Professional Documents
Culture Documents
Ped - Urn 05-1074
Ped - Urn 05-1074
Pressure Equipment
APRIL 2005
URN 05/1074
Contents
Page
Pressure Equipment - Essential features of the law
Product classification
Technical requirements
Conformity assessment
11
Enforcement
14
Other legislation
16
17
20
22
28
30
43
56
Pressure Equipment
- Essential features of the law
The Pressure Equipment Regulations 1999 (the PER SI 1999/2001)
implemented the Pressure Equipment Directive (PED 97/23/EC) in the
United Kingdom and entered fully into force on 29 November 1999. The PER
were amended in two respects by the Pressure Equipment (Amendment)
Regulations 2002 (SI 2002/1267) with effect from 30 May 2002. (For more details
see pages 6 and 15 below under Exclusions and Penalties respectively).
From 30 May 2002, pressure equipment and assemblies placed on the market
and put into service in the United Kingdom must comply with the PER.
General Requirements
Subject to the exclusions described below, the PER make it an offence for a
responsible person (see page 6) to place on the market, put into service or
otherwise supply pressure equipment and assemblies above specified pressure/
volume thresholds unless:
be safe;
There are twenty-five members of the Community - Austria, Belgium, Cyprus, Czech Republic,
Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, the Netherlands, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden and
the UK. The EEA adds Iceland, Liechtenstein and Norway. Directive 97/23/EC has been adopted
by the EEA Joint Committee and extends to the EEA.
Such devices include devices for direct pressure limitation, such as safety
valves and bursting discs, etc, and limiting devices which either activate
the means for correction or provide for shutdown or shutdown and lock
out, such as pressure switches or temperature switches, etc.
The responsible person may arrange for any, or all, of the activities involved in the
design and manufacture of an item of pressure equipment or an assembly to be
carried out by others. However, the responsible person retains overall responsibility.
Exclusions
The Regulations do not apply to equipment and assemblies:
listed at Annex A;
manufactured for use outside the EEA and placed on the market outside the
EEA;
placed on the market before 29th May 2002 and which complied with
the requirements legally applicable for placing on the market before
28th November 1999.
However, any subsequent major repair or modification to such a product with the
intention of placing it on the market may bring it within the scope of the PER and
it will be required to comply with the requirements. The Commissions Guide to
the Implementation of directives based on the New Approach and the Global
Approach sets out further detail on the scope of New Approach directives relating
to used and second-hand products and products imported from third countries.
More information on this publication and how to acquire it can be found on page
19.
placed on the market after use otherwise than in the course of business at
all times since manufacture or import (see Regulation 2(4) introduced by SI
2002/1267).
PRODUCT CLASSIFICATION
In order to know how the PER will apply to specific items of pressure equipment,
the manufacturer will need to classify the equipment according to its perceived
level of hazard by reference to the charts reproduced in Annex B. Equipment of a
relatively low hazard will be required to be manufactured according to 'sound
engineering practice' (SEP) (see page 10). Equipment that is classified as a higher
hazard than SEP is required to meet the relevant essential safety requirements of
the PER and, on that account, to be CE marked. It is allocated, in ascending order
of that hazard, to one of Categories I, II, III, or IV and the implications of this
categorisation are further explained on page 12. The following table shows which
chart in Annex B should be used for the various types of equipment.
Fluid Group
STEAM
GENERATORS
Chart
VESSELS
State of
contents
Gas
Liquid
PIPING
Gas
Liquid
b)
c)
With this information the manufacturer can identify the relevant chart in Annex B
(see table on previous page), and determine the correct classification of the
equipment by plotting the maximum allowable pressure and, in the case of vessels,
the volume in litres or, for piping, the nominal size (DN).
The maximum allowable pressure (PS) is the maximum pressure for
which the equipment is designed, as specified by the manufacturer.
b)
c)
d)
10
11
Category II
Category III
Category IV
Module
Modules
Modules
Modules
A1
B1 + D
B+D
D1
B1 + F
B+F
E1
B+E
B + C1
H1
Key
Module
Design
Production
Technical documentation
A1
Technical documentation
Type examination
B1
Design examination
C1
D1
Technical documentation
E1
Technical documentation
Unit verification
Unit verification
H1
b)
c)
CE marking requirements
Once conformity assessment has been completed, and if the equipment or
assembly complies with the provisions of the PER, the manufacturer will be required
to affix the CE marking to each item of pressure equipment or assembly and draw
up a declaration of conformity (see section below). The CE marking is as illustrated
in diagram 1 below. It should not be smaller than 5mm in its vertical height and the
proportions, as shown in diagram 2, should be maintained whatever its size. The
grid is for information only, and does not form part of the marking. The CE marking
will need to be affixed in a visible, easily legible and indelible fashion.
Diagram 1
Diagram 2
The presence of CE marking does not mean that the pressure equipment cannot
be challenged by an enforcement authority if they have reasonable grounds for
suspecting an infringement of the Regulations.
Suppliers should note that CE marking is not a European safety mark or quality
symbol intended for consumers and should not be presented as such. Its purpose
is to indicate to enforcement authorities that the pressure equipment to which it
relates is intended for sale in the Community and the EEA and signifies a
declaration, which is rebuttable, by the manufacturer or his authorised
representative that the equipment satisfies the requirements and is entitled to
access those markets. It should also be noted that CE marking is specific only to
a range of Directives. It can only be applied to products covered by such Directives
and under the conditions contained in them. While it is not an offence under the
Regulations to affix CE marking to items which are not pressure equipment or
covered by another Directive requiring CE marking, such an action could constitute
an offence under section 1 of the Trade Descriptions Act 1968 and may result in
prosecution and a subsequent fine. This can apply to any person in the supply
chain.
