PED Starter Kit - gowelding.com

1 PEDS tarter KitContents Manufacturers responsibility under the PED Template for the Hazard Analysis. This is the starting point, itshould consider all the external hazards acting on the item. Example Hazard analysis. PED Essential Safety Requirements. This is a list of theessential safety requirements plus a column to indicate howeach requirement has been met. This column already includessome suggested comments, which can be modified to suitparticular requirements. Any ESR that is applicable but can't besatisfied must be stated in your Instruction manual. Thecolumns with references to PD5500 and ASME are forinformation and can be deleted. The ESR descriptions can besimplified and tailored to suit specific applications. A rough outline of the declaration required by the PED. Detailsof its content are defined in the directive. It is a legally bindingdocument and must be signed by a senior person within yourorganisation.

2 Instruction Manual. Suggested format and content Questions. Useful extracts from the ped-eurodyne web sitePlease feel free to modify the templates to suit your applying a CE mark to a vessel a manufacturer is responsible for: - Providing a general description of the vessel. This should include its purpose andits intended contents. Ensuring that the vessel design pressure and temperature are the maximumforeseeable conditions that the vessel will experience in service. Properly designing the equipment so that it will be safe throughout its intendedlife. The design must be justified by calculations or burst tests. Ensuring that the vessel material is compatible with the intended vessel foreseeable modes of corrosion, erosion and material degradation must beconsidered. Stress corrosion cracking in Austenitic Stainless Steel is a majorproblem with vessels that contain water above 50 C.

3 This risk is significantlyincreased if the fluid level in the vessel is constantly changing. Producing Instruction Manuals covering Installation, operation and don t have to be elaborate, for a conventional vessel a one page documentmay be enough. ALL FORESEEABLE SAFETY HAZARDS MUST BEADDRESSED. The manual should also list all appropriate ESR s that can t bemet, such as fitting safety devices etc. (ESR ) Demonstrate that all the appropriate Essential safety requirements stated in thedirective, in particular ESR 1, have been met. The equipment or assembly must be identified by a name plate, or tag label if theitem is small. This must contain :- The name and location of the manufacturer,details of what the assembly includes (a serial number which identifies a list of theindividual items will suffice), Year of Manufacture, min and max pressure andtemperature, hydraulic test pressure and any other relevant information listed inESR The label must also contain a CE mark if the equipment is in category1 and above; and if a notified body is involved, their name and registrationnumber must be NDT operators must be approved by a RSA for Categories 3 and 4.

4 If theirapproval is via the ASNT system we will need a copy of the written practice and thequalifications of the responsible level the individual items have been installed, the rules of the directive have to beapplied again to the completed assembly. If the assembly is carried out on the enduser site and the user takes full responsibility for it, then the assembly is exempt fromthe PED global conformity rules, but the individual items in the assembly are stillsubject to PED : -Brief Description: -Hazard Control Measure {Please delete items in red, for information only}Maximum Temperature{What is the maximum foreseeable temperature the unit can see and what prevents it from being should be given to possible fault conditions and adequate safety margins.}Minimum temperature{The lowest operating or start-up temperature caused by: - ambient temperature, chemical reactions, storage ofliquefied gasses etc.}

5 }Maximum Pressure(Must exceed safety valve lift pressure){What is the maximum foreseeable pressure the unit can see and what prevents it from being should be given to possible fault conditions, such as one chamber of a multi chamber vesselleaking into another; static head of complete system.}Vacuum conditions{Vacuum caused by fast discharge or thermal reactions}Material Compatibility{Are the intended contents of the vessel compatible with the materials used in its construction? Considerationshould be given to corrosion and stress corrosion cracking, erosion, and brittle fracture at low temperature}Pressure surges, water hammer effects loadings, fatigue thermal stress.{Pipework flexibility analysis if appropriate}Explosion or blast damage, fire and flamehazard, domino effect. Escape of dangerousfluids, discharges etc.{Protection from fire or explosion of combustible contents}Damage to equipment during transportationand installation(Packaging, transport requirements, installation instructions etc.)

