1. Pressure Equipment Workshop September 2007 – Day 1
In-service inspection
Ed Haynes, Guy Baylac
Taiex PED & SPVD
Israel, September 2007

2. Layout
Introduction
Laison with the PED: extension of application, operating instructions
Presentation of two typical European legislations
Research, Pre-standardization and Data collection
Conclusion
Taiex PED & SPVD
Israel, September 2007

3. In-service inspection (ISI) – Introduction (1)
In-service inspection starts when the equipment is in service.
At present in-service inspection surveillance is within the competence of Member States, see PED Article 2, Surveillance of the market, point 2
The provisions of this Directive shall not affect Member States’ entitlement to lay down …, such requirements … to ensure that persons …are protected …during use of the pressure equipment or assemblies …provided this does not mean modifications …in a way not specified in this Directive.
Taiex PED & SPVD
Israel, September 2007

4. In-service inspection (ISI) – Introduction (2)
The user of the equipment is responsible for in-service inspection, maintenance and repair.
If there is a large consensus on the principles there are substantial differences in the planning of inspections and the selection of methods, which may introduce large discrepancies in operating costs.
Hence the need of comparison studies, harmonisation, research and standardization.
Taiex PED & SPVD
Israel, September 2007

5. extension of application and operating instructions
Liaison with the PED:
extension of application and operating instructions
Taiex PED & SPVD
Israel, September 2007

6. Extension of the domain of application of the PED
PED does not apply to the assemblies mounted on the site and after putting in service.
But, national legislations may decide that the provisions of Annex I are applicable to:
the assemblies mounted on the site
and
the repairs or modifications of pressure equipment
Taiex PED & SPVD
Israel, September 2007

7. Operating instructions and technical documentation (1)
The user must define the operating conditions of the equipment using the operating instructions and technical documentation
The following elements present a special interest for in-service inspection
Mounting including possibilities of inspection
Putting in service
Use
Maintenance including checks by the user
Taiex PED & SPVD
Israel, September 2007

8. Operating instructions and technical documentation (2)
But also
Hazard analysis with reference to hazards arising from misuse
Particular features of the Design
Reduced safety factors
Fatigue analysis (See details later)
Creep analysis with monitoring or without monitoring, inspection before creep damage index D reaches 0,5
Data concerning materials and fabrication
Materials data e.g. for repairs
Standard hydrotest or hydrotest at a higher test pressure
Taiex PED & SPVD
Israel, September 2007

9. Operating instructions for a vessel with fatigue operation (1)*
Tests during operation
Record in a suitable fashion the number of cycles occurring;
A plan should be prepared for the inspection of the vessel throughout its life;
The vessel should be internally inspected by VT, RT, UT, PT as relevant, at a period not later than 20 % of the allowable life (or the time when the fatigue damage index D reaches 0,2).
Early detection of incipient damage is essential: fatigue crack growth generally occurs exponentially;
* as given in Annex M of EN
Taiex PED & SPVD
Israel, September 2007

10. Operating instructions for a vessel with fatigue operation (2)
Supplement internal inspections by non-destructive tests on highly loaded locations especially by surface crack tests and UT;
For monitoring inaccessible areas a UT from the outside surface may be appropriate;
If the operating conditions deviate from those assumed during design or if damage in the wall is to be expected before the end of the next inspection interval owing to other operating influences, the inspection intervals should be shortened.
Conversely, if no incipient cracks are detected during regular inspections, the vessel may be operated further up to the next inspection in the interval laid down or agreed, even if the allowed lifetime as calculated has been reached or has been exceeded.
Taiex PED & SPVD
Israel, September 2007

11. Operating instructions for a vessel with fatigue operation (3)
Measures to be taken when D = 1
Non-destructive tests should be performed as completely as possible concentrating on the highly stressed locations;
If no cracks are detected in the non-destructive tests conducted in the inspection intervals and in the test above, continued operation may be allowed;
If cracks or crack-like defects or more extensive damage are found, the component should be replaced, unless continued operation appears admissible by virtue of appropriate measures.
Removal of cracks by grinding
Grinding the welds to remove all notches
Elimination of deformation restraints
Change in mode of operation
Repair by welding
Taiex PED & SPVD
Israel, September 2007

