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Containers and pipelines classified according to safety

regulations:
Planning, production and assembly
Guideline for Swiss nuclear installations ENSI-G11

Edition February 2009, Revision 2 of 1 June 2013
Containers and pipelines classified according to safety regulations:
Planning, production and assembly
Edition February 2009, Revision 2 of 1 June 2013
Guideline for Swiss nuclear installations ENSI-G11/d

content
Guideline for Swiss nuclear installations ENSI-G11/d
1 introductory remarks 1
2 Subject matter and scope 1
3 Legal basis 1
4 Basic requirements 2
4.1 building regulation 2
4.2 design specification 3
4.3 component categorization 3
4.4 hazard analysis 3
4.5 Supervision by the supervisory authority 4
4.6 Monitoring by the expert 4
5 planning 5
5.1 principles 5
5.2 Material, semi-finished product and welding filler material 5
5.3 Precautions for operation and handling 6
6 preliminary examination 7
Manufacture of materials, semi-finished products and welding
6.1 consumables 7
6.2 Design and construction 7
6.3 Manufacture of components 8
6.4 Assembly of components and systems 8
7 Production and assembly 9
7.1 Qualification of manufacturing processes 9
7.2 Certification of materials, semi-finished products and
Welding filler materials 10
7.3 manufacturing tests 10
7.4 divergences 11
7.5 rectifications 11
7.6 label 11
7.7 construction supervision 11
8 documentation 13
8.1 building documentation 13
8.2 instruction manual 14
9 List of references 14
Appendix 1: Terms (according to ENSI glossary) 16
Annex 2: design specification 19
Annex 3: hazard analysis 22
Annex 4: pretest documents 23
Annex 5: Qualification and construction supervision 26
1 introductory remarks
The Federal Nuclear Safety Inspectorate (ENSI) is the supervisory authority for nuclear safety
and security in Switzerland. In its capacity as supervisory authority or on the basis of a
mandate in a regulation, it issues directives. Guidelines are enforcement aids that concretize
legal requirements and facilitate uniform enforcement practice. In addition, they concretize the
current state of science and technology. ENSI may allow deviations in individual cases if the
proposed solution is at least equivalent in terms of nuclear safety and security.
2 Subject matter and scope

This directive regulates the detailed requirements for the planning, manufacture and
installation of safety-related vessels and pipelines, their supports and pressure-retaining
equipment for use in Swiss nuclear facilities (BRK). It shall also apply to core internals and to
safety equipment. The regulations concern modifications and repairs.
BRK and core internals belong both to the main mechanical components according to Art. 26
Para. 1 Bst. b of the Nuclear Energy Ordinance (KEV, SR 732.11) and to the mechanical
equipment MA and MB according to Annex 4 KEV.
The detailed requirements for the maintenance of BRK and core internals are subject to the
ENSI-B06 guideline; those for ageing monitoring are regulated in the ENSI-B01 guideline. The
requirements for transport and storage containers are contained in the ENSI-G05 guideline.
3 Legal basis
This Directive implements the following legal basis:
Art. 3 para. 2 of the Ordinance on Safety-related Containers and Pipelines in Nuclear
Installations (VBRK, SR 732.13).
Directive ENSI-G11/d
Containers and pipelines classified according to safety regulations: Planning, production and assembly
February 2009, Revision 2 of 1 June 2013 1
4 Basic requirements
The elimination or reduction of hazards arising from the operation of components can be
achieved by good design and construction, safety analysis and careful selection of materials.
The licence holder of a nuclear installation must comprehensively monitor and prove the quality
of the materials and components by means of targeted tests and inspections during planning,
manufacture and assembly. Suppliers and manufacturers must work according to a quality
management system that meets the nuclear requirements.
Protective measures are to be designed in such a way that the operation and maintenance of
the components are guaranteed without restrictions. Protective measures include in particular
shielding, insulation, equipment with a safety function and mechanical protective devices.
4.1 Building regulation1

The following regulations are approved as building regulations for planning, production and
assembly:
a. ASME Boiler and Pressure Vessel Code, Section III, Division 1
b. KTA safety standards
In particular, the regulations in ASME III, subsection NB to NG and KTA 3201, 3211, 3301 and
3401 apply.
Within a system only one of the building regulations according to letter a or letter b may be
used for components of safety classes SK1 to SK3. Excluded from this regulation are
components of the SK3 which were previously designed and built in accordance with building
regulations for non-nuclear applications. For these components as well as for components of
the SK4 recognized non-nuclear building regulations can be used.
For PWR systems, the requirements of the SK1 Construction Specification for Components
shall be applied to the secondary side of the steam generator with the connected live steam
and feed water lines up to and including the first insulation device as well as its supports and
suspensions.
This Directive lays down additional requirements to those laid down in the building codes. If
the above building regulations do not contain any regulations or deviations are defined, the
specific requirements shall be defined accordingly in the design specification.
1
Version according to Revision 2 of 1 June 2013
2 February 2009, Revision 2 of 1 June 2013
4.2 Design specification2
The licence holder of a nuclear installation is responsible for the preparation and content of
the design specification and for updating it. It may entrust third parties with the preparation of
the specification. In the case of modifications to components and parts as well as in the
procurement of spare parts, the design specification must be checked and, if necessary,
updated to the current state of the art.
As a rule, a specific design specification is required. For similar components (e.g. valves), a
basic specification (standard specification) can be supplemented by component-specific detail
specifications.
The design specification contains all information on the technical, quality-related and
organisational requirements for the component which are necessary for the manufacturer to
carry out his order and to define his responsibilities. For official supervision and monitoring by
the expert, the requirements in accordance with this guideline shall be taken into account in
the design specification.
Annex 2 shows the structure and content of a typical design specification.
4.3 Component categorization3

