Chinese Pressure Equipments Manufacturers Approval- How to Achieve Acceptance by Western End User
Liu Kai
CSSOPEBeijingBeijing
May 22, 2013
TÜV SÜD Chemie Service GmbH Folie 119.07.2013
Introduction
Investment projects in the chemical/petrochemical industryInvestment projects in the chemical/petrochemical industry
Global sourcing of equipmentGlobal sourcing of equipmentg q pg q p
P ti l f P ti l f Particular focus onbest cost countries (BCC) Particular focus onbest cost countries (BCC)
TÜV SÜD Chemie Service GmbH Folie 219.07.2013
Operators’ objectives on global sourcing
Leverage economic advantages of low-wage countries like Leverage economic advantages of low-wage countries like g g gChina
g g gChina
Ensure accustomed high quality to maximize availability and Ensure accustomed high quality to maximize availability and g q y yreliability
g q y yreliability
Meet delivery deadlinesMeet delivery deadlinesMeet delivery deadlinesMeet delivery deadlines
Fulfill national legal requirementsFulfill national legal requirementsFulfill national legal requirementsFulfill national legal requirements
Achieve the maximum intervals for in-service inspections according Achieve the maximum intervals for in-service inspections according to national lawto national law
TÜV SÜD Chemie Service GmbH Folie 319.07.2013
Preconditions
Comprehensive project specificationsComprehensive project specificationsComprehensive project specificationsComprehensive project specifications
Selection of manufacturerSelection of manufacturer
Coordination between operator/engineering company and inspection organizationCoordination between operator/engineering company and inspection organizationorganizationorganization
Europe:Coordination with the Notified Body and the chosen certified Europe:Coordination with the Notified Body and the chosen certified Coordination with the Notified Body and the chosen certified inspection authorityCoordination with the Notified Body and the chosen certified inspection authority
Advantage: both functions integrated in a single organizationAdvantage: both functions integrated in a single organization
TÜV SÜD Chemie Service GmbH Folie 419.07.2013
Requirements for Pressure Vessels in Europe
Pressure Equipment Directive 97/23/EC (PED)Pressure Equipment Directive 97/23/EC (PED)
Defining a code for compliance with the Essential Safety Requirements of the Defining a code for compliance with the Essential Safety Requirements of the PED is essentialPED is essential
TÜV SÜD Chemie Service GmbH Folie 519.07.2013
Standards / Codes
harmonised standards
EN 13445 1 8
non harmonised Specifications/codes
EN 13445-1...8unfired pressure vessels
EN 12952-1...17
AD 2000
CODAP 2000water tube boilers
EN 12953-1...14shell boilers
CODAP 2000
ASME Code dditi l i t+ additional requirements
EN 13480-1...8metallic industrial piping others
EN .......
TÜV SÜD Chemie Service GmbH Folie 619.07.2013
presumption of conformity
Application of Pressure Vessel Codes
SITUATION IN CHINA
Chinese code GB 150/151• Associated standards ONLY in Chinese
Chinese code GB 150/151• Associated standards ONLY in Chinese
National codes CODAP 2000, PED 5500, AD 2000 etc.• Not well known
National codes CODAP 2000, PED 5500, AD 2000 etc.• Not well known
EN 13445• First experience started
EN 13445• First experience started
ASME CodeASME Code•• Frequently used in international projects•• Frequently used in international projects
Differences between ASME and PED must be defined!
