Procedure for inspection of newly installed pressure vessels and also for annual inspection. Rogelio Garrido Simón Cairo, December 9, 2014 القاهرة، 9 ديسمبر.

Procedure for inspection of newly installed pressure vessels and also for annual inspection. Rogelio Garrido Simón Cairo, December 9, 2014 القاهرة، 9 ديسمبر 2014 جمهوريّة مصرالعربيّة

New Approach concept Conformity Assessment Harmonised standards / Direct compliance Essential Requirements

European Commission 3/61 Directives Essential requirements European standards bodies Standardization Harmonized standards Mandate Manufacturers Application of standards CONSUMER Product Presumption of Conformity / CE marking 3 d party testing and certification Product verification Member States Market surveillance Notified Body New Approach principles ONA INM AccreditsTraceability

E.R.S. FREE MARKET AUTHORITY COOPERATION PRESUMPTION OF CONFORMITY MARKET SURVEILLANCE CONFORMITY ASSESSMENT NOTIFY BODIES TRANSPOSITION New Approach principles

pillarsstakeholders NA pillars and their stakeholders pillarsstakeholders -essential requirements (Ers) - reference to technical specifications defined in harmonized standards - compliance of products with harmonized standards (ENs) and presumption of conformity to ERs -market surveillance = essential tool for NA enforcement -Egyptian authorities = legislators -Egyptian standardization bodies -Manufactures + certification bodies and notified bodies - National Authorities 5/61 New Approach principles

The content Essential requirements Essential requirements define the results to be attained, or the hazards to be dealt with, but do not specify the technicalsolutions for doing so. Conformity Assessment Define the system and procedures of conformity assessment Conformity assessment Bodies Regulation on conformity assessment bodies Accreditation System Accreditation is part of an overall system, including conformity assessment and market surveillance, designed to assess and ensure conformity with the applicable requirements Standards The standard was designed to be a common audit standard recognized by all members to reduce the cost of audits to members and suppliers. Ensures Safety, Legality and Quality of products but does not replace Legal obligations.

The content Market surveillance shall mean the activities carried out and measures taken by public authorities to ensure that products comply with the requirements set out in the legislation and do not endanger health, safety or any other aspect of public interest protection; Inspection and test at the instalation place Before putting in service, during it, or installation a pressure equipment inspection. Mandatory periodic inspection Examination, recognition, checks and tests necessary to ensure the security and functionality required by regulations are maintained. Inspection authority Inspections by the competent administration Surveillance and official control Supervision and control by the competent authority over all stakeholders

The content Essential requirements Conformity Assessment Conformity assessment Bodies Accreditation System Standards Market surveillance Initial inspection Regulatoy periodic inspection

Essential requirements DIRECTIVE 2014/68/EU OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 15 May 2014 on the harmonisation of the laws of the Member States relating to the making available on the market of pressure equipment

Essential requirements DIRECTIVE 2009/142/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 30 November 2009 relating to appliances burning gaseous fuels

Essential requirements: PED Pressure equipment and Assemblies : - design, - manufacture, - conformity assessment Limited to: - pressure hazard - pressure greater than 0.5 bar - equipment placed on the market OR put into service - assemblies placed on the market AND put into service Scope

Specifics requirements General requirements Design (parameters) Manufacturing Materials Pressure equipment flame or heated otherwise with risk of overheating Pipeline Quantitative specific requirements Essential Safety Requirements (ESRs) Essential requirements: PED

- General obligations for manufacturer (Prelim and ESR 1) - e.g. carry out hazard analysis incl. reasonably foreseeable misuse - to establish technical documentation file - Design and calculation (ESR 2) -Manufacturing (ESR 3) -Manufacturers capabilities, manufacturing/joining procedures - Materials (ESR 4) - Specific requirements (ESRs 5, 6, 7): - fired or otherwise heated pressure equipment, - piping, and - specific quantitative requirements (general rule) Essential Safety Requirements (ESRs) Essential requirements: PED

Conformity assessment

Manufacter Conformity Module A Module A1 Module A2 Module B Module C Module C1 Module C2 Module D Module E Module F Module D1 Module E1 Module F1 Module G Module H Module H1 DESIGNE PHASEMANUFACTURING PHASE Conformity assessment

NAB Acreditation EN 17000 DCT Application Tax Dossier National Authorities Evaluation technical competence + Inspection Resolution Authorization Notification MICOMMISSION Nº XXXX Notification body Acreditation necessary staff and facilities Requirements ………. O.N. FOR …… www.europa.eu.int (DOCE, BOE) Authorization of CAB