In the design of components, their components shall be classified into three categories,
namely:
a. safety-relevant pressure-retaining components
b. safety-relevant functionally important components
c. Non-safety-relevant components
4.4 Hazard analysis4

A hazard analysis must be prepared for all components during planning. The legal
requirements for occupational safety, radiation, health and accident protection must be
observed in all phases of assembly, commissioning and operation of the components until
after their decommissioning.
In addition to the intended use, the hazard analysis must also take into account possible
mistakes by the operating and maintenance personnel. The local conditions during operation
and maintenance of the components must be observed. Measures such as shielding, filters,
accessibility, radiation protection zones,
2
3
4
Lifting equipment and platforms must be defined and taken into account in the planning in such
a way that the safety of the personnel is guaranteed at all times.
Measures must be defined for the hazards identified which must be taken into account during
manufacture and assembly of the components. Possible residual risks for all operating states
of the components are listed in the operating instructions and specific measures and rules of
conduct are to be described.
Annex 3 shows the structure of a typical hazard analysis.
4.5 Supervision by the supervisory authority5

Design specification, component categorisation and hazard analysis belong to the search
documents of hierarchy level M2. They may be submitted separately to the supervisory
authority for examination.
In the case of minor changes in accordance with Art. 5.1.3 ENSI-A04 and thus with the
simplified form of approval, the design specification and the component categorisation must
be submitted to the supervisory authority. In the case of extensive changes in accordance with
Art. 5.1.3 ENSI-A04 and thus release at four hierarchy levels (M1 to M4), the design
specification, component categorisation and hazard analysis must be submitted to the
supervisory authority.
4.6 Monitoring by the expert6

In addition to supervision by the authority, the manufacture and assembly of the BRK and the
core internals are subject to supervision by an accredited Type A inspection body designated
by the supervisory authority in accordance with ISO/IEC 17020 (experts). The monitoring
comprises the examination of the design review documents (design review), the monitoring of
production and assembly as well as the examination of the documentation (construction
supervision).
The expert shall be subject to supervision:
- Pipelines of SK1 > DN 25 (1"), SK2 > DN 50 (2") and SK3 > DN 100 (4")
including their connected components
- Tanks of SK1 to SK3 as far as p-V > 1 (p: design overpressure in bar,
V: Volume in m3)
For heat exchangers, the criterion p-V shall be applied separately to the
primary and secondary sides. If it is fulfilled for one side, the entire heat
exchanger is subject to monitoring by the expert.
5
new chapter according to Revision 2 of 1 June 2013
6
- Safety valves of the monitored pipelines and vessels of SK1 to SK3
5 Planning7
5.1 principles
The minimum required safety surcharges can be found in the building regulations. Surcharges
to take into account the effects of corrosion, erosion, embrittlement and material fatigue must
be selected in such a way that the safety of the components is guaranteed at all times until
they are shut down.
Calculation design programs shall be validated in accordance with the state of the art and with
regard to their application. Their suitability shall be demonstrated to the authorized inspector
within the framework of the design review documents.
5.2 Material, semi-finished product and welding filler material

Materials, semi-finished products and welding consumables shall be procured in accordance
with the building regulations and taking into account the additional requirements of this
Directive. In addition to the materials approved by the design specification, other materials
suitable for nuclear applications and specified in technical standards may also be used,
provided that they meet the requirements of the design specification. In addition to the
requirements of the building regulations, the requirements listed below shall be complied with
when procuring the materials.
5.2.1 Limitation of cobalt content

In the case of austenitic materials and welding consumables which come into contact with the
primary water, the cobalt content (co-content) shall be limited as follows:
a. Materials in the neutron field of the reactor
core Co-content 500 ppm (0.05 %)
b. Tubes of steam generators, reheaters and HP preheaters (SWR) Co
content 1 000 ppm (0,1 %)
c. Other plant components Co-
content 2 000 ppm (0,2 %)
7
5.2.2 trace element contents
The contents of embrittlement- and corrosion-promoting trace elements (phosphorus, sulphur,
copper) for BRK and core internals of the mechanical safety classes SK1 and SK2 are to be
limited according to the "Supplementary Requirements" of the ASME Code (Section II, Part A
to D). When EN materials are used, the requirements of KTA (3201.1, Chapter 3.2.4.2 or
3211.1, Table A 1-1) shall be met.
5.2.3 auditability
The material quality shall be selected in such a way that the prescribed manufacturing and
weighing recovery tests can be carried out without restriction.
5.2.4 Verification of high-temperature strength properties

For safety-relevant pressure-retaining components of SK 1 and SK 2, an additional hot tensile
test at design temperature TA is specified for each required tensile test at room temperature T0
for design temperatures above 150°C (for heat-treated bolt material at design temperatures
above 300°C). The yield strength at elevated temperatures Rp0.2 (TA) and the tensile strength
at elevated temperatures Rm (TA) must be verified.
The specified minimum values for the hot tensile strength shall be either Su values according to
ASME, Section II-D, Table U, or modified specific minimum values calculated as follows (also
applies to heat resistant materials according to EN standards):
Rm (TA) = 1.1 - Rm (T0) - Rp0.2 (TA) / Rp0.2 (T0)
5.3 Precautions for operation and handling

