Polish Pressure Parts Manufacturers Meeting EC Requirements

1. PED 97/23/EC CERTIFICATION AS AN ELEMENT OF POLISH PROGRAMME FOCUSED ON MEETING THE EC REQUIREMENTS PED Workshop - Bratislava, 11-13 April

2. Presentation of Polish pressure part’s sector manufacturers 47-400 Racibórz 33 Łąkowa Street POLAND tel. 0 48 (32) 410 1000 www.rafako.com.pl info@rafako.com.pl • Established in 1949 • Production area 55 000 m2 • Total area 600 000 m2 • Number of employees ca. 1600

3. Presentation of Polish pressure part’s sector manufacturers • Conventional steam and hot water boilers • Fluidised bed boilers • Supercritical boilers • Heat recovery boilers for waste utilisation • Stoker fired boilers • Flue gas desulphurisation plants • Production of pressure components • Complex services - diagnostics - modernisation - repairs - design services

4. Presentation of Polish pressure part’s sector manufacturers Boiler components: - membrane walls - drums - coil pipes - collectors - rotary air preheaters - welded steel structures - flue gas and air ducts

5. Presentation of Polish pressure part’s sector manufacturers Environment protection has strengthened Polish manufacturers position on the European markets. Within the period 2000 - 2004 the Polish company signed contracts for delivery (in most cases including design, and erection) of ThermalWaste Utilisation Boilers to many European countries. So far their has delivered and assembled more than 40 units for thermalwaste utilisation plants in Europe – allacc. to PED requirements. The details of cladding processes on RAFAKO products are shown on the next few slides

6. Strategic technologies and their development for boiler application

7. Cladding applied on the components of thermal waste utilisation boilers

8. Presentation of Polish pressure part’s sector manufacturers Application progress of super critical boiler essentially depends on the availability and the intelligent use of creep resistance steels. For many key industry areas of Polish manufacturers are at the forefront of the development of new materials and their applications. This presentation includes some specific items related with a new steel grade for extreme environments and new welding technology for PED requirements being a part of development on European market

9. Strategic matierials and their development for boiler application As a proper partner of UC market investors, RAFAKO S.A. decided to take part in works within a framework COST 522 partnership. RAFAKO experience supports COST 522 within the field of boilers for supercritical steam parameters including new generation steel grade such as: - T23 and T24 steel grades - for membrane walls components (up to 5200C), • T/ P91 steel grades - for coils and headers, • T/ P92 - for coils and outlet SH headers (up to 6200C), • HCM12 and HCM12A for coils and SH headers • VM 12 - including 0,08%C, 12%Cr, 2,5%W and 1-2%Co • (up. to 6500C operation parameters)!

10. The standards of Polish manufacturers integrated system • In the last few years, a lot of Managements took decision to establish the Integrated System Management. • Where are a typical internationals standards being a part of System integrity: • - PN-EN ISO 9001:2001 edition • - PN-EN ISO 14001 • ASME CODE for stamp S, U and U2 • European Commission Directive No. 97/23/EC

11. The idea, areaof system’s integration Role of Integrated System Management Envi. Management System acc. to PN- EN ISO 14001 Environmental Environmental protection Quality Management System acc. to PN-EN ISO 9001 : 2000 and Directive No 97/23/UE Stability and effectivity of internal proces Clients Stockholders Quality and safety of acctivity Safety Management System acc. to PN 18001 Employees Designation 11

12. Presentation of Polish pressure part’s sector manufacturers Major objectives and principles of European Policy goods services Free transfer of capital people • Integration of PED requirements within national regulations of all EU member countries, • Uniform product compliance assessment procedures – modular compliance assessment, • Approval of Notified Bodies by EU member countries. 12

13. Presentation of Polish pressure part’s sector manufacturers PED scope – typical products - of application depending on equipment type • tanks (paragraph 1.1 of the Directive), • steam and hot water generators (paragraph 1.2), • pipelines (par 1.3), • protective and pressure equipment (paragraph 1.4) with defined risk potential. • Pressure equipment sepcified in PED paragraphs from 1.1 to 1.4 must meet basic requirements as set forth in attachment I. 13

14. Presentation of Polish pressure part’s sector manufacturers Main tasks of pressure equipment manufacturer in accordance with PED • defining the category of equipment (Art. 9 + attachment II), • selection of appropriate module (attachment II ), • risk specification and risk analysis (attachment I), • selection of materials (attachment I, chapter 4), • equipment design, fabrication and commissioning (att. I), • instruction of operation and maintenance (att. I, chapter 3.4), • elaboration of Declaration of Conformity (attachment VII), • product identification with CE mark (Art. 15). 14

15. Presentation of Polish pressure part’s sector manufacturers Modular compliance assessment procedure, module selection Modules define the criteria for conditions of „manufacture, control and testing”, which shall be applied by a manufacturer in order to confirm the product fabrication in accordance with PED requirements. Modules are related with product design and / or production stages. Eight basic modules and eight possible variants may be configured in various combinations. Modules define manufacturer’s tasks and – where applicable – tasks of Notified Body during the design, production, control and assessment stages. 15