Accreditation ‘accreditation’ shall mean an attestation by a national accreditation body that a conformity assessment body meets the requirements set by harmonised standards and, where applicable, any additional requirements including those set out in relevant sectoral schemes, to carry out a specific conformity assessment activity; ‘national accreditation body’ shall mean the sole body that performs accreditation with authority derived from the State;

 Public authority activity  Single national accreditation body Non competition principle Strict cross border policy  Separation of responsibilities NAB from NA  Information obligations  Recognition  Management of the peer evaluation EC can mandate to develop sectoral accreditation schemes Accreditation

Requirements for NABs Be independent of commercial motivations Operate on a not for profit basis Be authoritative, objective, impartial No competition between NABs and between NABs and accredited CABs Not be involved in conformity assessment for which they accredit other bodies Balanced involvement of stakeholders Member of EA and participation in peer evaluation (presumption of conformity+ mutual recognition)‏ Monitor CABs they have accredited  suspension/withdrawal of accreditation certificate Accreditation

Requirements for Member States NAB fulfils requirements  monitoring + corrective actions Appropriate resources to NAB NAB is deemed to exercise public authority, irrespective of legal status NAB undergoes peer evaluation Oversee peer evaluation Procedure for resolution of appeals Prove that CAB evaluated not using accreditation complies with requirements Accreditation

Conformity Assessment Bodies NAB Accreditation

NSB helps develop and promote standards TAB must use International standards to assess GOVERNMENT How the Standardisation Infrastructure operates TABs use standards / Mandatory requirements / scheme criteria Delivers Government recognises UKAS as the UK National Accreditation Body Conformity Assessment (testing & calibration labs, certification and inspection bodies or any independent evaluation) Business ( people, management systems, equipment organisations, products, etc) TAB Accreditation CONSUMERSPURCHASERS ConfidenceTrustAssurance Delivers Accreditation

ISO/IEC 17011 - Requirements for Accreditation Bodies for accreditation of: Standards for accreditation Manufacturer Certification bodies – for certification of: Laboratories Inspection bodies Products EN 45011 ISO/IEC 17065 for Persons ISO / IEC 17024 Products Persons Testing and Calibration Laboratories ISO / IEC 17025 Testing and Calibration ISO/IEC 17020 Inspection Supplier, manufacturer Management systems ISO/IEC 17021 Environmental, Quality etc Management Systems Accreditation

ModuleStandards A,A1,A2 EN ISO/IEC 17020 (EN ISO/IEC 17025) EN ISO/IEC 17025 EN ISO/IEC 17065/ EN 45011 (EN ISO/IEC 17025) B EN ISO/IEC 17065 (EN ISO/IEC 17025) EN ISO/IEC 17020 (EN ISO/IEC 17025) C,C1,C2 EN ISO/IEC 17020 (EN ISO/IEC 17025) EN ISO/IEC 17025 D,D1 EN ISO/IEC 17021 E,E1 EN ISO/IEC 17021 F,F1 EN ISO/IEC 17020 (EN ISO/IEC 17025) EN ISO/IEC 17025 G EN ISO/IEC 17020 (EN ISO/IEC 17025) ISO/IEC 17065/EN 45011 (EN ISO/IEC 17025) H EN ISO/IEC 17021 H1 EN ISO/IEC 17021 ISO/IEC 17065/EN 45011 (EN ISO/IEC 17025) Accreditation

ModuleStandards A,A1,A2 EN ISO/IEC 17020 (EN ISO/IEC 17025) EN ISO/IEC 17025 EN ISO/IEC 17065/ EN 45011 (EN ISO/IEC 17025) B EN ISO/IEC 17065 (EN ISO/IEC 17025) EN ISO/IEC 17020 (EN ISO/IEC 17025) C,C1,C2 EN ISO/IEC 17020 (EN ISO/IEC 17025) EN ISO/IEC 17025 D,D1 EN ISO/IEC 17021 E,E1 EN ISO/IEC 17021 F,F1 EN ISO/IEC 17020 (EN ISO/IEC 17025) EN ISO/IEC 17025 G EN ISO/IEC 17020 (EN ISO/IEC 17025) EN ISO/IEC 17065 (EN ISO/IEC 17025) H EN ISO/IEC 17021 H1 EN ISO/IEC 17021 EN ISO/IEC 17065 (EN ISO/IEC 17025) Accreditation