TÜV SÜD Chemie Service GmbH Folie 719.07.2013
Project specification - Principles
PED
DifferenceASME vs. PED
ASME CodeASME Code
Company standards Chemistry-specific quality requirements
TÜV SÜD Chemie Service GmbH Folie 819.07.2013
Project specification - Principles
PEDPED
EN 13445
Company standards Chemistry-specific quality requirements
TÜV SÜD Chemie Service GmbH Folie 919.07.2013
Conformity Assessment Procedures
TÜV SÜD Chemie Service GmbH Folie 1019.07.2013
Project specification – design
Generally greater wall thicknesses due to lower permissible stresses Generally greater wall thicknesses due to lower permissible stresses y g pASME VIII Div.1 vs. e.g. EN 13445, AD 2000
y g pASME VIII Div.1 vs. e.g. EN 13445, AD 2000
Flanges acc to ANSI standard or DIN EN for pipe connectionsFlanges acc to ANSI standard or DIN EN for pipe connectionsFlanges acc. to ANSI standard or DIN EN for pipe connectionsFlanges acc. to ANSI standard or DIN EN for pipe connections
Additional specifications required for fatigue, stability and additional Additional specifications required for fatigue, stability and additional loads – not covered by ASME VIII Div.1loads – not covered by ASME VIII Div.1
Definition of site-specific earthquake and wind load zonesDefinition of site-specific earthquake and wind load zonesDefinition of site-specific earthquake and wind load zonesDefinition of site-specific earthquake and wind load zones
Determination of technical documentation required for design review Determination of technical documentation required for design review according to module G of PEDaccording to module G of PED
TÜV SÜD Chemie Service GmbH Folie 1119.07.2013
Project specification - design
Technical documentation for design reviewTechnical documentation for design review
• Risk analysis
Technical documentation for design reviewTechnical documentation for design review
Risk analysis• Calculations• Manufacturing drawings• Parts lists• Parts lists• Welding regulations (WPS)• Heat treatment plans• Inspection and testing plans
(ITP)• etc.
TÜV SÜD Chemie Service GmbH Folie 1219.07.2013
Project specification - materials
• Materials acc. to ASME with Particular Material Appraisal (PMA)• Materials acc. to ASME with Particular Material Appraisal (PMA)pp ( )• Specification of chemical composition of ferritic steels to be welded and
formed:C ≤ 0 23 % (melt analysis)
pp ( )• Specification of chemical composition of ferritic steels to be welded and
formed:C ≤ 0 23 % (melt analysis) C ≤ 0.23 % (melt analysis)
C ≤ 0.25 % (piece analysis) P ≤ 0.035 %
S 0 025 %
C ≤ 0.23 % (melt analysis) C ≤ 0.25 % (piece analysis) P ≤ 0.035 %
S 0 025 % S ≤ 0.025 %• Rupture elongation 14%• Notched-bar impact value on ISO-V sample 27 J at lowest
S ≤ 0.025 %• Rupture elongation 14%• Notched-bar impact value on ISO-V sample 27 J at lowestNotched bar impact value on ISO V sample 27 J at lowest
operating temperature, but not greater than 20°C• Welded pipes 100% NDT (e.g. UT, ET)
Notched bar impact value on ISO V sample 27 J at lowestoperating temperature, but not greater than 20°C
• Welded pipes 100% NDT (e.g. UT, ET)
TÜV SÜD Chemie Service GmbH Folie 1319.07.2013
Project specification - materials
• Define plate formats and surface quality
• Material certificates acc to EN 10204
• Define plate formats and surface quality
• Material certificates acc to EN 10204• Material certificates acc. to EN 10204
• Material manufacturers with quality management
• Material certificates acc. to EN 10204
• Material manufacturers with quality managementsystem compliant with PED Annex I clause 4.3independently of material certificate 3.1 or 3.2system compliant with PED Annex I clause 4.3independently of material certificate 3.1 or 3.2
Appendix with scope of evaluated material and dimensions Appendix with scope of evaluated material and dimensions
TÜV SÜD Chemie Service GmbH Folie 1419.07.2013
Material Certificates
TÜV SÜD Chemie Service GmbH Folie 1519.07.2013
QA System of Material Manufacturer
TÜV SÜD Chemie Service GmbH Folie 1619.07.2013
QA System of Material Manufacturer
TÜV SÜD Chemie Service GmbH Folie 1719.07.2013
Project Specification - Manufacturing
• Welder qualification and PQR pursuant to PED Annex I, clause 3.1.2• Welder qualification and PQR pursuant to PED Annex I, clause 3.1.2q papproved by Notified Body or recognized third party
• PQR with weld consumables
q papproved by Notified Body or recognized third party
• PQR with weld consumablesPQR with weld consumables(brand and manufacturer)to be used in manufacturing
PQR with weld consumables(brand and manufacturer)to be used in manufacturing
• Define production tests longitudinal welds
T b t t b h t ld
• Define production tests longitudinal welds
T b t t b h t ld Tube-to-tube sheet welds
• Material marking/traceability during manufacturing
Tube-to-tube sheet welds
• Material marking/traceability during manufacturing• durable marking
• Approval of subcontractors by purchaser
• durable marking
• Approval of subcontractors by purchaser
TÜV SÜD Chemie Service GmbH Folie 1819.07.2013
Welding Procedure Qualification Record (WPQR)
TÜV SÜD Chemie Service GmbH Folie 1919.07.2013
Welder´s Qualification Test Certificate
TÜV SÜD Chemie Service GmbH Folie 2019.07.2013
Project Specification – QA/QC
• Specify non-destructive testing for the specific object
P iti M t i l Id tifi ti (PMI)
• Specify non-destructive testing for the specific object
P iti M t i l Id tifi ti (PMI) Positive Material Identification (PMI) Radiographic testing (RT) on
longitudinal and circumferential seams,
Positive Material Identification (PMI) Radiographic testing (RT) on
longitudinal and circumferential seams,tube-to-tube sheet seams, etc.
