TÜV HELLAS S.A.

1. TÜV HELLAS S.A. CYPRUS PED Workshop on the Implementation of The Pressure Equipment Directive “IMPLEMENTING THE PED IN GREECE“ `presented byLAMBROS ZACHOS Nicosia 3-5 October 2005

2. THE PRESSURE EQUIPMENT DIRECTIVE as implemented in Greece

3. PRESSURE EQUIPMENT DIRECTIVE 97/23/ECInitial problem for manufacturers and users

4. PRESSURE EQUIPMENT DIRECTIVE 97/23/EC 97/23/EC

5. Conformity assessment (Article 10 PED) • Before placing on the market, themanufacturer shall subject each itemof equipment to one of the conformityassessment procedures described inAnnex III, according to the conditionsgiven in this Article. • The conformity assessmentprocedures to be applied to an item ofpressure equipment with a view toaffixing the CE marking shall bedetermined by the category, asdefined in Article 9, in which theequipment is classified.

6. MODULE CONCEPT ACCORDING TO PED

7. CONFORMITY ASSESSMENT PROCEDURES PER CATEGORIE

8. USING MODULE B

9. USING MODULE B

10. USING MODULE F

12. SUMMARY The main problems with the use of PED are :

13. Notified Bodies in Greece – Third Party Inspection Agencies • Greek National Accreditation Body (ΕΣΥΔ) • Notified Bodies for specific Modules (as reported in the Annex of the Accreditation Certificate ) • Manufacturers in Greece • 1. Various manufacturing shops • 2. Construction Companies (Contractors) • 3. No major serial production of vessels, pressure parts

14. The know – how of the process is given by the owner – operator – end user. In these cases, where the know how transfer is not given, the Manufacturer cannot implement the essentially safety requirements satisfactory, creating problems to the Notified Body by the assessment. (e.g. catalysts to be used, material to be used). • For the Conformity Assessment some Modules or combination of modules are requesting a certified Quality Management System according to EN ISO 9001/2000. (e.g. B+D, B&F). The majority of the manufacturers, which are smaller shops, are not able to fulfill this requirement and to hold such a Certificate. Quality System certification not in the regulated sector.

15. Conformity Assessment according to Module H1. Need for a • certified Quality System and a supplementary Audit based on the • satisfaction of the PED requirements. What does the notified Body, • detailed Audit, unexpected visits ? • For the Module A1 it is recommended the final assessment by the • notified body. Some manufacturers miss this point. • Turn Key projects: • If the assembled station or pressure parts are to be erected and • assembled in an other country, the notified body shall witness • the final test – proof test on site, something which never happens, • since the equipment has to leave with the Certificate and the CE • Mark. Request by the Manufacturer.

16. The guidelines provided in the web, seem to get a large amount of needed information, creating a “package” bigger • than the Directive itself.Interpretation not always understood, difficulties to locate the requirement in the Text. • Module G for single production known to the Manufacturers, as the traditional Third Party inspection, but higher costs.

17. Material – Standards to be followed. American Standards API / ASTM do not require Impact testing, also not covered in the material certificate. The manufacturers miss often this point by ordering. Additional tests to be performed rise the costs for the manufacturer. • Surveillance problem by the Authorities (e.g. approval granted to a steam boiler after hydro test without CE)

18. WHAT KIND OF CLIENTS ? • Companies which manufacture pressure vessels for refineries • 2. PIPE WORKS : Audit to certify the possibility of the plant to manufacture pipes – Material Certification : 3.1.B & PED Certification to comply with the ESR’s. • 3. Chemical industries : Revision of piping, change of the design requirements • 4. Contractors : works like construction of HP steam piping for a Power plant, turn key projects like units in Refineries • 5. Companies for manufacturing Metering and Regulating stations, Compressor stations, Heat Exchangers, other Pressure vessels, Piping assemblies

19. INSPECTION OF PRESSURE EQUIPMENT ACORDING TO PED • GUIDE TO THE INSPECTORS as a requirement of the Accreditation Body. • 1. APPLIED NATIONAL REGULATION • NATIONAL AND INTERNATIONAL STANDARDS & • SPECIFICATIONS • HARMINIZED EUROPEAN STANDARDS • Ministerial Gazette 16289/33011999/ΦΕΚ Β’ 987/25.05.99 • AD MERKBLATT 2000, ASME, Codap , ANSI, EN 13445 • TRD, EN 12953

20. 2. EXPERIENCE OF PERSONNEL – APPROVAL OF INSPECTORS Based on the Notified Body’s Policy and Accreditation procedure 3. Measuring & Testing Equipment The calibrated measuring and testing equipment of the Manufacturer is to be used. It is on the responsibility of the Inspector to identify the testing equipment and to record the information on the Inspection Reports, so that the trace ability of the measured values is being assured.

21. 4. CHECK POINTS POINTS OF ATTENTION DURING INSPECTION ACCORDING TO PED

22. Classification of pressure equipment according to the : • risk • type(pressure vessel, piping, accessory) • fluid (liquid or gaseous) • type of fluid according to the risk (flammable-toxic-explosive etc.) • operating pressure and Volume (in case of vessels) or the diameter • (in case of piping) • Classification of Category (I, II, III, IV) • Pick up the correct and appropriate Module or combination of Modules, on which the Conformity Assessment will be based on. • Modules of a Category of higher risk can be selected by approval of the Manufacturer

23. The Conformity Assessment Procedure can be performed according to the risk ranked Category of the equipment, through out a combination of : 1.Design approval / Type Approval 2.Inspection during the construction 3.Quality Management System

24. CRITICAL CHECK POINTS FOR 1 & 2 a) Review of the Technical File (design, calculations and production methods) b) Material Certificates (according to table 3 of PED) c) Welding procedures d) Verification of Welders performance e) Verification of NDT technicians performance f) Visual / Dimensional controls during production g) Verification of NDT results h) Tightness tests i) Safety Valves controls j) Marking k) Operation Instructions l) Issue of Conformity Certificate

25. And in addition for item 3 • the quality assurance of the production or • the quality assurance of the product or • the whole quality assurance of the enterprise

26. At least following has to be taken into account during the • Assessment of the Quality Management System of the company: • assurance that the design documents are being well maintained • evaluation of the design results to be sure that these are correct • check the ability, the qualification and the experience of the • design personel • check the traceability and the conformity of the material used • check that the Welding procedures are properly qualified • check that the welders are properly qualified and certified • check NDT procedures, qualification of NDT personnel and • correct implementation of the testing frequency • check that the Measuring and Testing equipment are properly • calibrated • check that the Production, Inspection & Testing documentation • is properly maintained • check that the final tests are being performed as well as the • pressure tests

27. Internal Inspection Frequencies in years mandatory time based inspection D F B I L NL GB S Pressure Vessels 5 1-3 1-2 5 4 2,17 3 1,5-3 3 1 2 1,5 2 1,17 1 1,5 Boilers status : 2003

28. Thank you • for your kind attention.