ESR - Hazard Analysis

Document requirements for PED 2014/68/EU
S/N. Activity Description Requirement Action By Status as on 27.07.22

1 BV Offer Accepted and Signed offer shall be submitted to BV. Priya Closed
2 Application Form Filled and signed application form shall be submitted to NoBo by Manufacturer Prateek/Priya Open
Prateek/Sibin/
3 Design GA Drawing, Detailed drawing, BOM, Name Plate Drawing for Vessel, Piping and Assembly. In progress
Manoj
4 Hazard Analysis, ESR and OIM Shall be submitted to NoBo by Manufacturer fro Piping, Vessel and Assembly Prasoon/Prateek Open
5 Permanent Joining Procedures Shall be qualified to Construction Code+ PED and approved by RTPO/NoBo from EU 27. Prasoon Closed
6 Permanent Joining Personnel Shall be qualified to Construction Code+ PED and approved by RTPO/NoBo from EU 27. Prasoon Closed
Permanent Joining Personnel

7 Qualifications validity (time) covers the period Continuity shall be maitaind and approved by Manufacturer. Valid to cover the manufacturing duration. Prasoon Closed
of manufacture
All NDE by suitable qualified personnel.
8 NDE Personnel The personnel (including performer) shall be approved by a third-party organisation recognised by a Member Prasoon Closed
State pursuant to Article 20. (That is EU 27).
Shall be prepared and approved by Level 3 (ASNT & RTPO approved) of NDE subcontractor and
9 NDE Procedures Prasoon Closed
suitable to PED. Approved by Manufacturer.
10 Test Procedures Shall be prepared and approved by Manufacturer. Prasoon Closed
Manufacturer forming and or bending

11 Shall be approved by Manufacturer. Prateek Open
procedure(s)
Materials
PMA shall be prepared for selected materials. PMA shall be submitted to NoBo approval by
12 PMA (Particular Material Appraisal) Prasoon Open
Manufacturer
Required additional testing (e.g. KCV) has been

performed by the producer, an ISO 17025
13 Impact test at as per PMA. Prasoon Closed
accredited lab and under direct
witness of BV
Pressure Parts with EN 10204:2004
14 Direct inspection route. No additional documents required. NA NA
Inspection Certificate "type 3.2".
For Certificates “type 3.1”, material manufacturer shall have an appropriate quality-assurance system with ISO
Pressure Parts with EN 10204:2004 Inspection
15 9001-2015 certified by a competent body established within the European Union and have undergone a specific No Bo/Prasoon Open
Certificate "type 3.1". assessment for materials by a competent body established within the European Union.
Note 1: Shall be ISO 9001: 2015 and PED approval with specific product specification and
No Bo/Prasoon Open
grade/type from EU 27
Note 2: Approval shall be available with material manufacturer during the production of materials. No B/Prasoon Open
16 Calibration of equipment and instruments Shall be calibrated from ISO 17025 accreditated laboratory only. Prasoon Closed
17 EU Declaration Of Conformity (DOC) Shall be submitted to NoBo by Manufacturer Prasoon Open
18 Assembly List of items/equipment making the Assembly shall be prepared by Manufacturer. Prateek Open
19 Data sheet Mention Design Pressure, Design Temperature, Minimum Temperature, fluid name aslo. Prateek/Sibin Open
All items shall be CE marked with NoBo number to PED from EU 27 NoBo . Classified to proper
20 Bougthout items for Assembly Prateek/Priya Open
category.
Pressure Safety Valve shall be CE marked to category IV (Choose a module from Category IV) or
21 PSV Prateek/Priya Open
atleast classified in the same category as the equipment it protects.
Documents required for bougthout items
22 Certificate Of Conformity (COC) from NoBo Prateek/Priya Open
for Assembly
EU Declaration Of Conformity (DOC) from Manufactures Prateek/Priya Open
Name Plate copy (Name Plate photo should cover item traceability, design data, CE mark with NoBo
Manoj Open
Number)
Operation and Instruction Manual (OIM), at least mention use of equipment and protection against
Sekar Open
over pressure.
23 Article 4 (3), SEP DOC, NP, OIM Prasoon/Prateek Open
COC shall be prepared by NoBo, atleast 15 days time to issue to COC after submission of completed
24 Technical File Prasoon Open
Technical file by Manufacturer.
Status as on 26.07.22
Project Risk assessment

to be performed
Approval is by QA
Is under Process.
Complete Raw material
List required
Completed for the

materials received till
date
NA
Under Process
Under Process
Under Process
After FAT & Doc Review
What does NP and OIM

mean? BV to advise
After FAT & Doc Review

Chapter Tite Action By
Introduction
1 Prateek
- Company Profile
Quality Management System
2 Prasoon/Vishnu
- ISO Certificate
Details of Manufacturing and QC Facilities
3 - List of Production Equipment / Machinery. Prateek
- List of Monitoring & Measuring Devices
Technical Specifications, Range & Data sheets of

product
4 Sibin/Prateek
- Product specifications
- GA Drawings
Reference Codes and Standards
5 To be discussed with BV
- Master list of Documents of External Origin
Design Basis and Risk Analysis as per EN Codes
- Risk Assessment as per ISO 12100.
6 Prasoon/Sekar/Sibin
- Ignition Hazard Assessment as per IEC ISO
80079-36.
7 Type Test Reports Priya
Typical Quality File

