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INTERVENTIONS FOR CONFORMITY ASSESSMENT (EXCERPT) (Continued )

TABLE 49.16
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The following annexes complete this Section:
(a) Physical and mechanical properties of materials
(b) Recommendations for the installation of expansion joints
(Table 49.28)
(c) Recommendation for checking of metallic piping against
seismic events
(d) Allowable forces and moments on branches of pumps
49.5.5.4 Section C4, Supports, deals with design of the support-
ing system and with the calculation of supports (Fig. 49.9).
49.5.5.5 General annexes covering buried piping complete the
design chapter (Fig. 49.10).
49.5.6 Part Fabrication
This part provides fabrication rules for the various materials
covered by the Code according to the following sections:
(a) F1, rules applicable to all ferrous materials
(b) F2, rules applicable to nonaustenitic and nonstainless steel
constructions
(c) F3, rules applicable to austenitic stainless steel construc-
tions
(d) F4, rules applicable to fabrication of supports
Each section is divided into chapters that cover design of
–welded joints, forming, welding, tolerances (see Fig. 49.11 and
Table 49.29) and postwelded heat treatment.
Annexes complete these sections; Annex FA1 defines the per-
missible welded joints that depend on the construction category of
the piping (see Fig. 49.12).
49.5.7 Part Testing and Inspection
The chapters of this part define all the testing and inspection
operations to which piping is designed and manufactured in
accordance with Division 1 of the Code.
(a) Testing. The Manufacturer, under his responsibility, must
define the testing type and extent, which must meet the
requirements provided for in this Division of the Code for the
construction category under consideration (see Table 49.30).
Testing shall be carried out by a testing body or depart-
ment, independent of the production department of the
Manufacturer, in charge of performing the testing required by
the Division 1 of the Code and by the Technical Construction
data specified by the Purchaser. Regarding construction
category Ex, the testing shall be at least the testing provided
for in this Division for the construction category A.
(b) Inspection. The construction supervision shall be carried out
by a body or a department appointed by the Purchaser and
in charge of performing the contractual activities related to
the construction supervision that are required in the
Division 1 of the Code and in the construction technical data
specified by the Purchaser. Regarding construction category
Ex, the tasks to be carried out by the inspector shall be at
least those related to construction category A.
(c) Conformity Assessment. The specific requirements for pip-
ing that are within the scope of the PED and the conformity
of which must be assessed according to the procedures are
detailed (see Table 49.31).
49.5.8 Comparison to ASME B31.1 and B31.3
The main differences between CODETI® and ASME B 31.1
are as follows:
(a) The categories of piping are different.
(b) Guarantied properties given without additional require-
ments by the product standard (i.e., ASTM) are lower than
those given by European standards.
(c) Safety factors used in B31.1/B31.3 are higher than those
used in CODETI® (for time-independent conditions).
(d) Testing during and after fabrication is different in some
cases.
49.5.9 Future Developments
The principal development of Division 1 will address an alter-
native procedure for checking bolted flange connections. This
new method, based on the European Standard NF EN 1591, will
account for tightness criteria and loads due to each operating con-
dition including external loading.
Divisions 2 and 3 are in the course of preparation and will
cover the following:
(a) Division 2: pipeline transportation (aboveground or buried)
(b) Division 3: water transportation and steel penstock
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TABLE 49.17 SELECTION OF A CONFORMITY ASSESSMENT PROCEDURE

