Pressure Equipment Directive 97/23/EC
Essential Safety Requirements Annex I Checklist
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1. GENERAL
1.1 Pressure equipment must be designed, manufactured and inspected,
equipped and installed to ensure its safety during service in accordance
with the Manufacturer’s working instructions.
1.2 The Manufacturer must apply the following principles:
• eliminate or reduce hazards insofar as reasonably practical.
• apply appropriate protection methods against all hazards.
• inform end user of all residual hazards.
1.3 Pressure equipment must be designed against any foreseeable misuse
and/or adequate warning given against any misuse.
2 DESIGN
2.1 General
Pressure equipment must be designed to ensure that it is safe throughout
its intended design life and that all appropriate safety factors have been
incorporated.
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2.2 Design for Adequate Strength
2.2.1 The pressure equipment must be designed for all appropriate load
conditions for its intended use and take into account the following:
• internal/external pressure.
• ambient/operational temperatures.
• static pressure and mass of contents (operating and test).
• transportation, wind, earthquake loading.
• reaction forces and moments due to supports, attachments, piping
etc.
• corrosion and erosion, fatigue etc.
• decomposition of unstable fluids.
2.2.2 The design must be based on, as a general rule, a calculation method
and supplemented, if necessary, by an experimental design method.
2.2.3 Calculation Method
2.2.3 (a) Pressure Containment and other Loading Aspects
Allowable stresses must be limited with regard to any foreseeable failure
modes under operating conditions with the appropriate safety factors
applied. These requirements may be met by applying one or more of the
following:
• design by formula.
• design by analysis.
• design by fracture mechanics.
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2.2.3 (b) Resistance
The resistance of the pressure equipment must be established by
applying appropriate design calculations.
• the design pressure must not be less than the maximum allowable
pressure and take account of the static head, dynamic fluid forces
and the decomposition of unstable fluids.
• the design temperature must allow for appropriate safety margins.
• the design must take account of all possible combinations of
pressure/temperature.
• maximum stresses and peak stress concentrations must be within
safe limits.
• the calculation of the pressure containment must utilise values
appropriate to the material properties, based on documented data
and having appropriate safety factors.
• appropriate joint factors must be applied.
• the design must take account of all foreseeable degradation
mechanisms and highlighted in the operating instructions.
2.2.3 (c) Stability Aspects
Adequate precautions must be made to the equipment to ensure
structural stability during transportation and handling.
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2.2.4 Experimental design method.
The design of the pressure equipment maybe validated, in all or part by
an appropriate test programme being carried out on a representative
sample.
The test programme must be clearly defined prior to testing and the test
programme must include:
• a pressure strength test to check that equipment does not exhibit leaks
or deformation exceeding a determined threshold.
• if necessary, appropriate tests if creep or fatigue exists.
• where necessary, additional tests concerning other factors, i.e.
corrosion, external damage etc.
2.3 Provisions to ensure safe handling and operation.
The method of operation specified must be such as to prevent any
reasonable foreseeable risk in operation of the pressure equipment.
Particular attention to the following:
• closures and openings.
• dangerous discharge of pressure relief blow off.
• devices to prevent physical access into the equipment whilst pressure
or a vacuum exists.
• surface temperature.
• decomposition of unstable fluids.
Furthermore, quick release access doors must be equipped with devices
to prevent hazards from the fluid pressure or temperature.
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2.4 Means of Examination.
• pressure equipment must be designed and constructed in such a way as to
ensure that all necessary examinations can be carried out.
• the ability to determine the internal condition of the pressure equipment.
• the application of alternative methods to ensure the safe condition of the
pressure equipment.
2.5 Means of Draining and Venting
Where appropriate, the pressure equipment must be provided with methods
for draining and venting:
• to prevent water hammer, vacuum collapse, corrosion and chemical
reactions etc.
• to permit cleaning, inspection and maintenance.
2.6 Corrosion or Other Chemical Attack
Adequate allowance or protection against corrosion or other chemical attack
must be provided.
2.7 Wear
Adequate measures must be taken against the effects of erosion and abrasion:
• in the design, ie cladding, linings etc.
• by replacement parts.
• referenced in the operating instructions.
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2.8 Assemblies
Assemblies must be designed that:
• the components are suitable and reliable for their duty.
• the components are properly integrated and assembled.
2.9 Provisions for Filling and Discharge
Where applicable, the pressure equipment must be designed and
provided with accessories, or provision made for their fitting, to ensure
safe filling or discharge:
• on filling; by over filling or overpressurisation and fluid instability.
• on discharge; by uncontrolled release of fluid.
• on filling or discharge; unsafe connection or disconnection
2.10 Protection Against Exceeding the Allowable Limits of Pressure
Equipment
The pressure equipment must be fitted with, or appropriate provision
made for, the fitting of suitable safety devices which are determined on
the characteristics of the equipment.