EC Declaration of Conformity
An EC Declaration of Conformity is a written declaration by the manufacturer or
his authorised representative that the equipment to which the CE marking has
been affixed complies with the requirements of the Regulations.
A copy of the EC Declaration of Conformity is not required to accompany each
product but a copy should be retained by the responsible person who first places
the equipment on the market in the Community or EEA.
The declaration of conformity will need to contain the information set out in Annex F.
ENFORCEMENT
In Great Britain the Health and Safety Executive (HSE), and, for Northern Ireland,
the Health and Safety Executive for Northern Ireland (HSENI), are responsible for
enforcing the Regulations in relation to pressure equipment and assemblies for
use in the workplace.
In Great Britain trading standards authorities, and in Northern Ireland district
councils, are responsible for enforcing the Regulations in relation to pressure
equipment used in a non-work environment.
The HSE has 7 regions with offices throughout Great Britain and, in Northern
Ireland which is treated as one region, the HSENI office in Belfast. Each of these
offices can advise suppliers of equipment for use at work regarding current
standards and relevant legislation. HSE inspectors may also make preventive or
reactive visits to suppliers.
14
Suppliers of equipment wishing to ensure that their products meet the requirements
of the Regulations can make enquiries to one of the Notified Bodies, to HSEs
Infoline Service (Tel: 0845 345 0055) or to their nearest HSE office or, in Northern
Ireland, the Health and Safety Executive for Northern Irelands Information and
Advice Helpline (Tel: 0800 032 0121). Clearly it is in the suppliers own interest to
discuss at an early stage any problems they may be having in applying the
Regulations to their products.
Penalties
If tried in a Magistrates Court, the maximum penalty for contravening the
Regulations is currently a fine of 5,000 or, in some cases, imprisonment for up to
3 months, or both.
If tried in a Crown Court, the penalty for contravening the Regulations is currently
an unlimited fine or, in some cases, imprisonment for up to 2 years, or both.
It is for the courts to decide the penalty in each instance taking
into account the severity of the offence. The Pressure Equipment
(Amendment) Regulations 2002 (SI 2002/1267) provides for cases
to be tried in either the Magistrates or Crown Courts.
The Regulations provide a defence of due diligence.
Free circulation
Member States may not, on grounds of the hazards due to pressure, prohibit,
restrict or impede the placing on the market and putting into service of pressure
equipment and assemblies which comply with the provisions of the PED. Member
States are to presume that pressure equipment and assemblies bearing the CE
marking satisfy the provisions of the PED. The Member State in which the
equipment is eventually used can stipulate in which official language(s) of the
European Community the accompanying documentation is to be provided.
Safeguard procedure
Member States are required to take all appropriate measures to withdraw from
the market pressure equipment or assemblies bearing the CE marking which,
when used in accordance with its intended purpose, is liable to endanger the
safety of people and, where appropriate, domestic animals or property. The Member
State must immediately inform the European Commission of such action and give
reasons. Where, after consultation with the parties concerned, the Commission
finds that the measures are justified, it must inform the Member State taking the
action and the other Member States.
Member States are required to take action against anyone who affixes the CE
marking to pressure equipment or an assembly which does not comply and must
inform the Commission and other member States of the action taken.
15
OTHER LEGISLATION
Simple Pressure Vessels Directive
Certain vessels for air or nitrogen are covered by the Simple Pressure Vessels
Directive (SPVD) and are thus excluded from the PER The Simple Pressure
Vessels Directive (87/404/EEC as amended), implemented in the United Kingdom
by The Simple Pressure Vessels (Safety) Regulations (SI 1991/2749) as amended,
continues to apply to these products. A booklet describing its precise scope and
requirements, Product Standards - Simple Pressure Vessels, is available from
the STRD website at http://www.dti.gov.uk/strd/spvps.pdf and from the DTI
Publications Orderline on 0845 015 0010.
The Pressure Systems Safety Regulations
The Pressure Systems Safety Regulations 2000 (PSSR) (SI 2000/128) applies
to the design and construction of pressure equipment not covered by the Pressure
Equipment Regulations. PSSR applies to the use and ongoing integrity of pressure
systems.
The PSSR can be obtained from:
The Stationery Office Ltd (TSO)
51 Nine Elms Lane
London
SW8 5DR
Tel: 0870 600 5522
Fax: 0870 600 5533
E-Mail: mailto:customer.services@tso.co.uk
A copy of the Regulations may also be downloaded from the HMSOs website
http://www.legislation.hmso.gov.uk/si/si2000/20000128.htm
The Safety of Pressure Systems Approved Code of Practice (ACOP) L122 SI
2000 No. 128, which describes the PSSR for prospective users, is available at a
charge from:
HSE Books
PO Box 1999
Sudbury
Suffolk
CO10 2WA
Tel: 01787 881165
Fax: 01787 313995
or from the HSE website at: http://www.hsebooks.co.uk
16
17
FURTHER INFORMATION
Enquiries relating to the Regulations:
Department of Trade & Industry
Standards & Technical Regulations Directorate
Bay 331
151 Buckingham Palace Road
London SW1W 9SS
Tel: 0207 215 1437
Fax: 0207 215 1529
Website: http://www.dti.gov.uk/strd
Enquiries relating to Enforcement:
HSE Infoline
Tel: 0845 345 0055
Website: http://www.hse.gov.uk
Enquiries relating to standards which may be used to demonstrate
conformity:
Charles Barker
BSI Information Centre
389 Chiswick High Road
London W4 4AL
Tel: 0208 996 7474
Fax: 0208 996 7048
Website: http://www.bsi-global.com
Enquiries relating to the interpretation of the Directive across the European
Union and the implementation of the Regulations in other Member States:
A series of guidelines in the form of specimen Questions and Answers has been
developed by the European Commission in cooperation with government
representatives from the Member States and other parties with an interest in the
practical application of the Directive, e.g. industry, users and CABs. These are
organised into a series of headings and can be accessed on the European
Commissions pressure equipment website http://ped.eurodyn.com. This site
also contains details of contacts with responsibility for the PED in other Member
States and useful links e.g. to the CEN website.
