EN 13445-5:2002 (E)

Issue 27 (2007-06)

Annex A (normative) Inspection and testing of serially produced pressure vessels Model acceptance..............48
A.1 Introduction..........................................................................................................................................................48
A.2 Limitations for vessels permitted to be clasified as serially produced.........................................................48
A.3 Limitations for model ..........................................................................................................................................49
A.4 Prototype test.......................................................................................................................................................49
A.5 Model acceptance................................................................................................................................................49
A.6 Quality or manufacturing plan ...........................................................................................................................50
A.7 Inspection, non-destructive testing and pressure testing ..............................................................................50
A.8 Acceptance criteria .............................................................................................................................................52
A.9 Marking .................................................................................................................................................................52
A.10 Documentation/Certification ..............................................................................................................................53
A.11 Pressure testing using a statistical basis for serially produced vessels ......................................................53
Annex B (normative) Detailed dimensional requirements for pressure vessels.....................................................54
Annex C (normative) Access and inspection openings, closing mechanisms and special locking
elements ...............................................................................................................................................................56
C.1 General .................................................................................................................................................................56
C.2 Types and dimensions of access and inspection openings...........................................................................56
C.3 Types, location and minimum number of access and inspection openings ................................................57
C.4 Alternative requirements for sightholes openings on small vessels ............................................................59
C.5 Closing mechanisms and special locking elements .......................................................................................59
Annex D (informative) Leak Testing .............................................................................................................................68
D.1 General .................................................................................................................................................................68
D.2 Leak testing personnel .......................................................................................................................................68
Annex E (informative) Acoustic emission ..................................................................................................................69
E.1 General .................................................................................................................................................................69
E.2 Useful standards ................................................................................................................................................. 69
E.3 Acoustic emission personnel.............................................................................................................................69
E.4 Additional requirements ..................................................................................................................................... 69
Annex F (normative) Inspection and testing of pressure vessels or parts subject to creep................................. 71
F.1 General ................................................................................................................................................................ 71
F.2 Extent of inspection and testing ....................................................................................................................... 71
F.3 Performance of NDT and acceptance criteria................................................................................................ 72a
F.4 Records ............................................................................................................................................................. 72a
Annex G (normative) Inspection and testing of pressure vessels subject to cyclic loads ....................................73
G.1 General .................................................................................................................................................................73
G.2 Extent of inspection and testing ........................................................................................................................73
G.3 Performance and acceptance criteria ...............................................................................................................74
G.4 Technical documentation, additional requirements ........................................................................................74
Annex H (informative) Declaration of compliance with this standard ......................................................................75
Annex I (informative) Specific tests during construction to assist in-service inspection ................................... 76a
I.1 General .............................................................................................................................................................. 76a
I.2 Metallographic investigation ........................................................................................................................... 76a
I.3 Hardness measurements................................................................................................................................. 76a
I.4 Dimensional measurements............................................................................................................................ 76b
Annex ZA (informative) Clauses of this European Standard addressing essential safety requirements
or other provisions of the Pressure Equipment Directive 97/23/EC .............................................................77

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EN 13445-5:2002 (E)
Issue 32 (2008-10)

Foreword
This document (EN 13445-5:2002, EN 13445-5:2002/A2:2005, EN 13445-5:2002/A3:2006, EN 13445-
5:2002/A5:2006, EN 13445-5:2002/A4:2006, EN 13445-5:2002/A1:2007 and EN 13445-
5:2002/A10:2008) has been prepared by Technical Committee CEN/TC 54 "Unfired pressure vessels",
the secretariat of which is held by BSI.

