Idea Transcript
Chinese Pressure Equipments Manufacturers Approval - How to Achieve Acceptance by Western End User
Liu Kai
CSSOPE Beijing May 22, 2013
TÜV SÜD Chemie Service GmbH
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Introduction
Investment projects in the chemical/petrochemical industry
Global sourcingg of equipment q p
P ti l ffocus on Particular best cost countries (BCC)
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Operators’ objectives on global sourcing
Leverage g economic advantages g of low-wage g countries like China Ensure accustomed high g qqualityy to maximize availabilityy and reliability Meet delivery deadlines Fulfill national legal requirements Achieve the maximum intervals for in-service inspections according to national law
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Preconditions
Comprehensive project specifications Selection of manufacturer Coordination between operator/engineering company and inspection organization Europe: Coordination with the Notified Body and the chosen certified inspection authority Advantage: both functions integrated in a single organization
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Requirements for Pressure Vessels in Europe
Pressure Equipment Directive 97/23/EC (PED)
Defining a code for compliance with the Essential Safety Requirements of the PED is essential
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Standards / Codes
non harmonised Specifications/codes
harmonised standards EN 13445-1...8 13445 1 8 unfired pressure vessels
AD 2000
EN 12952-1...17 water tube boilers
CODAP 2000
EN 12953-1...14 shell boilers
ASME Code + additional dditi l requirements i t
EN 13480-1...8 metallic industrial piping
others
EN .......
presumption of conformity TÜV SÜD Chemie Service GmbH
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Application of Pressure Vessel Codes SITUATION IN CHINA
Chinese code GB 150/151 •
Associated standards ONLY in Chinese
National codes CODAP 2000, PED 5500, AD 2000 etc. •
Not well known
EN 13445 •
First experience started
ASME Code • Frequently used in international projects
Differences between ASME and PED must be defined!
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Project specification - Principles
PED Difference ASME vs. PED
ASME Code
Company standards
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Chemistry-specific quality requirements
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Project specification - Principles
PED
EN 13445
Company standards
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Chemistry-specific quality requirements
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Conformity Assessment Procedures
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Project specification – design
Generallyy ggreater wall thicknesses due to lower ppermissible stresses ASME VIII Div.1 vs. e.g. EN 13445, AD 2000 Flanges acc. acc to ANSI standard or DIN EN for pipe connections Additional specifications required for fatigue, stability and additional loads – not covered by ASME VIII Div.1 Definition of site-specific earthquake and wind load zones Determination of technical documentation required for design review according to module G of PED
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Project specification - design
Technical documentation for design review • • • • • • •
Risk analysis Calculations Manufacturing drawings Parts lists Welding regulations (WPS) Heat treatment plans Inspection and testing plans (ITP) • etc.
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Project specification - materials
• Materials acc. to ASME with Particular Material Appraisal pp ((PMA)) • Specification of chemical composition of ferritic steels to be welded and formed:
C ≤ 00.23 23 % (melt analysis) C ≤ 0.25 % (piece analysis) P ≤ 0.035 % S ≤ 0.025 0 025 %
• Rupture elongation 14% Notched-bar bar impact value on ISO ISO-V V sample 27 J at lowest • Notched operating temperature, but not greater than 20°C • Welded pipes 100% NDT (e.g. UT, ET)
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Project specification - materials
• Define plate formats and surface quality • Material certificates acc. acc to EN 10204 • Material manufacturers with quality management system compliant with PED Annex I clause 4.3 independently of material certificate 3.1 or 3.2 Appendix with scope of evaluated material and dimensions
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Material Certificates
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QA System of Material Manufacturer
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QA System of Material Manufacturer
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Project Specification - Manufacturing
• Welder qqualification and PQR ppursuant to PED Annex I, clause 3.1.2 approved by Notified Body or recognized third party • PQR with weld consumables (brand and manufacturer) to be used in manufacturing • Define production tests longitudinal welds Tube-to-tube T b t t b sheet h t welds ld
• Material marking/traceability during manufacturing • durable marking
• Approval of subcontractors by purchaser
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Welding Procedure Qualification Record (WPQR)
