UNDERSTANDING PED

REQUIREMENTS FOR DEISGN

CALCULATIONS
SPECIFIC REQUIREMENTS FOR PED
VESSEL DESIGN
ASME VIII DIV. 1 AND DIV.2 CAN BE USED AS A
DESIGN STANDARD FOR PED COMPLIANCE.
HOWEVER THERE ARE FEW SPECIFC
REQUIREMENTS.
WE WILL UNDERSTAND THEM IN THIS SESSION
Purpose of the Directive

• Harmonise national requirements

• Remove trading barriers

• Obtain acceptable safety level

24 September 2021
 Pressurised Equipment

Article 1 Section 2

• Pressure vessels
• Piping systems
• Safety accessories
Include elements attached to
pressurised parts, such as:
- Flanges, nozzles, couplings,
supports, lifting lugs, etc.
PE Directive - essential requirements

• All pressure equipment covered by the directive must satisfy the essential
requirements set out in Annex I:
– General
– Design
– Manufacturing
– Materials
– Specific pressure equipment requirements
• Fired/heated pressure equipment with a risk of
overheating
• Piping
• Safety factors for certain pressure equipment

24 September 2021
PE Directive - Classification of equipment

• Pressure equipment shall be classified by

category in accordance with Annex II,
according to ascending level of hazard
• Most vessels and piping are classified on
the basis of:
– their maximum allowable pressure PS, and
– their volume V or their nominal size DN, as
appropriate, and
– the group of fluids for which they are
intended,
(Appropriate tables for vessels or piping are given in Annex II.)

SRINIVASAN RAMAKRISHANN Slide 6 24 September 2021

PE Directive - fluid groups

• Group 1:
Dangerous fluids according to Article 2(2) in Directive 67/548/EEC defined as:
– Explosive
– Extremely flammable
– Highly flammable
– Flammable (where the maximum allowable
temperature is above flashpoint)
– Very Toxic
– Toxic
– Oxidizing
• Group 2:
Comprises all other fluids not referred to in Group 1

SRINIVASAN RAMAKRISHNAN Slide 7 24 September 2021

 Article 3 – Technical Requirements
The pressure equipment referred to in 1.1, 1.2, 1.3 and 1.4
must satisfy the essential requirements set out in Annex I
1.1. Vessels, except those referred to in 1.2 for:
(a) gases, liquefied gases, gases dissolved under pressure, vapors
and also those liquids whose vapor pressure at the maximum
allowable temperature is greater than 0,5 bar above normal
atmospheric pressure, (1 013 mbar) within the following limits:
– for fluids in Group 1 with a volume greater than 1 L and a
product of PS and V greater than 25 bar· L, or with a pressure
PS greater than 200 bar (Annex II, table 1),
– for fluids in Group 2, with a volume greater than 1 L and a
product of PS and V is greater than 50 bar·L, or with a pressure
PS greater than 1·000 bar, and all portable extinguishers and
bottles for breathing apparatus (Annex II, table 2);

SRINIVASAN RAMAKRISHNAN Slide 8 24 September 2021

Article 3 – Technical Requirements
(b) liquids having a vapor pressure at the maximum
allowable temperature of not more than 0,5 bar above
normal atmospheric pressure (1 013 mbar) within the
following limits:
– for fluids in Group 1 with a volume greater than 1 L and
a product of PS and V greater than 200 bar· L, or with a
pressure PS greater than 500 bar (Annex II, table 3),
– for fluids in Group 2 with a pressure PS greater than 10
bar and a product of PS and V greater than 10 000
bar·7L, or with a pressure PS greater than 1 000 bar
(Annex II, table 4).

SRINIVASAN RAMAKRISHNAN Slide 9 24 September 2021

Article 3 – Technical Requirements
1.2. Fired or otherwise heated pressure
equipment with the risk of overheating
intended for generation of steam or super-
heated water at temperatures higher than
110°C having a volume greater than 2L, and all
pressure cookers (Annex II, table 5)

SRINIVASAN RAMAKRISHNAN Slide 10 24 September 2021

Article 3 – Technical Requirements
1.4. Safety and pressure accessories intended
for equipment covered by 1.1, 1.2 and 1.3
including where such equipment is
incorporated into an assembly.