The recurring inspections in accordance with Annex 2 VBRK are regarded as necessary
inspections. Shields, insulations or mechanical protective devices shall be designed in such a
way that they can be dismantled and reassembled for the performance of maintenance work
without unacceptable radiation exposure. The components must be designed so that they can
be cleaned and decontaminated.
For weld seams at BRK of the mechanical safety classes SK1 and SK2, which are subject to
volumetric testing within the scope of operation (ultrasonic and X-ray tests), notch-free, flat
sheet metal grinding of the top layers and seam transitions is required. These weld seams
must be designed in such a way that they can be tested with manipulators.
On safety-relevant fittings, nozzles and fittings of the mechanical safety classes SK1 and SK2,
cylindrical test surfaces are to be provided as allowances for weld seams requiring inspection
using ultrasonic methods. The width of the test surfaces depends on the valid set of rules.
6 preliminary examination
The design review is a review of technical documents prior to the manufacture or assembly of
components (application documents of hierarchy M3 according to Annex 4 KEV). The
preliminary inspection is prescribed for modifications and repairs and is carried out on the basis
of the search documents of hierarchy M2 approved by the supervisory authority, taking into
account official requirements, regulations, building regulations, standards and specifications.
Preliminary inspection documents (VPU) shall be prepared for:
a. Manufacture of materials, semi-finished products and welding consumables
b. Design and construction
c. Manufacture of components
d. Assembly of components and systems
Requirements regarding the form and content of specific VPUs can be found in Appendix 4.
For the monitoring area pursuant to Section 4.6, the VPUs must be submitted to the expert
commissioned by the supervisory authority for examination in good time before the start of
production.
6.1 Manufacture of materials, semi-finished products and

welding consumables
The following documents, if applicable, shall be submitted to the expert:
a. material specification
b. heat treatment plan
c. Specification for non-destructive testing
d. specimen-taking plans
e. Specifications for heat treatments and special deformation and forming
processes
f. Specifications for reworking
g. Drawings as well as production and test sequence plans
6.2 Design and construction

a. Design drawing and parts lists with information on materials and semi-
finished products for tanks, heat exchangers, pumps and valves
b. System circuit diagram, design drawing and parts lists with information on
materials and semi-finished products for pipelines (type of pipes and fittings)
c. Calculation report on dimensioning, stress and fatigue analysis, earthquake
safety proofs
6.3 Manufacture of components

a. Assembly drawings, supplementary drawings and isometric drawings
b. List of materials, list of welding points
c. Construction test plan (production and test sequence plan)
d. Specification for heat treatments and special forming or shaping processes
e. Pickling and cleaning specification
f. Specification for pressure tests
g. Specification for functional tests, adjustment tests, quantity measurements
h. Specification for welds, procedure tests, batch tests of welding filler
materials
i. Specification for non-destructive testing
j. Specification for reworking
6.4 Assembly of components and systems

a. Drawing with parts list
b. List of materials, list of welding points
c. Assembly and test sequence plan (installation instructions)
d. Specification for welds, procedure tests, batch tests of welding filler
materials
e. Specification for pressure tests, functional tests, adjustment tests, quantity
measurements
f. Specification for non-destructive testing
g. Specification for reworking
h. installation specification
7 Production and assembly8
The licence holder is basically responsible for the quality of the source material and the quality
of the manufactured and assembled components, including compliance with the relevant
regulations and the completeness and technical correctness of the documentation. The
supervision of the expert commissioned by the supervisory authority essentially consists of the
supervision of special manufacturing processes and tests as well as the examination of the
documentation. The scope of testing of the expert in the context of the manufacture and
assembly of the BRK and core internals refers to the monitoring area in accordance with
Chapter 4.6 and is specified in Annex 5. The necessary documents shall be submitted to the
expert for inspection in good time before the work is carried out.
7.1 Qualification of manufacturing processes

Qualifications of forming processes as well as welding process, welder and manual skill tests
are subject to the supervision of the authorized inspector in accordance with Table 5-1.
Qualifications must be carried out on the basis of tested specifications and test plans.
The qualification of personnel, equipment and working procedures for the production of welded
joints required in accordance with Annex 1 No. 3.1 VBRK is generally given by:
a. the use of qualified welders who meet the requirements of the building
regulations or who are tested and qualified in accordance with ASME IX, EN
287, ISO 9606 or EN 1418.
Additional requirements from the construction regulation must be taken into
account.
b. the use of calibrated and periodically monitored welding equipment
c. the use of welding procedures qualified in accordance with the construction
regulation or in accordance with ASME IX or EN ISO 15614.
Additional requirements from the construction regulation must be taken into
account.
d. the use of approved welding filler materials in accordance with building
regulations
e. the application of tested specifications, welding plans and work instructions
In addition to the valid welder's examination, the welder must pass a manual skill test for
assembly welds on safety-relevant components.
8
The test piece to be welded should represent the most difficult welding seam and welding
position. The manual skill test shall be performed under the supervision of the authorized
inspector. The criteria for a successful manual dexterity test shall be laid down in writing in
advance.
Welders who do not pass the manual skill test shall be barred from producing welds on safety-
relevant components.
7.2 Certification of materials, semi-finished products