12. Use of design data for in-service inspection
The user must prepare an inspection plan
As shown by the example, the hazard analysis contained in the operating instructions gives useful information to select the inspection intervals and the critical locations
However the hazard does not take into account the consequence of the failure (damage to persons and environment, financial losses)
This is the reason why there is a consensus among users to utilize another parameter called criticity or risk and defined as follows:
( criticity = probability of failure x consequence of failure )
Taiex PED & SPVD
Israel, September 2007

13. Taiex PED & SPVD
Israel, September 2007

14. Modern approach to in-service inspection
The inspection plan is established in function of the criticity or risk : it is a risk-based analysis
The probability of failure is determined using a Fitness For Service analysis including
Fatigue
Creep
Corrosion
Fracture mechanics
Actual transients
Actual material properties
Taiex PED & SPVD
Israel, September 2007

15. Presentation of two typical European legislations UK and France
UK goal setting legislation
FR goal setting and prescriptive legislation
Taiex PED & SPVD
Israel, September 2007

16. (UK) Pressure Systems Safety Regulations 2000
Responsibilities for:
Designers
Manufacturers
Installers
Owners and Users
Repairers
Competent Persons
Taiex PED & SPVD
Israel, September 2007

17. (UK) Pressure Systems Safety Regulations 2000
Applicable to:
Rigid Pressure Vessels, Pipework, Protective Devices
Pipework and Protective Devices with Gas Cylinders
Pipelines and Protective Devices
There are some (partial) exemptions
Taiex PED & SPVD
Israel, September 2007

18. (UK) Pressure Systems Safety Regulations 2000
Relevant Fluid
Steam
Gas > 0,5 bar
Liquid with vapour pressure > 0,5 bar
Taiex PED & SPVD
Israel, September 2007

19. (UK) In-Service Inspection Requirements
Regulation 8 – Written Scheme of Examination
Regulation 9 – Examination in Accordance with the Written Scheme
Regulation 10 – Action in case of Imminent Danger
Taiex PED & SPVD
Israel, September 2007

20. (UK) Regulation 8 – Written Scheme of Examination
Owner/User must have a written scheme
Pressure vessels
Protective devices
Pipework
Certified by Competent Person
Reviewed periodically
Taiex PED & SPVD
Israel, September 2007

21. (UK) Content of Written Scheme
Parts to be Examined
Nature of Examinations
Preparations Required
Intervals between Examinations
Competent Person
Date of Certification
Taiex PED & SPVD
Israel, September 2007

22. (UK) Examination Frequency
Records for System/Similar Plant
Current Condition
Operating Conditions/Contents
Levels of Maintenance
Industry Guidance
Risk Based Inspection
Taiex PED & SPVD
Israel, September 2007

23. (FR) The French legislation on in-service inspection
The legislation is contained in:
Articles 17, 18 and 19 of the Decree of 13 December 1999 transposing the PED
The Ministerial Order of 15 March 2000, text of application of the articles of the Decree.
Taiex PED & SPVD
Israel, September 2007

24. The User is responsible for maintenance, surveillance and repairs
(FR) General requirements of the Decree dated 13 December 1999 (Article 17)
The User must keep the documentation available to the Inspection Authority
The User is responsible for maintenance, surveillance and repairs
Other requirements address
Installation and putting in service
Conditions of use
Repairs and modifications
Taiex PED & SPVD
Israel, September 2007

25. (FR) General requirements of the Decree dated 13 December 1999 (Article 18)
Pressure equipment may be subject to the following inspection operations of the Administration
Declaration of putting in service
Inspection at the time of putting in service
Inspection at periodic requalification
Inspection after repair or modification
Taiex PED & SPVD
Israel, September 2007

