Professional Documents
Culture Documents
Pressure Equipment
APRIL 2005
URN 05/1074
Contents
Page
1
2
Pressure Equipment
- Essential features of the law
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;
3
Failure to comply with the PER:
1
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.
4
The Pressure Equipment Regulations
1999 (SI 1999/2001)
APPLICATION
Scope: the PER apply to the design, manufacture and conformity assessment of
pressure equipment and assemblies of pressure equipment with a maximum
allowable pressure greater than 0.5 bar. The PER do not apply to excluded pressure
equipment and assemblies (see page 6), pressure equipment and assemblies
placed on the market before 29th November 1999 or pressure equipment or
assemblies placed on the market on or before 29th May 2002 if they comply with
the safety provisions in force in the UK on 29th November 1999 and do not bear a
CE marking (unless required by another Community Directive or any indication of
compliance with the PED.
Definitions:
5
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 duty to comply with the PER rests on any “responsible person” who places
pressure equipment and assemblies on the market or puts it into service. A
“responsible person” is defined in the Regulations as:
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
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.
6
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 Commission’s 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, or classified, in ascending order of hazard, in one of
Categories I, II, III, or IV, will be required to be manufactured according to ‘sound
engineering practice’ (SEP) (see page 10) The following table shows which chart
in Annex B should be used for the various types of equipment.
STEAM
VESSELS PIPING
GENERATORS
State of
Gas Liquid Gas Liquid
contents
Fluid Group 1 2 1 2 1 2 1 2
Chart 1 2 3 4 5 6 7 8 9
explosive;
extremely flammable;
highly flammable;
flammable (where the maximum allowable temperature is above flashpoint);
very toxic;
toxic;
oxidising.
Further references to CHIP are also available on the Health and Safety
Executive (HSE) CHIP site at http://www.hse.gov.uk/chip/index.htm.
A free leaflet or a priced guidance book on CHIP is available 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
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).
Where both the volume and the nominal size are considered
appropriate, both the relevant vessels and piping charts should be used
and the pressure accessory classified in the highest resulting category.
Safety accessories: are generally classified under Category IV unless they are
manufactured to protect specific pressure equipment in which case they may be
classified in the same category as the equipment they protect.
TECHNICAL REQUIREMENTS
The Regulations require that all pressure equipment and assemblies within their
scope must be safe when placed on the market and put into service.
9
Sound Engineering Practice (SEP)
In addition:
10
Harmonised European standards are reproduced as British Standards
and the reference numbers of these standards will be available from
BSI Business Information. Enquiries on the progress of these standards
should also be addressed to the BSI Information Centre (see page 18).
CONFORMITY ASSESSMENT
The higher the category, and therefore the greater the hazard, the more demanding
are the requirements. Equipment in Category I will be subject to the manufacturer’s
own internal production control. The modules for products in Categories II, III & IV
will require the involvement of ‘notified bodies’, appointed by Member States,
either in the approval and monitoring of the manufacturers’ quality assurance
system or in direct product inspection.
‘User inspectorates’ may also be appointed by Member States to carry out the
tasks of notified bodies within their own organisations under Modules A1, C1, F
and G only. The CE marking should not be affixed to pressure equipment and
assemblies assessed by user inspectorates.
11
The conformity assessment modules available for the different categories of
equipment are detailed below, along with a brief description in the key (fuller details
are provided in Annex E). Manufacturers may choose the module(s) which best
suit them, e.g. a manufacturer of Category II equipment may choose A1, D1 or
E1.
Key
B1 Design examination
D1 Technical documentation Quality assurance for production, final inspection and test
F Product verification
CE marking requirements
Diagram 1 Diagram 2
13
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
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.
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 HSE’s
Infoline Service (Tel: 0845 345 0055) or to their nearest HSE office or, in Northern
Ireland, the Health and Safety Executive for Northern Ireland’s Information and
Advice Helpline (Tel: 0800 032 0121). Clearly it is in the supplier’s 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 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.
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
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 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.