and welding consumables
The tests required in accordance with the building regulations and delivery standard are
listed in Table No.
5-2 and 5-3.
The manufacturing operations and tests to be documented by 3.2 certificates in accordance
with EN 10204 are subject to on-site monitoring by the expert of the supervisory authority and
are to be stamped with the personal identification by the expert.
For the manufacturing operations and tests to be documented by 3.1 certificates in accordance
with EN 10204, the expert of the supervisory authority generally checks the documentation.
Certified Material Test Reports (CMTR) according to the requirements of ASME III NCA 3860
are accepted instead of a material certificate 3.1 according to EN 10204.
Unless otherwise specified in the delivery or material standard or in the building specification,
material properties per batch shall be verified.
7.3 manufacturing tests

The necessary manufacturing tests in accordance with the building regulations and the
additional requirements specified in this Directive in accordance with Chapter 5.2 must be
carried out, recorded and certified in accordance with Table 5-2.
The performance and timing of the tests are determined by the design specification. Unless
otherwise specified in the design specification, the tests shall be performed in the discharge
state or after the last heat treatment. Non-destructive tests and dimensional checks performed
during the manufacture of larger components can also be replaced by intermediate tests during
production.
Only test equipment and measuring instruments which are calibrated at least once a year and,
if necessary, also adjusted are to be used. The factory or working standard must be subject to
periodic inspection by accredited testing and calibration laboratories in accordance with
ISO/IEC 17025.
The qualification of personnel, equipment and test procedures required in accordance with
Annex 1 No. 3.2 VBRK shall generally be performed and demonstrated in accordance with the
requirements of the construction regulation.
As an alternative, testing personnel can be employed who are qualified and certified at level 2
according to EN ISO 9712.
7.4 divergences
If nominal values or specified requirements are not achieved or deviations are found during
manufacture and assembly, this must be documented in the form of complete deviation
reports. The deviation report shall be examined by the expert. The test shall be entered in the
test plan. In the event that the deviation is left as it is, the admissibility must be justified.
7.5 rectifications
Improvements to the materials and semi-finished products as well as to the manufacture and
assembly of Category a and b components require deviation reports and are subject to
supervision by the expert of the supervisory authority. In the case of extensive subsequent
improvements, a test plan shall be prepared which shall be reviewed by the authorized
inspector. Repeated rectifications require the approval of the expert.
7.6 label
In order to ensure traceability from raw material to finished part, semi-finished products,
specimens, parts and components must be marked permanently. The requirements of Annex
1, No. 3.3 VBRK and the building regulation must be fulfilled.
7.7 construction supervision

The essential requirements of Annex 1, point 3.2 VBRK must be fulfilled.
Table 5-4 in Annex 5 shows the scope of construction supervision by the expert appointed by
the Supervisory Authority. These acceptances shall be included in the test plan as stopping
points. The control of the acceptance is confirmed by the expert with personal stamp and
signature in protocols and test plans.
7.7.1 final inspections

The final inspections required for acceptance shall be described in the design review plan and
performed accordingly.
Visual inspections shall be carried out after the pressure test with the authorized inspector as
internal and external inspections.
The design of the components and parts shall be checked on the basis of acceptance drawings
in the presence of the authorized inspector. The design mass (e.g. wall and weld seam
thicknesses, nozzle positions) as well as important installation masses are to be checked and
documented by means of dimensional checks. Any deviations found shall be documented ("as-
built" drawing), checked for admissibility and assessed.
For piping systems, "as-built" isometrics shall be recorded after assembly. The stress analyses
prepared for the piping systems shall be checked by means of as-built isometry and, if
necessary, supplemented.
7.7.2 pressure tests

Pressure tests shall be performed in accordance with a test specification tested by the
authorized inspector. All required non-destructive tests on welds must be carried out and
documented in advance.
The test specification shall contain at least the following information:
a. Requirements of the VBRK for the production and requirements of the
building regulation for the assembly
b. System diagram incl. test program with the pipe sections covered by the
pressure test with list of installed tanks, heat exchangers, pumps and valves
with data on system designation, manufacturer and serial number
c. Specification of test medium, test overpressure, test temperature, holding
time
d. Information regarding supply, venting, manometer connections
e. Criteria for assessing the examination
f. Type of certificate
7.7.3 functional checks

The planned functional tests shall be described in the construction test plan. For each test, a
specification with all the necessary information shall be drawn up, which shall be examined by
the authorized inspector within the framework of the design review.
8 documentation
The documentation of the design, manufacture and installation is part of the construction
documentation in accordance with Art. 27 KEV. The essential requirements in accordance with
Annex 1 No. 5 VBRK must be fulfilled.
All documents must be clearly marked so that they can be assigned to the individual BRKs
and core internals at any time and unmistakably. Particular attention must be paid to this:
a. unique designation with document number, revision index, issue date and
quality assurance signatures
b. Explanation of used abbreviations and symbols
c. Use of a recognised measuring system
d. Marking and explanation of changes
e. copyable and suitable for archiving
8.1 building documentation