- Quality Assurance Plan
- Material testing for chemical & mechanical Prasoon/Vishnu
8
properties of
Supplier
- Inspection – Cum – Testing Certificate
9 Safety Instruction Manual To be discussed with BV

10 Marking Details / Name Plate Details To be discussed with BV
11 Declaration Of Conformity To be discussed with BV
12 Disclaimer To be discussed with BV
SL no Package Pkge Design NOBO(BV) INVOLEMENT SELFBY
CERTIFICATION Item ATEX EMC LVD MSD CE marking PED Qty
pressure VEETECH
Tank-10m3 - - - - - CAT-1 1
Base Frame - - - - - - 1
Pressure transmitter (1/2'') Yes Yes - - Yes - 5
GWR type Level Transmitter,2'',150# Yes Yes - - Yes - 2
Flow Transmitter Yes Yes - - Yes - 3
IRCD (mechanical) - - - - Yes - 3
Biocide injection YES. ONLY FOR TANK. Pressure Safety Valve - - - - Yes - 2
1 package (1/2''Tubing 114.4barg NOT FOR COMPLETE YES Magnetic Level Gauge - - - - Yes - 1
Skid) SKID PVRV (2'') Yes - - - Yes - 1
Dosing pump and motor Yes - Yes Yes Yes - 2
Pulsation Dampener (Discharge) - - - - Yes - 2
Pressure gauge (1/2'') Yes - - - Yes - 2
Emergency Vent hatch (6'') Yes - - - Yes - 1
Junction Box Yes - - - Yes - 1
Local Control Panel Yes - - - Yes - 1
Tank-10m3 - - - - - CAT-1 1
Base Frame - - - - - - 1
Pressure Safety Valve - - - - Yes - 2
H2S Scavenger YES. ONLY FOR TANK. Magnetic Level Gauge - - - - Yes - 1
2 injection package 99 barg NOT FOR COMPLETE YES Vapor Lock ( Free issued by SLB) - - - - - - 1
(1/2''Tubing Skid) SKID Dosing pump and motor Yes - Yes Yes Yes - 2
PVRV (2'') Yes - - - Yes - 1
Base Frame - - - - Yes Yes 1
Piping - - - - Yes CAT-2 1
Offshore methanol YES FOR COMPLETE
Pressure Safety Valve - - - - Yes Yes 2
3 injection package (2'' 273 barg SKID NO Piping Strainer - - - - Yes - 2
XXS PIPING SKID) Pulsation Dampener (Suction & Discharge) - - - - Yes Yes 4
Tank-10m3 - - - - - SEP 1
Base Frame - - - - - - 1
Offshore corrosion Magnetic Level Gauge - - - - Yes - 1
4
inhibitor injection 5 barg N.A YES Vapor Lock ( Free issued by SLB) - - - - - - 1
package (1/2''Tubing Dosing pump and motor Yes - Yes Yes Yes - 2
Skid) Pulsation Dampener (Discharge) - - - - Yes - 2
PVRV (2'') Yes - - - Yes - 1
Tank-10m3 - - - - - SEP 1
Base Frame - - - - - - 1
Offshore scale Magnetic Level Gauge - - - - Yes - 1
5
inhibitor injection 199 barg N.A YES Vapor Lock ( Free issued by SLB) - - - - - - 1
package (1/2''Tubing Dosing pump and motor Yes - Yes Yes Yes - 2
Skid) Pulsation Dampener (Discharge) - - - - Yes - 2
PVRV (2'') Yes - - - Yes - 1
Base Frame - - - - - - 1
Onshore corrosion Pressure Safety Valve - - - - Yes - 2
6
inhibitor injection 114.4barg N.A YES
package (1/2''Tubing Pressure gauge (1/2'') Yes - - - Yes - 2
Skid) IRCD (mechanical) - - - - Yes - 4
Tank-10m3 - - - - - SEP 1
Base Frame - - - - - - 1
Flow Transmitter Yes - - - Yes - 2
Magnetic Level Gauge - - - - Yes - 1
Onshore scale inhibitor Vapor Lock ( Free issued by SLB) - - - - - - 1
7 injection package 114.4barg N.A YES Dosing pump and motor Yes - Yes Yes Yes - 2
(1/2''Tubing Skid)