EN 13445-5:2002 shall be given the status of a national standard, either by publication of an identical text
or by endorsement, at the latest by November 2002, and conflicting national standards shall be withdrawn
at the latest by November 2002. EN 13445-5:2002/A2:2005 shall be given the status of a national
standard, either by publication of an identical text or by endorsement, at the latest by December 2005,
and conflicting national standards shall be withdrawn at the latest by December 2005.
EN 13445-5:2002/A3:2006 shall be given the status of a national standard, either by publication of an
identical text or by endorsement, at the latest by November 2006, and conflicting national standards shall
be withdrawn at the latest by November 2006. EN 13445-5:2002/A5:2006 shall be given the status of a
national standard, either by publication of an identical text or by endorsement, at the latest by February
2007, and conflicting national standards shall be withdrawn at the latest by February 2007. EN 13445-
5:2002/A4:2006 shall be given the status of a national standard, either by publication of an identical text
or by endorsement, at the latest by June 2007, and conflicting national standards shall be withdrawn at
the latest by June 2007. EN 13445-5:2002/A1:2007 shall be given the status of a national standard, either
by publication of an identical text or by endorsement, at the latest by December 2007, and conflicting
national standards shall be withdrawn at the latest by December 2007. EN 13445-5:2002/A10:2008 shall
be given the status of a national standard, either by publication of an identical text or by endorsement, at
the latest by April 2009, and conflicting national standards shall be withdrawn at the latest by April 2009.

NOTE Issue 25 of EN 13445-5:2002 incorporates the specific provisions of EN 13445-3:2002/A2:2007 concerning

non-destructive testing of welded joints and final assessment for vessels designed by experimental methods.

Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent
rights.

This document has been prepared under a mandate given to CEN by the European Commission and the
European Free Trade Association, and supports essential requirements of EU Directive(s).

For relationship with EU Directive(s), see informative annex ZA, which is an integral part of this
document.

In this standard the Annexes A, B, C, F and G are normative and the Annexes D, E, H and I are
informative.

This European Standard consists of the following Parts:

Part 1: General.
Part 2: Materials.
Part 3: Design.
Part 4: Fabrication.
Part 5: Inspection and testing.
Part 6: Requirements for the design and fabrication of pressure vessels and pressure parts constructed
from spheroidal graphite cast iron.
CR 13445-7, Unfired pressure vessels - Part 7: Guidance on the use of conformity assessment
procedures.

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the
following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Cyprus,
Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy,
Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia,
Slovenia, Spain, Sweden, Switzerland and the United Kingdom.

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6.6 Non-destructive testing of welded joints

6.6.1 Extent of non-destructive testing

The required extent of non-destructive testing depends both on the testing group and the type of the welded joints.
Guidance to determine the required extent of testing is given in the following clauses.
For serially produced pressure vessels an alternative route is given in Annex A. This annex is not applicable to
vessels or vessel parts designed according to Design by Analysis – Direct Route of Annex B of EN 13445-3:2002
or designed according to 6.3 of EN 13445-3:2002. This annex is not applicable for vessels or vessel parts working
in the creep range.

6.6.1.1 Use of testing groups

6.6.1.1.1 General
The non-destructive testing of welded joints for final acceptance purposes shall depend upon the testing group or
subgroup of the welded joint under consideration.
In Table 6.6.1-1, testing groups 1, 2, 3 and 4 apply below the creep range. Testing groups 1, 2 and 3 are
subdivided into sub-groups 1a, 1b, 2a, 2b, 3a, 3b, in order to reflect crack sensitivity of the material. In Table F.2-1
of Annex F, testing sub-groups 1c and 3c apply to creep.
NOTE 1 The testing groups or sub-groups take into consideration the manufacturing difficulties associated with different
groups of steel, maximum thickness, welding process, service temperature range and joint coefficient. It is intended that any of
the testing groups will provide adequate integrity for typical applications within the limitations contained within Tables 6.6.1-1
and F.2-1.
For vessels (or vessel parts) designed according to Design by Analysis – Direct Route of Annex B of EN 13445-
3:2002 or designed according to 6.3 of EN 13445-3:2002, only testing group 1 is permissible.
NOTE 2 Further restrictions are given in Annex A of EN 13445-3:2002.
For vessels designed by experimental methods, the testing group to be considered for the vessel or vessel part
shall be determined according to the rules given in Table 6.6.1-1 and the possible limitations stated in 20.5 of EN
13445-3:2002.
NOTE 3 The weld joint coefficient is not used in design by the experimental method without calculation.
For vessels (or vessel parts) working in the creep range only testing groups 1c and 3c are permissible. The extent
of NDT is given in Table F.2-1 of Annex F. Testing groups 1, 2 and 3 are permissible for any welded joint not
subjected to creep.

