Mechanical

Engineering

Day 7
Pressure Equipment Directive PED
Pipelines

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Pressure equipment directive (PED) 97/23/EC

The directive:
Overview: slides 2 to 15
- Design
- Manufacturing and
- Conformity assessment of pressure equipment
Products:
- Pressure accumulators
- Heat transducers
- Steam boilers
- Industrial pipelines
- Safety devices (safety valves, shut-off devices, etc. - will be covered in a
separate section)
- Auxiliary pressurized devices, flanges, nozzles, etc.
Industries:
- Gas and oil industry
- Pharmaceutical and chemical industry
- Plastics industry
- Food/beverage industry
- High-temperature industry (manufacturing glass, paper, etc.)
- Energy production
- Gas storing and transport
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PED 97/23/EC
Fluid groups used for vessel/pipe classification
Group 1 comprises dangerous fluids.
A dangerous fluid is a substance or preparation covered by the definitions in
Council Directive 67/548/EEC
- classification, packaging and labeling of dangerous substances.
Group 1 comprises fluids defined as:
explosive,
extremely flammable,
highly flammable,
flammable (where the maximum allowable temperature is above flashpoint),
very toxic,
toxic,
oxidizing.
Group 2 comprises all other fluids not referred to in group 1.

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Vessels

Gas (*)

Liquid (**)

Fluid group 1

Fluid group 2

Fluid group 1

Fluid group 2

V>1L
PS x V > 25 bar L

V>1L
PS x V > 50 bar L

V>1L
PS x V > 200 bar L

PS > 10 bar
PS x V >10000 bar L

or

or

or

or

PS > 200 bar

PS > 1000 bar

PS > 500 bar

PS > 1000 bar

Diagram 1 (Chart 1)

Diagram 2

Diagram 3

Diagram 4

PS
V

PS
V

PS
V

PS
V

Category

Category

Category

Category

* 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)

( )

**) liquids having a vapour pressure at the maximum allowable temperature of not more than 0,5 bar above normal
atmospheric pressure, (1 013 mbar)
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Fired or otherwise heated

pressure equipment with
the risk of overheating
Steam or super-heated water
generators TS >110C i V >2 L

Pressure cookers

Diagram 5
PS
V
Category

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Piping

Gas (*)

Liquid (**)

Fluid group 1

Fluid group 2

Fluid group 1

Fluid group 2

DN > 25

DN > 32
PS x DN > 1000 bar

DN > 25
PS x DN > 2000 bar

PS > 10 bar
DN > 200
PS x DN > 5000 bar

Diagram 6

Diagram 7

Diagram 8
Diagram 9

PS
DN

PS
DN

PS
DN

Category

Category

Category

PS
DN
Category

* 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)

( )

**) liquids having a vapour pressure at the maximum allowable temperature of not more than 0,5 bar above normal
atmospheric pressure, (1 013 mbar)
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PED 97/23/EC

up 1
o
r
g
- Gas roup 2 q
Gas
f
rm o
o
f
r
la
Simi m
ra
diag

Example: PS = 10 bar, V = 80 L

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PED 97/23/EC

gas

d
liqui

t form
n
e
r
diffe grams
a
of di

Example: PS = 10 bar, V = 80 L

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PED 97/23/EC

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PED 97/23/EC
Pressure equipment classification: according to ascending level of hazard
(previously in numerous national standard - descending)
Category I =
Category II =
Category III =

Category IV =

Module A
Module A1,
D1,
E1
Modules B1 + D,
B1 + F,
B + E,
B + C1,
H
Modules B + D,
B + F,
G
H1

CONFORMITY ASSESSMENT
PROCEDURES

Low-hazard equipment classified into a separate group

handled in accordance with Sound Engineering Practice.
Such equipment is covered by directive SPVD-87/404/EC
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PED 97/23/EC
CONFORMITY ASSESSMENT PROCEDURES
Module A (internal production control)
Module A1