18
19
ANNEX A
networks for the supply, distribution and discharge of water and associated
equipment and headraces such as penstocks, pressure tunnels, pressure
shafts for hydroelectric installations and their related specific accessories;
OJ No L 147,
OJ No L 42,
(3)
OJ No L 84,
(4)
OJ No L 225,
(5)
OJ No L 207,
(6)
OJ No L 213,
(1)
(2)
9.6.1975, p. 40.
23.2.1970, p. 1.
28.3.1974, p. 10.
10.8.1992, p. 72.
23.7.1998, p. 1.
7.9.1995, p. 1.
20
equipment covered by Article 296 (1) (b) of the Treaty (i.e. specifically
designed and constructed for military purposes);
items specifically designed for nuclear use, failure of which may cause an
emission of radioactivity;
10
11
12
OJ No L 77,
OJ No L 169,
(9)
OJ No L 196,
(10)
OJ No L 100,
(7)
(8)
26.3.1973, p. 29.
12.7.1993, p. 1.
26.7.1990, p. 15.
19.4.1994, p. 1.
21
13
14
15
16
17
18
vessels designed for the transport and distribution of drinks having a PSV
of not more than 500 barL and a maximum allowable pressure not
exceeding 7 bar;
19
20
21
vessels designed to contain liquids with a gas pressure above the liquid of
not more than 0.5 bar.
(1)
(2)
(3)
(4)
ADR =
RID =
IMDG =
ICAO =
(1)
(3)
22
ANNEX B
Classification Charts
(See Page 7)
Notes:
The demarcation lines in the following charts indicate the upper limit for each
category. The charts are called tables in the Directive implementing the PER.
Charts for gases include gases, liquefied gases, gases dissolved under pressure,
vapours and also those liquids whose vapour pressure at the maximum allowable
temperature is greater than 0.5 bar above normal atmospheric pressure (1 013
mbar).
Charts for liquids include liquids having a vapour pressure at the maximum
allowable temperature of not more than 0.5 bar above normal atmospheric pressure
(1 013 mbar).
The charts assign each piece of equipment to a firm category. Over classification
of equipment, e.g. declaring it to be category IV when it is category II, is expressly
prohibited. See Commission's Guideline 2/25 on the http://ped.eurodyn.com
website.
Chart 1
Maximum
allowable
pressure
(PS)
(bar)
10000
IV
PS = 1000
1000
III
PS = 200
00
10
=
V
00
2
PS
=
V
50
= 25
PS
V =
PS SV
V =1
200
100
10
Sound Engineering
Practice (SEP)
II
III
IV
PS = 0.5
0.5
0.1
10
100
1000
10000
Volume (V)(L)
Exceptionally, vessels intended to contain an unstable gas and falling within categories I or II
on the basis of Chart 1 must be classified in category III
23
Chart 2
Vessels for Group 2 gases
PS
(bar)
10000
IV
PS = 3000
III
PS = 1000
200
00
30
00
10
10
PS
V
PS
V
V
PS
100
V
PS
V =1
1000
50
20
0
IV
PS = 4
SEP
1
II
III
PS = 0.5
0.5
0.1
10
100
1000
10000
V(L)
Exceptionally, portable extinguishers and bottles for breathing equipment must be classified
at least in category III
Chart 3
Vessels for Group 1 liquids
PS
(bar)
10000
II
V =1
III
1000
PS = 500
500
V
PS
100
II
=
0
20
PS = 10
10
SEP
PS = 0.5
0.5
0.1
10
100
1000
24
10000
V(L)
Chart 4
Vessels for Group 2 liquids
PS
(bar)
V = 10
10000
II
PS = 1000
1000
PS = 500
500
V
PS
100
00
10
0
PS = 10
10
SEP
PS = 0.5
0.5
0.1
10
100
1000
10000
100 000
V(L)
Exceptionally, assemblies intended for generating warm water at temperatures not greater
than 110OC which are manually fed with solid fuels and have a product of pressure and volume
greater than 50 bar litres, must be subject either to an EC design examination (Module B1)
with respect to their conformity with Sections 2.10, 2.11, 3.4, 5(a) and 5(d) of the essential
safety requirements, or to full quality assurance (Module H).
Chart 5
Steam Generators
V =2
PS
(bar)
1000
100
PS = 32
32
IV
V
PS
=
SEP
=
0
20
V
PS
=
50
II
III
V = 1000
V
PS
00
30
10
PS = 0.5
0.5
0.1
10
100
1000
10000
V(L)
25
Chart 6
Piping for Group 1 gases
DN = 25
DN = 100
PS
(bar)
1000
II
III
100
DN = 350
DN = 100
0
50
=3
0
00
=1
SEP
DN
DN
PS
PS
10
PS = 0.5
0.5
0.1
10
25
100
350
1000
Nominal size
(DN)
Exceptionally, piping intended for unstable gases and falling within categories I or II must be
classified in category III.
Chart 7
Piping for Group 2 gases
PS
(bar)
DN = 250
1000
II
DN = 100
DN = 32
III
100
SEP
10
PS
D
N
00
50
=
N
00
D
35
PS N =
D
PS
10
00
0.5
0.1
10
32
100 250
1000
10000
PS = 0.5
DN
Exceptionally, all piping containing fluids at a temperature greater than 350OC and falling
within category II must be classified in category III.