IRCD (mechanical) - - - - Yes - 2
PVRV (2'') Yes - - - Yes - 1
Tank-20m3 - - - - - SEP 1
Base Frame - - - - - - 1
Piping - - - - Yes SEP 1
Pressure Safety Valve - - - - Yes Yes 2
TEG(Glycol) injection Magnetic Level Gauge - - - - Yes - 1
8 package 3.3 barg N.A YES Piping Strainer - - Yes - 2
(2'' Sch40 PIPING SKID) Dosing pump and motor Yes - Yes Yes Yes - 2
PVRV (2'') Yes - - - Yes - 1
Heat Tracing Panel Yes - - - Yes - 1
Tank-10m3 - - - - - SEP 1
Base Frame - - - - - - 1
MEG oxygen scavneger Magnetic Level Gauge - - - - Yes - 1
9 package (1/2''Tubing 5.5 barg N.A YES Dosing pump and motor Yes - Yes Yes Yes - 2
Skid) Pulsation Dampener (Discharge) - - - - Yes Yes 6
PVRV (2'') Yes - - - Yes - 1
Temperature transmitter Yes - - - Yes - 1
Base Frame - - - - Yes SEP 1
Pressure Safety Valve(Loose Supply) - - - - Yes Yes 2
Sodium Carbonate Piping Strainer - - - - Yes - 2
10 injection package (2'' 3.2 barg N.A yES Dosing pump and motor Yes - Yes Yes Yes - 2
Sch40 PIPING SKID)
Pulsation Dampener (Suction & Dischaege) - - - - Yes Yes 4
Base Frame - - - - Yes SEP 1
Pressure Safety Valve(Loose Supply) - - - - Yes Yes 2
Sodium Hydroxide Piping Strainer - - - - Yes - 2
11 injection package (2'' 3.8 barg N.A YES Dosing pump and motor Yes - Yes Yes Yes - 2
Sch40 PIPING SKID) Pulsation Dampener (Suction & Discharge) - - - - Yes Yes 4
Tank-0.75m3 - - - - - - 1
Base Frame - - - - - - 1
Ammonia Injection Magnetic Level Gauge - - - - Yes - 1
12 package 20 barg N.A YES PVRV (2'') Yes - - - Yes - 1
(1/2''Tubing Skid)
Pulsation Dampener (Suction & Discharge) - - - - Yes - 4
Tank-0.75m3 - - - - - - 1
Base Frame - - - - - - 1
Oxygen Scavenegr Magnetic Level Gauge - - - - Yes - 1
13 Package A 20 barg N.A YES PVRV (2'') Yes - - - Yes - 1
(1/2''Tubing Skid)
Tank-1m3 - - - - - - 1
Base Frame - - - - - - 1
New Biocide Injection Magnetic Level Gauge - - - - Yes - 1
14 Package (South Side) 5 barg N.A YES PVRV (2'') Yes - - - Yes - 1
(1/2''Tubing Skid) Dosing pump and motor Yes - Yes Yes Yes - 2
Hazard Analysis
Causes of hazard
1.0 INTERNAL
1.1 FLUID
More flow / high level
Transition flow / Surge
High pressure
Supply fault
Blow-by from upstream eqpt.
Fire
Exothermic reation
Internal Explosion
Low pressure / vacuum
Pressure pulsation
High temperature
Low temperature service
Brittle fracture
Endothermic reaction
Corrosive fluids
Errosive Liquids / sands
Others
1.2 MACHINERY
Vibration form mixers/pumps etc.
Mechanical loads to support
Weir plates
Cavitation
Others
1.3 Fatigue Due to
Pressure fluctuations
Vidrations of pipework
Machinery (pumps, compressors etc)

1.4 OTHERS
HEATERS (Electric / Steam)
Electrostatic devices
Injection points, dosing etc.
Wash connections
Steam out connections
Hydro test fluid compatabilty
Others
2.0 EXTERNAL
2.1 Mechanical loads on nozzles
Ext. piping connected to nozzles
2.2 Mechanical loads on Equipment

Vessel Burried
Wind
Blast ( External )
Seismic
Snow loads
Inertia (eg. on moving platforms )
Transportation (acceleration )
2.3 Mechanical impact