Standards A standard (French: Norme, German: Norm) is a technical document designed to be used as a rule, guideline or definition. It is a consensus-built, repeatable way of doing something. Standards are created by bringing together all interested parties such as manufacturers, consumers and regulators of a particular material, product, process or service. All parties benefit from standardization through increased product safety and quality as well as lower transaction costs and prices. A standard (French: Norme, German: Norm) is a technical document designed to be used as a rule, guideline or definition. It is a consensus-built, repeatable way of doing something. Standards are created by bringing together all interested parties such as manufacturers, consumers and regulators of a particular material, product, process or service. All parties benefit from standardization through increased product safety and quality as well as lower transaction costs and prices.

Standards Essential requirements Essential requirements lay down the necessary elements for protecting the public interest Essential requirements are mandatory. Only products complying with essential requirements may be placed on the market and put into service Essential requirements must be applied as a function of the hazards inherent to given product Essential requirements Essential requirements lay down the necessary elements for protecting the public interest Essential requirements are mandatory. Only products complying with essential requirements may be placed on the market and put into service Essential requirements must be applied as a function of the hazards inherent to given product

Presumption of conformity Conformity with a national standard that transposes a harmonised standard, whose reference has been published, confers a presumption of conformity with the essential requirements. References (such as titles, identification numbers) of national standards must be published in the Official The application of harmonised standards, which give a presumption of conformity, remains voluntary in the field of New Approach. Thus, the product may be manufactured directly on the basis of the essential requirements. Presumption of conformity Conformity with a national standard that transposes a harmonised standard, whose reference has been published, confers a presumption of conformity with the essential requirements. References (such as titles, identification numbers) of national standards must be published in the Official The application of harmonised standards, which give a presumption of conformity, remains voluntary in the field of New Approach. Thus, the product may be manufactured directly on the basis of the essential requirements. Standards

The World Standards Cooperation (WSC) Multi-discipline and cross-sector For electrotechnology For telecommunications The leading international standardization organizations

The European Standards Bodies Multi-discipline and cross-sector For electrotechnology For telecommunications The leading international standardization organizations

Standards

Market surveillance “The purpose of market surveillance is to ensure that the provisions of applicable regulations“ Market surveillance shall mean the activities carried out and measures taken by public authorities to ensure that products comply with the requirements set out in the relevant legislation and do not endanger health, safety or any other aspect of public interest protection;

Market surveillance Regulation on market surveillance of products ?? Regulation on general safety of products ?? National Authorities: Responsabilities

Chapter 8 of the Blue Guide and some of the articles of the above mentioned directives are the principles of market surveillance for all new approach directives. This chapter sets out: Principles of market surveillance Market surveillance activities Corrective actions Complementary activities Safeguard clause procedures Protection of CE marking Information exchange systems Administrative cooperation Products imported from third countries Market surveillance General principles http://ec.europa.eu/enterprise/policies/single-market-goods/files/blue-guide/guidepublic_en.pdf

Market surveillance cannot take place during the design and production stages that is before the manufacturer has taken formal responsibility for the conformity of the products. However, this does not exclude collaboration between the market surveillance authority and the manufacturers and suppliers.” Although the market surveillance authority may make a check on the production premises after non- compliance has been discovered to verify whether or not a systematic error can be established. Market surveillance General principles

Market surveillance must take place between t1 (placing on the market) and t2 (putting into use). The following diagram clearly illustrates this process. This diagram presents the general pragmatic principal: Market surveillance General principles t t1t1 t2t2 Put in the market put into service Directives Scope General Provisions Esential requirements CA CABR DC MC Supervisors sanctions annexes Directives Scope General Provisions Esential requirements CA CABR DC MC Supervisors sanctions annexes RT Initial inspecions Periodical inspections CBR Annexes RT Initial inspecions Periodical inspections CBR Annexes

Market surveillance may include inspections on the market and in the field, inspection of documents, and special surveillance campaigns Market surveillance

Initial inspection Installation MUST designed the security must be ensured through the expected life Installation companies must be registered in the register of the competent body The installations require technical project except lower risk installations The installation of pressure equipment in categories I to IV or similar equipment MUST be performed by authorized installation company according to the appropriate category. (Can also be performed manufacturers or users if they meet the requirements of Annex I to installation companies) Will be installed under conditions allowing the subsequent realization of maintenance and control, and periodic inspections specified in the regulations. Changes in location of facilities will be considered as a new installation