26
Chart 8
Piping for Group 1 liquids
PS
(bar)
DN = 25
III
1000
PS = 500
500
100
II
D
PS
N
=
00
20
SEP
10
PS = 10
I
1
PS = 0.5
0.5
0.1
10
25
100
1000
10000
DN
Chart 9
Piping for Group 2 liquids
PS
(bar)
DN = 200
II
1000
500
PS = 500
SEP
100
I
=
N
D 00
PS 50
10
PS = 10
PS = 0.5
0.5
0.1
10
100
1000
27
10000
DN
ANNEX C
PRESSURE EQUIPMENT CLASSIFICATION
Maximum allowable
pressure greater than
0.5 bar ?
Note
Note :: X,
X, YY and
andZZ are
are
entry
points
for
pressure
entry points for pressure
accessories
accessories and/or
and/or
assemblies
assemblies
No
Yes
Equipment excluded
from PED?
(Annex A)
Yes
No
Vessel
Steam Generator
Determine state of
fluid contents
(Page 7)
Piping
Determine state of
fluid contents
(Page 7)
Gas
Liquid
Gas
Liquid
Determine
fluid group
(Page 7)
Determine
fluid group
(Page 7)
Determine
fluid group
(Page 7)
Determine
fluid group
(Page 7)
Group 1
Group 2
Table 1
Table 2
Group 1
Group 2
Table 3
Table 4
Group 1
Table 5
Table 6
Group 2
Table 7
Table 8
Group 2
Table 9
Group 1
Category
Module (Annex E)
SEP
I
II
III
IV
28
Safety Accessories
Pressure Accessories
Manufactured for
specific
equipment
Yes
Classified in the
same category as
the equipment it
protects.
No
Yes
Assemblies
Go to
point X
No
Choose a module
from Category 4
Go to
point Z
Yes
Go to
point Y
Go to
point Z
29
ANNEX D
The obligations arising from the essential requirements listed in this Annex for pressure
equipment also apply to assemblies where the corresponding hazard exists.
2.
The essential requirements laid down in the Regulations are compulsory. The obligations
laid down in these essential requirements apply only if the corresponding hazard exists for
the pressure equipment in question when it is used under conditions which are reasonably
foreseeable by the manufacturer.
3.
The manufacturer is under an obligation to analyse the hazards in order to identify those
which apply to his equipment on account of pressure; he must then design and construct it
taking account of his analysis.
4.
The essential requirements are to be interpreted and applied in such a way as to take
account of the state of the art and current practice at the time of design and manufacture
as well as of technical and economic considerations which are consistent with a high degree
of health and safety protection.
1.
GENERAL
1.1.
1.2.
In choosing the most appropriate solutions, the manufacturer must apply the principles set
out below in the following order:
1.3
Where the potential for misuse is known or can be clearly foreseen, the pressure equipment
must be designed so as to prevent danger from such misuse or, if that is not possible,
adequate warning given that the pressure equipment must not be used in that way.
2.
DESIGN
2.1
General
The pressure equipment must be properly designed taking all relevant factors into account
in order to ensure that the equipment will be safe throughout its intended life.
The design must incorporate appropriate safety coefficients using comprehensive methods
which are known to incorporate adequate safety margins against all relevant failure modes
in a consistent manner.
30
2.2
2.2.1
The pressure equipment must be designed for loadings appropriate to its intended use
and other reasonably foreseeable operating conditions. In particular, the following factors
must be taken into account:
internal/external pressure,
reaction forces and moments which result from the supports, attachments, piping,
etc.
Various loadings which can occur at the same time must be considered, taking into account
the probability of their simultaneous occurrence.
2.2.2.
2.2.3.
Calculation method
(a)
(b)
design by formula,
design by analysis,
Resistance
Appropriate design calculations must be used to establish the resistance of the
pressure equipment concerned.
31
In particular:
(c)
the calculation pressures must not be less than the maximum allowable
pressures and take into account static head and dynamic fluid pressures
and the decomposition of unstable fluids. Where a vessel is separated
into individual pressure-containing chambers, the partition wall must be
designed on the basis of the highest possible chamber pressure relative
to the lowest pressure possible in the adjoining chamber,
the maximum stresses and peak stress concentrations must be kept within
safe limits,
the calculation for pressure containment must utilise the values appropriate
to the properties of the material, based on documented data, having regard
to the provisions set out in section 4 together with appropriate safety factors.
Material characteristics to be considered, where applicable, include:
tensile strength,
fatigue data,
impact strength,
fracture toughness,
Stability aspects
Where the calculated thickness does not allow for adequate structural stability, the
necessary measures must be taken to remedy the situation taking into account
the risks from transport and handling.
32
2.2.4.
A pressure strength test, the purpose of which is to check that, at a pressure with
a defined safety margin in relation to the maximum allowable pressure, the
equipment does not exhibit significant leaks or deformation exceeding a determined
threshold.
The test pressure must be determined on the basis of the differences between the
values of the geometrical and material characteristics measured under test
conditions and the values used for design purposes; it must take into account the
differences between the test and design temperatures;
2.3.
(b)
where the risk of creep or fatigue exists, appropriate tests determined on the basis
of the service conditions laid down for the equipment, for instance hold time at
specified temperatures, number of cycles at specified stress-levels, etc;
(c)
where necessary, additional tests concerning other factors referred to in 2.2.1 such
as corrosion, external damage, etc.
In particular, pressure equipment fitted with an access door must be equipped with an
automatic or manual device enabling the user easily to ascertain that the opening will not
present any hazard. Furthermore, where the opening can be operated quickly, the pressure
equipment must be fitted with a device to prevent it being opened whenever the pressure
or temperature of the fluid presents a hazard.
33
2.4.
2.5.
