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NO-HLD-10-T016-580070_rev00 - IFI

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IDESA
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33203 Gijón

CONTENTS

1. INTRODUCTION. OBJECT

2. GENERAL CHARACTERISTICS OF THE EQUIPMENT


2.1 Description of the pressure equipment
2.2 Intended used
2.3 Operating and design conditions
3. ANALYSIS OF RISKS
3.1 Identification of risks
3.2 Reduction of risks
3.3 Residual hazards

4. CLASSIFICATION OF FLUID AND VESSEL


4.1 Fluid
4.2 Pressure equipment
4.3 Category of the pressure equipment
4.4 Module for evaluating the compliance
4.5 Summary

5. ACTIONS WITH THE EQUIPMENT


5.1 Design pressure and temperature
5.2 Tolerances regarding thickness
5.3 Purging and ventilation system

6. STANDARDS
6.1 Base materials (for pressure parts)
6.1.1. Harmonised standards
6.1.2. Particular material appraisal
6.1.3. European approval of materials

7. MATERIALS
7.1 General concepts
7.2 Mechanical properties
7.3 Welding Materials

8. DESIGN
8.1 Calculation method
8.2 Allowable stresses
8.3 Stress level
8.4 Pressure of hydrostatic test
8.5 Calculations
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9. OPERATION ELEMENTS AND SAFETY ACCESORIES

10. MANUFACTURING PROCESSES


10.1 Welding processes and personnel
10.2 Pressure test
10.3 Protection of surfaces

11.TESTS AND VERIFICATIONS


11.1 Welding
11.2 Verification

12.MARKING (according to Annex I, point 3.3)

13.MANUFACTURER’S INSTRUCTIONS

14.SUMMARY OF ESSENTIAL SAFETY REQUIREMENTS

ANNEX 1.CALCULATIONS

ANNEX 2.DRAWINGS

ANNEX 3. SPECIFICATIONS OF MATERIALS

ANNEX 4. MANUFACTURER’S INSTRUCTIONS

ANNEX 5. MANUFACTURING PROCEDURES

ANNEX 6. APPROVAL OF THE PERSONNEL WHO MAKES THE NON-


DESTRUCTIVE TEST
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1. INTRODUCTION. OBJECT

The purpose of this documentation is to carry out a design examination and a assessment of
conformity of an equipment made up of a pressure device , within the scope of the European
Directive 97/23/CE passed on the 29th of May, 1997 (adopted in Spain by virtue of the RD 769/1999
transposed on the 7th of May).

As the maximum allowable pressure (PS) in the equipment, which is herein-below described, is
higher than 0.5 bar, it is included within the scope of application of the above-mentioned Directive, in
accordance with section 1, subsection 1 of said Directive.
It is not included within the exclusions of application mentioned in section 1, subsection 3. Thus, the
Directive may be applicable to this case.

This equipment is designed to be installed in NORWAY. Therefore, all the working and design
conditions fulfill the requirements specified in the NORWAY Regulations.

NOTE:

At the end of the summary of this dossier, there is an indication table which shows the relationship
of the different sections of Annex I of the Directive 97/23/CE (essential safety risks) and the
chapters of this dossier where each of them is specified.
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2. GENERAL CHARACTERISTICS OF THE


EQUIPMENT

2.1 DESCRIPTION OF THE PRESSURE EQUIPMENT

Cylindrical pressure vessel constructed of carbon steel


It is going to be specifically used as:
Compressed Air Receiver in Martin Linge Gas Field

The pressure vessel is mainly made up of a cylindrical body and two heads (refer to the drawings
attached to the dossier), with the following characteristics:

Manufacturing material P-355 NL2


Shape: Cylindrical
Position: Vertical
Diameter: 3300 (I.D.)
Length: 15950 mm (max. length)
Geometrical capacity: 119,7 m³.
Empty weight: 26,036 Tn
Weight full of water: 145,726 Tn
With holes to carry out its corresponding functions.
With supports in the expected position.
Shape of the heads: F1 Semielliptical 2:1
F2 Semielliptical 2:1

2.2 INTENDED USED.

Compressed Air Receiver

2.3 OPERATING AND DESIGN CONDITIONS


Maximum allowable pressure: 15,5 bar
Max. allowable temperature: 70 ºC
Min. allowable temperature: -10 ºC
Test pressure: 25,1 bar
Product:
Compressed Air
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3.- ANALYSIS OF RISKS


In accordance with the preliminary remarks of Annex I of the Directive, the analysis of the risks of
the equipment shall be carried out by manufacturer.