6.6.1.1.2 Testing groups 1, 2 and 3

It is intended that a single testing group is applied to the entire vessel.
When the vessel is made of several sections (courses), a combination of testing groups 1, 2, and 3 is permissible
providing that the requirements of Table 6.6.1-1 are met.
If a combination of testing groups is necessary, for example as the result the use of DBA Direct Route, of the
Alternative Route, of design in the creep range or for fatigue in a section (course), the following shall apply:
a) in each section (course) of the vessel, the testing group of the shell governing welded joints, where present,
shall determine the minimum testing group for all the welds, including the nozzle welds, in that section;
b) the testing group of the weld between two welded sections of different testing groups shall be the higher of the
two testing groups;
c) the minimum testing group (i.e. the one with the lower level of NDT) of the welds between a welded component
and a seamless one (not welded), or between two seamless components, shall be determined by the available
thickness (i.e. actual thickness less tolerances less corrosion allowance) at the weld. Where the available
thickness is greater than 1,17 (this is equivalent to 1/0,85) times the minimum thickness, the testing group of
the weld shall be 3 as a minimum requirement. Otherwise it shall be testing group 1 or 2 according to Table
6.6.1-1.

6.6.1.1.3 Testing group 4

Testing group 4 shall be used as a single group for the entire vessel and shall not be used with any other testing
group.

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6.6.1.1.4 Demonstration of satisfactory experience for testing group 2

Satisfactory experience shall be a minimum amount of welds or vessels of successfully produced and tested within
the scope/parameters of the welding procedure approval test, as given below:

in case of groups 1.1, 1.2 and 8.1 materials, the successful production is 25 consecutive pressure vessels or
50 consecutive metres of governing welded joints;

in case of materials of other groups, it is 50 consecutive pressure vessels or consecutive 100 m of governing
welded joints;

experience in material group 3.1 covers experience in material groups 1.1, 1.2 and 1.3;

experience in material group 1.3 covers experience in material groups 1.1, 1.2;

experience is accepted as long as there is a valid welding procedure approval test for a more critical or at least
a comparable material.

Any imperfection requiring repair during the process of demonstrating experience shall require that the
manufacturer start again the complete demonstration process.

Subsequently, (after demonstration of experience) isolated imperfections shall be handled in accordance with 6.5.3.
and shall not affect the demonstration of experience.

However, multiple, systematic or process imperfections shall be investigated, corrected and the full demonstration
of experience repeated. Such imperfections tend to be repetitive and similar in nature. They can be the result of
inadequate welding parameters (e.g. resulting from equipment malfunction, a too large range of parameters,
incorrect use of parameters within the range of approval) or operator error. In the case of inadequate parameters,
consideration of requalification of the Welding Procedure Specification (WPS) should be performed.

Documentary evidence of the process of demonstration of experience shall be maintained by the manufacturer.

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NOTE Alternatively, when a vessel is lined or coated by a process which could impair the integrity of the
structure e.g. glass lining, it is permissible to reduce the proof test pressure after completion of lining to not less than
1,1 times the maximum allowable pressure P provided that the standard proof test has been applied before lining.
s

For coated or lined vessels which have jackets attached after the lining process (but not welded directly
to the lined vessel) the jacket shall be subject to a proof test of 1,25 P .
s

10.2.3.2.3 The pressure equipment shall be provided with the prescribed marking (e.g. nameplate) at
the time when the proof test is performed at the latest, and when there are a number of pressurized
compartments at the time when the final proof test is performed.

10.2.3.2.4 If it is not practicable, due to size or mode of manufacture, to proof test a complete vessel the
test procedure to be followed shall be approved at the design stage.

10.2.3.2.5 If water is used as the test fluid, the quality of the water used shall be such as to prevent both
corrosion and any residual impervious solids.