Means of examination
(a)
(b)
(c)
Other means of ensuring the safe condition of the pressure equipment may be
applied:
where opening the pressure equipment would adversely affect the inside,
or
where the substance contained has been shown not to be harmful to the
material from which the pressure equipment is made and no other internal
degradation mechanisms are reasonably foreseeable.
2.6.
to avoid harmful effects such as water hammer, vacuum collapse, corrosion and
uncontrolled chemical reactions. All stages of operation and testing, particularly
pressure testing, must be considered,
2.7.
Wear
Where severe conditions of erosion or abrasion may arise, adequate measures must be
taken to:
2.8.
Assemblies
Assemblies must be so designed that:
the components to be assembled together are suitable and reliable for their duty,
all the components are properly integrated and assembled in an appropriate manner.
34
2.9.
2.10.
on filling:
(b)
(c)
2.11.
(a)
safety accessories;
(b)
Safety accessories
comply with appropriate design principles in order to obtain suitable and reliable
protection. These principles include, in particular, fail-safe modes, redundancy,
diversity and self-diagnosis.
35
2.12.
External fire
Where necessary, pressure equipment must be so designed and, where appropriate, fitted
with suitable accessories, or provision made for their fitting, to meet damage-limitation
requirements in the event of external fire, having particular regard to its intended use.
3.
MANUFACTURING
3.1.
Manufacturing procedures
The manufacturer must ensure the competent execution of the provisions set out at the
design stage by applying the appropriate techniques and relevant procedures, especially
with a view to the aspects set out below.
3.1.1.
3.1.2
Permanent joining
Permanent joints and adjacent zones must be free of any surface or internal defects
detrimental to the safety of the equipment.
The properties of permanent joints must meet the minimum properties specified for the
materials to be joined unless other relevant property values are specifically taken into
account in the design calculations.
For pressure equipment, permanent joining of components which contribute to the pressure
resistance of equipment and components which are directly attached to them must be
carried out by suitably qualified personnel according to suitable operating procedures.
For pressure equipment in categories II, III and IV operating procedures and personnel
must be approved by a competent third party which, at the manufacturers discretion, may
be:
To carry out these approvals the third party must perform examinations and tests as set
out in the appropriate harmonised standards or equivalent examinations and tests or must
have them performed.
3.1.3.
Non-destructive tests
For pressure equipment, non-destructive tests of permanent joints must be carried out by
suitably qualified personnel. For pressure equipment in categories III and IV, the personnel
must be approved by a third-party organisation recognised by a member State (1).
3.1.4
Heat treatment
Where there is a risk that the manufacturing process will change the material properties to
an extent which would impair the safety of the pressure equipment, suitable heat treatment
must be applied at the appropriate stage of manufacture.
3.1.5.
Traceability
Suitable procedures must be established and maintained for identifying the material making
up the components of the equipment which contribute to pressure resistance by suitable
(1)
See Page 11
36
means from receipt through production, up to the final test of the manufactured pressure
equipment.
3.2.
Final assessment
Pressure equipment must be subjected to final assessment as described below.
3.2.1.
Final inspection
Pressure equipment must undergo a final inspection to assess visually and by examination
of the accompanying documents compliance with the requirements of the Regulations.
Tests carried out during manufacture may be taken into account. As far as is necessary on
safety grounds, the final inspection must be carried out internally and externally on every
part of the equipment, where appropriate in the course of manufacture (e.g. where
examination during the final inspection is no longer possible).
3.2.2.
Proof test
Final assessment of pressure equipment must include a test for the pressure containment
aspect, which will normally take the form of a hydrostatic pressure test at a pressure at
least equal, where appropriate, to the value laid down in 7.4.
For category I series-produced pressure equipment, this test may be performed on a
statistical basis.
Where the hydrostatic pressure test is harmful or impractical, other tests of a recognised
value may be carried out. For tests other than the hydrostatic pressure test, additional
measures, such as non destructive tests or other methods of equivalent validity, must be
applied before those tests are carried out.
3.2.3.
3.3.
(b)
(1)
The Regulations require that where the equipment is to be placed on the market and put into service in
the UK, the instructions, marking, labelling and information are in English. Other member States may
require that such information is provided in the official language of that member State.
37
(c)
intended use,
The CE marking and the required information must be given on the pressure equipment or
on a dataplate firmly attached to it with the following exceptions:
3.4.
where the pressure equipment is too small, e.g. accessories, the information
referred to in (b) may be given on a label attached to that pressure equipment:
labelling or other adequate means may be used for the mass to be filled and the
warnings referred to in (c), provided it remains legible for the appropriate period of
time.
(1)
use,
(b)
(c)
If appropriate, these instructions must also refer to hazards arising from misuse in
accordance with 1.3 and particular features of the design in accordance with 2.2.3.
The Regulations require, to the extent that it is needed for safe and correct use of pressure equipment
and assemblies, that where equipment is to be placed on the market in the UK, the information required
in Sections 3.3 and 3.4 is to be provided in English. Other member States may require that such information
is provided in the official language of that member State.
38
4.
MATERIALS
Materials used for the manufacture of pressure equipment must be suitable for such
application during the scheduled lifetime unless replacement is foreseen.
Welding consumables and other joining materials need fulfil only the relevant requirements
of 4.1, 4.2(a) and the first paragraph of 4.3, in an appropriate way, both individually and in
a joined structure.
4.1.
4.2
have appropriate properties for all operating conditions which are reasonably
foreseeable and for all test conditions, and in particular they should be sufficiently
ductile and tough. Where appropriate, the characteristics of the materials must
comply with the requirements of 7.5. Moreover, due care should be exercised in
particular in selecting materials in order to prevent brittle-type fracture where
necessary; where for specific reasons brittle material has to be used appropriate
measures must be taken;
(b)
(c)
(d)
(e)
(a)
(b)
(c)
4.3.