3.1 IDENTIFICATION OF RISKS.


Three risks are considered:
a) Increase/ Dicrease of pressure
b) Increase/ Dicrease of temperature
c) Increase/ Dicrease of flow
d) Increase/ Dicrease of level
e) Mechanical breakage.
f) Leaks of the stored product.
g) Fire.

3.2 REDUCTION OF RISKS

In accordance with chapter 1 of Annex I of the Directive, equipment is designed, manufactured and
controlled in such way that the vessel safety is guaranteed under reasonably-expected conditions and
in accordance with the manufacturer’s instructions.
With the purpose of reducing the risks derived from the cases mentioned above, a product has been
designed, taking into account the following concepts:
a) Increase/ Dicrease of pressure
- The installation of safeties pressure devices on the equipment shall be enough in order to
assure that the equipment will work in the conditions of pressure for which the equipment
was designed. See annex 4.
- In case of the equipment is working out of design pressure condition, there are a risk of
mechanical breakage.
b) Increase/Dicrease of temperature
- The installation of safeties temperature devices on the equipment shall be enough in order
to assure that the equipment will work in the conditions of pressure for which the
equipment was designed. See annex 4.
- In case of the equipment is working out of design temperature condition, there are a risk of
mechanical breakage.
c) Increase/Dicrease of flow
- The increase/Dicrease of the flow inside the equipment does not have any direct
consequence over the equipment, indirectly can carry out an increase/Dicrease of
pressure/temperature, in which case the previous points a and b must be considered.
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d) Increase/Dicrease of the level


- The installation of safeties related to the levels shall be made in such a way that the levels
are not surpassed for which the equipment was designed.
- In case of the equipment is working out of design levels condition, there are a risk of
mechanical breakage.
e) Mechanical breakage
- The appropriate election of materials, specific for pressure vessels. To see section 7.
- Accomplishment of calculations according to recognized design code for pressure vessels,
with classification of the vessels in attention to the existing risks. To see section 8.
- Election of an suitable system of inspection, according to the previous points (in agreement
with the EC directive and the design code). To see section 11.
- Accomplishment of test of resistance.
- Election of a suitable protection system that prevents the Dicrease of thicknesses due to
corrosion processes. To see section 10.
- The installation of safety and control devices in the equipment, shall be instaled in such a
way that they can assure the work conditions are within design conditions. To see annexed 4.
f) Leaks of the stored product.
- Watertightness in the connections of the tank.
g) Risks in case of fire.
- The risks that are derived from the declaration of a fire near of the vessel could be palliated
mainly through an appropriate installation with systems adapted against fires, establishments
of safe distances, etc....

3.3 RESIDUAL HAZARDS

The existence of residual hazards is not considered, because the persons who are going to be in
charge of controlling this equipment are qualified for performing said works.
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4.- CLASSIFICATION OF FLUID AND VESSEL


4.1 FLUID

Fluid Classification : it is included in group 2 in accordance with article 9 of the Directive.


It is Compressed Air according to the data sheet included in annex 6.

4.2 PRESSURE EQUIPMENT


· The equipment which is going to be manufactures is defined in the Directive as a pressure vessel, in
accordance with section 1, subsection 2.1, and it is included in the definition of vessel provided with
by section 1, subsection 2.1.1.
Classification of the vessel: It is included in the section 3, sub section 1,1 a).

4.3 CATEGORY OF THE PRESSURE EQUIPMENT


The category (section 9, point 1) of the vessel is obtained based on the tables included in Annex II,
and taking into account the maximum allowable pressure and the equipment volume (refer to section
2).
As the fluid is included in group 2 (as it has been previously stated), and the PSxV product is higher
than 50 bar x litre, table 2 of Annex II is applied, in accordance with the first comment of paragraph
a) of the subsection 1.1 of section 3 of the Directive.
With the values:
PS= 15,5 Barg
V= 119.700 Liters
Ps x V= 1.855.350 bar x liter.
From table 2 of Annex II, the category of the vessel may be obtained:
CATEGORY IV

4.4 MODULE FOR CONFORMITY ASSESSMENT


In order to carry out the Conformity Assessment in accordance with article 10, the Directive
establishes several possible procedures (modules) according to the category of the equipment.
Among the different options the Directive suggests (section 10, point 1.3)
for the established category, module G is chosen.
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4.5 SUMMARY

· Classification of fluid: Group 2


· Classification of vessel: It is included in the section 3, sub section 1,1 a).
· Category of the vessel: IV
· Module for the conformity assessment G
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5. ACTIONS WITH THE EQUIPMENT

Equipment is designed to bear the loads corresponding to the expected usage, and specifically, those
mentioned in the Directive, Annex 1, subsection. 2.2.1. For this purpose, the actions to be taken into
account are herein-below defined:

5.1 DESIGN PRESSURE AND TEMPERATURE


The inside design pressure will mainly be determined by the balance pressure between liquid-gas,
which is a function of the stored fluid temperature. With the maximum design temperature, fluid
exerts a maximum pressure of 15,5 bar.