A copy of the Regulations may also be downloaded from the HMSO’s website
http://www.legislation.hmso.gov.uk/si/si2000/20000128.htm
HSE Books
PO Box 1999
Sudbury
Suffolk
CO10 2WA
Tel: 01787 881165
Fax: 01787 313995
16
USEFUL INFORMATION AND CONTACTS
The Pressure Equipment Regulations 1999 (SI 1999/2001) and the amending
regulations (SI 2002/1267) can be obtained from:
A copy of the Regulations may also be downloaded from the HMSO’s website
http://www.hmso.gov.uk/stat.htm
The complete text of the Pressure Equipment Directive was published in the Official
Journal of the European Communities (No. L181 of 9 July 1997 - ISBN 011 916
0927). Copies of the Official Journal can be obtained from The Stationery Office
as above. A copy of the Directive can be downloaded from the Commission’s
website http://ped.eurodyn.com.
Please note that DTI does not supply copies of the Regulations, of
standards or of Directives.
Where compliant equipment is denied proper access to the market in other EEA
countries, Action Single Market will offer advice and assistance.
E-mail: mailto:asm@dti.gsi.gov.uk
Website: http://www.dti.gov.uk/europe/asm
17
FURTHER INFORMATION
Website: http://www.dti.gov.uk/strd
HSE Infoline
Website: http://www.hse.gov.uk
Charles Barker
BSI Information Centre
389 Chiswick High Road
London W4 4AL
Website: http://www.bsi-global.com
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
Commission’s 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
Guidance on the scope, philosophy and application of New Approach Directives
is available in the “Guide to the implementation of directives based on the New
Approach and Global Approach” (the Blue Guide) at the European Commission’s
website:
http://europa.eu.int/comm/enterprise/newapproach/legislation/guide/index.htm
19
ANNEX A
2 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;
(1)
OJ No L 147, 9.6.1975, p. 40. as last amended by Commission Directive 94/1/EC
(2)
OJ No L 42, 23.2.1970, p. 1. as last amended by Commission Directive 95/54/EC
(3)
OJ No L 84, 28.3.1974, p. 10. as last amended by the 1994 Act of Accession.
(4)
OJ No L 225, 10.8.1992, p. 72. as last amended by the 1994 Act of Accession.
(5)
OJ No L 207, 23.7.1998, p. 1.
(6)
OJ No L 213, 7.9.1995, p. 1.
20
Council Directive 73/23/EEC of 19 February 1973 on the
harmonization of the laws of the member States relating to electrical
equipment designed for use within certain voltage limits (7),
7 equipment covered by Article 296 (1) (b) of the Treaty (i.e. specifically
designed and constructed for military purposes);
8 items specifically designed for nuclear use, failure of which may cause an
emission of radioactivity;
(7)
OJ No L 77, 26.3.1973, p. 29. as last amended by Directive 93/68/EEC
(8)
OJ No L 169, 12.7.1993, p. 1. as last amended by Directive 98/79/EC
(9)
OJ No L 196, 26.7.1990, p. 15. as last amended by Directive 93/68/EEC
(10)
OJ No L 100, 19.4.1994, p. 1.
21
13 pressurized pipes for the containment of transmission systems, e.g. for
electrical power and telephone cables;
18 vessels designed for the transport and distribution of drinks having a PS•V
of not more than 500 bar•L and a maximum allowable pressure not
exceeding 7 bar;
19 equipment covered by the ADR (1), the RID (2), the IMDG (3)
and the ICAO
Convention (4);
21 vessels designed to contain liquids with a gas pressure above the liquid of
not more than 0.5 bar.
(1)
ADR = European Agreement concerning the International Carriage of Dangerous Goods by Road.
(2)
RID = Regulations concerning the International Carriage of Dangerous Goods by Rail.
(3)
IMDG = International Maritime Dangerous Goods Code.
(4)
ICAO = International Civil Aviation Organization.
