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Hartford Steam Boiler International GmbH - The European Pressure Equipment Directive
The European Pressure Equipment Directive 97/23/EC. 97/23/EC A presentation for DESCON Engineering Ltd. (LMW)
The Hartford Steam Boiler International GmbH

Notified Body for:
Product certification Assessment of Quality Systems Joining Personnel Certification through HSB Group NDE through MOU with BINDT
Appointment by ZLS, Germany,

Number 0871
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Hartford Steam Boiler International GmbH - The European Pressure Equipment Directive Hartford Steam Boiler International GmbH - The European Pressure Equipment Directive
The Hartford Steam Boiler International GmbH

Actively participates in PED German Notified Body Forums UK N tifi d Body Forums Notified B d F Brussels Notified Body Forum Are a member of the Technical Response sub-group promoting: - uniformity of application of rules - equivalent levels of safety
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The System A Member State selects a government

department to oversee the implementation of the Directives - UK DTI, Germany - DAR DTI
DTI - DAR etc appoints body to accredit competent bodies UKAS, ZLS etc UKAS - ZLS etc audit potential NoBos
NoBo i/d number issued by Brussels
Notified Bodies
Implementation of the Directive

29th November 1999 to 28th May 2002
Transition period, use PED or existing regulations
Not responsible for market surveillance - Member State activity only Meet minimum requirements of technical and administrative competency equivalent to competency, EN 45000 series Perform activities specified in Directive, includes inspection and quality system approval Appointed to perform specific duties Product and quality system approval, welder, brazer, etc..... qualifications, EAM
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29th May 2002

PED only
Recognised Third Party

Appointed to perform personnel certification and
Enforcement & Safeguard

Products with marking and declaration of conformity must not be refused placement on market or putting into service p g Marking that may be confused with CE marking is prohibited Member States are responsible for Market Surveillance Safeguard Clause
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approve permanent jointing procedures. A Notified Body may also be a recognised Third Party
Marking
Not until Declaration of Conformity is issued must be distinct, legible, indelible I di t product satisfies all ESR' Indicates d t ti fi ll ESR's Indicates all relevant directives are satisfied Affixed to product or data plate of each vessel or assembly Affixed by manufacturer or agent in EC Accompanied by ID No. of Notified Body involved
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National Law
Each Member State or MRA country must implement the Directive into its own National Law Technical requirements of the PED must not be changed
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Scope of the PED

all Pressure Equipment > 0.5 bar gauge vacuum vessels are excluded
Who is responsible?
The manufacturer or an Authorized Representative is the person responsible for declaring that the pressure equipment meets all the requirements of the directive directive. Are not mandatory
A written agreement between the manufacturer and Authorised Representative is necessary
Authorized Representatives
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Manufacturer outside EU If an Authorised Representative is not appointed

Someone must be be responsible for maintaining technical documents
could be either an agent importer, installer, or user.
The PED specifies:

Hazard Categories Essential Safety Requirements Conformity Assessment Procedures Notified Body Involvement
There is no allowance made for sharing partial responsibilities

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Hazard Categories
Type of fluid-Group 1-dangerous Group 2 - not dangerous Nature of fluid - gas - liquid Pressure, bar Volume, litres
Hazard Categories
Use appropriate table to establish hazard category (9 tables - 4 vessels, 4 piping, 1 fired) Example: Pressure Vessel containing Hydrogen (Dangerous) = Fluid group 1 Gas (Liquefied gas) 1000 bar 100 litres
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Hydrogen vessel
Determine if contents is dangerous - yes PED Article 9 - 2.1. 67/548/EEC may be needed (user should determine in most cases). Go to Article 3
Article 3, 1.1 Vessels

a) liquefied gas First indent - Group 1 fluids
Vessel example PSV = 100000 Since V greater than 1 litre and PSV greater than 25bar 1 or, PS greater than 200 bar Vessel - inside the scope of PED Refer to Annex II table 1
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Hartford Steam Boiler International GmbH - The European Pressure Equipment Directive Hartford Steam Boiler International GmbH - The European Pressure Equipment Directive
Annex II table 1 1000 bars Category IV
Conformity Assessment Modules