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2.11 Safety Accessories
2.11.1 Safety Accessories
• be designed and constructed to be reliable and suitable for their
intended duty, including maintenance and testing.
• be independent or unaffected by other functions.
• comply with appropriate design principles in order to obtain suitable
and reliable protection.
2.11.2 Pressure Limiting Devices
These devices must be designed so that pressure will not permanently
exceed the maximum allowable design pressure except for short pressure
surges of 1.1 times the design pressure.
2.11.3 Temperature Monitoring Devices
These devices must have an adequate response time on safety grounds.
2.12 External Fire
Where appropriate, the pressure equipment must be fitted with, or
appropriate provision made for, the fitting of suitable equipment/devices
to meet damage-limitation requirements in the event of an external fire.
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3. Manufacturing
3.1 Manufacturing Procedures
The manufacturer must ensure the competent execution of the provisions
set out at the design stage by applying appropriate techniques and
relevant procedures.
3.1.1 Preparation of the Component Parts
Preparation of the component parts must not give rise to defects or
cracks or changes in mechanical characteristics likely to be detrimental to
the safety of the pressure equipment.
3.1.2 Permanent Joining
• permanent joints and adjacent zones must be free of any surface or
internal defects detrimental to the safety of the equipment.
• properties to meet the minimum specified for the materials to be
joined or taken into account in the design calculations.
• permanent joining of components to be carried out by suitably
qualified personnel according to suitable operating procedures.
• for pressure equipment in Categories II, III and IV , the operating
procedures and personnel must be approved by a Recognised Third
Party/Notified Body.
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3.1.3 Non-Destructive Tests
For pressure equipment, non-destructive tests of permanent joints must
be carried out by suitably qualified personnel.
• for Category III and IV equipment, the personnel must be approved
by a Recognised Third Party.
3.1.4 Heat Treatment
Where applicable, suitable heat treatment must be applied at the
appropriate stage of manufacture.
3.1.5 Traceability
Suitable procedures must be established and maintained for identifying
the materials making up the components of the equipment which form
the pressure containment.
3.2 Final Assessment
Pressure equipment must be subjected to a final assessment as described
below.
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3.2.1 Final Inspection
Pressure equipment must undergo a final inspection to assess visually
and by examination of accompanying documentation, compliance with
the requirements of the Directive:
• account taken of tests carried out during manufacture.
• internal and external examination as far as possible on all components
to be carried out.
3.2.2 Proof Test
Final assessment of the pressure equipment must include a test for the
pressure containment, normally a hydrostatic pressure test to the
requirements given in 7.4.
• Category I series produced equipment can be tested on a statistical
basis.
• where the hydrostatic test is harmful or impracticable, alternative
tests of a recognised value maybe carried out
3.2.3 Inspection of Safety Devices
For assemblies, the final assessment must include a check on the safety
devices intended to check full compliance with the requirements
referenced in 2.10.
3.3 Marking and Labelling
In addition to the CE marking, the following must also be provided:
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3.3 (a) For all Pressure Vessels:
• the name and address or other means of identification of the
manufacturer.
• the year of manufacture.
• identification of the pressure equipment according to its nature.
• essential maximum/minimum allowable limits.
3.3 (b) Depending on the Type of Pressure Equipment
• the volume V of the pressure equipment in L (Litres).
• the nominal size for piping DN.
• the test pressure PT applied in bar and date.
• safety device set pressure in bar.
• output of the pressure equipment in kW.
• supply voltage in V (Volts).
• intended use.
• filling ratio in kg/L.
• maximum filling mass in kg.
• tare mass in kg.
• the product group.
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3.3 (c) Any further information necessary for safe installations, operation or use,
maintenance or inspection should also be provided, and any warnings
against misuse must be fixed to the equipment.
3.4 Operating Instructions
3.4 (a) All items of pressure equipment when placed on the market must be
accompanied with instructions for the user, containing all the necessary
safety information relating to:
• equipment mounting, including assembling of different pieces of the
pressure equipment.
• putting into service.
• use.
• maintenance, including checks by the user.
3.4 (b) The instructions must cover all the information attached on the pressure
equipment in accordance with 3.3.
3.4(c) If appropriate, these instructions must also refer to hazards arising from
misuse.
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4. Materials
Materials used for the manufacture of pressure equipment must be
suitable for the required application during the scheduled lifetime unless
replacement is expected.
4.1 Materials for Pressurised Parts
4.1 (a) They must have appropriate properties for all the operating and test
conditions and should be sufficiently ductile and tough (reference should
be made to 7.5). The effect of brittle fracture should also be considered if
applicable.
4.1 (b) They must be chemically resistant to the fluid contained in the pressure
equipment.
4.1 (c) They must not be significantly affected by ageing.
4.1 (d) They must be suitable for the intended processing procedures.
4.1 (e) They must be selected to reduce undesirable effects from the joining
process.
4.2 (a) The manufacturer must define in an appropriate manner the values
necessary for the design calculations (referred to in 2.2.3) and the
essential characteristics of the materials and their treatment (referred to
in 4.1).