(1)
for pressure equipment in categories III and IV, particular appraisal as referred to
in the third indent of (b) must be performed by the notified body in charge of
conformity assessment procedures for the pressure equipment.
The equipment manufacturer must take appropriate measures to ensure that the material
used conforms with the required specification. In particular, documentation prepared by
the material manufacturer affirming compliance with a specification must be obtained for
all materials.
A European approval for materials (EAM) is a technical document defining the characteristics of materials
intended for repeated use in the manufacture of pressure equipment which are not covered by any
harmonised standard. European approvals for materials will be issued in draft form, at the request of one
or more manufacturers of materials or equipment, by a notified body specifically designated for the task
and will then be subject to the approval of the procedure laid down in Article 11 of the PED.
39
For the main pressure bearing parts of equipment in categories II, III and IV, this must take
the form of a certificate of specific product control.
Where a material manufacturer has an appropriate quality-assurance system, certified by
a competent body established within the community and having undergone a specific
assessment for materials, certificates issued by the manufacturer are presumed to certify
conformity with the relevant requirements of this section.
SPECIFIC PRESSURE EQUIPMENT REQUIREMENTS
In addition to the applicable requirements of sections 1 to 4, the following requirements apply to the
pressure equipment covered by sections 5 and 6.
5.
steam and hot-water generators, such as fired steam and hot water boilers,
superheaters and reheaters, waste-heat boilers, waste incineration boilers,
electrode or immersion-type electrically heated boilers, pressure cookers, together
with their accessories and where applicable their systems for treatment of feedwater
and for fuel supply, and
process-heating vessels for other than steam and hot water generation, such as
heaters for chemical and other similar processes and pressurised food-processing
equipment.
6.
(a)
(b)
sampling points are provided where required to allow evaluation of the properties
of the fluid so as to avoid risks related to deposits and or corrosion,
(c)
(d)
(e)
PIPING
Design and construction must ensure:
(a)
that the risk of overstressing from inadmissible free movement or excessive forces
being produced, e.g. on flanges, connections, bellows or hoses, is adequately
controlled by means such as support, constraint, anchoring, alignment and
pre-tension;
(b)
that where there is a possibility of condensation occurring inside pipes for gaseous
fluids, means are provided for drainage and removal of deposits from low areas to
avoid damage from water hammer or corrosion;
40
7.
(c)
that due consideration is given to the potential damage from turbulence and
formation of vortices; the relevant parts of 2.7 are applicable;
(d)
that due consideration is given to the risk of fatigue due to vibrations in pipes;
(e)
that, where fluids of Group 1 are contained in the piping, appropriate means are
provided to isolate take off pipes the size of which represents a significant risk;
(f)
that the risk of inadvertent discharge is minimised; the take-off points must be
clearly marked on the permanent side, indicating the fluid contained;
(g)
that the position and route of underground piping is at least recorded in the technical
documentation to facilitate safe maintenance, inspection or repair.
7.1.
Allowable stresses
7.1.1.
Symbols
Re/t, yield limit, indicates the value at the calculation temperature of:
the upper flow limit for a material presenting upper and lower flow limits
the 1.0% proof strength for austenitic steel and non-alloyed aluminium
the 0.2% proof strength in other cases.
Rm/20 indicates the minimum value of the ultimate strength 20C
Rm/t designates the ultimate strength at the calculation temperature.
7.1.2.
The permissible general membrane stress for predominantly static loads and for
temperatures outside the range in which creep is significant, must not exceed the smaller
of the following values, according to the material used:
in the case of ferritic steel including normalized (normalized rolled) steel and
excluding fine-grained steel and specially heat-treated steel, 2/3 of Re/t and 5/12 of
Rm/20 ;
or, alternatively, and if its elongation after rupture exceeds 35%, 5/6 of Re/t
and 1/3 of Rm/t ;
in the case of non-alloy or low alloy cast steel, 10/19 of Re/t and 1/3 of Rm/20 ;
in the case of aluminium alloys excluding precipitation hardening alloys 2/3 of Re/t
and 5/12 of Rm/20 .
41
7.2.
Joint coefficients
For welded joints, the joint coefficient must not exceed the following values:
for equipment subject to destructive and non-destructive tests which confirm that
the whole series of joints show no significant defects :1,
for equipment not subject to non-destructive testing other than visual inspection:
0.7.
If necessary, the type of stress and the mechanical and technological properties of the
joint must also be taken into account.
7.3
7.4.
7.5.
that corresponding to the maximum loading to which the pressure equipment may
be subject in service taking into account its maximum allowable pressure and its
maximum allowable temperature, multiplied by the coefficient 1.25, or
Material characteristics
Unless other values are required in accordance with other criteria that must be taken into
account, a steel is considered as sufficiently ductile to satisfy 4.1(a) if, in a tensile test
carried out by a standard procedure, its elongation after rupture is no less than 14% and its
bending rupture energy measured on ISO V test piece is no less than 27 J, at a temperature
not greater than 20C but not higher than the lowest scheduled operating temperature.
42
ANNEX E
Module A
Internal production control
This module describes the procedure by which manufacturer, or his authorised
representative established in the Community, ensures and declares that pressure
equipment satisfies the requirements of the Regulations which apply to it. It does
not require the involvement of a notified body.
Manufacturer:
a list of the harmonised standards applied and a description of the solutions adopted
to meet the essential safety requirements where harmonised standards have not been
applied
test reports
affix CE marking
Module A1
Internal production control with monitoring of final assessment
In addition to the requirements of Module A:
Manufacturer:
43
Notified Body:
ensure manufacturer performs final assessment according to Section 3.2 of the essential
safety requirements
assess number to sample and whether it is necessary to perform or have performed, all or
part of final assessment on the samples
Manufacturer:
Module B
EC type - examination
This module describes the part of the procedure whereby a Notified Body ascertains
and attests that a representative example of the production meets the provisions
of the Regulations which apply to it.