Category I - Module A Category II - Modules A1, D1, E1 Category III - Modules B1 + D1, B1 + F, B + E, B + C1, H Category IV - Modules B + D, B + F, G , H1
100 litres
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Hazard Category I
Module A - self declaration by the manufacturer
Hazard Category II
Module A1 - manufacturers self declaration with random monitoring of final assessment by the Notified Body Module D1 - production quality assurance Module E1 - product quality assurance
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Hazard Category III

Module B1 + D - EC design examination by the
Notified Body plus production quality assurance Module B1 + F - EC design examination plus product y y verification by the Notified Body Module B + E - EC type examination by the Notified Body plus product quality assurance Module B + C1 - EC type examination plus random final examination by the Notified Body Module H - full quality assurance
Hazard Category IV
Module B + D - EC type examination by the Notified Body plus production quality assurance Module H1 - full quality assurance plus EC design examination and special surveillance of final assessment by the Notified Body Module B + F - EC type examination plus product verification by the Notified Body Module G - EC unit verification by the Notified Body
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Selection of Modules
Conventional Inspection
Conformity Assessment
Quality Assurance
Cat I II III IV
Single prod Mass prod Single prod Mass prod A A1 B1 + F G A* A1* B + C1 B+F D1 or E1 B1 + D or H H1 D1 or E1 B+E or H B+D
Module B - EC type examination - may be applicable to a family - Notified Body on application will; review technical documentation verify conformance with ESRs perform examinations and tests issue EC type examination certificate
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* final test for mass produced vessels may be on a statistical basis

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Module B1 - EC design examination - Notified Body will on application y pp

Modules A1, C1, F, G - Direct inspection
review technical documentation verify conformance to ESRs perform examinations to verify manufacturers solutions meet ESRs issue EC design examination certificate
similar to traditional system of inspection by independent third party A1 and C1 is a monitoring activity only by the Notified Body
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All quality assurance modules require as initial assessment by a Notified Body followed by periodic surveillance and unexpected visits ISO 9000 approval may give presumption of conformity for those relevant elements that meet the Directive Surveillance visits involve examination of product and records relating to production since last visit - Notified Body may require tests to be performed
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Comments on quality assurance systems

Approval must be to the Directive - not ISO or ASME Approval must be from a Notified Body Manufacturers may choose to have approval for the PED and ISO certification. Notified Bodies who are also accredited for ISO Certification may perform both functions - HSB can provide these services
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Methods of documenting PED quality systems

Manufacturers with ISO 9000 certification will have to prepare additional documentation to meet Directive
- They will either
Quality system supplement to an ISO program

Similarly addressed to an ASME supplement Supplements already detailed procedures prepared for ISO Ensures conformity to specific requirements Is easier to provide for presumption of conformity
incorporate the requirements into their program - manufacturers would then be subject to the auditing of these additional requirements during their ISO system audits. prepare a supplement that addresses the specific requirements of the PED
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Quality system supplement

Supplements to address specifics of PED
Quality system supplements continued

Materials Joining materials Non Destructive testing g Training Records Monitoring of the quality system Notified Body
Document Control
Conformity assessment Design Alignment of National Codes with Directive Manufacturing

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Conformity Assessment options

Manufacturer may choose from options applicable to
each category There is always a quality assurance option There is always an inspection option
An hazard analysis is a prerequisite to performing design