In addition, specifications covering composite materials falling
or not within the scope of the PED are being prepared.
49.6 PRESENTATION OF COVAP®
49.6.1 Scope
COVAP® (Code for construction of steam boilers and super
heated water boilers) is published by SNCT. COVAP is based on
the French Standard Series NF E 32-100, which was withdrawn
when the new European regulation (PED) came into being. This
Code deals with steam boiler and superheated water boilers and
covers the two basic types of boilers. (firetube and watertube).
According to the Code, a boiler consists of all parts subject to
pressure from water inlet (including valves) to the steam or super
heated water header (including outlet valves, where relevant, or
the last welded joint or flange at outlet of the header). This covers
all reheaters, economizers, piping, and safety accessories connected
directly to the boiler without intervening valves (i.e., subject to
the risk of overheating).
The rules of this Code have been developed to cover equipment
that must comply with the requirements of the PED. They can
also be applied to boilers subject to other regulations.
49.6.2 Links with PED
COVAP® 2003 is in full conformity with the PED due to the
following:
(a) Integration of PED hazard categories (Article 9, Article 10,
and Annex II) in General
(b) Integration of PED conformity assessment procedures
(Article 10 and Annex III) in Testing and Inspection
(c) Conformity with PED essential safety requirements (Annex I)
in the relevant parts of COVAP®
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FIG. 49.7 DETERMINATION OF HAZARD CATEGORY FOR A PIPING CONTAINING A DANGEROUS GAS
Regarding hazard categories, Fig. 5 given in Annex II of the
PED for “fired or otherwise heated pressure equipment with the
risk of overheating intended for generation of steam or superheat-
ing water” has been included in Part G of COVAP(see Fig. 49.13).
Part G also provides figures for vessels and piping to cover
other equipment included in the concept of “assembly” defined by
the PED (“several pieces of pressure equipment assembled by a
Manufacturer to constitute an integrated and functional whole”).
These figures define four hazard categories (I, II, III, and IV in
ascending order) depending on four parameters as follows:
(1) nature of fluid (gas or liquid)
(2) dangers from fluid (flammable, explosive, toxic, oxidizing)
(3) volume of the vessel, V (liters)
(4) operating pressure, P (bar)
Determination of the hazard category of a boiler should not be
considered as a hazard analysis (which, in other respects, is
required by Annex I of the PED).
49.6.3 Main Concepts
49.6.3.1 Failure Modes. The failure modes to which the ves-
sels are likely to be subjected are classified into two types.
(a) Failure Modes of Primary Type. Failure modes of primary
type are modes for which the failure results from the
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TABLE 49.18 RISK ASSESSMENT FOR PIPING FALLING WITHIN THE SCOPE OF THE PED
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TABLE 49.19 RISK ASSESSMENT: ADDITIONAL CRITERIA FOR PIPING BEYOND THE SCOPE OF THE PED

TABLE 49.20 DETERMINATION OF THE CONSTRUCTION CATEGORY IN CODETI®

application or maintenance of a loading of a given intensity (1) incremental collapse

as follows: (2) fatigue cracking
(1) gross plastic deformation
(2) plastic instability (bursting) 49.6.3.2 Construction Categories. The concept of construc
(3) elastic and elastic-plastic instability (buckling) tion categories enables the construction quality of a boiler to be
(4) creep rupture adapted and consistent with its future working conditions. This
(5) brittle fracture concept has been significantly modified to be consistent with the
concept of PED hazard categories.
(b) Failure Modes of the Secondary Type. Failure modes of the
secondary type are modes for which the failure results from (a) In COVAP® 2003, the determination of the construction cat-
repeated variations in loadings as follows: egory of a boiler is based on the following:
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TABLE 49.21 NOMINAL DESIGN STRESS