Maximun pressure: 15,5 bar.


Maximun allowable pressure : 15,5 bar.

This will be the maximum inside pressure at which the equipment may work. Therefore, all the
necessary elements must be forecasted in order to guarantee that a higher value will not be achieved.
Said elements are the pressure devices which controls the opening and closure of the different
pressure control valves installed in the entrance lines.
Static pressure, caused by the liquid column, (both during operation as well as during test
performance) is taken into account for design purposes.

The minimum and maximum rated temperatures will be -10 / 70 ºC

5.2 TOLERANCES REGARDING THICKNESS


Inner corrosion: 3 mm
Outer corrosion: 0 mm
Wear and tear: as it is a static equipment, no wear and tear due the operation
will take place.

5.3 PURGING AND VENTILATION SYSTEM.


The vessel is purged/drained through nozzles N03 (3')' and N06 (4'')
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6.- STANDARDS

A.- DEPOSIT (SHAPE AND SIZE)


There are no harmonised standards.
Thickness will be determined by design pressure and temperature.

B.- SHAPE OF HEADS


The head F1 is Semielliptical 2:1. The size of these heads are mentioned in DIN 28013 Standard.
The material is P-355 NL2

C.- MATERIAL OF THE PLATE


The plate used for pressure equipment is P-355 NL2

D. MATERIAL OF THE NECKS OF NOZZLES.


The nozzle necks used for pressure equipment are P-355 NL2 / SA-333 Gr.6

E. MATERIAL OF FLANGES / FORGING.

The flanges used for pressure equipment are SA-350 LF2 Cl.1

6.1 BASE MATERIALS (FOR PRESSURE PARTS)


The materials (base materials) used for manufacturing the equipment -and which are going to be
under pressure- are defined by means of one of the following ways (Annex I, point 4.2b):
Usage of harmonised standards.
Specific evaluation of materials.
European approval of materials.

6.1.1. Harmonised standards


If they exist, harmonised standards can be used for the design.
In this equipment, there is not harmonised standard.
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6.1.2 Particular material appraisal.


When harmonised standards are not used, as in this case, a particular material appraisal or a European
approval of the materials will be carried out.
As it is a IV category equipment, the particular material appraisal will be carried out by the Notified
Body in charge of the assessment, as it is so specified in Annex I, point 4.2.c of the Directive.
A specific evaluation of the materials is performed for the head, shell, pipes and forging (refer to
annex 3).

Standard Quality Element

EN10028-3 P-355 NL2 Shell

EN10028-3 P-355 NL2 Heads

EN10028-3 /
P-355 NL2 / SA-333 Gr.6 Nozzle necks
ASTM

ASTM SA-350 LF2 Cl.1 Flanges / Forging

6.1.3 European approval of materials.


For the other elements, the Directive specifies the possibility to use the European approval of the
materials by the notified Body specifically designated for this task.
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7.- MATERIALS
7.1 GENERAL CONCEPTS
Only those materials which are under pressure conditions and those which may compromise the
safety of the facilities are the object of calculation and standards.

All the materials under pressure conditions (shell, heads and nozzles) must be supported their
corresponding certificates according to a determined specification (Annex 1, point 4.3). When the
materials’ supplier has a quality assurance system already certified by a recognised Authority,
certificates may agree with the EN 10204 3.1 standard; in other cases, they must agree with the type:
3.2 of the same standard. In annex 3 of this document, the specifications of the materials to be used
are shown.
Besides, all the materials under pressure must be identified (Annex 1, point 3.1.5), so tracing
capability is thus guaranteed.

YES (AT -10ºC)

Materials used for this project fulfil the safety requirements which are equivalent to those mentioned
in Annex I, point 7 of the PED 97/23/CE, according to PD5500 2012 ED

7.2 MECHANICAL PROPERTIES


The mechanical properties of materials must be in according with the code used. Also, all materials
properties shall evaluated by notified body involved in assessment of conformity.
Materials used for this project are safe for chemical and mechanical requirements.

7.3 WELDING MATERIALS

They are included in welding procedures specifications involved in the project.