6 }Vessel stability{Wind / Seismic / Snow / Possible collapse during filling}Operational hazards And Possible Misuse{Quick release doors Also possible collision damage from vehicles and cranes }Equipment: - 2000 Litre Batch Reactor vessel Serial No XXXXXXB rief Description: - The vessel has been constructed using 316L Stainless Steel with a Carbon Steel outer Jacket. It is suitable for containing anyliquid or gas that is chemically compatibly with the materials used in its Control MeasureMaximum TemperatureMaximum temperature stated in design specification = 180 C. End user to ensure suitable controls and safetymargins exist to prevent it from being exceededMinimum temperatureLowest foreseeable operating temperature stated in design specification = -29 CMaximum Pressure(Must exceed safety valve lift pressure)Maximum Pressure stated in design specification = 6 bar g.

7 End user to ensure that a suitable safety device isfitted to prevent it from being conditionsLowest foreseeable operating pressure stated in design specification = Full VacuumMaterial CompatibilityClient responsible for ensuring that the intended contents of the vessel will be compatible with 316L Stainlesssteel. Brittle fracture of the carbon steel jacket at 29 C to be assessed by PD5500 Annex DPressure surges, water hammer effects loadings, fatigue thermal considered as not stated in design specification. However PD5500 code rules allow for reasonable pipeloadings and pressure surges. No allowance has been made for thermal fatigue; it is assumed that heating andcooling of the vessel will be carefully controlled to minimise thermal or blast damage, fire and flamehazard, domino effect. Escape of dangerousfluids, discharges vessel has not been designed to accommodate blast damage, flame impingement or any other externalhazard.

8 The vessel will be subject to 10% radiography and 100% surface crack detection to minimise risk to equipment during transportationand installationPackaging and despatch instruction to be stabilityVessel to be adequately supported on three legs. Adequate attachment to floor to be provided by end userOperational hazards And Possible MisuseAll operational hazards to be assessed by the end 15/10/02 PED Essential Safety Requirements - Comparison with BS 5500 and ASME VIII Div 1 The European Pressure Equipment Directive 97/23/EC, (PED), places full responsibility upon the manufacturer of pressure equipment to comply with the provisions of theDirective. On completion of all design, manufacturing, inspection and testing procedures, and after verification of conformity, the manufacturer can make a Declaration ofConformity with the PED.

9 The manufacturer can then affix the CE marking which ensures that the equipment will have freedom of movement within the important requirement is that the manufacturer must comply with all the Essential Safety Requirements, (ESRs), in Annex 1 of the PED which are relevant to theequipment for which he makes the Declaration of following table provides a summary of all the ESRs and shows, by reference to the relevant clauses in BS 5500 and ASME VIII Div 1, where it is considered that thesecodes satisfy the in brackets refer to notes at the end of the Essential Safety RequirementASMEVIII Div 1BS must be designed, manufactured and checked, andinstalled in such a way as to ensure its safety when put into servicein accordance with the manufacturer s instructions.(6)(1)Equipment design and manufacture checked by {#yourcompany#} QA system and inspected by RSAI nstallation:- Responsibility of end must apply the principles set out below in thefollowing order:- eliminate or reduce hazards as far as is reasonably practicable,- apply appropriate protection measures against hazards- inform users of residual hazards(6)(1)Refer to Hazard pressure equipment designed to prevent danger from misuseor, adequate warning given.

10 (6)(1)Refer to Hazard pressure equipment must be properly designed to be safethroughout its intended life. Design must incorporate appropriatesafety to design be designed for loadings appropriate to its intended to design for adequate strength based on:2 15/10/02- a calculation method and supplemented if necessary by an experimental design an experimental design method without calculation, when the product of the maximum allowable pressure PS and the volume V is less than 6 000 (3)Refer to design (a)The allowable stresses for pressure equipment must be limitedhaving regard to reasonably foreseeable failure modes, safetyfactors must be applied to. Requirements may be met by applying one of the following methods:- design by formula- design by analysis- design by fracture mechanics;Note:- Design by analysis or fracture mechanics only permittedwhere formulas do not existUG-23(8)*U-2(g)Section 3 Annex AAnnex UDesign stresses in accordance with PED and PD5500requirementsDesigned by PD5500 (b)Appropriate design calculations must be used to establish theresistance of the pressure equipment concerned.