

Category I

Category II

Category III

Category IV


I A AII A1 D1 A1 E1III B+E B+C1 H B1+D B1+F HIV B+D B+F H1 G H

Applicable ModulesBatch (series) One-Off Produc.

Category

H

E

D

H1

E1D1

A

A1

C1G

One-off productionwith Q/A

One-off productionwithout Q/A

Batch serieswith Q/A

Batch serieswithout Q/A

F

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Materials

Mate

rials

Accepta

nce

Desig

n Q

ualit

y S

yste

m A

ssessm

ent

Pro

duction Q

ualit

y S

yste

m A

ssessm

ent

Fin

al In

spection a

nd T

est Q

ualit

y S

yste

m

Assessm

ent

EC

Desig

n E

xam

ination

EC

Type E

xam

ination

EC

Desig

n E

xam

Cert

ific

ate

EC

Type E

xam

ination C

ert

ific

ate

Pers

onel Q

ualif

ication A

ppro

val

Weld

ing a

nd N

DT

Pro

cedure

Appro

val

ND

T P

ers

onnel Q

ualif

ication A

ppro

val

Fin

al In

spection a

nd F

inal D

ocum

enta

tion

Check

Pre

ssure

Test

Safe

ty A

ccessories Insta

llation C

heck (

if

applic

able

)

Confo

rmity D

ecla

ration

Confo

rmity C

ert

ific

ate

I All A Internal Controll of Production M M M M M M M M M M M

All A1 Internal Manufacturing Check (1) M M M RTP RTP M M M/I M/I M/I M

Type D1 Production Quality Assurance M I I M M RTP RTP M M M/I M/I M/I M

Product E1 Product Quality Assurance M I M RTP RTP M M M/I M/I M/I M

B1 EC Design Examination NB I I RTP

D Production Quality Assurance I I RTP RTP M M/I M/I M/I M

B1 EC Design Examination NB I I RTP

F Product Verification RTP RTP M I I I M I

B EC Type Examination NB I I I RTP RTP RTP

E Product Quality Assurance I RTP RTP M M/I M/I M/I M


C1 Conformity to Type RTP RTP M M/I M/I M/I M

Type H Full Quality Assurance NB I I I M M RTP RTP RTP M M/I M/I M/I M

Product H Full Quality Assurance (3) NB I I I M M RTP RTP RTP M M/I I M/I M


D Production Quality Assurance I I RTP RTP M M/I M/I M/I M


F Product Verification RTP RTP M I I I M I

Product G EC Unit Verification NB I RTP RTP RTP M I I I M I

All H1 Full Quality Assurance (2) NB I I I I I RTP RTP RTP M M/I M/I M/I M

(1) with Monitoring of the Final Assessment M Manufacturer(2) with Design Examination and Special Surveillance of the Final Assessment NB Notified Body(3) for one-off production of vessels and equipemnt the NB shall perform the Final Assessment for each unit I Notified body in charge of conformity assessment

RTP Recognized Third Party (art. 13) or NB

Final AssessmentCE marking

/ Certification

Conformity Assessment Modules Table

Permanent Joints

CH

OIC

ES

MODULES

CA

TE

GO

RY

Type and Design Examination

Fab

ricati

on

an

d T

ests

Quality System

IV

III

II

Product

Type

Product

Type

Type

Type



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MODULES - Examples B+C1

(Cat. III - Bacth Series)


Module C1(Conformity to Type)ð Compliance of Manufacturing Processes with the Type Examination Cert. (M)ð CE Mark the Equipment. (M)ð Perform the Final Inspection and Proof Test (Annex I sect. 3.2) (M)ð Perform the monitoring of the production with un-expected visits (NB)ð Verify that the manufactuter actually performs the Final Assessment(NB)ð Affix the NB identificatiion Number (NB)

Module B (EC Type examination)ð Application content (M)ð Description of the Equipment and Technical Documentation(M)ð Review of Technical Documentation by NBð Verify if the E.S.R. are fullifilled (NB)ð Assess the material selection if not covered by Harmodized Std. or European

Approval. (NB)ð Issue the EC Type Examination Certificate (NB)

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Module E (Product Quality Assurance)ð Application to a NB to assess the QA System Compliance to PED (M)ð Description of the Equipment and Technical Documentation(M)ð Assess the QA according to PED requirements and pay surveillance visits (NB)ð Perform the Final Inspection and Proof Test (Annex I sect. 3.2) (M)ð Pay un-expected visits to verify that the QA system is correctly applied and

functioningð Affix the NB identificatiion Number (NB)



MODULES - Examples B+E

(Cat. III - Bacth Series)


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Module D (Product Quality Assurance)ð Application to a NB to assess the QA System Compliance to PED (M)ð Description of the Equipment and Technical Documentation(M)ð Assess the QA according to PED requirements and pay surveillance visits (NB)ð Perform the final inspection and Proof Test (Annex I sect. 3.2) (M)ð Pay un-expected visits to verify that the QA system is correctly applied and