Surface-crack testing (PT, MT) Tightness testing (LT)
tube-to-tube sheet seams, etc. Surface-crack testing (PT, MT) Tightness testing (LT)
e.g. of tube-to-tube sheet seams
• Certified NDT personnel acc. to PED, Annex I, clause 3.1.3 on the basis of
e.g. of tube-to-tube sheet seams
• Certified NDT personnel acc. to PED, Annex I, clause 3.1.3 on the basis of EN 473 or SNT-TC-1AEN 473 or SNT-TC-1A
TÜV SÜD Chemie Service GmbH Folie 2119.07.2013
Project Specification – Documentation
Detailed documentation in English with regard to determination of Detailed documentation in English with regard to determination of Detailed documentation in English with regard to determination of inspection intervals and changes/repairsDetailed documentation in English with regard to determination of inspection intervals and changes/repairs
• As-built drawings• Reports on PQR`s and welders’ qualifications• Qualifications of NDT personnel• List of pressure-bearing parts with assignment to material certificates• Material certificates for pressure-bearing parts• Reports on production tests• Heat treatment certificates • Non-destructive test reports• Test report for final and pressure test• Certificate of conformity• Declaration of conformity• Operating manual
TÜV SÜD Chemie Service GmbH Folie 2219.07.2013
Value of Experience
Constantly update manufacturer selectionConstantly update manufacturer selectiony py p• Employee fluctuation/competence drain
Detailed and unambiguous technical specificationDetailed and unambiguous technical specificationg pg p• Leave no room for interpretation
Provisional dimensioning of critical apparatus (e.g. columns)Provisional dimensioning of critical apparatus (e.g. columns)• Comparability of quotations
Clarification meeting with manufacturer prior to placing orderClarification meeting with manufacturer prior to placing order• Common understanding of the specification• Participants: expert from Notified Body, customer• English and Chinese language skills requiredg s a d C ese a guage s s equ ed
Pre-inspection meetingPre-inspection meeting• Review of implementation of the specification requirements
TÜV SÜD Chemie Service GmbH Folie 2319.07.2013
Value of Experience
Design review documentation reflects customary standardDesign review documentation reflects customary standardDesign review documentation reflects customary standardDesign review documentation reflects customary standard
Problems with special calculationsProblems with special calculationsProblems with special calculationsProblems with special calculations
• Proof of stability under consideration of earthquake, wind nozzle loads• Local proof of nozzle loads• Local proof of nozzle loads• Fatigue proof
Material manufacturers with PED-compliant certified quality Material manufacturers with PED-compliant certified quality assurance system not readily availableassurance system not readily available
Material certificates not provided punctually at start of fabricationMaterial certificates not provided punctually at start of fabricationMaterial certificates not provided punctually at start of fabricationMaterial certificates not provided punctually at start of fabrication
TÜV SÜD Chemie Service GmbH Folie 2419.07.2013
Value of Experience
D bl t i l ki d i f t iD bl t i l ki d i f t iDurable material marking during manufacturingDurable material marking during manufacturing
TÜV SÜD Chemie Service GmbH Folie 2519.07.2013
Value of Experience