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8.- DESIGN
8.1 CALCULATION METHOD
According to the Directive (Annex I, point 2.2.2), the design of the equipment will be based on a
calculation method (Annex I, point 2.2.3), without being necessary to complete it with an
experimental method.
For the calculation, it will be used a high prestige design code of pressure equipment, providing the
proper safety margins. The following code is chosen:

Design code: PD5500 2012 ED

8.2 ALLOWABLE STRESSES

The allowable tensions considered will depend on the design code.

8.3 CONSTRUCTION CATEGORY

A construction category in accordance with table 3.4-1 of PD5500 2012 ED

shall be agreed between the purchaser and manufacturer for each pressure containing
component of the vessel.
A component is defined as a part of pressure equipment which can be considered as an
individual item for the purpose of calculation.

Vessel Category: --

8.4 PRESSURE OF HYDROSTATIC TEST


It is established that the pressure test will be the one calculated according to the code: PD5500 2012
ED

Pt = 25,1 bar

8.5 CALCULATIONS

Calculations are carried out based on the design code chosen (PD5500 2012 ED )
The calculations performed and results are shown in Annex 1 of this document.
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9.- SAFETY ACCESORIES

The valves and other equipment which may be connected to the equipment are not part of this
conformity assessment. These elements will be defined and supplied by the customer, and their
evaluation will be made during the design process of the whole facility, after the manufacturing and
supply of the equipment.

In general, all the valves to be supplied for the equipment must be:

*Adaptable to the equipment connections (the same thread, flange,...).


*Suitable for the function they will have to carry out
*Made of materials which should be compatible with the equipment and the product to be stored
inside.
The pressure limiter devices shall be such that guarantee that never an overpressure (momentary)
greater of 10% of the pressure of design PS is reached.
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10.- MANUFACTURING PROCESS

As it has previously been said in section 7, the materials to be shall must not be then considerably
modified by the manufacturing processes to be used or, in other words, the manufacturing processes
used should not considerably modify the properties of the materials and, specifically, the elongation
and impact values specified in the Directive and indicated in subsection 7.1.
Steel transformation is carried out by means of forming, drawing, oxi-cutting and mechanising
procedures
In the Annexes, the manufacturing procedures are shown.
Preparation of the components (Annex 1, point 3.1.1) will be carried out in such a way that they do
not cause any defect or break on the pieces, or changes of the mechanical characteristics, which may
affect safety.
Manufacturing processes expected in the deposit do not imply any changes of the material properties
which may cause the equipment integrity to be in danger. Therefore, no heat treatment will be applied
(Annex 1, point 3.1.4).

As it has already been explained in subsection 7.1, materials under pressure conditions must be duly
marked ( to assure the traceability). During manufacturing processes, such identification will be kept
so that the complete traceability of these elements may be carried out.

10.1 WELDING PROCESSES AND PERSONNEL


Welding processes will be performed in such a way that continuity in the chemical and physical
properties of the materials to be welded are guaranteed.

They will be carried out by qualified personnel and by approved procedures. Both personnel and
procedures must be approved by an independent qualified Authority (notified body or independent
third party by a Member State and published in the Official Bulletin of the European Community in
order to fulfil the requirement about pressure equipment, established in the Directive) for the pressure
equipment of the II, III and IV categories.

Procedures to be used will be described in the corresponding manufacturing drawings.

10.2 PRESSURE TEST

When the manufacturing process has finished, each equipment will have to undergo a hydrostatic test
at the pressure defined in paragraph 8.
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10.3 PROTECTION OF SURFACES

By using the proper coating, the equipment will be protected against external aggressive agents.

The external coating process will be the following:

External painting system: 1

Internal painting system: 3E

Painting system for supports: 1

Painting system for bolting: 1


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11.- TESTS AND VERIFICATIONS

11.1 WELDING

All tests to carry out are addressed in inspection points program I.P.P. Nº: 2/942-100A

Welding controls will be carried out by qualified personnel. As it is a IV category equipment,


personnel should have been approved by a third party recognised by a Member State (Annex I, point
3.1.3 and section 13).

11.2 VERIFICATION

Equipment will undergo a final verification which will consist of:

* Final inspection: visual verification and control of the documents, as per IPP. For those aspects
which are not possible to be verified at the end of the manufacturing process of the equipment, a
verification during the process will be carried out.