The construction documentation for the planning, manufacture and assembly of components
shall include at least the following, clearly marked and tested documents:
a. Design specification and hazard analysis
b. pretest documents
c. completed inspection plans for each component provided with the
fabrication number of the component
d. Deviation reports and certificates of rectification (to be noted in the
inspection plan)
e. Certificates of all manufacturing operations and tests listed in the
construction test plan
f. Material certificates for components and welding consumables (to be
documented per component in the material list)
g. Reports on procedure tests, welder tests, batch testing of welding filler
materials, qualification of manufacturing processes
h. construction supervision report
If individual parts of components are prefabricated, they must be documented accordingly.
8.2 instruction manual
The essential requirements of Annex 1, point 3.4 VBRK must be fulfilled. Notes on the content
and creation of operating instructions can be found in VDI Guideline 4500.
9 List of references
This Directive refers to the following principles:
a. ASME Boiler and Pressure Vessel Code, Section III

Rules for Construction of Nuclear Facility Components, Division
1 Subsection NB, Class 1 Components
Subsection NC, Class 2 Components
Subsection NCA 3860, Certification Requirements
Subsection ND, Class 3 Components Subsection
NE, Metal Containment Vessels Subsection NF,
Support Structures Subsection NG, Core Support
Structures
b. ASME Boiler and Pressure Vessel Code, Section

II Materials
Part A to D
c. ASME Boiler and Pressure Vessel Code, Section IX

Welding and Brazing Qualifications
d. KTA safety standards
KTA 3201 Components of the Primary Circuit of Light Water Reactors
Parts 1 to 3, Materials and Product Forms, Design,
Construction and Calculation, Fabrication
KTA 3211 Pressure- and Activity-Retaining Components of Systems
Outside the Primary Circuit, Parts 1 to 3, Materials and Product
Forms, Design, Construction and Calculation, Manufacturing
KTA 3301 Post-heat removal systems of light water reactors
KTA 3401 Steel Reactor Containers, Parts 1 to 3, Materials and Product
Forms, Design, Construction and Calculation, Manufacture
e. Technical standards
EN 287 Testing of welders
EN ISO 9712 Non-destructive Testing - Qualification and
Certification-
of personnel for non-destructive testing
EN 1418 welding personnel
EN 10204 Metallic products - Types of test certificates-
tions
EN ISO 9606 Testing of welders
EN ISO 15614 Requirements and qualification of
welding processes
for metallic materials - Welding procedure tests
ISO/IEC17020 General criteria for the operation of different Ty-
of bodies carrying out inspections
ISO/IEC 17025 General requirements for the competence of
Testing and calibration
laboratories VDI Guideline 4500 Technical
documentation
Revision 2 of the Directive was adopted by ENSI on 1 June 2013.

The Director of ENSI: sign. H. Wanner
Appendix 1: Terms (according to ENSI glossary)
component
A component is an individual part of a component. A group of components that serve a purpose
in interaction is considered a component.
attestation
A certificate is a paper document that contains a positive statement about an audit or other
document. Certificates can consist of certificates, minutes, attestations or certificates.
manufacture
According to VBRK production includes all measures for the production of material, semi-
finished products and components as well as the assembly of the components in the
manufacturing company.
repair
The repair includes all measures to restore the target state of technical means of a system as
well as measures to return them to their functional state.
core internals
Core internals are internals in the reactor pressure vessel which serve to support, guide and
hold the elements of the reactor core (fuel elements, control rods, etc.) as well as the guidance
of the primary medium.
component
A component is a self-contained part of a system that performs a specific function. Examples
are Tanks, pumps, shut-off valves, heat exchangers, pipelines, supports (including steel
construction)9, suspensions, vibration dampers.
Mechanically active component10

Mechanically active is a component with moving parts whose function is required during and
after a malfunction. Mechanically active components must be tight and functional during the
load case. The incidents in which functional safety must be maintained are specified in detail
in the specification.
9
10
inserted within the framework of Revision 2 of 1 June 2013
Mechanical equipment MA
Mechanical equipment MA are components with influence on the 1st construction approval.
MA equipment includes reactor pressure vessels, primary circuit lines, pressurizers, main
coolant pumps, steam generators and steel containments.
Mechanical equipment MB
Mechanical equipment MB are the other components of the mechanical safety classes SK1 to
SK4.
assembly
Assembly is the installation of a component in the nuclear installation.
rework
A rework is the removal of a deviation if the production was defective.
repair
Repair is understood to mean a repair. These are technical measures taken on defective
components or component parts to restore the specified target condition.
Safety-relevant pressure-retaining components

Safety relevant pressure retaining components are parts of components which are relevant for
integrity and safety. These include in particular pipelines, containers, housings of valves and
pumps, flanges, covers and screws. 11
Safety-relevant functionally important components

Safety-relevant functionally important components are parts of components that are relevant
for the function and safety of the components. This includes in particular the functional parts
of pumps, valves, pipelines and containers as well as their installation.
Safety classified vessels and pipelines in nuclear installations (BRK)12