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Welder´s Qualification Test Certificate
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Project Specification – QA/QC
• Specify non-destructive testing for the specific object Positive P iti Material M t i l Identification Id tifi ti (PMI) Radiographic testing (RT) on longitudinal and circumferential seams, tube-to-tube sheet seams, etc. Surface-crack testing (PT, MT) Tightness testing (LT) e.g. of tube-to-tube sheet seams
• Certified NDT personnel acc. to PED, Annex I, clause 3.1.3 on the basis of EN 473 or SNT-TC-1A
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Project Specification – Documentation
Detailed documentation in English with regard to determination of inspection intervals and changes/repairs • • • • • • • • • • • •
As-built drawings Reports on PQR`s and welders’ qualifications Qualifications of NDT personnel List of pressure-bearing parts with assignment to material certificates Material certificates for pressure-bearing parts Reports on production tests Heat treatment certificates Non-destructive test reports Test report for final and pressure test Certificate of conformity Declaration of conformity Operating manual
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Value of Experience
Constantlyy update p manufacturer selection • Employee fluctuation/competence drain
Detailed and unambiguous g technical specification p • Leave no room for interpretation
Provisional dimensioning of critical apparatus (e.g. columns) • Comparability of quotations
Clarification meeting with manufacturer prior to placing order • Common understanding of the specification • Participants: expert from Notified Body, customer • English g s aandd C Chinese ese language a guage sskillss required equ ed
Pre-inspection meeting • Review of implementation of the specification requirements
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Value of Experience
Design review documentation reflects customary standard Problems with special calculations • Proof of stability under consideration of earthquake, wind nozzle loads • Local proof of nozzle loads • Fatigue proof
Material manufacturers with PED-compliant certified quality assurance system not readily available Material certificates not provided punctually at start of fabrication
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Value of Experience
D bl material Durable t i l marking ki dduring i manufacturing f t i
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Value of Experience
Intensive quality assurance required e.g. in welding of joints – seam preparation, tack welding, compliance with WPS
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Value of Experience
M hi i off sealing Machining li surfaces f off llarge apparatus t flflanges iin fifinall state t t
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Summary
Global sourcing of equipment in investment projects Best cost countries offer economic advantage Consult Notified Body and certified inspection agency on project specification Constantly update manufacturer selection ASME Code and EN 13445 as basis Intensive QA/QC and expediting necessary Objective is max. inspection interval for in-service inspections
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TÜV SÜD BU Chemical, Oil & Gas Expertise Responsibility Expertise. Responsibility. Trust Trust. Sustainability Sustainability.
TÜV SÜD Chemie Service GmbH 19.07.2013
Business Unit Chemical, Oil & Gas: In figures
3
Continents
33
Locations worldwide
900 1 500 1.500
Staff worldwide
Cli t Clients
TÜV SÜD Chemie Service GmbH
Business Unit Chemical, Oil & Gas: We are there when you need us – all over the world.
Glasgow Minneapolis Detroit Los Angeles Houston Texas
Antwerp
H d office Head ffi Germany G Milan
Beijing Shanghai Mumbai
Singapore
Key : Countries in which TÜV SÜD Chemie Service has representation TÜV SÜD Chemie Service Germany, Benelux, Italy, UK
TÜV SÜD South Asia Chemical Services
TÜV SÜD China Chemical Services
TÜV SÜD Chemie Service GmbH
TÜV SÜD PetroChem Inspection Services Inc.
TÜV SÜD Singapore Chemical Services
TÜV SÜD Chemie Service GmbH
BU Chemical, Oil & Gas: We have deep roots ...
TÜV SÜD Chemie Service GmbH
2005
Evolved from BAYER's Technical Inspection p Unit
2006
Acquisition of Signum Gesellschaft für Anlagensicherheit Acquisition of the materials / welding technology units of R&M Spezialitäten
2007
Establishment of TÜV SÜD China Chemical Services Acquisition of TÜV SÜD PetroChem Inspection Services
2008
Establishment of TÜV SÜD Benelux Chemical Services
2009
Establishment of TÜV SÜD Singapore Chemical Services Acquisition of the Technical Inspection Unit of DOW Olefinverbund
2010
Establishment of TÜV Ü SÜD Ü Italia Chemical Services
2011
Establishment of TÜV SÜD South Asia Chemical Services
2012
Integration of TÜV SÜD NEL
... and a solid foundation – TÜV SÜD.
800
L ti Locations worldwide ld id
1 700 1,700
Milli Millions in i revenues in i 2011
17 200 17,200 25%
St ff worldwide Staff ld id
40%
35% Industry
TÜV SÜD Chemie Service GmbH
Mobility
Certification
Chemical Business Unit Chemical, Oil & Gas is part of the Industry Segment.
Thank you for your attention! You find us:
ACHEMASIA 2013 Booth P21
www.tuev-sued.de
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