*Test: the equipment will have to undergo a pressure test, as it is so specified in section 10.2

* The hydrotest pressure is at least 1,43 times the pressure design


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12.- MARKING (according to Annex I, point 3.3)

The equipment includes a nameplate, with at least the following information:

CE Marking CE

No. of the notified authority 0056

IDESA. Parque Científico


Manufacturer’s identification Tecnológico C/Profesor Potter nº
105 Gijón. España.
Serial number 2/942-100A

Design code PD5500 2012 ED

Allowable presure (Min /Max )Ps 15,5 bar

Ts (Min./Max.) -10 / 70 ºC

Hydrotest presure Hydrotest presure date 25,1 bar / /2014

Fluid group 2
Volume (V) 119700 L
Empty weight 26,036 Tn

Intended use Compressed Air Receiver

Year of manufacturing 2014


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13.- MANUFACTURER’S INSTRUCTIONS

Directive states that the manufacturer will provide the following information regarding instructions:
* Whenever it is necessary, instructions regarding assembly, commissioning, usage and
maintenance, prepared by the manufacturer. All these activities must be performed in accordance
with said instructions (Annex I, point 1.1 and 3.4A).
* Specifications about the existing risks which are not eliminated in the design and manufacturing
(Annex I, point 1.2).
* If it is known or expected, the possible wrong usage of the equipment (Annex I, points 1.3 and
3.4c).
* If any, the characteristics which are essential for the life of the equipment, such as theoretical
corrosion tolerance, number of fatigue cycles,....(Annex I, point 2.2.3).
Considering the analysis of risks and characteristics of the equipment –both mentioned in this dossier-
and taking into account that the handling of the equipment is going to be carried out by qualified
personnel, it is not necessary to issue instructions regarding its installation or handling.

Nevertheless, useful indications are included in Annex 4 (according to the Directive, section 4, point
2, they are written in the language used in the country of destination).
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14.- SUMMARY OF ESSENTIAL SAFETY


REQUIREMENTS

A table by means of which the sections of Annex I of the Directive (essential safety risks) may be
related with the different sections of this document, is herein-below included.

Annex I PED Essential Safety Requirement Dossier


97/23/CE Chapter
Obs. Analysis of risks
3
Prelim.
1 General
1.1 Safety ensurement 3.2
1.2 Principles for assessing safety 3, 13
1.3 Design to prevent danger from foreseeable misuse 3, 13

2 Design
2.1 Safety coefficients 8.2
2.2.1 Design for the intended use 5
2.2.2 Calculation method 8.1
2.2.3(a) Safety factor. Design by formula, analysis or fracture mechanics 8.2
2.2.3(b) Resistance. Calculation pressures, calculation temperature, stresses, 5.1, 5.2, 7.1,
characteristics of materials, joint factors,forseeable degradation mechanisms, 8.2, 8.5, 13
instructions to features wich are relevant to the life of equipment

2.2.3(c) Structural stability 8.1


2.2.4 Experimental design method Not
applicable
2.3 Provisions to ensure safe handling and operation 3
2.4 Means of examination 11
2.5 Draining and venting systems 5.3
2.6 Corrosion and other chemical actions 5.2, 10.3
2.7 Wear and tear 5.2
2.8 Assembly Not
applicable
2.9 Filling and pumping-out See anex 4

2.10 Protection against exceeding the allowable limits 9

2.11.1 Safety accessories 9


2.11.2 Pressure limiting devices 9

2.11.3 Temperature monitoring devices 9


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2.12 External fire 3

3 Manufacturing
3.1.1 Preparation of components parts 10
3.1.2 Permanent joints and adjacent zones 10.1
3.1.3 Non-destructive tests 10.2, 8.4, 11
3.1.4 Heat treatment 10

3.1.5 Traceabitity 10.1


3.2.1 Final inspection 11
3.2.2 Hydrostatic pressure test 8.4, 10.2, 11
3.2.3 Check for safety devices Not
applicable
3.3 Marking 12
3.4 Operating instructions 13
7.3
4 Materials
(welding)
4.1.(a) Material properties 7.1
4.1.(b) Chemical resistance 7.1

4.1.(c) Ageing 7.1


4.1.(d) Intendeded processing procedures 7.1
4.1.(e) Avoiding undersirable effects when joining 7.1
4.2.(a) Values for design 7
4.2.(b) Technical documentation 6.1
4.2.(c) Specific evaluation 6.1.2
4.3 Material certificates 7.1
Not
5 Fire or process heated pressure equipment applicable
Not
6 Piping
applicable
7 Supplementary requirements to sections 1 to 6
7.1 Allowable stresses 7.2, 8.2
7.2 Joint coefficients 8.3
7.3 Pressure limiting devices 9

7.4 Hydrostatic test pressure 8.4, 10.2


7.5 Material characteristics 7.1
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ANNEX 1. CALCULATIONS

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