For stainless steel vessels in group 8 the following requirements apply:

For vessels without access for cleaning or containing construction elements/joints which permit an
-6
ingress of water - water analysis shall be limited to maximum 1 × 10 chloride content;

For vessels with access and which shall be cleaned immediately after the proof test - water analysis
-6
shall be limited to maximum 20 × 10 chloride content;

For all vessels, a greater chloride content than in 1) or 2) is permissible, subject to documented
technical justification in the hazard analysis.

NOTE Where other liquids are used additional precautions may be necessary depending on the nature of the
liquid.

10.2.3.2.6 All temporary pipes and connections and blanking devices shall be designed to withstand the
test pressure and shall not form a part of what is to be supplied with the vessel. Following the
performance of the proof test, all pipes and connections and blanking devices shall be either removed at
once or positively marked in order to prevent incorrect use. In case of bolted connections the bolts
supplied shall be used and the tightening shall be uniform and to a degree no greater that necessary for
sealing purposes.

10.2.3.2.7 Vessels which have been repaired during or following the pressure test shall again be
subjected to the specified proof test after completion of the repair and any required post weld heat
treatment (PWHT).

10.2.3.2.8 No vessel shall be subject to any form of shock loading such as hammer testing when
undergoing proof testing.

10.2.3.2.9 All deviations from these basic requirements shall be approved at the design stage.

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10.2.3.3 Standard hydrostatic test

10.2.3.3.1 For a single-compartment vessel 1) subjected to internal pressure, working below the creep range,
and designed according to testing group 1, 2 or 3, the test pressure, applied as internal pressure at the highest
point of the chamber of the vessel for either horizontal or vertical test positions, shall be as specified in a). The
modifications of the test pressure due to the hydrostatic pressure are specified in b).

Special provisions are given in c) for single-run governing welds and in d) for complete vessels or parts of vessels
working in the creep range.

a) The test pressure shall be determined by the greater of:

fa
Pt 1,25 P d (10.2.3.3.1-1)
fT
d
or

Pt 1,43 Ps (10.2.3.3.1-2)

where:

Pt is the test pressure measured at the highest point of the chamber of the vessel in the test position;

P d and Td are the coincident design pressure and design temperature values for the maximum pressure load
case;

Ps is the maximum allowable pressure of the vessel;

f a is the nominal design stress for normal operating load cases of the material of the part under consideration at
the test temperature;

fT d is the nominal design stress for normal operating load cases of the material of the part under consideration at
temperature Td ;

fa fa
Since the ratio depends on the material of the part under consideration, the value to be used for
fT fT
d d
calculation of Pt shall not be less than the smallest ratio obtained considering the different materials of the main
pressure bearing parts (e.g. shells, ends, tubesheets of heat exchangers, tube bundles, main flanges but ignoring
bolting associated to main flanges). Main pressure bearing parts do not include pressure rated standard flanges
and bolting designed without calculation according to the rules of paragraph 11.4.2 of EN 13445-3:2002.

NOTE 1 The rules of paragraph 11.4.2 of EN 13445-3 deal with the use of standard flanges without calculation.

1) The case of multi-compartment vessels is covered in 10.2.3.3.3

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Pt , Ps , f a and f T d shall have consistent units.

The maximum pressure load case is that set of coincident design pressure and design temperature which
gives the highest test pressure.

If the bolting associated with the main flanges is overstressed due to the test pressure, the test pressure
may be reduced until the bolt stresses are acceptable.

The design of the vessel shall be such that in no part the test pressure exceeds the maximum permissible
pressure for testing load cases defined in 3.15b of EN 13445-3:2002 according to the relevant design
rules of EN 13445-3:2002. For Design By Formulae (DBF) and Design By Analysis (DBA) according to
Annex C, the maximum permissible pressure is determined using the nominal design stress given in
Table 6-1 for testing load cases. For DBA – Direct Route according to Annex B, the maximum permissible
pressure is determined using the safety coefficients for testing load cases given in Tables B.8-3 and B.8-
4.

NOTE 2 For testing load cases during final assessment the corrosion allowance may be ignored (but not for any
in service test).