BRK are tanks, pipelines, fittings and pumps, including their pressurised equipment such as
flanges, nozzles and couplings as well as their supports, brackets and supporting elements.
BRK also includes safety equipment such as safety valves and bursting discs as well as limiting
devices such as pressure, temperature and fluid level switches.
11
12
inserted within the framework of Revision 2 of 1 June 2013
system
A system is a combination of mechanical or electrical components required to perform a
particular function.
Annex 2: design specification
The specification shall contain information on the following points:
a. Scope of the specification
Exact component designation, interfaces to other components or building
structures.
b. Organizational specifications
Obligations of a technical and organisational nature to clearly delimit the
responsibilities of the purchaser, manufacturer or third party in relation to the
specified delivery requirements. Obligations of the participants vis-à-vis the
supervisory authority and the monitoring organisation designated by it.
c. Building regulations and supplementary principles
Establishment of binding regulations (building regulations, standards) for the
design, materials, manufacture and testing of components.
d. Description of the component
System designation, plant designation, safety-related classification,
earthquake class, tasks and mode of operation, operating modes,
designation as mechanically active or inactive component, designation of
component categories.
e. design principles
All data required for the determination of the constructive design and the
main dimensions of the component, for the material selection and for the
calculation of the component such as:
Design and operating data (pressures, temperatures, flow rates, etc.),
accident data (pressures, temperatures, pressure and temperature
transients, accelerations, etc.), medium data, environmental conditions
(pressure, temperature, humidity, radiation, etc.) for normal and accident
conditions, expected service life.
f. materials
Requirements regarding materials, material specifications and material testing
such as: Material selection, material designations, material acceptance
documents (material specifications, sampling plans and lists), tests and test
certificates, semi-finished products and welding consumables, hot tensile
specimens and material lists.
g. Constructive design
Requirements on the constructive design with regard to maintenance and
repeat tests, ageing monitoring and corrosion protection, information on
standard parts (flanges, gaskets, screws etc.), actuators of valves, execution
of wall thickness transitions, supports and anchorages.
h. calculations
Requirements for design calculations and stress analyses, such as
information on loads, transients, load combinations (for standard operation
and accident conditions), influence and consideration of the surrounding
medium on the safety margins, in particular for fatigue design.
i. manufacture
These include, among other things: Requirements for the start of manufacture,
choice of manufacturing process, information on welding, shaping processes
and heat treatments, marking of semi-finished products, finished parts, welds
and fittings, carrying out repairs and assembly procedures.
j. final inspections
All tests and trials carried out during acceptance and commissioning of the
component shall be specified. These include pressure, leakage and
functional tests, test runs and endurance tests of mechanically active
components, other tests with mechanically active components such as
determination of characteristics, dynamic behaviour, emergency running
properties, tests to prove integrity or operating behaviour under
earthquake loads.
k. Drying, cleaning, preservation and surface protection
Specific requirements for drying, cleaning and preserving the component
and surface protection.
l. Packaging and shipping
Specific requirements regarding packaging and transport of the component
to prevent corrosion, damage and contamination.
m. quality assurance
The requirements for the manufacturer's quality assurance measures and
the documents to be prepared shall be specified.
n. documentation
Requirements for the construction documentation (Art. 27 KEV), the quality
controls performed and the acceptance and commissioning tests performed
shall be specified.
o. References and Supplements
A list shall include all references with document number, author, title, date
of issue and revision index.
Annex 3: hazard analysis
The following points must always be dealt with in the hazard analysis:
a. Definition of the scope of application of the component
b. Identification of hazards
c. Determination of the hazard potential
d. Determination of security measures
e. Definition of test criteria for safety measures
f. Processing of residual risks (operating instructions)
Annex 4: pretest documents
Preliminary test documents must be prepared for all safety-relevant parts and components in
the event of modifications and repairs. They must be clearly marked so that they can be
assigned to the individual components at any time and unmistakably.
Detailed information on the content of selected design review documents is set out below.
A4.1 material specification

The material specification includes all requirements for procurement, manufacturing and
testing of materials and semi-finished products, such as:
a. Product form, e.g. forging, bar steel, casting
b. Scope of application and mechanical safety class, building regulations,
directives
c. Material designation according to standard
d. Information on heat treatment and surface properties
e. Requirements for material identification
f. Handling of rework and deviations
g. Packaging requirements
h. Information on the scope of testing, tests subject to acceptance, required
certificate
i. Detailed information on material testing such as scope of testing in
accordance with building regulations, design specification, material
characteristics (nominal values, etc. for chemical, mechanical and electrical
properties, etc.), etc. Analysis, tensile strength, hardness, notched bar
impact strength), material sample (number, type, direction, position,
identification of samples), test conditions (test method, test temperature, test
lot, possibly test specification)
A4.2 material list

In the material list, all requirements for the documentation and testing of the material
designations and material identification shall be specified in tabular form:
a. Listing of components with indication of position; number, article number,
dimension, designation, component category, material designation, material
specification, material standard, product form requirements, required
certificate, marking of acceptance by manufacturer, expert or customer
b. Columns for the acceptance of the documentation with heat and sample
number, component identification, test note/evidence check by
manufacturer, purchaser and expert
A4.3 list of welding joints

All information for the final identification of the weld seams must be specified in the weld joint
list. That includes: List of welding points with indication of position, designation, component
category, welding filler material, material specification, required certificate, marking of
acceptance by manufacturer, expert or purchaser.
A4.4 Construction test plan (production and test sequence plan)