Eqpt. vulnerability to vehicle impact
Others
2.4 Fire
Pool fires, jet fires etc.
Others
3.0 ENVIRONMENTAL
Outside wet
Outside arid
Outside hot
Outside cold
Deposit , spillage of corrosive Material on
external surface of eqpt.
Others
4.0 ADDITIONAL
Any potential scope for operator error
Any other identifiable hazards
Hazard Analysis
Precautions taken Accept (Yes/No)
Corrosive, construction material is Stainless Steel 316L grade Yes

Not applicable Yes
Flowmeter provided in the discharge line NA
Applicable. Any inadvertent closure of Isolation Valves at pump discharge is Yes
the design basis for the Pressure Safety valve.
NA NA
Not applicable, end user scope NA
Throughout the operartion of the Pump, the fluid is kept in stable liquid state. NA
Hence fire scenario is not applicable.
The pump is only used to pressurize and transfer the Methanol from one destination to Yes
the other. There is no mixing of additional chemical or change in process with in the
skid. Throughout the operation of the Pump, the fluid is kept in stable liquid state and
there is no (exothermic) reaction applicable.
Not applicable. NA
Designed to Full Vacuum condition NA
Pressure pulsation is controlled by using pulsation dampener. Yes
Not applicable NA
Not applicable NA
System is designed to MDMT and all pressure parts above 5mm thk are Impact Yes
tested.
No reactions involved. Yes
Yes, all wetted parts are Stainless steel. Yes
Non-errosive liquids / No solids. Yes
Nil
There are no vibrations inside the Pump housing. Yes

Adequate supports and clampings are provided Yes
Not applicable NA
Throughout the operation of the Pump, the Methanol is kept in stable liquid state. Yes
Positive head is always maintained using pulsation dampener at pump suction. Hence
there is no chance for cavitation
Not applicable NA
Pressure fluctuations from the pump are controlled by using pulsation dampeners. Yes
Pressure fluctuations from the pump are controlled by using pulsation dampeners. In Yes
addition, adequate supports and clampings are provided to arrest vibrations.
Pump, permanantly bolted to base frame. Yes
Not Applicable NA
Not applicable NA
Yes : Applicable Yes
Not applicable NA
Not applicable NA
Yes : Stainless Steel Material NA
Not applicable
Not applicable NA
External piping is in client scope.Neccessary stress analysis shall be done by NA
client.
Not applicable NA
Not applicable NA
Not applicable NA
Yes : Applicable. Vessel is designed suitable for below G Loading:
Gx=0.91, Gy=0.91, Gz=0.91 (SSE)
Gx=0.36, Gy=0.36, Gz=0.36 (OBE)
Not applicable NA
Not applicable NA
Not applicable. Skid will be placed on temporary wooden pallets and packed inside NA
a wooden box for transportation to site.
Speed restriction to be imposed on transport vehicle. Skid will be placed on temporary Yes
wooden pallets and packed inside a wooden box for transportation to site.
Not applicable NA
NA
Not applicable NA
Not applicable NA
Not applicable NA
Not applicable NA
Not applicable NA
Not applicable NA
Not applicable NA
Not applicable NA
Nil / Necessary alarms and trips are included in customer scope Yes
Nil NA
RESSURE EQUIPMENT DIRECTIVE 2014 / 68 / EU
HAZARD ANALYSIS & ESSENTIAL SAFETY REQUIREMENTS

Section PED Essential Safety Requirements
1 GENERAL
1.1 Equipment must be designed, manufactured and checked, installed
in such a way as to ensure its safety when put into service in
accordance with the manufacturer’s instructions
1.2 Principles to be applied to:

- Eliminate or reduce hazards as far as is reasonably practicable;
- Apply appropriate protection measures against hazards which
cannot be eliminated.
-Where appropriate, inform users of residual hazards and
indicate whether it is necessary to take appropriate special measures
to reduce the risks at the time of installation and/or use.
1.3 Pressure equipment to be designed to prevent danger from

foreseeable misuse.
Warning to be given against misuse.
2 DESIGN
2.1 General
Pressure equipment to be designed to ensure safety throughout
intended life.
2.2 Design for adequate strength
2.2.1 To be designed for loadings appropriate to its intended use.
—
internal/external presure, — ambient and operational temperatures,
— static pressure and mass of contents in operating and test
conditions, — traffic, wind, earthquake loading, — reaction forces
and moments which result from the supports, attachments, piping,
etc., — corrosion and erosion, fatigue, etc., -- decomposition of
unstable fluids.
2.2.2 To be designed for adequate strength based on a calculation method

and supplemented if Necessary, by experimental design method.
2.2.3 (a) Allowable stresses to be limited with regard to foreseeable failure

