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Pressure Equipment Workshop September 2007 – Day 1 Pressure Equipment Directive (PED) Overview

Pressure Equipment Workshop September 2007 – Day 1 Pressure Equipment Directive (PED) Overview Ed Haynes, Marcel Broekhoven, Guy Baylac. The “New Approach”. New Approach to Technical Harmonisation and Standards

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Pressure Equipment Workshop September 2007 – Day 1 Pressure Equipment Directive (PED) Overview

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  1. Pressure Equipment Workshop September 2007 – Day 1 Pressure Equipment Directive (PED) Overview Ed Haynes, Marcel Broekhoven, Guy Baylac

  2. The “New Approach” New Approach to Technical Harmonisation and Standards This is part of the mechanism to bring European Member States together but avoiding having to agree every detail

  3. New Approach: Background & overview • Access to Community Market (EEA) • Competitiveness encouraged • Technical harmonisation to support the common market • 19 sectors to date • Essential (Health and Safety) Requirements (ESRs) • Conformity to be established to ESRs • Conformity assessment procedures relate to risks • Manufacturer’s responsibility • CE marking of products placed on the market • Self certification / Notified Bodies Assessment • Various intervention mechanisms for authorities • Harmonised Standards provide presumption of conformity

  4. New Approach (2) • Regulates risks, and not products • More than 1 risk related directive may apply to the same product e.g. PED, Low Voltage, Machinery • Regulation based on risk management instead of technical solutions • Regulation introduces a wide flexibility for manufacturers, in choice of technological means of meeting ESRs, and conformity assessment 

  5. New Approach (3) • Use of European standards gives presumption of conformity; however use of ENs is voluntary • Authorities accept that conformity assessment can be carried out on their behalf by independent bodies • Conformity assessment procedures reflect risk categories • Manufacturers can call upon any Notified Body from throughout the European Union • Conformity assessment always covers design and production, but may be in two stages • Choice between product or quality assurance route

  6. The Pressure Sector • Sizeable market in Europe (€ billions) • Covers a wide variety of products • Previously heavily regulated at national level with deeply rooted “national” codes • Dates back to the Industrial Revolution • Related to worker and consumer safety • A technically complex subject • Some indications of concern at global level

  7. New Approach - Pressure • In accordance with the principles of the “New Approach”, the design and the manufacture of pressure equipment are subject to essential safety requirements. • This means that Member States cannot prohibit, restrict or impede the placing on the market or putting into service of pressure equipment complying with the provisions of the Directive (bearing the CE marking).

  8. Pressure Equipment Directive (PED) Ensures free movement of goods for products: • which fall within its scope • which meet the ESRs, • have completed Conformity Assessment • or are Art 3.3 (SEP) equipment. • PED harmonises the previously fragmented European Pressure Equipment market • Important message for trade

  9. PED The Pressure Equipment Directive 97/23/EC of the European Parliament on the approximation of the laws of the Member States concerning pressure equipment “Done at Brussels 29 May 1997. For the European Parliament (President). For the Council (President)”

  10. PED 97/23/EC Recital - 27 “Whereas” clauses set the scene 21 Articles 7 Annexes: ESR, Graphs, Modules, Criteria for Notified Bodies, Recognised Third Party Organisations and User Inspectorates, “CE” Marking, and Declaration of Conformity

  11. Recital Recital 5 Items and assemblies Recital 14 Essential Safety Requirements and Final assessment Recital 16 CEN, CENELEC Harmonised Standards Recital 19 Conformity Assessment

  12. Articles Article 1 Scope and definitions – next 3 slides Article 2 Market surveillance – later in my talk Article 3 Technical Requirements - Annex I Essential Safety Requirements Article 8 Safeguard clause Article 10 Conformity Assessment Article 15 CE Marking – indicates legal declaration

  13. PED: Scope Pressure equipment and Assemblies : - design, - manufacture, - conformity assessment Limited to: - pressure hazard - pressure greater than 0.5 bar (gauge or 1.5 bar absolute) - equipment placed on the market OR put into service - assemblies placed on the market AND put intoservice

  14. Definitions 1- Vessel housing for containment of pressurised fluids 2- Piping pipe or system of pipes mainly for transport of fluids – includes hoses, expansion joints, fittings 3- Safety accessory protects against exceeding allowable limits 4- Pressure accessory operational function e.g. valves, fittings

  15. Assemblies • Several pieces of pressure equipment, provided • the result is integrated • the result is functional • they are a whole • they are assembled by one manufacturer NOTES: a- the assembly can be built in a workshop or on-site b- there is no upper limit to an assembly c- when not placed on the market, assemblies are not covered

  16. Essential Safety Requirements - PED annex I • General obligations for manufacturer (Prelim and ESR 1) • Design and calculation (ESR 2) • Manufacturing (ESR 3) • Materials (ESR 4) • Specific requirements in addition to 1 - 4: • ESR 5 fired or otherwise heated pressure equipment, • ESR 6 piping, • ESR 7 (general rule) Specific quantitative requirements