26. (FR) General requirements of the Decree dated 13 December 1999 (Article 19)
When an industrial establishment operates, under its responsibility and under the management of its inspection service, planified and systematic inspection actions ensuring the safety of pressure equipment the French Administration of the location of the establishment may
recognize this inspection service
authorize the performance of all or part of the inspections according to article 18
authorize the adjustment of the periodicity of the periodic requalification (Adjusted Regime)
Taiex PED & SPVD
Israel, September 2007

27. (FR) In-service inspection rules
Described in the Ministerial Order dated 15 March 2000
Modified by the Ministerial Orders of 13 October 2000 and 30 March 2005.
The regime of follow-up is based on two components:
Periodic Inspections
Periodic requalifications by hydrostatic test (except derogation of the Central Commission of Pressure Equipment)
Two cases are provided:
General Regime (fixed maximum time intervals between two inspections)
Adjusted (flexible) Regime (for the sites having an Inspection Service Recognised by the French Administration according to provisions of the Circular DM-T/P )
Taiex PED & SPVD
Israel, September 2007

28. (FR) General regulatory Regime (fixed maximum time intervals between two inspections )
Pressure vessels:
Periodic Inspection months maxi
Periodic Requalification 10 years maxi
Steam generators:
Periodic Inspection months maxi
Piping:
Periodic Inspection inspection programme established by the User. No imposed periodicity
Periodic Requalification 10 years. Only certaines lines are concerned in function of PS et DN values (PS> 4 bar & DN > 100)
Taiex PED & SPVD
Israel, September 2007

29. (FR) Adjusted Regime of the Chemical and Petrochemical industries*
Principle: Inspection planning is based on the criticity (also called risk).
( criticity = probability of failure x consequence of failure )
Inspection Plans are established according to a methodology in conformity with a professional guide approved by the Administration.
2 guides exist for different periodicities of inspection :
Periods of 5 & 10 years. Guide DT 32 of U.I.C. and U.F.I.P.
Periods > 5 & 10 ans. Guide DT 84 of U.I.C. and U.F.I.P. (presently limited to 6 & 12 years), applicable after a successful period of 5 years spent at the 5/10 years regime.
* Also applicable to the Energy Sector
Taiex PED & SPVD
Israel, September 2007

30. (FR) Adjusted Regime Pressure vessels:
Periodic Inspection inspection plan established by the User. Intervals up to 5 years ( 6 ) maxi
Periodic Requalification 10 years (12 ) maxi
Steam Generators : Same as for Pressure vessels
Piping:
Periodic Inspection inspection programme established by the User. Intervals up to 10 years ( 12 ) maxi
Periodic Requalification 10 years (12). Only certain lines are concerned in function of the values of PS et DN (PS> 4 bar & DN > 100)
Taiex PED & SPVD
Israel, September 2007

31. (FR) Professional Guide DT 84: Contents
Purpose of the guide
Domain of application
Dispositions necessary to apply the methods
Method of elaboration of an inspection plan
Management of experience feedback
Revision of inspection plans
Documentation
Annexes
Degradation modes
Adequacy of NDT methods to damages
Experience feedback
Special provisions applicable to certain families of equipments
Limit critical operating conditions
Removal of insulation for inspections or periodic requalifications
Taiex PED & SPVD
Israel, September 2007

32. (FR) Circular DM – T/P
The recognition of an Inspection Service depends on the condition of meeting certain requirements:
requirements based on the principles of the standard NF EN :1995 “General criteria for the operation of various types of bodies performing inspection“.
complementary requirements specific to Technical Inspection.
Taiex PED & SPVD
Israel, September 2007

33. (FR) Requirements of Circular DM – T/P 32 510
Normative and regulatory references
Administratives requirements
Independence, impartiality and integrity
Confidentiality
Organisation and Management
Quality System
Personnel
Installations and equipments
Methods and inspection procedures
Manipulation of samples and objects presented to Inspection
Records
Inspection reports and inspection certificates
Sub-contracting
Claims and appeal
Co-operation.
Taiex PED & SPVD
Israel, September 2007