Manufacturer:
lodge application for EC type-examination with a Notified Body which must include
Notified Body:
identify parts designed in accordance with harmonised & other relevant standards
assess materials when not in conformity with harmonised standard or European approval
and check material certificates
approve procedures for permanent joining or check they have been previously approved
verify that staff are qualified or approved for permanent joining and non-destructive testing
where harmonised standards have been applied, perform appropriate examinations and
tests to establish that they have actually been applied
44
where harmonised standards have not been applied, perform appropriate examinations and
tests to establish whether the essential safety requirements have been met
Manufacturer:
Module B1
EC design-examination
This module describes the part of the procedure whereby a Notified Body ascertains
and attests that the design of an item meets the provisions of the Regulations
which apply to it.
Manufacturer:
lodge application for EC design examination with Notified Body which must include
Notified Body:
identify components which are designed in accordance with harmonised standards and those
which are not
verify staff are qualified or approved for permanent joining & non-destructive testing
where harmonised standards have not been applied, perform appropriate examinations to
establish whether the essential safety requirements have been met
45
Manufacturer:
Module C1
Monitoring of final assessment
This module describes procedures whereby the manufacturer, or authorised
representative established in the Community, ensures and declares that the
pressure equipment is in conformity with the type as described in the EC typeexamination certificate (see Module B) and satisfies the requirements of the
Regulations which apply to it.
Manufacturer:
ensure that the manufacturing process produces pressure equipment which complies with
the type as described in the EC type-examination certificate and with the requirements of the
Regulations
Notified Body:
ensure manufacturer performs final assessment according to Section 3.2 of the essential
safety requirements
Manufacturer:
46
Module D
Quality assurance for production, final inspection and testing
This module describes procedures whereby the manufacturer ensures and declares
that the pressure equipment conforms with the type described in the EC typeexamination certificate (see Module B) or the EC design-examination certificate
(see Module B1) and satisfies the requirements of the Regulations which apply to
it.
Manufacturer
operate an approved quality system for production, final inspection and testing (eg ISO 9002)
which ensures compliance of the pressure equipment with the type described in the EC type
examination certificate or the EC design-examination certificate and with the requirements
of the Regulations which apply to it
lodge application for assessment of quality system with a Notified Body as described under
Module D1 below but with the addition of technical documentation for the approved type and
a copy of the EC type-examination certificate or EC design-examination certificate
Notified Body:
include in the auditing team at least one member with experience of assessing the pressure
equipment technology
presume conformity in respect of the elements of the quality system which implement a
relevant harmonised standard (eg ISO 9002)
carry out surveillance visits to ensure that the manufacturer fulfils the obligations arising
from the approved quality system
carry out periodic audits such that a full reassessment is carried out every 3 years
carry out unexpected visits to verify that the quality system is functioning correctly
Manufacturer:
affix CE marking and identification number of Notified Body responsible for surveillance
NB For category III and IV vessels for Group 1 gases, Group 2 gases and Group 1 liquids and
steam generators, the Notified Body, when performing unexpected visits, must take a sample of
equipment and perform or have performed, the proof test referred to in Section 3.2.2 of the essential
safety requirements
47
Module D1
Quality assurance for production, final inspection and testing
This module describes procedures whereby the manufacturer ensures and declares
that the items of pressure equipment satisfy the requirements of the Regulations
which apply to them.
Manufacturer:
operate an approved quality system for production, final inspection and testing (eg ISO 9002)
which must ensure compliance of the pressure equipment with the requirements of the
Regulations which apply to it.
lodge application for assessment of quality system with a Notified Body which includes
quality records, such as inspection reports and test data, calibration data, reports
concerning the qualifications or approvals of the personnel concerned,
particularly with permanent joining
Notified Body:
include in the auditing team at least one member with experience of assessing the pressure
equipment technology
presume conformity in respect of the elements of the quality system which implement a
relevant harmonised standard (eg ISO 9002)
carry out surveillance visits to ensure that the manufacturer fulfils the obligations arising
from the approved quality system
carry out periodic audits such that a full reassessment is carried out every 3 years
carry out unexpected visits to verify that the quality system is functioning correctly
48
Manufacturer:
affix CE marking and identification number of Notified Body responsible for surveillance
NB For category III and IV vessels for Group 1 gases, Group 2 gases and Group 1 liquids and
steam generators, the Notified Body, when performing unexpected visits, must take a sample of
equipment and perform or have performed, the proof test referred to in Section 3.2.2 of the essential
safety requirements
Module E
Quality assurance for final inspection and testing
This module describes the procedures whereby the manufacturer ensures and
declares the equipment is in conformity with the type described in the EC typeexamination certificate (see Module B) and satisfies the requirements of the
Regulations which apply to it.
Manufacturer:
operate an approved quality system for final inspection and testing (eg ISO 9003) under
which each item of pressure equipment must be examined and appropriate tests carried out
to ensure its conformity with the requirements of the Regulations which apply to it.
lodge application for assessment of quality system with a Notified Body as described under
Module E1 below but with the addition of technical documentation for the approved type and
a copy of the EC type-examination certificate
examine and test equipment as set out in relevant harmonised standard, or equivalent and,
particularly, carry out final assessment as referred to in Section 3.2 of the essential safety
requirements
Notified Body:
include in the auditing team at least one member with experience of assessing the pressure
equipment technology
presume conformity in respect of the elements of the quality system which implement a
relevant harmonised standard (e.g. ISO 9003)
carry out surveillance visits to ensure that the manufacturer fulfils the obligations arising
from the approved quality system
carry out periodic audits such that a full reassessment is carried out every 3 years
carry out unexpected visits to verify that the quality system is functioning correctly
49
Manufacturer:
affix CE marking and identification number of Notified Body responsible for surveillance
NB For category III and IV vessels for Group 1 gases, Group 2 gases and Group 1 liquids and
steam generators, the Notified Body, when performing unexpected visits, must take a sample of
equipment and perform or have performed, the proof test referred to in Section 3.2.2 of the essential
safety requirements
Module E1
Quality assurance for final inspection and testing
This module describes the procedure whereby the manufacturer ensures and
declares that the equipment satisfies the requirements of the Regulations that
apply to it.