NOTE 3 The pressure test is not aimed to dimension the pressure vessel. However, possible increase of the
thickness of tall vessels tested in the vertical position may be necessary to meet the criteria of EN 13445-3:2002.

b) For vessels with hydrostatic pressure during operation which exceeds 3% of the design pressure the
test pressure shall be modified according to equation 10.2.3.3.1-3:

Pt, mod Pt ( Phyd, ope Phyd,test ) but always: Pt, mod Pt (10.2.3.3.1-3)

where:

Pt, mod is the modified test pressure

Pt is as determined in a)

Phyd, ope is the maximum hydrostatic pressure during operation

Phyd, test is the maximum hydrostatic pressure during hydrostatic test

NOTE This modified test pressure is decisive only when the hydrostatic pressure during operation is higher than
the hydrostatic pressure during test. This is possible if the vessel in operation contains liquid with specific gravity
higher than the specific gravity of the test medium or if a vertical vessel is tested in the horizontal position.

c) For vessels with single-run governing welds not made by fully mechanical welding (see Table 6.6.1-1)
and inspected according to 6.6.2.3.2 a), the proof test pressure shall be as given in a) but replacing 1,25
by Fk in formula 10.2.3.3.1-1.

fa
Pt Fk Pd (10.2.3.3.1-4)
fT
d

The values of Fk are given by Table 10.2.3.3.1-1.

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BLANK PAGE

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Table 10.2.3.3.1-1 — Value of Fk

Actual thickness Corrosion maximum shape deviations

Fk
of the shell allowance h : peaking
(measured after test)
e c ew : excess weld
e 4 mm 2,1 c 1 mm h 0,5 ew 0,75 emin
h 0,5 emin
c 1 mm
ew 0,75 emin
e 4 mm 2,0 c 1 mm h 0,5 ew 0,5 emin
2,1
h 0,5 emin
c 1 mm
ew 0,5 emin
4 e 5 mm 1,9 c 1 mm h 0,5 ew 0,5 emin
2,1 c 1 mm 1
h emin
3
ew 0,25 emin
5 e 7 mm 1,8 c 1 mm 1
h emin
4
2,0 c 1 mm
ew 50% of allowed value
given in Table 6.6.3-1
7 e 10 mm 1,7 c 1 mm 1
h emin
6
1,9 c 1 mm ew 50% of allowed value
given in Table 6.6.3-1

In Table 10.2.3.3.1-1:

emin is the minimum possible fabrication thickness, as defined in EN 13445-3

h is the peaking after test, measured as defined in EN 13445-4

ew is the excess weld, as illustrated by h in number 1.9 of EN ISO 5817:2003

The circumferential membrane stress in the main seams with the actual or nominal thickness shall not exceed
c
the nominal design stress f test given in Table 6-1 of EN 13445-3 for testing and exceptional load cases but shall
be greater or equal to 0,85 f test .

During the hydrotest a value of 1 for the weld joint coefficient z defined in EN 13445-1 shall be used.

It is acceptable to replace the actual or nominal thickness by emin .

d) For complete vessels or parts of vessels working in the creep range, the test pressure shall be calculated as in
a) above but with f T d replaced by f nc,T the nominal design stress for normal operating load cases of the
d
material of the part under consideration at design temperature Td of the maximum pressure load case, using time-
independent material characteristics.

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EN 13445-5:2002 (E)
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If the required time-independent characteristics are not available in the materials standard at that temperature they
may be determined as follows:

For vessels designed to testing group 1c (see Table F.2-1): at the highest temperature for which time-
independent characteristics are available in the materials standard;

For vessels designed to testing group 3c (see Table F.2-1): using Annex S of EN 13445-3;

Alternatively time-dependent material characteristics can be taken.

From the three methods described above for determining the nominal design stresses for normal operating load
cases, a consistent method shall be used for all parts.

NOTE 1 The level of the test pressure has no relevance to the safety of the vessel with respect to creep behaviour. It has
been established to assure consistency with operation below the creep range.