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4.2 (b) The manufacturer must provide technical documentation relating to
compliance with material specifications of the Directive in one of the
following forms:
• materials comply with harmonised standards.
• materials covered by European approval of pressure equipment
materials.
• particular material appraisal.
4.2 (c) For Category III and IV equipment, the particular material appraisal
must be carried out by the Notified Body in charge of the conformity
assessment.
4.3 The manufacturer must take appropriate measures to ensure that the
material conforms with the required specification and the documentation
prepared by a material manufacturer confirms compliance with a
specification. For main pressure parts in Categories II, III and IV this
must take the form of a certificate of specific product control.
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SPECIFIC PRESSURE EQUIPMENT REQUIREMENTS
In addition to the applicable requirements of the above Section’s 1 to 4, the following requirements apply to the pressure equipment covered by Section’s 5 and 6.
5 Fired or Otherwise Heated Pressure Equipment with a Risk of
Overheating
This pressure equipment includes:
• steam and hot water generators.
• process-heating vessels other than steam or hot water generation.
This pressure equipment must be calculated, designed and constructed
so as to minimise the risk of loss of containment due to overheating.
a) Appropriate means of protection must be provided to restrict
operating parameters in order to avoid risk of local and general
overheating.
b) Sampling points must be provided for the evaluation of properties
of the fluid so as to avoid risks from deposits and/or corrosion.
c) Adequate provisions must be made to eliminate the risk of damage
from deposits.
d) Means must be provided for the safe removal of residual heat after
shutdown.
e) Steps must be taken to avoid the dangerous accumulation of
combustible substances and air, or flame blowback.
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6. Piping
The design and construction must ensure:
a) the risk of overstressing from inadmissible free movement or
excessive forces being produced is adequately controlled.
b) where there is a possibility of condensation occurring inside pipes for
gaseous fluids there are means provided for drainage and the
removal of deposits from low areas.
c) due consideration is given to the potential damage from turbulence
and the formation of vortices.
d) due consideration is given to the risk of fatigue due to pipe vibration.
e) that, where fluids of Group 1 are contained in the piping, appropriate
means are provide to isolate ‘take-off’ pipes.
f) the risk of inadvertent discharge is minimised.
g) the position and route of underground piping is at least recorded in
the technical documentation.
7. Specific Quantitative Requirements for Certain Pressure Equipment
The following provisions apply as a general rule only. If however they
are not fully applied, the manufacturer must demonstrate that
appropriate measures have been taken to achieve an equivalent overall
level of safety. The subsequent provisions listed in this section
supplement the requirements of Section’s 1-6 for the pressure equipment
to which they apply.
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7.1 Allowable Stresses
7.1.1 Symbols:
• Re/t - Yield strength at the design temperature.
the upper flow limit for a material presenting upper and lower limits.
the 1.0% proof strength of austenitic steel and non alloyed aluminium.
the 0.2% proof strength in all other cases.
• Rm/20 - Tensile strength at 20°C
• Rm/t - Tensile strength at the design temperature.
7.1.2 The maximum permissible general membrane stress for static pressure
loading, for equipment being operated outside the temperature range
where creep is significant must not exceed the lowest value below:
• Ferritic steels (including normalised (normalised rolled) steel and
excluding fine grained steel and specially heat-treated steel), 2/3 Re/t
or 5/12 Rm/20.
• Austenitic steels:
if its elongation after rupture exceeds 30%, 2/3 Re/t.
if its elongation after rupture exceeds 35%, 5/6 Re/t or 1/3 Rm/t.
• Non alloy or low cast steel, 10/19 Re/t or 1/3 Rm/20.
• Aluminium, 2/3 Re/t.
• Aluminium alloys (excluding precipitation hardening alloys), 2/3 Re/t
or 5/12 Rm/20.
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7.2 Joint Co-efficients
For welded joints, the joint coefficient must not exceed the following:
• for equipment subject to destructive and non-destructive tests which
confirm that the whole series of joints show no significant defects: 1.00.
• for equipment subject to random non-destructive testing: 0.85.
• for equipment not subject to non-destructive testing other than visual
inspection: 0.70.
7.3 Pressure Limiting Devices
The momentary pressure surge (referred to in 2.11.2) to be kept to 10% of
the design pressure.
7.4 Hydrostatic Test Pressure
The hydrostatic test pressure (referred to in 3.2.2) must not be less than:
• the maximum loading to which the pressure equipment may be subject
in service, taking account its maximum allowable pressure and
temperature, multiplied by the coefficient 1.25, or
• the maximum allowable pressure multiplied by the coefficient 1.43,
whichever the greater.
7.5 Material Characteristics
A steel is considered to be ductile if its elongation after rupture is not less
than 14%, and its impact strength measured on a standard ISO ‘V’ test-
piece at 20°C, or the lowest scheduled operating temperature is greater
than 27J.
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