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 Vessels for Group 1 gases
pressure
(PS)
(bar)
10000
IV
1000 PS = 1000
III
PS = 200
200
V =1
100
PS
•V
=
PS
10
00
•V
=
PS S•V
2 00
•V =
10
P
= 25
50
Sound Engineering
1 Practice (SEP) I
II III IV
PS = 0.5
0.5
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
Chart 2
PS Vessels for Group 2 gases
(bar)
10000 IV
PS = 3000
III
1000 PS = 1000
V =1
200
PS
100
•V
PS
=
•V
30
PS
00
=
•V
10
PS = IV
00
•V 20
= 0
10 50
PS = 4
SEP
1
I II III PS = 0.5
0.5
Exceptionally, portable extinguishers and bottles for breathing equipment must be classified
at least in category III
Chart 3
PS Vessels for Group 1 liquids
(bar)
10000
II
III
V =1
1000
PS = 500
500
100
PS
II
•V
=
20
0
PS = 10
10
SEP I
1
PS = 0.5
0.5
24
Chart 4
PS Vessels for Group 2 liquids
(bar)
10000
V = 10
I II
PS = 1000
1000
PS = 500
500
PS
100
•V
I
=
10
00
0
PS = 10
10
SEP
1
PS = 0.5
0.5
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
PS
(bar)
V =2
1000
100
PS = 32
32
IV
PS
SEP
•V
10
=
30
00
PS
•V
=
PS
V = 1000
20
•V
0
=
1
50
I II III
PS = 0.5
0.5
25
Chart 6
Piping for Group 1 gases
PS
(bar)
DN = 100
DN = 25
1000
II III
100
PS
PS
• DN
•
DN
=1
=3
00
50
0
10
0
SEP
DN = 100
1 DN = 350
I PS = 0.5
0.5
Nominal size
0.1 1 10 25 100 350 1000
(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)
I II
DN = 100
DN = 250
DN = 32
1000
III
100
SEP PS
10 •D
N
=
10
00
PS N =
PS
•D
•D
N
=
50
1
35
00
00
PS = 0.5
0.5
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)
III
DN = 25
1000
PS = 500
500
100 II
PS
•D
N
=
20
SEP
00
10 PS = 10
1
PS = 0.5
0.5
Chart 9
PS Piping for Group 2 liquids
(bar)
II
DN = 200
1000
PS = 500
500
SEP
100
I
PS 50
PS = 10
• D 00
10
N
=
1
PS = 0.5
0.5
27
ANNEX C
Maximum allowable
No
pressure greater than
Note 0.5 bar ?
Note :: X,
X, YY and
andZZ are
are
entry points for pressure
entry points for pressure Yes
accessories
accessories and/or
and/or
assemblies
assemblies Equipment excluded
Yes
from PED?
(Annex A)
No
Determine type of Pressure
Equipment
(Page 5)
Determine maximum allowable pressure in bar and Determine maximum allowable pressure in bar
volume in litres and DN
28
AND CONFORMITY ASSESSMENT
Go to
point Z
29
ANNEX D
PRELIMINARY OBSERVATIONS
1. 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. Pressure equipment must be designed, manufactured and checked, and if applicable
equipped and installed, in such a way as to ensure its safety when put into service in
accordance with the manufacturer’s instructions, or in reasonably foreseeable conditions.
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 Design for adequate strength
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.
The allowable stresses for pressure equipment must be limited having regard to
reasonably foreseeable failure modes under operating conditions. To this end,
safety factors must be applied to eliminate fully any uncertainty arising out of
manufacture, actual operational conditions, stresses, calculation models end the
properties and behaviour of the material.
These calculation methods must provide sufficient safety margins consistent, where
applicable, with the requirements of section 7.
The requirements set out above may be met by applying one of the following
methods, as appropriate, if necessary as a supplement to or in combination with
another method:
design by formula,
design by analysis,
(b) Resistance
31
In particular:
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,
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. Experimental design method
The design of the equipment may be validated, in all or in part, by an appropriate test
programme carried out on a sample representative of the equipment or the category of
equipment.
The test programme must be clearly defined prior to testing and accepted by the notified
body responsible for the design conformity assessment module, where it exists.
This programme must define test conditions and criteria for acceptance or refusal. The
actual values of the essential dimensions and characteristics of the materials which constitute
the equipment tested shall be measured before the test.
Where appropriate, during tests, it must be possible to observe the critical zones of the
pressure equipment with adequate instrumentation capable of registering strains and
stresses with sufficient precision.
(a) 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;
(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.
The method of operation specified for pressure equipment must be such as to preclude
any reasonably foreseeable risk in operation of the equipment. Particular attention must be
paid, where appropriate, to:
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. Means of examination
(a) Pressure equipment must be designed and constructed so that all necessary
examinations to ensure safety can be carried out;
(b) Means of determining the internal condition of the equipment must be available,
where this is necessary to ensure the continued safety of the equipment, such as
access openings allowing physical access to the inside of the pressure equipment
so that appropriate examinations can be carried out safely and ergonomically;
(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.
