TÜVIS-Prüfgrundlagen: AD 2000 Code, Volume 1, Register A  AD 2000-Merkblatt A 6

Replaces Page – Version – Page 1  Version 11.2014

Publisher: Verband der TÜV e. V. (VdTÜV)

− For technical experts of TÜV only − Reprint not permitted −

Safety devices against AD 2000-Merkblatt

excess pressure A6
TÜVIS PCE-safety devices January 2003 edition *)

These TÜVIS-Prüfgrundlagen provide a tool for experts. The documents contain the relevant regulations. Interpretations
and explanations developed by technical committees are included. Please consider that the individual documents differ with
regard to their mandatory application. VdTÜV has taken all reasonable measures to ensure the accuracy of this translation
but regrets that no responsibility can be accepted for any error, omission or inaccuracy. In cases of doubt or dispute,
the latest edition of the German text only is valid.

The AD 2000-Merkblätter are prepared by the seven associations listed below who together form the "Arbeitsgemeinschaft Druckbehälter"
(AD). The structure and the application of the AD 2000 body of regulations and the procedural guidelines are covered by AD 2000-Merkblatt G 1.
The AD 2000-Merkblätter contain safety requirements to be met under normal operating conditions. If above-normal loadings are to be
expected during the Operation of the pressure vessel, this shall be taken into account by meeting special requirements.
If there are any divergences from the requirements of this AD 2000-Merkblatt, it shall be possible to prove that the standard of safety of
this body of regulations has been maintained by other means, e.g. by materials testing, tests, stress analysis, operating experience.
Fachverband Dampfkessel-, Behälter- und Rohrleitungsbau e.V. (FDBR), Düsseldorf
Hauptverband der gewerblichen Berufsgenossenschaften e. V., Sankt Augustin
Verband der Chemischen Industrie e.V. (VCI), Frankfurt/Main
Verband Deutscher Maschinen- und Anlagenbau e.V. (VDMA), Fachgemeinschaft Verfahrenstechnische Maschinen
AD 2000-Merkblatt

und Apparate, Frankfurt/Main

Stahlinstitut (VDEh), Düsseldorf
VGB PowerTech e.V., Essen
Verband der Technischen Überwachungs-Vereine e.V. (VdTÜV), Essen.
The above associations continuously update the AD 2000-Merkblätter in line with technical progress. Please address any proposals for
this to the publisher:
Verband der Technischen Überwachungs-Vereine e.V., P.O. Box 103834, D-45038 Essen.

Contents

0 Foreword 4 Designation and documentation

1 Scope 5 Performance of tests
2 General 6 Information an servicing and reports
3 Requirements for PCE-safety
devices

0 Foreword accordance with AD 2000-Merkblatt A 1 or AD 2000-Merk-

blatt A 2, or of pipe gauges, is not possible or would not meet
The AD 2000 body of regulations can be applied to satisfy
the intended purpose. Systems of this kind are characterized
the basic safety requirements of the Pressure Equipment
by the fact that, by making use of process control engineering
Directive, principally for the conformity assessment in
(PCE), they operate in such a manner that the service over-
accordance with Modules "G" and "B + F".
pressure does at no time exceed the permissible value by
The AD 2000 body of regulations is structured along the lines more than 10 % (PCE-safety devices).
of a self-contained concept. If other technical rules are used
in accordance with the state of the art to solve related Prob-
lems, it is assumed that the overall concept has been taken 2 General
into account.
PCE-safety devices encompass in particular those devices
The AD 2000 body of regulations can be used as appropriate
necessary for the logging of measured data, conversion of
GmbH, D-10772 Berlin

for other modules of the Pressure Equipment Directive or for

measured data, and the initiation of measures. Examples of
different sectors of the law. Responsibility for testing is as
possible measures, individual or combined, include the
specified in the provisions of the relevant sector of the law.
following:
— Isolation or shutdown of the pressure generator;
1 Scope — Shutting-off the admission of substances that contribute to
the elevation of the pressure;
Berlin
www.beuth.de