TABLE 49.22 PERMITTED COMBINATIONS OF THE DIFFERENT NOMINAL DESIGN STRESSES AND PIPING
CATEGORIES, FOR OPERATING CONDITIONS BEYOND THE CREEP RANGE OF THE MATERIAL
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TABLE 49.23 WELDED JOINT COEFFICIENT
(1) hazard category of the boiler (I, II, III, or IV) obtained
from the PED
(2) assessment of the potential hazard of failure
(3) the consequence of a failure
(b) The selection of the construction category has significant
consequences on the construction of the boiler. The most
important are the following:
(1) the type of certificate for the material (specific testing or
nonspecific testing)
(2) the safety factors applied on tensile strength and on
yield strength (see Table 49.32)
(3) the weld joint efficiency (z ⫽ 1.0; 0.85; 0.7)
These requirements are summarized in Table 49.33.
49.6.4 Part Material
Part M defines the minimum conditions to be fulfilled for the
selection of materials, conditions regarding the use of the
products, drawing up of orders, supplying, possibilities of using
products taken from stock, testing, and marking of products.
(a) Boilers Falling Within the Scope of the PED. The products
intended for the fabrication of boilers or boilers components
must be defined by one of the following documents:
(1) a supporting harmonized European standard for materials.
(2) a material data sheet resulting from a European
approval for materials for pressure equipment;
(3) a particular material appraisal. For piping falling within
hazard category III, the particular appraisal shall be per
formed by the Notified Body in charge of the conformi-
ty assessment procedures for the piping.
For the products intended for the fabrication of a
boiler not subject to the essential safety requirements
of the above-mentioned documents, the rules of para.
(b) below apply.
(b) Boilers Beyond the Scope of the PED. The products intend
ed for the fabrication of boilers or boilers components shall
be defined by referring to a standard or, in the absence of
such a standard, to a particular specification that attests that
these products are suitable for the intended use.
According to the grouping of materials listed in Table 49.34
(taken from EN 288-3), the selection of a material and acceptance
criteria are related to construction category.
The rules of this part are completed by the following six
Annexes:
(1) prevention of risk of brittle fracture based on fracture
mechanics.
(2) prevention of risks of corrosion.
(3) safe products intended for the manufacture of piping
subject to the essential safety requirements of the
European PED or the relevant French transposing regu-
lations (Decree 99-1046). This Annex allows the use of
materials that are not covered by European standards
but that are covered by other recognized standards (i.e.,
French or German standards).
49.6.5 Part Design
The Code provides two complementary types of design rules:
specific design rules (DBF ⫽ design by formula) and general
design rules (DBA ⫽ design by analysis).
(a) The specific design rules cover the most usual components
and welded joints subject to common loadings (i.e., pressure).
In these rules, the thickness of the component is determined by
a direct formula, or the strength of the component is checked
by formulas or graphs. Due to this type of pressure equipment,
special attention is paid to the determination of design temper-
atures. No other justification is necessary if these rules are
used in accordance with their conditions of applicability. The
following is covered by the specific design rules:
(1) cylindrical shell
(2) spherical shell
(3) rectangular header
(4) formed ends
(5) flat ends
(6) openings in cylindrical or spherical shells and in formed
ends
(7) water or steam pipes
In addition to the above rules, specific rules regarding fire-tube
boilers are provided (e.g., for tubesheet and furnace; see Fig. 49.14).
(b) The general design rules are intended to be used when the spe-
cific rule do not apply. In these rules, which are covered in
Annexes CA1 and CA2, the check of the strength is performed
by complying with criteria regarding stresses or stress ranges.
Determination of the required stresses shall be performed
either numerically, analytically, or experimentally.
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TABLE 49.24 MATERIAL GROUPING

49.6.6 Part Fabrication
This part deals with the fabrication of boilers or boiler compo-
nents. Two complementary sets of design rules are provided in the
following sections:
(a) F1, rules applicable to all ferrous materials
(b) F2, rules applicable to nonaustenitic and nonstainless steel
constructions
(c) F3, rules applicable to austenitic stainless steel construc-
tions
Each section covers the following topics: design of welded
joints, forming, welding, tolerances, and postweld heat treatment
(see Table 49.35).
Annexes complete these sections; Annex FA1 defines the per-
missible joints according to the construction category of the boiler
(see Table 49.36).
49.6.7 Testing and Inspection
The various sections of this part define the testing and inspec-
tion operations to which boilers must be subjected.
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TABLE 49.25 STEEL GRADES AND MAXIMUM PERMISSIBLE THICKNESSES IN RELATION TO CONSTRUCTION
CATEGORIES
49.6.7.1 Testing. A testing body or department independent of
the production department of the Manufacturer shall carry out the
testing. The Manufacturer, under his responsibility, shall define
the testing type and extent, which shall meet as a minimum the
requirements provided for in the Code for the construction catego
ry under consideration (see Table 49.37).
49.6.7.2 Inspection. The construction supervision shall be car
ried out by a body department appointed by the Customer (named
“Principal”) in COVAP.
49.6.7.3 Conformity Assessment. The Code defines the specif-
ic requirements for boilers that are within the scope of the PED
The conformity assessment must be performed according to Table
I.10.4.3.1 of the Code (see excerpt, Table 49.38).
TABLE 49.26 SAFETY FACTORS
Depending on the hazard category of the vessel, conformity
assessment may be carried out by the Manufacturer or by a
Notified Body, in accordance with one of the given procedures
(see Table 49.39).
The inspection body may be any of the following:
(a) the inspection department of the Principal.
(b) a specialized body selected by the Principal.
(c) a department of the Manufacturer in charge of performing
all or part of the supervision of the construction; after agree-
ment between the parties involved, a certified quality system
of the Manufacturer is implemented under the responsibili-
ty of the Manufacturer.
The Principal in the order shall specify the procedure regarding
the activities of the inspection body.
49.6.8 Comparison to ASME BPVC Section I
The scope of COVAP® 2003 is similar to the scope of ASME
BPVC Section I, except that miniature boilers are not specifically
addressed and locomotive, portable, and traction service boilers
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TABLE 49.27 COMPONENTS