MODULES - Examples B+D

(Cat. IV - Bacth Series)

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Module F (Product Verification)ð Compliance of Manufacturing Processes with the Design Examination Cert. (M)ð CE Mark the Equipment. (M)ð Verify that personnell performing the Permanent Joint are qualified. (NB)ð Verify that Material Certificates are in compliance with PED (Annex I sect. 4.3) (NB)ð Perform the final inspection and Proof Test (Annex I sect. 3.2) (NB)ð Affix the NB identificatiion Number (NB)



MODULES - Examples B+F

(Cat. IV - Bacth Series)


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Module H (Full Quality Assurance, Cat. III)ð Application to a NB to assess the QA System Compliance to PED (M)ð Description of the Equipment and Technical Documentation(M)ð Assess the QA according to PED requirements and pay surveillance visits (NB)ð Perform the final inspection and Proof Test (Annex I sect. 3.2) (M)ð Pay un-expected visits to verify that the QA system is correctly applied and


Module H1 (Full Quality Assurance, Cat. IV)As for Module H with the following additional activities:

ð Examination of Design (NB)ð Issue of an EC-Design Certificate (NB)ð Increase of the survelliance with special care to the Final Inspection and

Proof Test (Annex I sect. 3.2) (NB)

MODULES - Examples

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MATERIALS


Particular AppraisalManufacturer (Cat I and II )

Harmonized Standard

European Approval

Particular Appraisal N.B. (b)

(Cat III and IV)

N.B. (a)

CEN


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PERMANENT JOINING

Welding

Brazing

Riveting

Gluing

Expanding

Joints which cannot be disconnected except by

destructive methods


Category I Category II Category III Category IV

Permanent Joint Procedure

No approval R.T.P. or N.B. R.T.P. or N.B. R.T.P. or N.B.

Permanent Joint Personnel

No approval R.T.P. or N.B. R.T.P. or N.B. R.T.P. or N.B.

NDE of Permanent Joints Personnel

No approval No approval R.T.P. or N.B. R.T.P. or N.B.

Category of riskType of task

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- Name and address (identification of the manufacturer)- Year of manufacture- Identification of pressure equipment- Essential maxi/mini allowable limits

- Volume V in L- Nominal size DN- Test pressure PT in Bar- Date of pressure test- Safety device set pressure in Bar- Intended use- Filling ratio in kg/l- Maximum filling mass in kg- Tare mass in kg- Product group (1 or 2)- Etc...

MARKING



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Assembly Safety Device

Val

ve

Lev

el G

lass

Piping

Pump(Out of PED)

Vessel

INSTRUMENTATION & AUTOMATIONINVOLVEMENT

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ü Define a Company General Policy for PED implementation in its own Europen Plants

ü A set of documents issued by Company may need to be modified to contain all the information required/needed for PED implementation

ü If needed for QA modules the Quality System shall be adapted tothe PED

ü Pressure Equipment Classificationü Prescription from Costumersü Information from Costumers

General



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Pressure Accessories (cat. I, II and III)TP is not the Manufacturer but purchase themfrom other.

Gauges

Valves

ü Standard Production (Batch Series)There are advantage in using Q/A Modules,Suppliers are going to use H module tocover all applicable categories

ü Non-Standard Production (One-OffProd. and Big Valves)Both Q/A and not Q/A modules may beapplied without big difference. The choicecould be left to the Manufacturer.


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Safety Valves,Rupture Disks,and Instrument whenlinked to EmergencySystems

Safety Accessories (cat. IV)TP is not the Manufacturer but purchase themfrom other.

ü Standard Production (Batch Series)There are advantage in using Q/A Modules,Suppliers are going to use H1 module tocover all applicable categories

ü Non-Standard Production (One-OffProd. and Big Valves)Both Q/A and not Q/A modules may beapplied without big difference. The choicecould be left to the Manufacturer. I



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ü The costumer shall give some additional information such as:wFluidwCategorywThe intended used to avoid any limitation of use in conflictwith the required use.

Prescription/Information from Costumers


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Notified Bodies

PROPOSAL WARNING

The PED leave the «Manufacturer» free to Choice the Notified Body .The Costumer may or may not leave its manufacturersfree to choice the NBIf the client defines a specific NB it shall be carrefully considered in the Proposal stageA specific statement shall be incicated in the Inquiriesand in the bids

Assessment ModuleSelection

The PED leave the «Manufacturer» free to choice theAssessment Module upon those applicable.The Costumer may or may not leave its manufacturersfree to choice the ModulesIf the client defines a specifics Modules it shall be carrefully considered in the Proposal stage



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Web sites

uOfficial Site:uhttp://ped.eurodyn.comuhttp://europa.eu.int/comm/enterprise/newapproach/standardization/harmstds/reflist/equippre.htmluhttp://europa.eu.int/comm/enterprise/newapproach/legislation/nb/en97-23-ec.pdfuwww.tukes.fi/englanti/pressure_equipment/directives/pressure_directive.html


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