This AD 2000-Merkblatt is applicable for systems of automa-

Verlag

tically controlled safety devices for the prevention of unwan- — Shutting-off the heating system;
D-10772

ted overpressures in pressure vessels of process plants, in — Bringing into Operation an emergency-cooling system;
© Beuth

circumstances where the use of safety devices in — Introduction of reaction inhibitor;

erlag GmbH,
uth.de

*) Supersedes September 2001 edition; | = Amendments to previous edition

VdTÜV e. V. für tuev_sued_ag (Kdnr.: 200006)
 TÜVIS-Prüfgrundlagen: AD 2000 Code, Volume 1, Register A 
Replaces Page – Version –
− For technical experts of TÜV only − Reprint not permitted −
Opening of suitable pressure-relief devices, e.g. dischar-
ging the vessel contents into a blowdown system, where
necessary accompanied by the additional Operation of gas
scrubbers (e.g. absorption columns).
13 Requirements for PCE-safety devices
3.1 General requirements
The PCE-safety devices shall be suitable for preventing the
maximum allowable pressure from being exceeded by more
than 10 %. To this end, the system comprising these arrange-
ments shall be designed to suit the possible pressure-gene-
ration conditions at the process plant. The initiation of measu-
res shall be indicated by optical or acoustic means.
3.2 Use of fail-safe, self-monitoring, or redundant
PCE-safety devices
PCE-safety devices and their components shall either:
— be fail-safe,
— be designed in accordance with the redundancy principle,
or
— shall be of the seif-monitoring type.
In single-channel form, the seif-monitoring type may be con-
sidered only if a pressure increase at the plant can take place
so slowly that sufficient time is available for the correction of
the unsafeguarded state.
In the case of electrical components of PCE-safety devices
the requirements are satisfied for example if the stipulations
in 8.7 of DIN VDE 0116 are met. This also applies where
appropriate, for non-electrical components.
3.3 Safe position in the event of failure of energy
supply
The PCE-safety devices shall, in addition to meeting the
requirements of clause 3.2, in the event of the failure or the
unacceptable fluctuation of the energy supply, assume a
defined safe position that ensures the safety of the plant. The
supply of energy necessary to this end shall be available in
such a form that, even in the presence of a fault, the safe Posi-
tion is still realized, e.g. by means of spring tension, stored
pressure. If, in the event of the failure or unacceptable fluctu-
ation of the energy supply, the safe position cannot be assu-
med or a safe Position of an unequivocal nature cannot be
defined, the energy supply shall be safeguarded through the
implementation of special measures, e.g. by means of a
standby power supply.
3.4 Safeguards to prevent resetting
The PCE-safety devices shall be safeguarded to prevent the
unintentional resetting of the limit values relevant to safety
devices, e.g. by restricting access to the resetting device, by
using tools.
4 Designation and documentation
The PCE-safety devices shall be given designations, and the
designations shall be incorporated in a suitable documenta-
tion system — e.g. P&I diagrams (DIN 28004, Part 1), PCE-
classification schedules, device lists — in such a manner
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AD 2000-Merkblatt A 6
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that their unequivocal identification is possible. The function,
the limit values relevant to safety, and the technical data for
the devices, shall be distinguishable. lt shall be possible for
reference to be made to the documentation in the
acceptance-testing certification procedure (see clause 5).
5 Performance of tests
For assemblies, the suitability of the system of PCE-safety
devices is verified within the framework of the acceptance or
the acceptance test of the pressure vessel. This process in-
cludes the examination of the documents relating to the sys-
tem and its components. The documents to be examined
include in particular a description of the Operation of the
PCE-safety device, and the documentation as specified in
clause 4.
With reference to the documents examined, functional
testing of the system or — where this is not possible — of the
individual components is carried out in conjunction with an
assessment of the effectiveness of the safety measures
achieved with the system.
AD 2000-Merkblatt
Any modification of the system of PCE-safety devices, which
is viewed as an essential modification of the mode of op-
eration, and also any alteration of the limit values of the PCE-
safety devices relevant to safety devices, necessitate rete-
sting.
6 Information on servicing and reports
Through servicing, i.e. regular inspections, maintenance and
corrective measures, the serviceability of the PCE-safety
devices shall be ensured. For the execution of careful inspec-
tions, maintenance and corrective measures, the operator is
required to employ individuals with specialized knowledge.
The latter, in addition to their general specialized knowledge,
are required to have been familiarized with the special opera-
tional conditions.
The corrective measures to be implemented are governed,
in terms of their nature and scope and intervals between
them, by practical experience. There is a particular need for
regular functional tests by the operator. The intervals
between tests shall be fixed by the operator in keeping with
the operational conditions, the recommendations of the
manufacturer and of the relevant third party being adopted
as the basis; however, at least one functional test per year
is considered necessary.
lt is the responsibility of those individuals with specialized
knowledge to produce a report on the functional tests and
corrective measures. The following particulars at least shall
be included in the report:
— Pressure vessel/plant concerned;
— Designation of PCE-safety device with reference to the
documentation specified in clause 4;
— Nature of measures implemented;
— Results of functional tests, verification of limit values;
— Details of any devices replaced;
— Date, name and signature.
The reports shall be kept at least until the next recurrent test.