SRINIVASAN RAMAKRISHNAN Slide 11 24 September 2021

 Sound Engineering Practice (SEP)
Pressure equipment and/or assemblies below or equal to the
limits in sections 1.1, 1.2 and 1.3 and section 2 respectively
must be designed and manufactured in accordance with the
sound engineering practice of a Member State in order to
ensure safe use. Pressure equipment and/or assemblies must
be accompanied by adequate instructions for use and must
bear markings to permit identification of the manufacturer or
of his authorized representative established within the
Community. Such equipment and/or assemblies must not
bear the CE marking referred to in Article 15.

SRINIVASAN RAMAKRISHNAN Slide 12 24 September 2021

Equipment Categorisation [Gp.1 Gases]

Ps PSV = 1000
PSV = 200
PSV = 50
PSV = 25

(Not to Scale)

SEP I II III I
V
Ps = 0.5
V = 1 Litre

TABLE1 : VESSELS FORGROUP1 GASES V

SRINIVASAN RAMAKRISHNAN Slide 13 24 September 2021

PE Directive - conformity assessment procedures

The conformity assessment procedures to be

applied for the various categories are as
follows:

– Category I
- Category III - Category IV
• Module A
- Module B1 + D - Module B + D
- Module B1 + F - Module B + F
– Category II - Module B + E - Module G
• Module A1 - Module B + C1 - Module H1
• Module D1 - Module H
• Module E1

SRINIVASAN RAMAKRISHNAN Slide 14 24 September 2021

 Tasks of Notified body

➢ QS audits and verification of QS implementation.

➢ Shop inspection & Spot checks on pressure equipment
➢ Review of welders certificates, welding procedure qualification records
and NDE operators certificates or
➢ Approval of welders and welding procedure qualifications
➢ Approval of NDE procedures & operators qualification
➢ Review of fabrication documentation
➢ Design Examination
➢ Particular Material Appraisal
➢European Approval of pressure vessel Materials
➢ Type Examination ( if applicable)

SRINIVASAN RAMAKRISHNAN Slide 15 24 September 2021

Technical Document file

The technical documentation must enable an assessment to be made of the

conformity of the pressure equipment with the requirements of the Directive
which apply to it. It must, as far as is relevant for such assessment, cover the
design, manufacture and operation of the pressure equipment and contain:
a general description of the pressure equipment,
•conceptual design and manufacturing drawings and diagrams of
components, sub-assemblies, circuits,
•descriptions and explanations necessary for an understanding of the
said drawings and diagrams and the operation of the pressure
equipment,
•a list of the standards referred to , applied in full or in part, and
descriptions of the solutions adopted to meet the essential
requirements of the Directive where the standards referred to in
Article 5 have not been applied,

Version Slide 16 24 September 2021

Technical Document file

• The reference numbers of which have been published in the Official Journal of
the European Communities, and hence giving presumption of conformity to
the essential requirements for the directive in question.
• The necessary supporting evidence for the adequacy of the design solution, in
particular where the standards referred to in Article 5 have not been applied in
full; this supporting evidence must include the results of tests carried out by
the appropriate laboratory of the manufacturer or on his behalf,
• Results of design calculations made, examinations carried out, etc.,
• Information regarding the qualifications or approvals required under sections
3.1.2 and 3.1.3 of Annex I.
• Test reports
• User handbook or operating manual
• Hazard analysis
• PMA
• Supplier list
• ESSENTIAL SAFETY REQUIREMENT(ESR) CHECK LIST