NOTE 2 Use of the time-independent characteristics at the highest temperature for which they are available in the materials
standard (when no such characteristics are available at Td ), gives a lower test pressure, but nevertheless provides adequate
demonstration of strength in the context of testing group 1c.

NOTE 3 The nominal design stress values given in Annex S of EN 13445-3 are based on a logical extrapolation into the
creep range of the time-independent characteristics given in the materials standard below the creep range.

NOTE 4 Use of the time-dependent material characteristics gives a higher test pressure and therefore assures a
conservative demonstration of strength.

10.2.3.3.2 For testing group 4 vessels the test pressure shall not be less than that determined by the following
equations :

For materials of the Group 1.1:

if c 1 mm
and (measured peaking 0,5 excess weld) 0,5 emin
f emin
Pt 2,2 Pd a (10.2.3.3.2-1)
fT emin c
d

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 EN 13445-5:2002 (E)
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if c 1 mm
0,75 emin
0,5 emin
0,75 emin
fa e min
Pt 2,0 Pd
fT e min c
d

emin

For materials of the Group 8.1:

fa
Pt 1,85 Pd
fT
d
0,5 emin

10.2.3.3.3

Pd Td

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10.2.3.3.4 For full or partial jacketed vessels, the inner vessel shall be subject to the maximum differential
pressure caused by the vacuum in the adjacent chamber. An identical approach shall apply in determining
the test pressure for the jacket.

Therefore the determination of the test pressure given by formulae (10.2.3.3.1-1) and (10.2.3.3.1-2) for full or
partial vacuum is modified by replacing Pd by Pd v in formula (10.2.3.3.1-1) and Ps by Ps v in
formula (10.2.3.3.1-2)
where
v = 0,1 (full vacuum);
v 0,1 (partial vacuum);
v = 0 (no vacuum).

In the above formulae, the pressures are expressed in MPa.

For vessels of full or partial vacuum in ½ coil or ½ pipe or box channels designed to EN 13445-3, as
illustrated in figure 8.5-11 or 8.5-12, the external pressure caused by vacuum can be ignored when
determining the test pressure.

Where it is reasonably practicable, single wall vessels subject to operation under vacuum conditions should
be tested under vacuum or applied external pressure to simulate vacuum conditions.

The pressure whether resulting from external pressure or from vacuum should be 1,25 times the external
design pressure, if possible, but in no case less than the external design pressure.

10.2.3.3.5 The temperature of the pressurization liquid shall satisfy all of the following requirements:

a) 5 K above solidification point;

b) 10 K below atmospheric boiling point;

c) and shall be of sufficient temperature that the risk of brittle fracture is avoided (See EN 13445-2,
Annex B).

Thick wall vessels shall not be pressurized until the metal temperature is approximately equal with the
pressurisation medium. During the hydrostatic test the vessel external shall remain dry. If the toughness of
the material or of the component imposes a limit on the test temperature according to annex B of EN 13445-
2:2002 or on the rate at which the pressure is increased, account shall be taken of this and documented in
the test data certificate.

10.2.3.3.6 Vents shall be provided at all high points of the vessel to purge possible air pockets while filling
the vessel. There shall also be adequate venting before drainage to prevent collapse particularly in the case
of large thin wall vessels. Attention shall be given to the support of the vessel during test to protect individuals
from additional risk and the vessel from damage.

10.2.3.3.7 Glasses of sight glasses shall be submitted to an individual proof test at 2 times the design
pressure prior to fitting them on to the vessel. During the proof test of the vessel, measures shall be taken to
protect the personnel from bursting of the glasses e.g. protection covers.

10.2.3.3.8 Pressure of vessels under test shall be gradually increased to a value of approximately 50 % of
the specified test pressure, thereafter the pressure shall be increased in stages of approximately 10 % of the
specified test pressure until this is reached. The required test pressure shall be maintained for not less than
30 min. At no stage shall the vessel be approached for close examination until the pressure has been
positively reduced by at least 10 % to a level lower than that previously attained. The pressure shall be
maintained at the specified close examination level for a sufficient length of time to permit a visual inspection
to be made of all surfaces and joints.

40