chinese pressure equipments manufacturers...

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)


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


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


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


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 .......


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!


Project specification - Principles

PED

DifferenceASME vs. PED

ASME CodeASME Code

Company standards Chemistry-specific quality requirements


Project specification - Principles

PEDPED

EN 13445

Company standards Chemistry-specific quality requirements


Conformity Assessment Procedures


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


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.


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)


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


Material Certificates


QA System of Material Manufacturer


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


Welding Procedure Qualification Record (WPQR)


Welder´s Qualification Test Certificate


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


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


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


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


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


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


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


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 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 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


... 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


Thank you for your attention!Thank you for your attention!You find us:

ACHEMASIA 2013Booth P21

www.tuev-sued.de


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