16. Presentation of Polish pressure part’s sector manufacturers Module A Module C Module D Module B CЄ ModuleE Manufacturer Module F Module G Module H/ H1

17. Presentation of Polish pressure part’s sector manufacturers *scope of RAFAKO S.A. PED certification

18. Presentation of Polish pressure part’s sector manufacturers Manufacturer’s responsibility during the design stage • Elaboration of risk analysis is viewed as the main task • Risk analysis components include: • risk / risk source identification, • risk level assessment, where • Risk analysis – systematic use of available information in risk identification and assessment. • Risk analysis shall serve as the basis for proper risk assessment and acceptance. • Risk R = probability of failure x effects of failure 18

19. Presentation of Polish pressure part’s sector manufacturers Manufacturer’s responsibility concerning materials requirements • a) Shall be specified in harmonised norms – EN • (materials defined in attachment A to EN 12952 – 2), • b) Shall be certified with European material certificate, approval - EMDS, • c) Or with special material approval – EAM (PMA). • Manufacturer’s responsibility within the field of application of materials • Providing of materials for the whole period of equipment use – if replacement is not foreseen, • Assure material properties compatible with estimated conditions of operation and testing, • Assure appropriate material properties, e.g. In case of steel • Kv 27J lub 35J przy Tmin’ oraz A5 14% lub 16%, 19

20. Specification of requirements for materials in acc. with EN 10204 Presentation of Polish pressure part’s sector manufacturers Materials for pressure equipment Main pressure parts. Category I Other pressure parts. Category II, III, IV Main pressure parts. Category II, III, IV Other parts and materials Manufacturer’s Quality System. Direct inspection 3.1 B 3.1 C or 3.2 2.2 2.1

21. Presentation of Polish pressure part’s sector manufacturers Manufacturer’s responsibility within the field of manufacture • Manufacturer has to assure the application of appropriate procedures, manufacturing techniques – within the field of permanent joints, which, in accordance with the Directive, include: • welding and tube expansion in tubesheets • Additionally, manufacturer has to provide procedures for: • plastic forming such as bending, rolling, • execution of production joints in accordance with qualified procedure, • execution of joints by qualified personnel e.g. Welders, • performance of non-destructive testing by qualified personnel, • assure the properties of permanent joints at the level of minimum required properties of assembled materials. 21

22. Presentation of Polish pressure part’s sector manufacturers Manufacturer’s responsibility within the field of manufacture • Qualifications of personnel shall be confirmed by: • Approovel of manufacturing procedures of equipment categories II, III and IV – in acc. with Art. 12, attachment I to Directive – in acc. with EN 288 (approved by Third Party or Notified Body) • Welders qualification – in acc. with Art. 12, attachment I – in acc. with EN 287 (approved by Notified Body), • qualification (certification) of non-destructive testing personnel for equipment categories III and IV – in acc. with Art. 13, attachment I – certification in acc. with EN 473,(approved by Third Party), • Assure full traceability of materials throughout manufacturing processes, • Assure documented records throughout manufacturing processes - traceability, 22

23. Presentation of Polish pressure part’s sector manufacturers Selected scope of responsibility within manufacturers System • product design– application of appropriate compliance assessment procedure, module selected on the basis of attachment III to Directive and contact with Notified Body; • welding, manufacturing technology and Quality Control- assurance of qualified techniques, manufacturing processes, inspection and control methods for permanent joints – in acc. with items 3.1.2 and 3.1.3 of att. I (Permanent Joints and Non-destructive Testing) • purchasing –verification of suppliers of materials and services, control of suppliers’ system certificates – see item 4 att. I (Materials) – • EN 12953 norm - 5, attachment F„Buyer’s responsibility” • „The scope of Buyer’s (e.g. investor, operator) responsibility includes ordering the plant at qualified boiler manufacturer so as to assure the achievement of required quality and safety of operation” 23

24. Presentation of Polish pressure part’s sector manufacturers All pressure equipment manufactured for European Union market must meet PED No 97/23/UC requirements. The certificate of RAFAKO S.A. is valid within the scope of the equipment described in the following integrated standards: EN 12952 - Boiler and pressure vessel, EN 12953 - Great boiler.....…, EN 13445- Non heated pressure vessel, EN 13480 - Pipeline... EN 764 –Pressure equipment. Technol..

25. Presentation of Polish pressure part’s sector manufacturers Advantages resulting from system certification in accordance with PED requirements • Customers are notified about our ability to meet system requirements in the processes of design, manufacture, inspection & testing as well as assessment of compliance, • Product quality and safety of manufacture are seen as basic requirements for RAFAKO • All manufacture and control activities are correctly specified, planned and carried out, • Properly prepared quality documents related with both manufacturing and inspection & control activities, • RAFAKO gains knowledge and skills required in order to enable it to export CE-marked equipment to all EU member countries, • Reduction of manufacturing costs thus creating competitive advantage, • Meeting of Customer requirements results in Customer satisfaction and trust • . 25

26. Presentation of Polish pressure part’s sector manufacturers THANK YOU FOR YOUR ATTENTION • . 26