Chinese Pressure Equipments Manufacturers Approval

- How to Achieve Acceptance by Western End User

Liu Kai

CSSOPE
Beijing
May 22, 2013

TV SD 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
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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 20C
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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Welders 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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TV SD
BU Chemical, Oil & Gas
Expertise Responsibility
Expertise.
Responsibility. Trust
Trust. Sustainability
Sustainability.

TV SD Chemie Service GmbH

19.07.2013

Business Unit Chemical, Oil & Gas:

In figures

Continents

33

Locations
worldwide

900
1 500
1.500

Staff worldwide

Cli t
Clients

TV SD 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 TV SD Chemie
Service has representation
TV SD Chemie Service
Germany, Benelux, Italy, UK

TV SD South Asia
Chemical Services

TV SD China
Chemical Services

TV SD Chemie Service GmbH

TV SD PetroChem
Inspection Services Inc.

TV SD Singapore
Chemical Services

TV SD Chemie Service GmbH

BU Chemical, Oil & Gas:

We have deep roots ...

TV SD Chemie Service GmbH

2005

Evolved from BAYER's Technical Inspection

p
Unit

2006

Acquisition of Signum Gesellschaft fr Anlagensicherheit

Acquisition of the materials / welding technology units of
R&M Spezialitten

2007

Establishment of TV SD China Chemical Services

Acquisition of TV SD PetroChem Inspection Services

2008

Establishment of TV SD Benelux Chemical Services

2009

Establishment of TV SD Singapore Chemical Services

Acquisition of the Technical Inspection Unit of DOW
Olefinverbund

2010

Establishment of TV
SD
Italia Chemical Services

2011

Establishment of TV SD South Asia Chemical Services

2012

Integration of TV SD NEL

... and a solid foundation TV SD.

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

TV SD 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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