modes, safety Requirements may be met by applying one of the
following methods
- Design by formula
- Design by analysis
- Design by fracture mechanics
2.2.3 (b) Resistance- Appropriate design calculations must be used to
establish the resistance of the pressure equipment concerned. 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.
- The calculation temperature must allow for appropriate safety
margin
- The design must take appropriate account of all possible
combinations of pressure and temperature which might arise under
reasonably foreseeable operating --the maximum stresses and peak
stress concentrations shall be kept within safe limits,
— the calculation for pressure containment shall utilise the values

appropriate to the properties of the material, based on documented
data, having regard to the provisions set out in point 4 together with
appropriate safety factors. Material characteristics to be considered,
where applicable, include: — yield strength, 0,2 % or 1,0 % proof
strength as appropriate at calculation temperature, — tensile
strength, — time-dependent strength, i.e. creep strength, — fatigue
data, — Young’s modulus (modulus of elasticity), — appropriate
amount of plastic strain, — bending rupture energy, — fracture
toughness.— appropriate joint factors shall be applied to the
material properties depending, for example, on the type of non-
destructive testing, the materials joined and the operating conditions
envisaged,
the design shall take appropriate account of all reasonably

foreseeable degradation mechanisms (e.g. corrosion, creep, fatigue)
commensurate with the intended use of the equipment. Attention
shall be drawn, in the instructions referred to in point 3.4, to
particular features of the design which are relevant to the life of the
equipment, for example:— for creep: design hours of operation at
specified temperatures, — for fatigue: design number of cycles at
specified stress levels, — for corrosion: design corrosion allowance.
2.2.3 © Calculations to allow for adequate structural stability including

transport and the equipment will be placed on temporary wooden
pallets and packed inside a wooden box for transportation to site.
2.2.4 Design by experimental method must be validated by an appropriate

test programme on a sample representative of the equipment.
Test programme must be clearly defined and must include a pressure
strength test.
2.3 Provisions to ensure safe handling and operation

Methods specified for operation of equipment to preclude any
foreseeable risk,
with attention being paid to:
- closures and openings
- Discharge of pressure relief blow-off.
- Access whilst pressure or vacuum exists.
Methods specified for operation of equipment to preclude any
foreseeable risk,
with attention being paid to:
- closures and openings
- Discharge of pressure relief blow-off.
- Access whilst pressure or vacuum exists.
- Surface temperature, taking account of intended use.
- Decomposition of unstable fluids.
- Access doors equipped with devices to prevent hazard from
pressure`
2.4 Means of examination
2.4 (a) To be designed & constructed so that examinations to ensure safety
can be carried out.
2.4 (b) Means of determining the internal condition of the equipment must
be available.
2.4 (c) Other means of ensuring the safe condition of the pressure
equipment-
— where it is too small for physical internal access,
— where opening
the pressure equipment would adversely affect the inside, 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.
2.5 Means of draining and ventilation

Means to be provided for draining and venting where necessary :--
To avoid water hammer, vacuum collapse, corrosion & chemical
reactions.-- To permit cleaning, inspection & maintenance.
2.6 Corrosion or other chemical attacks

Adequate allowance or protection to be provided against corrosion
2.7 Wear
Where erosion or abrasion may arise, adequate measures must be
taken to :
- Minimize that effect by appropriate design e.g. replacement of
parts instruction.
2.8 Assemblies
Assemblies to be designed so that :-
Components to be assembled are suitable and
reliable for their duty-
- Components
to be properly integrated and assembled.
2.9 Provision for filling and discharge

To be provided with accessories or provision made for their fitting to
ensure safe
filling or discharge with respect to hazards :
on filling; by overfilling or over pressurization and instability
- On discharge; by uncontrolled release of fluid.
- On unsafe connection and disconnection.
2.1 Protection against exceeding the allowable limits of pressure equipment

Where the allowable limits could be exceeded, the pressure
equipment must be fitted with, or provision made for the fitting of,
suitable protective devises determined on the basis of the particular
characteristics of the equipment or assembly.
2.11 Safety accessories

2.11.1 Safety accessories must:- be designed and constructed as to be
reliable and suitable for their intended
duty:
- be independent of other functions:
2.11.2 Pressure limiting devices must be so designed that the pressure will
not permanently exceed the maximum allowable pressure.
2.11.3 Temperature monitoring devices must have an adequate response
time.
2.12 External fire
Where necessary, pressure equipment must be so designed and
where appropriate, fitted with suitable accessories to meet danger
limitation requirements in the event of external fire.
3 MANUFACTURING
3.1 Manufacturing procedures
Manufacturer to carry out competent execution of
provisions set out at design stage and apply appropriate techniques
and procedures.
3.1.1 Preparation of component parts must not to give rise to defects or
cracks or Changes on mechanical characteristics likely to affect the
safety of the pressure equipment.
3.1.2 Permanent joining and adjacent zones-- to be free from surface or
internal defects detrimental to safety-- properties to meet minimum
specified for materials to be joined or taken into
account in design calculations-- permanent joining to be carried out
by suitably qualified personnel according to suitable operating
procedures
- - personnel and procedures to be approved by third party for
category II,III & IV equipment
3.1.3 Non-destructive tests of permanent joints to be carried out by

suitably- personnel to be approved by third party for category III &
IV equipment
3.1.4 Suitable heat treatment to be applied at appropriate stage of
manufacture
3.1.5 Traceability-Materials making up component parts to be identified by
suitable means from receipt, through production up to final test
3.2 Final assessment