Construction test plans are to be drawn up separately for plant production and construction
site production with a list of the production and test steps in chronological order. The order is
binding, a change requires the agreement of the expert.
General information
a. Manufacturer, plant, component or assembly designation, if known,
component number according to plant identification system
b. assembly drawing number
c. Safety and earthquake class
d. Design specification and building regulation
e. Number of the corresponding material list
For each production step

a. receiving inspection
b. Numbering of the production steps or the welding seam
c. Name and description of the manufacturing step
d. Specifications, standards, drawings to be applied
e. Implementation by the manufacturer or subcontractor
f. Acceptance by manufacturer, expert or purchaser
g. Inspection of documentation by manufacturers, experts or operators
h. Welding: Reference to welding plan with details for welding procedure
qualification, welder qualification and batch testing
i. Stop points for customers, manufacturers and experts
A4.5 calculation report
The calculation report shall contain the following information:
a. Scope: Indication of the components or parts to which the calculation
applies.
b. applicable design specification and construction regulation
c. Explanation of the procedure and assumptions made
d. Calculation methods, theoretical basics and the used programs
e. Load data: Load combinations and their classification
f. geometrical data and material properties used
g. Presentation of the results
h. Evaluation of the results, comparison with the permissible values
i. References, literature references, references, technical delivery and
acceptance conditions of the purchaser
Annex 5: Qualification and construction supervision
Table No. 5-1 Qualification of manufacturing processes
Table 5-1 regulates the scope of testing of the authorized inspector commissioned by the
authority in the qualification of procedures for manufacture, assembly and repair. The scope
of testing refers to the safety-relevant parts and components whose manufacture is monitored
by the authorized inspector in accordance with Chapter 4.6. In special cases, the supervisory
authority may require additional monitoring steps.
Positions designated by X shall be included as breakpoints in the design review plan
(production and test sequence plan).
welder examination
Manual skill test (welder)

Procedure test (welding)
shaping
Monitoring by the expert
proceed
Incoming inspection of materials, semi-finished products and
welding filler materials
X X X X
materials
Material Certificates and Material Identification X X X X
Material re-stamping / marking of test pieces X X X X
Handling of welding filler materials X X X
Qualification of welders X X13

seam preparation X X X
procedure execution X X X X
Heat treatment, temperature control X X
Non-destructive testing according to the procedure X X X X
Execution control according to the procedure X X X X
Identification of the specimens X X X X
Control of the chemical analysis of the weld metal14 X
Mechanical-technological tests X X X X
Documentation check for completeness and correctness15 X X X X
13
new according to Revision 2 of 1 June 2013
14
15
Certificates for the production of materials and semi-finished
Table No. 5-2 products
begetting16
SK 1 SK 2 SK 3
component
categories
scrutiny a b a b a b
Certification of the smelting process for forging
3.1 3.1 3.1 3.1 3.1 3.1
pieces with thicknesses > 100 mm
Confirmation of the standardized heat treatments and the
simulated heat treatment in accordance with building
regulations 3.21 3.1 3.21 3.1 3.1 3.1
finally the mechanical-technological tests
Chemical Analysis2 3.1 3.1 3.1 3.1 3.1 2.2

Analysis of castings and forgings with finished castings and
forgings
3.1 3.1 3.1 3.1 3.1 3.1
weights >500kg
Determination of grain size for austenitic materials 3.1 3.1 3.1 3.1 2.2
Determination of the delta-ferrite content in austenitic
3.1 3.1 3.1 3.1 3.1
materials
Intergranular corrosion test with medium wetted austeni-
3.2 3.2 3.1
materials
Tensile test3 3.21 3.1 3.21 3.1 3.1 3.1

Hot tensile test at design temperature3 3.21 3.21
Notched bar impact test3 3.21 3.1 3.21 3.1 3.1 3.1
Hardness test (min. 3 hardness indentations)3 3.21 3.1 3.21 3.1 3.1 3.1
Further mechanical-technological tests on pipes 3.21 3.1 3.21 3.1 3.1 3.1
pressure test 3.21 3.1 3.21 3.1 3.1 3.1
Volumetric testing (UT, RT) 3.21 3.1 3.21 3.1 3.1
Surface crack testing (PT, MT) 3.21 3.1 3.21 3.1 3.1
Verwechslungsprüfung 3.1 2.2 3.1 2.2 2.2 2.2
Visual inspection and dimensional control 3.21 3.1 3.21 3.1 3.1 3.1
identification control 3.21 3.1 3.21 3.1 3.1 3.1
1 Acceptance test certificate 3.1 with:
‐ Forgings, pipes, fittings and plates for components ≤ DN 50 (2")

‐ Bar material Ø ≤ 50 mm (2")
‐ Automated testing, e.g. ultrasonic testing of sheet metal and pipes
‐ Materials and semi-finished products for welding procedure tests and welder tests
‐ Screws, nuts and other fasteners ≤ M24 (1")
2 Chemical analyses: at least one sample per melt and quality
3 Mechanical-technological tests: At least one sample per melt, heat treatment lot and measurement
16
For bolts, nuts and other fasteners ≤ M12 (1/2") the tests do not have to be certified. Each
piece must be stamped with the manufacturer's mark and the quality of the material.
This applies to component category c:
The tests required by the design specification do not have to be certified. The licence holder
shall ensure that the correct material quality is used in accordance with the building
regulations, parts list or specification. Each piece must be marked with the manufacturer's
mark, the short name and quality of the material. 17
17
Table No. 5-3 Certificates for the manufacture of welding consumables
fabrics18
Welding filler materials for examinations SK1 SK2 SK3
-Joint welding seams on component category a

chemical analysis1 each
3.1 3.1 3.1
batch
mechanical technolo- 3 3
gical tests 2 3.2 3.2 3.1
-Joined welding seams on component category b