Adequate means must be provided for the draining and venting of pressure equipment
where necessary:
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
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. Provisions for filling and discharge
Where appropriate, the pressure equipment must be so designed and provided with
accessories, or provision made for their fitting, as to ensure safe filling and discharge in
particular with respect to hazards such as:
(a) on filling:
Where, under reasonably foreseeable conditions, the allowable limits could be exceeded,
the pressure equipment must be fitted with, or provision made for the fitting of, suitable
protective devices, unless the equipment is intended to be protected by other protective
devices within an assembly.
The suitable device or combination of such devices must be determined on the basis of the
particular characteristics of the equipment or assembly.
(b) where appropriate, adequate monitoring devices such as indicators and/or alarms
which enable adequate action to be taken either automatically or manually to keep
the pressure equipment within the allowable limits.
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.
These devices must be so designed that the pressure will not permanently exceed the
maximum allowable pressure PS; however a short duration pressure surge in keeping with
the specifications laid down in 7.3 is allowable, where appropriate.
These devices must have an adequate response time on safety grounds, consistent with
the measurement function.
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
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.
Preparation of the component parts (e.g. forming and chamfering) must not give rise to
defects or cracks or changes in the mechanical characteristics likely to be detrimental to
the safety of the pressure equipment.
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.
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).
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.
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).
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.
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.
For assemblies, the final assessment must also include a check of the safety devices
intended to check full compliance with the requirements referred to in 2.10.
(b) depending on the type of pressure equipment further information necessary for
safe installation, operation or use and, where applicable, maintenance and periodic
inspection such as:
intended use,
(c) where necessary, warnings fixed to the pressure equipment drawing attention to
misuse which experience has shown might occur.
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:
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.
use,
(b) Instructions must cover information affixed to the pressure equipment in accordance
with 3.3, with the exception of serial identification and must be accompanied,
where appropriate, by the technical documents, drawings and diagrams necessary
for a full understanding of these instructions;
(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.
(1)
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.
(a) 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) be sufficiently chemically resistant to the fluid contained in the pressure equipment;
the chemical and physical properties necessary for operational safety must not be
significantly affected within the scheduled lifetime of the equipment;
(e) be selected in order to avoid significant undesirable effects when the various
materials are put together.
4.2 (a) The pressure equipment manufacturer must define in an appropriate manner the
values necessary for the design calculations referred to in 2.2.3 and the essential
characteristics of the materials and their treatment referred to in 4.1;
(b) the manufacturer must provide in his technical documentation elements relating
to compliance with the materials specifications of the Directive in one of the following
forms:
(c) 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.
4.3. 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.
(1)
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.
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.
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.
(a) appropriate means of protection are provided to restrict operating parameters such
as heat input, heat take-off and, where applicable, fluid level so as to avoid any
risk of local and general overheating,
(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) adequate provisions are made to eliminate risks of damage from deposits,
(d) means of safe removal of residual heat after shutdown are provided,
6. PIPING
(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
(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.
The following provisions apply as a general rule. However, where they are not applied,
including in cases where materials are not specifically referred to and no harmonised
standards are applied, the manufacturer must demonstrate that appropriate measures
have been taken to achieve an equivalent overall level of safety.
This section is an integral part of this Annex. The provisions laid down in this section
supplement the essential requirements of sections 1 to 6 for the pressure equipment to
which they apply.
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
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.
The momentary pressure surge referred to in 2.11.2 must be kept to 10% of the maximum
allowable pressure.
For pressure vessels, the hydrostatic test pressure referred to in 3.2.2 must be no less
than:
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
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 20°C but not higher than the lowest scheduled operating temperature.
42
ANNEX E
Module A
Internal production control
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
Manufacturer:
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
if an EC design-examination certificate is refused, provide detailed reasons
Manufacturer:
Module C1
Monitoring of final assessment
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 type-
examination 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 type-
examination 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
assess proposed changes to the quality system
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
means of monitoring quality and the quality system
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
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
manufacturer’s quality assurance system,
56