(internal manufacturing checks with

monitoring of the final assessment)

Module B (EC type-examination)

Module B1

(EC design-examination)

Module C1

(conformity to type)

Module D

(production quality assurance)

Module D1

(production quality assurance)

Module E (product quality assurance)

Module E1

(product quality assurance)

Module F

(product verification)

Module G

(EC unit verification)

Module H

(full quality assurance)

Module H1

(full quality assurance with design examination and special

surveillance of the final assessment)
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PED 97/23/EC

Design and construction of pressure equipment important factors

internal/external pressure,
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.
Various loadings which can occur at the same time must be considered,
taking into account the probability of their simultaneous occurrence.
Safe handling and operation
Particular attention must be paid, where appropriate, to:
closures and openings,
dangerous discharge of pressure relief blow-off,
devices to prevent physical access whilst pressure or a vacuum exists,
surface temperature taking into consideration the intended use,
decomposition of unstable fluids.

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The conformity to the PED is ruled by the Harmonized Standards used as a benchmark.
In Germany (and cont. part of Europe) the conformity to PED is alternately ruled by the AD 2000
Code, which is adapted to the Harmonized Standards and conservatively evolved from earlier AD Code .

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14

The conformity to the PED is ruled by the Harmonized Standards used as a benchmark.
In Germany (and cont. part of Europe) the conformity to PED is alternately ruled by the AD 2000
Code, which is adapted to the Harmonized Standards and conservatively evolved from earlier AD
Code.

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15

DESIGNING THE PRESSURE VESSELS

- general requirements for calculations Main physical properties and structural requirements need to be taken into account
during the design of pressure vessels (PV).
The calculation is for the parts of the PV that are made of low carbon non-alloyed,
low alloyed and alloyed steel, cast steel, cast iron, copper, aluminum and their alloys.
Calculation of smallest thickness / dimensions of vessel parts must result in prevention of
plastic deformations and destruction / catastrophic failure of PV in exploitation.

Design pressure
The vessel or part of the vessel under gage pressure (in the remainder of the pres.: pressure),
is calculated taking into account the design pressure that must not be lower than the highest
pressure in the vessel during exploitation.
When calculating a part of the vessel that is at the same time exposed to both external
and internal pressure, the calculation must be done separately for each of these pressures.
For vessels under vacuum, p = 1 bar
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Design temperature
Design temperature is determined by the actual temperature of the material that is
expected under operating conditions for the observed part of the vessel.
If different temperatures of the material are expected for different parts of the vessel,
then the calculation for these parts is performed using these temperatures.
If the temperature of the wall of the structural part of the vessel shell
is between -10 C and 20C the calculation temperature is presumed to be +20 C.

Strength
Strength of the vessel material will be determined depending on the design temperature.
In general, yield point value is accepted as the critical value:
- yield strength Y or
- proof (conventional) strength p0,2,(p1.0 for more ductile materials, A > 30%)
depending on the shape of the stress-strain curve of the material.
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If working conditions affect the strength dependence not only on temperature but also on
service time, the appropriate critical strength is the lower value between the yield
point and term strength after 100 000 hours of work (B/100000) at known design temperature.
It is also necessary to take into consideration the safety factor.

DESIGN STRENGTH =

CRITICAL STRENGTH VALUE

SAFETY FACTOR

!!

Design strength (f in EN, K/S in AD Merkbl.) calculated based on the critical strength
which shouldnt be reached during the exploitation

Safety factor
values of safety factor in regard to the yield point are given in the next slide,
that is, continuous time strength for most commonly used structural materials
for making pressure vessels exposed to internal pressure.

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Safety factor values

Type of material

Material safety factor at calculating

temperature (S)

Material safety factor at

testing pressure (S')

Steel

1.5

1.1 (1.05) (*)

Cast Steel

2.0 (1.9)

1.5 (1.33)

Aluminum and
aluminum alloys

1.5

1.1(1.05)
* following designation is used:
AD Merkblaeter value (EN 13445 value)
(if the two values are different)

( )

For vessels with external heating/cooling

(double jacket or an outer half-pipe coil) it is necessary to take into account the
effect of external pressure !! !!