Analyse hazards that:
- result from pressure p - result from other hazards - determine these
Approval to a higher module is acceptable

except equipment outside the scope of PED and within SEP (Article 3 para. 3 cannot be CE Marked Safety devices are almost always Category IV
Determine effect and likelihood of occurrence Consider state of the art Design to be safe for intended use and foreseeable misuse
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Hazard analysis
Design hierarchy
- to eliminate or reduce hazards - to apply appropriate protection - to inform users of residual hazards
Hazard analysis
Potential contributors to failure
- frequency of start up - conditions of use - in-service supervision - in-service inspection - complexity of equipment - working life of equipment
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Hazard analysis
Consequences of possible failure
persons and property proximity of exposure effect on adjacent equipment economic effect energy released explosion risk toxicity, flammability temperature
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Hazard analysis
Possible failure modes
lamella tearing/ageing brittle fracture corrosion/erosion fatigue hydrogen induced cracking overheating overload plastic instability stress corrosion cracking
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Hazard analysis
Potential loadings - internal/external pressure - weight of equipment, contents and attachments supe posed oads - superimposed loads - supports - cyclical and dynamic reactions - wind, seismic and traffic - impact - thermal gradients and expansion - structural stability handling and transport - external fire
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Hazard analysis
Must also address NDE
Must identify suitable material Must be documented

- HSB provide a design checklist
shall form part of technical documentation
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Essential Safety Requirements (ESRs)

Design - Harmonised standards give presumption
of conformity however:

Essential Safety Requirements

Manufacturing
manufacturing procedures
material preparation and inspection p p p material identification and traceability heat treatment joining procedures and personnel control NDE and personnel control final assessment - inspection and proof test marking and labelling instructions for use
they do not address all ESRs they are not mandated

when other standards are used manufacturer
must show that all ESRs have been satisfied Other standards ASME Section VIII Div 1, 2, 3 CODAP, AD Merkblatt, PD5500. Standards may not be intermixed
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Specific requirements
- for fired equipment - piping

Materials
Suitable for the application and the lifetime of the equipment Sufficiently chemical resistant Not significantly affected by ageing Suitable for intended processing Selected to avoid undesirable effects when various materials are put together
Quantitative requirements
max membrane stress joint coefficients pressure limiting devices pressure test material properties

impact - 27J at 20oC ductility - 14% elongation

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Materials
Welds and HAZ must:
- have same properties as base metal
Material selection
Materials shall be selected ONLY from the following methods - Harmonised standard

Materials must:
- be accompanied by documentation issued by the material manufacturer affirming conformance to the specification
unlikely to be available until Summer 2002 initially limited material selection available by a Notified Body appointed to perform activity performed and approved for specific applications
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- European Approval for Material
- Particular Material Appraisal
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Particular Material Appraisal (PMA)

Issued by individual pressure equipment manufacturer Pressure equipment in categories III and IV q p g Notified Body participates in approval
- disadvantage - possible challenge under safeguard clause
Particular Material Appraisal

Verify material specification meets ESRs Issue PMA certificate for suitable range Wh Where material specification d t i l ifi ti does not guarantee t t meeting ESRs, perform additional tests
- issue PMA for that cast number only unless specification has ranges
materials regarded as acceptable in Member States prior to PED will continue to be favourably viewed by Notified Bodies
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Suitable for repeated use in designated range Only significant option available
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Issuing a PMA
Example using ASME SA 516 - 60
Ductility, elongation > 14% min - specification minimum 21% on 50 mm Toughness, 27J at lowest temperature - specification minimum 20J at - 460C
Issuing a PMA
Example using ASME SA 106-B
Ductility, elongation > 14% min - specification minimum 22% on 50 mm Toughness, 27J at lowest temperature - specification - NO GUARANTEED IMPACT TEST PROPERTIES Suitable for processing Not affected by ageing Not welded ALTERNATIVE REQUIRED OR TEST EACH CAST
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use BS5500 appendix D to ratio impact value increase by 1.5 Joules per 10C, range 18 - 47 J. This equates to 27J at - 43.30C
Suitable for processing Not affected by ageing Not welded
Issuing a PMA Example using ASME SA 240-316L