-Welded claddings on component categories a and b chemical analysis1 each
3.1 3.1 3.1
-Overlay welding on valve seats, sliding surfaces batch
-Welded joint seams on supports of me-
chanically active BRK
-non-pressure-bearing joint welds on componentka-
tegorie a mechanical technolo-
-Procedure and welder tests on component categories gical tests 2 3.1 3.1 3.1
a and b
joint welding seams and build-up welds at
Component
category c chemical analysis1 each
2.2 2.2 2.2
-Welded joint seams on supports of me- batch
chanically inactive BRK
-Temporary welds
mechanical technolo-
gical tests 2 2.2 2.2 2.2
1 For austenitic CrNi welding consumables, the delta ferrite content must also be certified.
2 Notched bar impact bending test only for ferritic weld filler materials
3 Acceptance test certificate 3.1 for welded joints for:
‐ Forgings, pipes, fittings and plates for components ≤DN 50mm (2")
18
Table No. 5-4 Scope of construction supervision19
Table 5-4 specifies the scope of construction supervision of the expert commissioned by the
supervisory authority for the manufacture, assembly and repair of safety-relevant parts and
components.
The positions indicated by X shall be included as stopping points in the design review plan
(manufacturing and test sequence plan). The expert monitors the manufacturing and testing
steps on site.
Manufacturing operation/testing/inspection SK1 SK2 SK3
Checks before starting work

Incoming inspection for materials, semi-finished products and welding
consumables X X
Material re-stamping for certificate 3.2 X X
Checks on the validity of procedures and qualifications
Batch testing of welding filler materials X X
welder qualifications X X
Qualifications of examiners for non-destructive testing X X
shaping processes
Implementation of the forming process X X
Execution of heat treatments X X
non-destructive testing after shaping X X
Welding
non-destructive tests before welding X X
Dimensional checks of the weld seam preparation X X
Carrying out the welding work X X
Execution of heat treatments X X
non-destructive tests after welding X X
Non-destructive testing
Carrying out the tests X X
19
dimensional control
Dimensional controls and as-built recording X X
Further inspections and tests
Checking the tightening torques of bolted connections X X
Visual inspection of parts and components X X
pressure test X X
functional checks X X
Repairs and improvements
Inspection of deviation report, inspection plan, etc. X X X
Non-destructive testing of the ground area X X X
Carrying out the welding work X X X
non-destructive testing after welding X X X
Documentation check after completion of the work X X X
Special checks
Special audits at the request of the supervisory authority X X X
documentation
documentation verification X X X
ENSI, CH-5200 Brugg, Industriestrasse 19, telephone +41 (0)56 460 84 00, fax +41 (0)56 460 84 99, info@ensi.ch, www.ensi.ch

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Containers and pipelines classified according to safety

Guideline for Swiss nuclear installations ENSI-G11

Guideline for Swiss nuclear installations ENSI-G11/d

2 Subject matter and scope

4.1 Building regulation1

4.3 Component categorization3

4.4 Hazard analysis4

4.5 Supervision by the supervisory authority5

4.6 Monitoring by the expert6

5.2 Material, semi-finished product and welding filler material

5.2.1 Limitation of cobalt content

5.2.4 Verification of high-temperature strength properties

5.3 Precautions for operation and handling

6.1 Manufacture of materials, semi-finished products and

6.2 Design and construction

6.3 Manufacture of components

6.4 Assembly of components and systems

7.1 Qualification of manufacturing processes

7.2 Certification of materials, semi-finished products

7.3 manufacturing tests

7.7 construction supervision

7.7.1 final inspections

7.7.2 pressure tests

7.7.3 functional checks

8.1 building documentation

a. ASME Boiler and Pressure Vessel Code, Section III

b. ASME Boiler and Pressure Vessel Code, Section

c. ASME Boiler and Pressure Vessel Code, Section IX

Revision 2 of the Directive was adopted by ENSI on 1 June 2013.

Mechanically active component10

Safety-relevant pressure-retaining components

Safety-relevant functionally important components

Safety classified vessels and pipelines in nuclear installations (BRK)12

A4.1 material specification

A4.2 material list

A4.3 list of welding joints

A4.4 Construction test plan (production and test sequence plan)

For each production step

Manual skill test (welder)

Material Certificates and Material Identification X X X X

Material re-stamping / marking of test pieces X X X X

Handling of welding filler materials X X X

Qualification of welders X X13

Heat treatment, temperature control X X

Non-destructive testing according to the procedure X X X X

Execution control according to the procedure X X X X

Identification of the specimens X X X X

Control of the chemical analysis of the weld metal14 X

Documentation check for completeness and correctness15 X X X X

Chemical Analysis2 3.1 3.1 3.1 3.1 3.1 2.2

Tensile test3 3.21 3.1 3.21 3.1 3.1 3.1

identification control 3.21 3.1 3.21 3.1 3.1 3.1

1 Acceptance test certificate 3.1 with:

‐ Forgings, pipes, fittings and plates for components ≤ DN 50 (2")

-Joint welding seams on component category a

gical tests 2 3.2 3.2 3.1

-Joined welding seams on component category b

Manufacturing operation/testing/inspection SK1 SK2 SK3

Checks before starting work

Material re-stamping for certificate 3.2 X X