Intensive quality assurance required e.g. in welding of joints – seam Intensive quality assurance required e.g. in welding of joints – seam Intensive quality assurance required e.g. in welding of joints seam preparation, tack welding, compliance with WPSIntensive quality assurance required e.g. in welding of joints seam preparation, tack welding, compliance with WPS
TÜV SÜD Chemie Service GmbH Folie 2619.07.2013
Value of Experience
M hi i f li f f l t fl i fi l t tM hi i f li f f l t fl i fi l t tMachining of sealing surfaces of large apparatus flanges in final stateMachining of sealing surfaces of large apparatus flanges in final state
TÜV SÜD Chemie Service GmbH Folie 2719.07.2013
Summary
Global sourcing of equipment in investment projectsGlobal sourcing of equipment in investment projects
Best cost countries offer economic advantageBest cost countries offer economic advantage
Global sourcing of equipment in investment projectsGlobal sourcing of equipment in investment projects
Consult Notified Body and certified inspection agency on project specificationConsult Notified Body and certified inspection agency on project specification
Constantly update manufacturer selectionConstantly update manufacturer selection
Intensive QA/QC and expediting necessaryIntensive QA/QC and expediting necessary
ASME Code and EN 13445 as basisASME Code and EN 13445 as basis
Objective is max. inspection interval for in-service inspectionsObjective is max. inspection interval for in-service inspections
Intensive QA/QC and expediting necessaryIntensive QA/QC and expediting necessary
TÜV SÜD Chemie Service GmbH Folie 2819.07.2013
TÜV SÜD BU Chemical, Oil & GasExpertise Responsibility Trust SustainabilityExpertise. Responsibility. Trust. Sustainability.
TÜV SÜD Chemie Service GmbH19.07.2013
Business Unit Chemical, Oil & Gas: In figures
3 Continents3
33
Continents
Locations 33
900
worldwide
Staff worldwide900
1 500
Staff worldwide
Cli t1.500 Clients
TÜV SÜD Chemie Service GmbH
Business Unit Chemical, Oil & Gas: We are there when you need us – all over the world.
H d ffi GGlasgow
Houston TexasShanghai
Head office Germany
BeijingMinneapolis
DetroitMilan
Antwerp
Los Angeles
SingaporeMumbai
Key : Countries in which TÜV SÜD ChemieService has representation
TÜV SÜD South AsiaChemical Services
TÜV SÜD China Chemical Services
TÜV SÜD Chemie ServiceGermany, Benelux, Italy, UK
TÜV SÜD Chemie Service GmbH
TÜV SÜD PetroChemInspection Services Inc.
TÜV SÜD SingaporeChemical Services TÜV SÜD Chemie Service GmbH
BU Chemical, Oil & Gas: We have deep roots ...
2005 Evolved from BAYER's Technical Inspection Unitp
2006Acquisition of Signum Gesellschaft für AnlagensicherheitAcquisition of the materials / welding technology units ofR&M SpezialitätenR&M Spezialitäten
2007Establishment of TÜV SÜD China Chemical ServicesAcquisition of TÜV SÜD PetroChem Inspection Services
2008 Establishment of TÜV SÜD Benelux Chemical Services
Establishment of TÜV SÜD Singapore Chemical Services2009
Establishment of TÜV SÜD Singapore Chemical ServicesAcquisition of the Technical Inspection Unit of DOW Olefinverbund
Ü Ü
2011 Establishment of TÜV SÜD South Asia Chemical Services
Establishment of TÜV SÜD Italia Chemical Services2010
Integration of TÜV SÜD NEL2012
TÜV SÜD Chemie Service GmbH
... and a solid foundation – TÜV SÜD.
800 L ti ld id8001 700
Locations worldwide
Milli i i 2011
17 2001,700 Millions in revenues in 2011
St ff ld id17,20025%
Staff worldwide
Business Unit Chemical 40%
35%
25% Business Unit Chemical, Oil & Gas is part of the Industry Segment.
35%Industry Mobility Certification
TÜV SÜD Chemie Service GmbH
Thank you for your attention!Thank you for your attention!You find us:
ACHEMASIA 2013Booth P21
www.tuev-sued.de
TÜV SÜD Chemie Service GmbH Folie 3419.07.2013