SRINIVASAN RAMAKRISHNAN Slide 17 24 September 2021

 ACCEPTANCE OF ASME
MATERIALS AS PER ESR 7.1.2

THIS THE FIRST EXERCISE WE NEED TO DO IF WE WANT TO

USE ASME MATERIALS.
ESR 7.1,2 PROVIDES FORMULA FOR CALCULATIONS BASED
ON YILED OR TENSILE STRENGTHS

WE WILL SEE FEW WORKSHEETS AS EXAMPLES

NEXT IMPORTANT CALCULATION SPECIFIC TO PED

HYDRTO TEST CALCULATIONS

PED REQUIRES HYDRO TEST AT 1.43 X DESIGN PRESSURE.
SINCE THIS IS HIGHER THAN ASME UG99b, YOU NEED TO
CALCULATE THE STRESS DUE TO THIS HIGH PRESSURE AND
ENSURE THAT IT IS WITHIN 90% OF THE YIELD.
 PMA DOCUMENTATION
THIS IS THE NEXT STEP A DESIGNER SHOULD DO FOR PED
VESSELS
PMA IS Particular Material Appraisal for Material
Pressure Equipment Directive (97/23/EC)
IT IS DOCUMENTATION OF ASME MATERIALS FOR SOME
SPECIFIC REQUIREMENTS OF THIS DIRECTIVE.
FOLLOWING ARE THE POINTS TO BE COVERED
1. OPERATING CONDITIONS- WHICH INCLUDES
1. ALLOWABLE PRESSURE RANGE
2. AND ALLOWABLE TEMPERATURE RANGE
OF A PARTICULAR VESSEL UNDER PED DESIGN
 PMA DOCUMENTATION-CONTD
COMPLIANCE WITH ESSENTIAL SAFETY REQUIREMENTS
FOR MATERIALS.
• PROPERTIES LIKE YS AND UTS
• DUCTILITY PROPERTIES
• TOUGHNESS
• IMPACT ON AGEING
• SUITABLE FOR INTENDED PROCESS
• MATERIAL TRACEABILITY
• TYPE OF CERTIFICATION
• CHEMICAL COMPOSITIONS
• EXPLANATORY NOTES TO SUPPORT
 PMA DOCUMENTATION-CONTD
Conclusion:
The applicable requirements of the Council Directive No 97/
23/EC is complied with if all conditions specified in this
Particular Material Appraisal are fulfilled. The named material
specification may be used for the construction of pressure
equipment intended for use within the stated limits, provided
that Material meets all the requirements of ASME Sec II Part A,
Ed 2013 Specification SA 516 GR 70
PMA DOCUMENTATION- SAMPLE
PMA DOCUMENTATION- SAMPLE
EXPLANATORY NOTES:
1. ASTM A 516 Grade 70 may be used as an alternative to ASME SA 516 Grade 70
2. ASME SA-516 does not specify elevated temperature properties for this steel.
Hence Verification Testing at Elevated Temperature is required. Acceptance criteria
shall be ASME Sec II Part D Table Y1 & Table U as applicable.
3. Impact testing shall be carried out for material at (-) 29° C or lower & the
resultant Bending rupture energy shall not be less than 27 Joules according to
clause 7 5 of Directive 97/23/EC
4. Equipment have been manufactured satisfactorily in the past from this material
& not shown any sign of Failure during Forming, Welding etc.
5. According to PED annex 1 para 4 3 and PED Working Group "Pressure" Guideline
Nos 7/2 and 7/16 material certificates of type 3.1 according to EN 10204:2004,are
acceptable only if the material manufacturer is operating a quality-assurances
system which is certified by a competent body established within the European
Community, and having undergone a specific assessment for materials Otherwise,
material certificates of type 3 2 according to EN 10204:2004 shall apply
 CALCULATION OF MEMBRANE STRSS AS PER PED FOR
HYDROSTATIC STRESS CONDITION
Design Pressure 21.265
MAWP 24.177
As per PED 97/23/EC, Annex. 1,7.4

Ph 1.43 MAWP 34.57311

R 628
Allowable stress at Design Temperature 20000Psi 1406.173Kg/cm2
Allowable Stress at 50Degc 20000Psi 1406.173
Stress ratio 1
P 0.38SE 534.3458
P< 0.38SE
t 9.583956 14
E 1
t(SE-0.6P) PR
tSE PR+0.6Pt
Sh (PR+0.6Pt)tE
954.4871

THIS IS LESS THAN 90% OF YE 1265.55. HENCE OK

 ESSENTIAL SAFETY REQUIREMENT- CHECK LIST

THIS IS ANOTHER IMPORTANT DOCUMENT TO FULFILL THE PED

DOCUMENTATION REQUIREMENT.
THIS CHECKLIST CONTAINS A NUMBER DESIGN AND
FABRICATION POINTS.
WE WILL REVIEW THE DESIGN POINTS ONLY HERE THROUGH A
SAMPLE CHECKLIST
Sub-Section Essential Safety Requirement Applicable Application Details Specific Documents for compliance

§ (yes / no) Standard (Code)