Manufacturer:
operate an approved quality system for final inspection and testing (eg ISO 9003) under
which each item of pressure equipment must be examined and appropriate tests carried out
to ensure its conformity with the requirements of the Regulations which apply to it.
lodge application for assessment of quality system with a Notified Body which includes
quality records, such as inspection reports and test data, calibration data, reports
concerning the qualifications or approvals of the personnel concerned,
particularly with permanent joining
Notified Body:
include in the auditing team at least one member with experience of assessing the pressure
50
equipment technology
presume conformity in respect of the elements of the quality system which implement a
relevant harmonised standard (eg ISO 9003)
carry out surveillance visits to ensure that the manufacturer fulfils the obligations arising
from the approved quality system
carry out periodic audits such that a full reassessment is carried out every 3 years
carry out unexpected visits to verify that the quality system is functioning correctly
Manufacturer:
affix CE marking and identification number of Notified Body responsible for surveillance
NB For category III and IV vessels for Group 1 gases, Group 2 gases and Group 1 liquids and
steam generators, the Notified Body, when performing unexpected visits, must take a sample of
equipment and perform or have performed, the proof test referred to in Section 3.2.2 of the essential
safety requirements
Module F
Product verification
This module describes the procedure whereby the manufacturer, or his authorised
representative established in the Community, ensures and declares the pressure
equipment is in conformity with the type as described in the EC type-examination
certificate or the EC design-examination certificate and satisfies the requirements
of the Regulations which apply to it.
Manufacturer:
ensure that the manufacturing process produces pressure equipment which is in conformity
with the type described in the EC type-examination certificate (see Module B) or EC design
examination certificate (see Module B1) and the requirements of the Regulations which
apply to it
Notified Body:
examine and test each item of pressure equipment, as set out in the relevant harmonised
standard or equivalent, to verify that every item conforms to the type and the requirements of
the Regulations
verify qualifications of personnel responsible for permanent joining of parts and non-destructive
51
examination
carry out, or have carried out, final inspection and proof test as referred to in Section 3.2 of
the essential safety requirements
Manufacturer:
ensure that the certificates of conformity issued by the Notified Body are available on request
Module G
Unit verification
This module describes the procedure whereby the manufacturer ensures and
declares the pressure equipment which has been issued with a certificate of
conformity for tests carried out satisfies the requirements of the Regulations which
apply to it.
Manufacturer:
lodge application for unit verification with a Notified Body which must include
Notified Body:
assess materials used where they do not conform to a relevant harmonised standard or
European materials approval
verify personnel responsible for permanent joining of parts and non-destructive testing
52
perform, during manufacture, appropriate tests set out in relevant harmonised standards or
equivalent to ensure conformity with Regulations
carry out final inspection and perform, or have performed, proof test
Manufacturer:
affix CE marking
ensure that the certificates of conformity and declaration of conformity are available on request
Module H
Full quality assurance
This module describes the procedures whereby the manufacturer ensures and
declares that the pressure equipment satisfies the requirements of the Regulations
which apply to it.
Manufacturer:
implement an approved quality system for design, manufacture and final inspection and
testing (eg ISO 9001) which must ensure compliance of the pressure equipment with the
requirements of the Regulations which apply to it
lodge application for assessment of the quality system with a Notified Body which includes
quality records, such as inspection reports and test data, calibration data, reports
concerning the qualifications or approvals of the personnel concerned,
particularly with permanent joining
53
Notified Body:
include in the auditing team at least one member with experience of assessing the pressure
equipment technology
presume conformity in respect of the elements of the quality system which implement a
relevant harmonised standard (eg ISO 9001)
carry out surveillance visits to ensure that the manufacturer fulfils the obligations arising
from the approved quality system
carry out periodic audits such that a full reassessment is carried out every 3 years
carry out unexpected visits to verify that the quality system is functioning correctly
Manufacturer:
affix CE marking and identification number of Notified Body responsible for surveillance
NB For category III and IV vessels for Group 1 gases, Group 2 gases and Group 1 liquids and
steam generators, the Notified Body, when performing unexpected visits, must take a sample of
equipment and perform or have performed, the proof test referred to in Section 3.2.2 of the essential
safety requirements
For one-off production of category III steam generators the Notified Body must perform or have
performed the proof test referred to in Section 3.2.2 of the essential safety requirements for each
unit
54
Module H1
Full quality assurance with design examination
and monitoring of the final assessment
In addition to the requirements of Module H:
Manufacturer:
lodge application for examination of the design with a Notified Body. The application must
enable the design, manufacture & operation of the pressure equipment to be understood
and enable conformity with the relevant requirements of the Regulations to be assessed. It
must include
Notified Body:
carry out increased surveillance of the final assessment in the form of unexpected visits
which must include examinations on the pressure equipment
assess any modifications to the approved design and give additional approval
55
ANNEX F
DECLARATION OF CONFORMITY
(See Page 14)
where appropriate, name and address of the notified body which carried out
the inspection,
where appropriate, name and address of the notified body monitoring the
manufacturers quality assurance system,
56