Pressure equipment to be subjected to final assessment as below
3.2.1 Equipment must undergo a final inspection to assess visually and by
examination complied of the accompanying documents compliance
with the requirements of the directive. The final inspection must be
carried out internally and externally on every part of the equipment,
where appropriate in the course of manufacture
3.2.2 Final assessment must include a test for the pressure containment
aspect, which will normally take the form of a hydrostatic pressure
test.
For category 1 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 recognized value may be carried out.
3.2.3 For assemblies, safety devices to be checked to confirm compliance

with requirements of ESR’S at 2.10
3.3 Marking and labeling
In addition to the CE marking, the following information must be
provided
3.3(a) The name and address of the manufacturer and, where appropriate,
of his authorized representative established within the Community.
The year of manufacture
Identification of the pressure equipment
Essential maximum / minimum allowable limits
3.3.(b) Depending on the type of equipment, further information necessary
for safe installation, operation or use and, where applicable,
maintenance and periodic inspection.— the volume V of the pressure
equipment in L, the nominal size for piping DN, — the test pressure
PT applied in bar and date, — safety device set pressure in bar, —
output of the pressure equipment in kW, — supply voltage in V
(volts), — intended use, — filling ratio kg/L, — maximum filling mass
in kg, — tare mass in kg, — the fluid group.
3.3(c) Where necessary, warnings fixed to the equipment, drawing

attention to misuse which experience has shown might occur.
3.4 Operating instructions

All relevant operating instructions to be provided for the user
containing all safety information in accordance with this section.
4 MATERIALS
Materials for pressure equipment to be suitable during life time
unless replacement is foreseen
welding consumables and other joining materials to fulfill
requirements of 4.1, - 4.2 (a) and first part of 4.3
4.1 Materials for pressurized parts
4.1(a) Materials for pressurized parts to have appropriate properties for all
operating and test conditions
To be sufficiently ductile and tough
Characteristics of materials to comply with ESR’s at 7.5
To be selected in order to prevent brittle type fracture
4.1(b) To be sufficiently chemically resistant to the fluids contained in the

pressure equipment
4.1(c) Not be significantly affected by aging
4.1(d) Be suitable for the intended processing procedures.

4.1(e) Be selected in order to avoid significant undesirable effects when the
various materials are put together.
4.2
4.2(a) Manufacturer must define in an appropriate manner the values
necessary for the design calculations referred to in 2.2.3
4.2(b) Manufacturer to provide technical documentation relating to
compliance with materials specifications of directive in one of the
following forms;
by using materials which comply with harmonized standards
by using materials covered by a European approval of pressure
equipment materials
4.2(c) For equipment in category III & IV particular material appraisal to be
performed by notified body in charge of conformity assessment.
4.3
Manufacturer to take appropriate measures to ensure
Material used conforms to specification
- Documentation by material manufacturer confirms compliance
with a specification
- Documentation for main pressure parts in categories II,III
& IV to be a - Certificates issued by material manufacturer who has
appropriate quality assurance system
5.0 FIRED OR OTHERWISE HEATED PRESSURE EQUIPMENT WITH RISK OF OVERHEATING

Equipment to be calculated, designed and constructed so as to avoid
or minimize risk of a significant loss of containment from
overheating, in particular….
6.0 PIPING
Design and construction shall 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;
( c) that due consideration is given to the potential damage from

turbulence and formation of vortices; the relevant parts of point 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 shall 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.
7.0 SPECIFIC QUANTITATIVE REQUIREMENTS FOR CERTAIN PRESSURE EQUIPMENT

7.1 Allowable stresses
7.1.1 Symbols
7.1.2 The permissible general membrane stress for predominantly static

loads and for temperatures outside the range in which creep is
significant shall not exceed the smaller of the following values,
according to the material used:
7.2 Joint coefficients