Initial inspection Once the construction ends or assembly, for putting in service the installations including pressure equipment, documentation must be submitted to authorities, evidencing the installation security Before putting into service testing should be performed at the location of the site, check for proper operation and offers safe conditions of use The trials and tests carried out must be certified by an approved inspection body, or by the manufacturer The competent authority may require testing location of the site will be monitored by an approved inspection body in the application of this Regulation on pressure equipment. Put in service

Initial inspection

Article 6. Periodic inspections All EP in categories I to IV must undergo regular inspections and tests to ensure the maintenance of technical and safety conditions. For the type of inspection intervals and agent inspector is necessary to categorize the pressure equipment: DATA Maximum allowable pressure: PS (bar) Volume: V (l) Nominal diameter: Dn (mm) -Pipes Product: PS x V (bar x l) Fluid Type Type of pressure equipment RATING TABLES CATEGORIES (I, II, III, IV) Mandatory periodical inspection

IAT_BUSI_NOV09 RATING TABLES Mandatory periodical inspection

TABLE 2. EQUIPMENT SUBJECT TO ACTION FLAME OR CONTRIBUTION FOR HEAT Mandatory periodical inspection Level Inspection Who?periodicity Categories I II III IV Level AInstaller or manufacturer 1 year Level BI.B.3 yeras Level CI.B.6 years

INSPECTION LEVEL LEVEL A: IN SERVICE Checking the documentation of pressure equipment. Visual inspection of pressure parts, safety accessories, control devices and regulatory conditions. Shall be made by installation companies of the category, or the MANUFACTURER USER if credited or have the technical means and human required for installation companies. Mandatory periodical inspection

LEVEL B: OUT OF SERVICE It will include a check of level A. Visual inspection of all areas subject to greater stresses and corrosion. Checking thicknesses. Checking and testing of safety accessories. END's deemed necessary You will be performed by a I.B. Mandatory periodical inspection INSPECTION LEVEL

LEVEL C: Out of service inspection with pressure test It will include an inspection of level B. Hydrostatic pressure test under the conditions and pressures: a) Same as the first test b) Suitable labeling c) In any substitute special test specified by the manufacturer or authorized by the competent body of the autonomous region. You will be performed by a O.C.A. Periodic inspections of level B and C shall be recorded on the installation plate and periodic inspections. Mandatory periodical inspection

1.1 Level A (The frequency of these inspections will be annual). WHAT HAS BEEN PERFORMING The inspection also include the following checks: a)Existence and updating documentation corresponding to: 1.maintenance and operation of the boiler 2.warm water (only for steam boilers and hot water) b)Clean and inspect the flue and pressure parts c)Operation of the operating elements and assurances of the boiler d)Maintenance conditions of site boiler and safety instructions, including fire protection. e)Circuit sealing gases f)Visual inspection of the fluid pipe using the boiler ON THE WORK WILL BE WRITTEN BY DOCUMENTARY EVIDENCE REGISTRATION,. Mandatory periodical inspection CHECKING THE DOCUMENTATION? EQUIPMENT UNDER PRESSURE. Depending on the type of intervention may be: Authorization of put in service The Certificate of technical direction The Certificate of installation. The Periodic Inspection Certificate, previously performed. VISUAL INSPECTION FOR ALL PARTS OF PRESSURE SAFETY ACCESSORIES, CONTROL DEVICES AND REGULATORY CONDITIONS

1.2 Level B (The periodicity of this survey will be every 3 years). Besides indicated for inspection Level A, Perform a complete inspection and STATUS DOCUMENTATION OF THE BOILER, according to Paragraphs 4 and 6 of the UNE 9-103. (INSPECTION IN "OFF AND RUNNING") a) Checking documentary and availability: documentation of the boiler, The installation plate Previous periodic inspections Installation certificate project Certificate of conformity or manufacture certificate, Operating Instructions Boiler Maks c) Running Test: Regulation and sealing of safety valves and relief (running or bank). Checking the automatic regulation Safety Automation. b) Inspection of the boiler elements: Visual inspection before and after cleaning additional tests deformations, Weld beads, Thickness measurement, Accessories and safety valves, Gauges and thermometers Home and flues Refractory work, Electrical circuit, Virotillos and suspenders (in firetubes boilers) Gussets (in firetubes boilers) Pipe, tube sheets and manifolds (in firetubes B.) Smoke boxes (in firetubesboilers) Structure and fastenings of tubes to drums and manifolds (in Watertube boilers). Economizers, superheaters and reheaters (water tube boilers) Tube bundles or coils (water tube boilers) Mandatory periodical inspection