34. Comparison between the two legislations - summary
Good agreement on principles
Goal-setting legislation in UK
Flexibility of In-Service Inspection
Practical nature of Written Schemes
Reduced costs by increasing inspection intervals
Reduced downtime using alternative inspection techniques
Goal-setting and prescriptive legislation in FR
Goal-setting legislation for general requirements
Flexibility of inspection in large sectors (petro-chemical industries and energy sector)
Additional costs due the systematic use of the hydrotest for requalification. (See EPERC TG 3 paper on the EPERC TP Website).
No comparison of the safety records of the two systems available
Taiex PED & SPVD
Israel, September 2007

35. Comparison Study – issues
Is this affecting free-movement or the internal market?
What are the differences amongst Member States?
Should the arrangements be harmonised?
Fixed term or risk-based inspection?
What are the objectives and beneficiaries - Trade, Economic, Safety, Citizens?
An overview report is being prepared for the Commission
Taiex PED & SPVD
Israel, September 2007

36. Research and Standardization
Taiex PED & SPVD
Israel, September 2007

37. Harmonisation of legislations in a global market
A goal-setting legislation for in service inspection in the spirit of the Pressure Equipment Directive is requested by EPERC
To reduce cost discrepancies resulting from different national regulations
To foster the development of Risk-Based Inspection (RBI)
To increase the safety by concentration of available means on critical locations (higher criticity)
The legislation could be supported by the standards resulting from the following R&D actions supported by DG Research
RIMAP
FITNET
Standardization could begin on principles, terminology, ...
Taiex PED & SPVD
Israel, September 2007

38. RIMAP This is a 3-level process with
RIMAP Principles and procedure at the top level,
Tools at the second level and
Application workbooks at the third level – inspection planning and optimisation, benchmarking, and sectors including power, petrochemical, steel etc
Taiex PED & SPVD
Israel, September 2007

39. CEN WA 24
CEN Workshop Agreement on Risk-based inspection and maintenance procedures will cover the basic RIMAP procedure and its application with examples.
Due for publication November 2007
The research work on the model of degradation should continue
Taiex PED & SPVD
Israel, September 2007

40. FITNET FITNET is a network on Fitness For Service addressing
Fatigue
Creep
Fracture Mechanics
Corrosion
FITNET has published 3 volumes (2006)
Volume I: FITNET FFS Procedure
Volume 2: CASES STUDIES AND TUTORIALS
Volume 3: ANNEX
A CEN Workshop Agreement is in preparation
Taiex PED & SPVD
Israel, September 2007

41. Replacement of requalification by hydrotest by other tests
EPERC Report ˝Considerations on the hydrotest,˝  available on the Website, distinguishes
Cases where the hydrotest appears justified
Cases where it is not useful or even detrimental
In the second case, the Report suggests the use of RBI with Fitness for Service methods for planning inspections with appropriate NDT, as this is already done in some countries
EPERC also wishes the publication of the CEN Worshop Agreement FITNET in 2007
Taiex PED & SPVD
Israel, September 2007

42. Experience feedback
The importance of experience feedback for RIB is well known in the development of calculation models
French Union of Chemical Industries and Union of Petrochemical Industries have established data banks of experience feedback
Similar data banks exist in other countries
It is suggested to evolve towards a European data bank
Taiex PED & SPVD
Israel, September 2007

43. Conclusion
A lot of actions have been performed in Europe in the domain of in-service inspection with the support of the European Commission, Member States and Industry
There is a large agreement on the principles, but noticeable differences among Member States in inspection planning and selection of methods, inducing large differences in operation costs but not significant difference in safety
In the global market of today economic issues are essential
A European goal-setting legislation supported by European Standards would reduce cost distortions between countries due to in-service inspection and would foster sustainable safety and European competitiveness.
Taiex PED & SPVD
Israel, September 2007