Welding joints
7.3 Pressure limiting devices
Pressure limiting devices, particularly for pressure vessels. The
momentary pressure surge must keep to 10% of the maximum
allowable pressure
7.4 Hydrostatic test pressure, particularly for pressure vessels
For pressure vessels, the hydrostatic test pressure referred to in
point 3.2.2 shall be no less than either of the following:
— 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,
— the maximum allowable pressure multiplied by the coefficient
1,43, whichever is the greater.
7.5 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 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 a ISO V test-piece is no less than 27J at
a temperature not greater than 20ºC but no higher than the lowest
scheduled operating procedure.
DIRECTIVE 2014 / 68 / EU
TIAL SAFETY REQUIREMENTS

Compliance
a) Manufactured to International Standards & quality

system requirements and compliance to Directive
2014/68/EU.
b) ASME B 31.3 Design, and Inspection by
NOBO.
c) Installation : Responsibility of end user.
Refer to hazard analysis.
Refer to hazard analysis.
Safety of the equipment is ensured following ASME B 31.3-

design requirements.
Yes. Refer to design calculations
Yes. Refer to design calculations
1) Design stresses in accordance with ASME Section II

Part D Ed.2021.
2) Piping has been designed in accordance with ASME

B 31.3. [ Design by Formula ]
Complied. Refer to Design Calculations.
The equipment will be placed on temporary wooden

pallets and packed inside a wooden box for tansrportation
to site.
Hydrotest will be conducted as per PED being the highest

of the requirements. Refer to G.A drawings and Design
calculations and Hydrotest procedure.
Equipment design for its highest possible operating

conditions. Piping is designed to withstand full vacuum.
Safety measures are detailed in Operation Manual and
to be followed by the user during installation and
Operation.
Equipment design for its highest possible operating
conditions. Piping is designed to withstand full vacuum.
Safety measures are detailed in Operation Manual and
to be followed by the user during installation and
Operation.
Design, Construction and NDE are performed as per ASME

B31.3 and as per NO BO approved NDE procedure. Full
Radiography is considered for the piping.
N/A, 3" piping only.
3" piping only, for outside visual examination and access

gratings are provided. -
Construction material is austenitic stainless steel and there
is no other internal degradation mechanisms within the
system.
a) Vent & Draining point is provided.

b) Service is corrosive, constructed with Stainless
Steel materials. Pulsation dampener provided to avoid
water hammering issue.
c) Drip tray is provided to do cleaning, grating are provided
for access for inspection and maintenance.
Corrosive service, but constructed with Stainless Steel

materials to avoid corrossion. Corossion allowance is
considered in design.
Not applicable.
Yes, applicable. Components are properly integrated and
assembled and tested. All components are Atex certified,
hydrotested as applicable and CE marked.(Pressure
transmitter, Flow Transmitter, Pressure Safety Valve, Piping
Strainer, Pulsation Dampener (Suction &
Discharge),Pressure gauge,Dosing pump and motor,
Junction Box, Local Control Panel etc.)
Filling of the system is by gravity flow (from storage tank),

which is in end user scope. Level control will be provided
on inlet connection, which is in end user scope.
Safety valves are fitted on down stream Piping.
ure equipment
PSV are fitted at a maximum limit of 1.1 x MAWP. To
indicate the pressure and flow : CE certified pressure
gauge, pressure transmitter and flow transmitter are
provided.
PSV are fitted at a maximum limit of 1.1 x MAWP. ESD are

equiped on LCP.
Piping is equipped with the Pressure Safety

Valves at a maximum limit of 1.1 x MAWP.
Not Applicable.
ESD are equiped on LCP.
Complied, Manufacturing Process control route card is

implemented and Inspection test plan implemented.
Components used are with no defects and are inspected

prior to installation on the pressure equipment. NDE are
performed on components to ensure no defects prior to
installation.
Complied, Permanant joining procedures are prepared as
per the requirement of PED directive. Personnel and
procedures are approved by NOBO.
Complied, RT & PT carried out as per NDE procedure

approved by NOBO.
Not Applicable.
Material traceability is ensured with qualified procedures

and records in the Manufacturer's facility.
Complied.
Hydro static test will be carried out in accordance with the

requirements of ASME B 31.3. Ed 2020 , witness by NOBO.
Complied.
Complied and refer Name plate drawing

Refer the IOM.
Yes. Warnings stamp will be fitted.
Refer the IOM.
As per ASME Section II Part A/C Ed.2021 and ASME Section

II Part D Ed.2021
Complied.
Material selection in accordance with the requirements of

ASME Section II Part A/C Ed.2021 and ASME Section II Part
D Ed.2021 and/or Particular Material Appraisal (PMA)
Complied. Refer Particular Material Appraisal for Wetted

parts of Pressure Equipment, All pressure equipment
construction materail is stainless steel 316L grade.
Complied. Refer Particular Material Appraisal for Wetted

parts of Pressure Equipment.
yes, complied.
yes, complied, all pressure equipment construction
material is stainless steel 316L grade.
Material design stress calculated by ASME Section II