1.2 Level C (The periodicity of this survey will be every 6 years). Besides inspection indicated for Level B, for existing boilers a hydrostatic test must be done according to paragraph 5 of the standard? UNE 9-103 (Pp = 1.3 Pd). (INSPECTION IN "OFF AND RUNNING"). In boilers with CE marked test pressure shall be the greater of: 1.43 x 1.25 x PS or material Maximum voltage test temperature / temperature Idem admisibledel design. 1.25 (S20 / STS) And: a)Checking documentation (Idem as indicated in Level B. Check availability in the boiler room And update with maintenance, water control and periodic inspections) b)Testing the items of the boiler In firetube boilers END will be held: 100% solder bonding backplate with fireplace or with tubular chamber plate household 100% of the welds of the furnace tube 50% of the binding of rear tubular plate tubes of the first step, if the fuel is gaseous and 10% for other fuels. 100% of the binding of virotillos the camera? Home and rear tube plate when the fuel is gaseous and 50% for the other fuels. c) Hydrostatic Testing d) Performance tests.. Water-tube boilers, other fluid Heat is conducted END: 100% welds joining the tube bundles to manifolds, reheaters or superheaters. 30 Mandatory periodical inspection

2.1 Level A and B (The periodicity of this survey will be ANNUAL). Inspections shall be conducted in accordance with what has been said earlier in this REP and ITC. Further inspections are conducted with the following criteria: a)General inspection (visual of the accessible parts From inside the boiler) b)Boilers: Will open and inspect the upper and lower reboilers (if any), with change of joints affected, checking: Existence of corrosion inside. Existence of sludge, chemical analysis and Inside the mainhole of the tubes Plunges the boilers State. State support and internal accessories c)Solera: the state of the refractory be inspected d)Feed manifolds. Inspection with similar scope to that of the boilers, with visual inspection inside the manifold. e)Safety valves. They shall be removed to ensure its perfect condition, free of mold, Inlays, check drainage discharge and no blockages. f)Inspection of the blower inlet areas Absence of cracks and correct alignment. g) Control Ultrasonic Thickness: you will measure thickness of the tubes in points and percentages indicated When a thickness locate in a tube whose speed corrosion is higher than usual, be mandatory continuing measurements along this tube Contiguous to narrow the affected area. Each user shall record the thickness measured, As wellas maximum corrosion rates and the same trends. Within one year maximum, will change those Lengths of pipe whose thickness, depending on the speed expected corrosion as trends in that area compromise the safety of the boiler within 2 years, reached the end of that period the thickness? minimum calculated according to code adopted. h) Other controls for bimetallic tubes. END of PT for check for any cracks or cracks in stainless Lacapa tubes. Check sampling. Mandatory periodical inspection

2.1 Level A and B (The periodicity of this survey will be ANNUAL) Continuation: i) valves. All valves shall be reviewed low pressure circuit, checking the status of the closure elements j) Gas pipes. They must be cleaned and inspected the condition and tightness of the flues and evaporators contact live. k) Welding on pressure retaining parts If repairs are made, should be done with the manufacter recommendation and the building techniques used. They should also review the transition welds between bimetallic tubes and steel carbon l) Instrumentation and other safety devices. General inspection, especially control water level, pressure and temperature of the generator. Check that the connecting lines between the devices and the generator are free of any Substance that can lead to obstruction. : m) Inspection and control fins. An ocular inspection must be done of the fins in the fireplace, using penetrating liquids or another system when signs of cracks are observed. n) peaks casting. Is replaced each year. The peak was examined replaced by ultrasound and hydraulic testing and may be recoverable in the event of being his Satisfactory condition. 32 2.2 Level C (The periodicity of this survey will be of 3 years) Mandatory periodical inspection

rogelio.garrido@madrid.org

Procedure for inspection of newly installed pressure vessels and also for annual inspection. Rogelio Garrido Simón Cairo, December 9, 2014 القاهرة، 9 ديسمبر.

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Procedure for inspection of newly installed pressure vessels and also for annual inspection. Rogelio Garrido Simón Cairo, December 9, 2014 القاهرة، 9 ديسمبر.

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Presentation on theme: "Procedure for inspection of newly installed pressure vessels and also for annual inspection. Rogelio Garrido Simón Cairo, December 9, 2014 القاهرة، 9 ديسمبر."— Presentation transcript:

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