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19

Weakening coefficient (AD Merkblaetter) - Joint coefficient (EN 13445)

This coefficient (, z) takes into account weakening of the pressure vessel
structure due to:
- connecting of elements (referring to inseparable connections such as welding
and soldering)
- existence of openings in the individual elements of the vessel, needed to
construct pipe connections, introduce stirrers into the vessel, etc.

To highlight the difference in the source of weakening coefficient values (AD Merkbl),
the value that relates to the quality of the welded joint is marked with and the value
related to the existence of an opening is marked with A.

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Example
Type of welds
according to
regul. used in Serbia

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Joint coefficient (EN 13445)

For the calculation of required thickness of
certain welded components
(e.g. cylinders, cones and spheres),
design formulae contain
z - the joint coefficient of the
governing welded joint(s) of the component

Examples of governing welded joints are:

- longitudinal or helical welds in a cylindrical shell;
- longitudinal welds in a conical shell;
- any main weld in a spherical shell/end;
- main welds in a dished end
fabricated from two or more plates.

Types of welds according to EN

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Joint coefficient (EN 13445) contd.

The following welded joints are not governing welded joints:
- circumferential weld between a cylindrical or conical shell and a cylinder, cone, flange
or end other than hemispherical;
- welds attaching nozzles to shells;
- welds subjected exclusively to compressive stress.
For normal operating load cases, the value of z is given in following table.
It is related to the testing group (allowed class) of the governing welded joints.
Joint coefficient and corresponding testing group

0.85

0.7

Testing Group

1, 2

In parent (base) material, away from governing joints, z = 1.

Testing groups are specified in EN 13445-5:2009, Clause 6.
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Allowances
To ensure a minimum required calculated wall thickness of a structural element
of the vessel, according to the required service life,
allowances c1, c2 and c3 must be adopted - to take into account reduction in wall thickness
c1, c2 and c3 - designations acc. to AD code in EN: c and (figure will be shown later)
Allowance c1 is for permissible deviation of measures of the material.
In the use of structural material that is not resistant to corrosion,
allowance c1 is permissible negative deviation of measures (thickness)
according to the applicable standards for the accepted material.
When using materials resistant to corrosion (primarily referring to austenitic
stainless steels and non-ferrous metal alloys), it is often not necessary
to take into account the negative measures tolerances.
Allowance c2 is added to the computational wall thickness due to the reduction of the
thickness of sheet metal by corrosion and wear.
For ferrite steels - usually in the range of 1 - 1.5 mm, and for thicker walls
(s 30 mm), it is not necessary to take it into account.
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Allowance c2 can be omitted when the vessel walls are protected against effects of the
working medium, e.g. with rubber, textile, synthetic material coatings, etc.., but must be taken
into account when applying metal coatings.
If the working medium is very corrosive, or if in latter use it will not be possible to view the
interior of the vessel, a higher value of c2 (up to 3 mm) is adopted.
When using stainless steels (not only austenite) and non-ferrous metals, allowance c2 is
determined for each specific case; in general case c2 = 0.
Allowance c3 is added in case of brickwork lining, due to the additional stresses
values of c3 are determined by the standards.

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Thickness designations
The inter-relation of the various definitions of thickness
EN 13445

AD
code

s se

AD
code
s

EN 13445

c2
c1

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DESIGNATION COMPARISON
According to
AD Merkbl.
Symbol

According to
EN 13445
Symbol

Outside diameter of
cylindrical shell

Da

De

Calculation pressure

Calculation
temperature

Coefficient of welded
joint

Required thickness

Proof strength

ReH Rp0,2 Rp1,0

Nominal design stress

K/S

Distance between
two reinforcements

Safety factor

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EN 13445

27