Ductility, elongation > 14% min - specification minimum 40% on 50 mm g , p Toughness, 27J at lowest temperature - specification minimum NO GUARANTEED IMPACT TEST PROPERTIES - JUSTIFY USE Suitable for processing Not affected by ageing Not welded
Justification for lack of impact test properties

SA240-316L - This material does not require impact testing
the base metal, weldments and HAZ are always ductile - supported by Section VIII Div 1 - UHA51
- No ductile/brittle transition occurs above minimum metal temperature - The material does not suffer in-service degradation at the normal temperatures
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pressure equipment materials main pressure bearing parts in cats II, III, IV main pressure bearing parts cat I, pressure parts other than main in categories I to IV, attachments to cat II, III, IV parts other parts
Marking
marking min height 5 mm
Notified Body identification number Name and address of manufacturer MAP, maximum and minimum temperature Serial number
quality system route inspection certificate EN10204 3.1.B
direct inspection route inspection report EN10204 3.2 or inspection certificate EN 10204 3.1.C test report EN10204 2.2 certificate of compliance with the PO EN10204 2.1
Additional marking Other marking - eg type, year

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Note Material manufacturers outside of the EU requires QS approval by EU Cert body

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Typical nameplate
The Company, address
Additional marking
The following may also be required
- volume - nominal pipe size - test pressure - safety device set pressure - output - supply voltage - intended use, filling ratio - maximum filling mass, tare mass - product group
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0871
MAP 520 bar maximum T 2000C Minimum T - 200C Type - model AI 11 Year Built serial number 01
Documentation
Declaration of conformity to the PED Additionally certificates as appropriate
- EC type approval certificate - EC design examination certificate - product certificate of conformity
Compliance with the PED

Determine hazard category y Choose conformity assessment module Appoint Notified Body for Categories II, III, IV Choose acceptable materials Design to meet ESRs
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Instructions - installation, operation, maintenance.

- inspection, repair, decommissioning
Application to HSB International GmbH for Notified Body services

Apply to HSB International - Client uses HSBI application forms - application identifies Clients requirements - HSBI Lingen identifies requirements HSBI staff allocated for design reviews, audits, inspections etc
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Hartford Steam Boiler International GmbH - The European Pressure Equipment Directive

The Hartford Steam Boiler International GmbH

Appointment by ZLS, Germany,

The Hartford Steam Boiler International GmbH

The System A Member State selects a government

Implementation of the Directive

29th May 2002

Recognised Third Party

Enforcement & Safeguard

Scope of the PED

Manufacturer outside EU If an Authorised Representative is not appointed

The PED specifies:

There is no allowance made for sharing partial responsibilities

Article 3, 1.1 Vessels

Annex II table 1 1000 bars Category IV

Conformity Assessment Modules

Hazard Category III

* final test for mass produced vessels may be on a statistical basis

Comments on quality assurance systems

Methods of documenting PED quality systems

Quality system supplement to an ISO program

Quality system supplement

Quality system supplements continued

Conformity assessment Design Alignment of National Codes with Directive Manufacturing

Conformity Assessment options

An hazard analysis is a prerequisite to performing design

Approval to a higher module is acceptable

Must identify suitable material Must be documented

shall form part of technical documentation

Essential Safety Requirements (ESRs)

Essential Safety Requirements

they do not address all ESRs they are not mandated

Essential Safety Requirements

Essential Safety Requirements

impact - 27J at 20oC ductility - 14% elongation

- European Approval for Material

- Particular Material Appraisal

Particular Material Appraisal (PMA)

Particular Material Appraisal

Suitable for processing Not affected by ageing Not welded

Issuing a PMA Example using ASME SA 240-316L

Justification for lack of impact test properties

quality system route inspection certificate EN10204 3.1.B

Additional marking Other marking - eg type, year

Note Material manufacturers outside of the EU requires QS approval by EU Cert body

Compliance with the PED

Instructions - installation, operation, maintenance.

Application to HSB International GmbH for Notified Body services

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