  17. Essential Safety Requirements (ESRs) • Preliminary observations • ESRs are compulsory • Manufacturer must carry out hazard analysis then design and construct taking account of the results of the analysis • Take account of state of the art, technical and economic considerations consistent with a high degree of Health & Safety protection • General: ESR 1 • e.g. include reasonably foreseeable misuse; • eliminate hazards • protect against them • advise residual hazards (In this order of priority)

  18. Essential Safety Requirement (ESR 2) • 2.1, 2.2 • Take account of all relevant factors for intended lifetime • Apply safety coefficients, comprehensive methods, safety margins against relevant failure modes: • pressure, temperature, traffic, wind, seismic, reaction forces, corrosion, erosion, fatigue, decomposition of unstable fluids

  19. Essential Safety Requirement (ESR 2) 2.2.3, 2.2.4 Design by calculation (DBF, DBA, Fracture mechanics) Supplement by experimental method (DBE) (e.g. strain gauging, burst test, fatigue test, creep test) DBE without design by calculation has a size limit of 6000 bar*litres for vessels; 3000 bar*mm for piping

  20. Essential Safety Requirement (ESR 2) 2.3, 2.5, 2.9 Safe handling and operation (openings, closures, pressure relief) 2.6, 2.7 Corrosion, chemical attack, wear 2.8 Assemblies – Note no limit on size of assembly, and the term “sub-assembly” is not used 2.10, 2.11 Protection and Safety accessories

  21. Essential Safety Requirement (ESR 3) Manufacturing – “suitable procedures” manufacturers capabilities, manufacturing/joining procedures, (approval of procedure and personnel) Non-destructive testing (approval of personnel) Final inspection – internal and external; proof test to the greater of: max allowable pressure x 1.43 or ratio of allowable stresses x 1.25 Marking and labelling (as a min – manufacturer’s name and address, year, identification, essential max/min allowable limits) CE marking Operating instructions- relate to ESR 1

  22. Essential Safety Requirement (ESR 4) Materials Limited requirements for welding consumables 4.1 a) Appropriate properties – particularly ductility and toughness, quantified in 7.4 for steels as 14% elongation, 27 J Charpy) 4.2 Use Harmonised standards or EAM or PMA 4.3 Certification “affirming compliance with a specification” (EN 10204 explains this and the options)

  23. Essential Safety Req’ts (ESRs 5 - 7) • Specific requirements (ESR 5): • fired or otherwise heated pressure equipment • Specific requirements (ESR 6):- piping • General rule (ESR 7) • allowable stresses given • Joint coefficient related to extent of NDT • Pressure surge limited to + 10% • Hydrostatic test pressure formula (mentioned previously) • Characteristics for steels (mentioned previously)

  24. Harmonised Standards (ENs) • Developed following Commissionmandate M/071 to CEN • Designated by CEN as candidate for harmonisation • Substantiating the Essential Safety Requirements of the PED • Use not mandatory but provide presumption of conformity • Important examples of product standards: • EN 13445 (unfired pressure vessels), EN 13480 (piping), • EN 12952 (water tube boilers), EN 12953 (shell boilers)

  25. Harmonised Standards • Type 1: • - Provide a means of fulfilling at least one ESR • Contain an annex Z to provide a reference between the pertaining section of the EN and the ESRs of the PED • Give Presumption of Conformity to those ESRs of the PED which are addressed, when the standard is cited in the OJEU. • List of standards recently published in OJ on 2006-12-19 C311/31 to C 311/44 - Seehttp://ec.europa.eu/enterprise/newapproach/standardization/harmstds/reflist/equippre.html

  26. Standards under PED mandate • About 30 CEN and ECISS Technical Committees are developing standards providing presumption of conformity to the PED • Currently 232 European Standards have been cited in the Official Journal of the European Union as providing presumption of conformity to the PED • A further 70 are in development. • Co-operation continues with ISO via the Vienna Agreement • There about a further 600 supporting standards

  27. Standards under SPVD mandate • 20 European Standards (EN) have been cited in the OJEU as providing presumption of conformity to the SPVD (87/404/EEC) • A further 3 are in development.

  28. Harmonised Standards: Challenges • Avoiding situations detrimental to European standardisation: • National standard organisations are obliged to withdraw documents conflicting with ENs (98/34/EC) and • National regulation must not discriminate certain solutions • Interest of all players, including European industry: • economically efficient and safe ENs • ENs competitive with other standards internationally

  29. PED Annex Z “Once this standard is cited in the OJ under [the] Directive and [it] has been implemented as a national standard in at least one Member State, compliance with the clauses of this standard given in Table ZA.1 confers, within the limits of the scope of this standard, a presumption of conformity with the corresponding Essential Requirements [of the] Directive and associated EFTA regulations.”

  30. Question 1 Can we use standards other than EN in pressure equipment? Answer YES as long as the manufacturer meets the essential safety requirements in the PED. [Commercial considerations may apply ie. the overall cost may be greater]

  31. Question 2 How do I know that AD 2000, CODAP, PD5500, ASME or other non-EN standard meets the Essential Safety Requirements? Answer You do not know, unless the manufacturer: • reviews his arrangements for complying with ESRs and • the Notified Body accepts this, where it is involved in Conformity Assessment.

  32. Question 3 Does this mean that the manufacturer takes on additional responsibility by not using EN? Answer YES – other standards do not confer Presumption of Conformity with the ESRs.

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