Sub-Section
PRELIMINARY OBSERVATIONS
1 The obligations arising from the essential
requirements listed in this Annex for pressure
equipment also apply to assemblies where the
corresponding hazard exists. N NA - -
2 The essential requirements laid down in the
Directive are compulsory. The obligations laid
down in these essential requirements apply only if
the corresponding hazard exists for the pressure Designed as per Calculations & Drawing.
High Pressure Autoclave –
equipment in question when it is used under
conditions which are reasonably foreseeable by Working Pressure – 200 Bar
Y ASME Sec.VIII Div
the manufacturer. Design Pressure – 220 Bar
2-2015
3 The manufacturer is under an obligation to analyze Designed as per
the hazards in order to identify those, which apply ASME Sec.VIII
to his equipment on account of pressure; he must
then design and construct it taking account of his Div 2-2015
Y
analysis.
4 The essential requirements are to be interpreted FEA Report
and applied in such a way as to take account of
the state of the art and current practice at the
time of design and manufacture as well as of Y Designed as per FEA, due to Cyclic Loads
technical and economic considerations, which are
consistent with a high degree of health and safety ASME Sec.VIII Div
protection.
2-2015
 ESR- GENERAL
instructions, or in reasonably foreseeable

conditions.
In choosing the most appropriate solutions, the Operation
manufacturer must apply the principles set out Y Instructions/safety
below in the following order: notes

Y
- eliminate or reduce hazards as far as is
reasonably practicable
1.1 Pressure equipment must be designed, Y
1.2 -manufactured
apply appropriate
and checked, protection measures
and if applicable
against
equipped andhazards which
installed, cannot
in such be eliminated
a way as to ensure
its safety when put into service in accordance Designed as per Operation Instructions/safety notes to
-with where
the appropriate,
manufacturer’sinform users of Y be developed by Morgan
residual hazards and indicate whether it is ASME Sec.VIII Div
necessary to take appropriate special
measures to reduce the risks at the time of 2-2015
installation and/or use.

1.3 Where the potential for misuse is known or can

be clearly foreseen, the pressure equipment
must be designed to prevent danger from such
misuse or, if that is not possible adequate warning
given that the pressure equipment must not be
used in that way.
N
 2. DESIGN

2.1 The pressure equipment must be properly

designed taking all relevant factors into
General Designed as per Designed as per Design Report
account in order to ensure that the equipment will
be safe throughout its intended life. Y ASME Sec.VIII Div Code
2-2015
The design must incorporate appropriate safety
coefficients using comprehensive methods,
which are known to incorporate adequate
safety margins against all relevant failure
modes in a consistent manner.

2.2 The pressure equipment must be designed for Y

loadings appropriate to its intended use and
Design for ASME Sec VIII Div
other reasonably foreseeable operating
Adequate conditions. In particular, the following factors 2
Strength must be taken into account:
- internal/external pressure
Y
2.2.1 - ambient and operational temperatures
Y Design Report Design Report
- static pressure and mass of contents in
operating and test conditions Y
 2.2.3 (a) Pressure containment and other loading aspects

The allowable stresses for pressure

Calculation
Y Designed as per
equipment must be limited having regard to reasonably
Method foreseeable failure modes under operating conditions.
ASME Sec.VIII Div
To this end, safety factors must be applied to eliminate
fully any uncertainty arising out of manufacture, actual
2-2015
operational conditions, stresses, calculation models and
the properties and behavior of the material.

These calculation methods must provide sufficient

safety margins consistent, where applicable, with the
requirements of section 7.

The requirements set out above may be met by

applying one of the following methods, as appropriate,
if necessary as a supplement to or in combination with
another method: Design Report
- design by formula

– design by analysis
– design by fracture mechanics;

(b) Resistance [cf. strength]

Y
SAMPLE ESR CHECKLIST WILL SHOW THE OTHER
POINTS TO BE CONSIDERED.

THE DESIGN AND QA TEAM SHOULD SIT TOGETHER

AND FILL THE FORM AND ATTACH SUPPORT
DOCUMENTS LIKE
• DESIGN CALCULATIONS
• DESIGN REPORT (BY NOTIFIED BODY)
• O&M MANUAL
• SAFETY PROCEDURES
• HAZID REPORTS
• ETC.
 PROCESS STEPS FOR DESIGN AS PER PED

1. GET THE APPROPRIATE MODULE FROM NOTIFIED BODY

2. CALCULATE ALLOWABLE STRESS ACCEPTANCE FOR MATERIALS
3. PERFORM DEISGN CALCULATIONS AS PER ASME CODE
4. PERFORM HYDRO TEST CALCS AS PER PED
5. PREPARE PMA FOR ALL PRESSURE PART MATERIALS
6. PREPARE ESR CHECKLIST WITH SUPPORT DOCUMENTS
7. GET ALL THIS THINGS REVIEWED BY NB
8. THEY WILL ISSUE APPROVAL FOR DESIGN.
9. THEN PROCEED WITH MANUFACTURING AS SPECIFIED BY PED.