Part D Ed.2021
Material selected as Harmonized with the Design code.
Please refer to Particular Material Appraisal records.
Equipment belongs to PED Category - II (piping),
Particular Material Appraisal is performed by the
manufacturer.
Yes, As per PMA.
ITH RISK OF OVERHEATING

N/A
a) Manufactured to International Standards & quality

system requirements and compliance to Directive
2014/68/EU.
b) ASME B 31.3 Design, and Inspection by
NOBO.
Complied, flanges, connections, instrument tubings, cables

etc are adequately controlled by means of support,
anchoring with proper alignment and arresting pre-tension.
Not applicable, liquid medium.
Not applicable.
Pulsation dampeners and clampings are provided to avoid

vibration and there by fatigue if any.
Not applicable
RESSURE EQUIPMENT
Complied, refer calculation
Allowable design stresses to ASME Section II Part D

Ed.2021(Refer Particular Material Appraisal).
As per ASME B 31.3 and as mentioned in the GA drawing.
Piping is equipped with the Pressure Safety

Valves at a maximum limit of 1.1 x MAWP.
s
hydro test will be conducted as per ASME B 31.3 ED 2020
and as per approved hydrotest procedure inspected by
NOBO.
All materials used for Piping construction are Stainless

steel. However, all items are impact tested at -15ºC of
mimimum 32J value.

ESR - Hazard Analysis

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ESR - Hazard Analysis

Uploaded by

Copyright:

Available Formats

Document requirements for PED 2014/68/EU

S/N. Activity Description Requirement Action By Status as on 27.07.22

Permanent Joining Personnel

10 Test Procedures Shall be prepared and approved by Manufacturer. Prasoon Closed

Manufacturer forming and or bending

Required additional testing (e.g. KCV) has been

23 Article 4 (3), SEP DOC, NP, OIM Prasoon/Prateek Open

Project Risk assessment

Completed for the

After FAT & Doc Review

What does NP and OIM

After FAT & Doc Review

Technical Specifications, Range & Data sheets of

Typical Quality File

9 Safety Instruction Manual To be discussed with BV

Machinery (pumps, compressors etc)

2.2 Mechanical loads on Equipment

2.3 Mechanical impact

Corrosive, construction material is Stainless Steel 316L grade Yes

There are no vibrations inside the Pump housing. Yes

HAZARD ANALYSIS & ESSENTIAL SAFETY REQUIREMENTS

1.2 Principles to be applied to:

1.3 Pressure equipment to be designed to prevent danger from

2.2.2 To be designed for adequate strength based on a calculation method

2.2.3 (a) Allowable stresses to be limited with regard to foreseeable failure

— the calculation for pressure containment shall utilise the values

the design shall take appropriate account of all reasonably

2.2.3 © Calculations to allow for adequate structural stability including

2.2.4 Design by experimental method must be validated by an appropriate

2.3 Provisions to ensure safe handling and operation

2.5 Means of draining and ventilation

2.6 Corrosion or other chemical attacks

2.9 Provision for filling and discharge

2.1 Protection against exceeding the allowable limits of pressure equipment

2.11 Safety accessories

3.1.3 Non-destructive tests of permanent joints to be carried out by

3.2 Final assessment

3.2.3 For assemblies, safety devices to be checked to confirm compliance

3.3(c) Where necessary, warnings fixed to the equipment, drawing

3.4 Operating instructions

4.1(b) To be sufficiently chemically resistant to the fluids contained in the

4.1(c) Not be significantly affected by aging

4.1(d) Be suitable for the intended processing procedures.

5.0 FIRED OR OTHERWISE HEATED PRESSURE EQUIPMENT WITH RISK OF OVERHEATING

(a) that the risk of overstressing from inadmissible free movement or

(b) that where there is a possibility of condensation occurring inside

( c) that due consideration is given to the potential damage from

(g) that the position and route of underground piping is at least

7.0 SPECIFIC QUANTITATIVE REQUIREMENTS FOR CERTAIN PRESSURE EQUIPMENT

7.1.2 The permissible general membrane stress for predominantly static

7.2 Joint coefficients

7.5 Material characteristics

TIAL SAFETY REQUIREMENTS

a) Manufactured to International Standards & quality

Refer to hazard analysis.

Refer to hazard analysis.

Safety of the equipment is ensured following ASME B 31.3-

Yes. Refer to design calculations

Yes. Refer to design calculations

1) Design stresses in accordance with ASME Section II

2) Piping has been designed in accordance with ASME

Complied. Refer to Design Calculations.

Complied. Refer to Design Calculations.