Вы находитесь на странице: 1из 45

Presentation for ITER DAs

Regulations:
Pressure and Nuclear pressure
equipment

JP. LONGIN and Th. JOURDAN


October, 2007
List of Regulatory documents applicable to
pressure and nuclear pressure equipment

• French regulations
• PE and conformity assessment
• NPE and conformity assessment
• Who is doing what
• Risk analysis and ESR
• Procedures and welding
• Material
• Summary

2
List of Regulatory documents applicable to
pressure and nuclear pressure equipment
Final
Design Manufacture inspection Installation Operation
Evaluation of conformity Monitoring in service

EU Pressure equipment directive (PED) 97/23/EC


From 29 may 2002 the PED is obligatory throughout the European Union

PRESSURE EQUIPMENT

French decree dated 13 December 1999 concerning pressure equipment


Transposition of PED + provisions applicable to operating equipment
FR
French order dated 21 December 1999 French order dated 15 March 2000
Classification and Evaluation of the conformity of PE Pressure equipment operation

NUCLEAR PRESSURE EQUIPMENT

French order dated 12 December 2005 concerning nuclear pressure equiment (NPE)
Same principal as in PED, specific classification, evaluation of conformity, operation and monitoring
3
What is a Pressure Equipment ?

Component part

Parts for equipment


No specific requirement – Not under PED

Type of Pressure equipment


equipment Vessels, piping, pressure accessories, safety accessories
Where applicable, pressure equipment includes elements
attached to pressurized parts such as nozzles, flanges, elbows,
The definitions are supports, lifting lugs etc…
same for PE and Under PED
NPE

Assembly
Several pieces of pressure equipment assembled by a
manufacturer to constitute an integrated and functional role
Under PED

4
What is a Pressure Equipment ?

Product classification
 PS > 0.5 bar
 Fluid: gas and liquid
 Level of fluid danger : group 1 or group 2
 Pressure and volume or DN

Product classification categories


 SEP : Sound Engineering Practice
 4 Categories : I, II, III and IV

Conformity assessment
 SEP : No conformity assessment
 Category I : Manufacturer declaration
 Categories II, III, IV : Manufacturer declaration and Notified Body evaluation 5
Conformity assessment procedure for PE

Conformity assessment procedures


Quality System
Without QA With QA
Mode of
Mass-produced Single unit Mass-produced Single unit
manufacturing

Category I A Internal production control

A1 Internal manufacturing checks D1 E1


Category II
+ monitoring of the final assessment Production QA Product QA

B+E H
B1 + F EC type-examination
Full QA
B + C1 + qa products
Category III EC type-examination
EC design-examination
+ Conformity to type
+ product B1 + D
verification
EC design-examination
+ production QA

B+F B+D H1
G
Category IV EC type-examination EC unit EC type-examination Full QA
+ product verification verification + design examination
+ production QA
+ survey of the
final assessment
6
Conformity assessment procedure for PE

EC unit verification
Module G Conformity assessment for :
PE up to cat IV
Manufacturer

The application must contain :


Must apply to NB for unit verification  Name and address of the manufacturer
 technical documentation

The technical documentation must contain :


Technical documentation  a general description of the PE
 conceptual design and manufacturing drawings
 descriptions and explanation necessary for an understanding of
the said drawings
 List of standards and description of the solutions adopted to
meet the ESR of PED
 result of design calculations made, examinations carried out
 test report
Notified Body

In particular, the Notified Body must :


Must examine design and  examine the technical documentation
construction of each item of PE  asses the material used where these are not in conformity with
the relevant harmonized standard
 check the certificate issued by the material manufacturer
Perform appropriate test during  approve the procedures of the permanent joining or check that
manufacture as set out the relevant they have been previously approved
standard or equivalent examination  verify the qualifications or approvals for welders and NDT
personnel
to ensure conformity with the ESR
 carry out the final inspection, have performed the proof test,
examine the safety devices if necessary
7
Conformity assessment procedure for PE

EC unit verification
Module G Conformity assessment for :
PE up to cat IV

Notified Body

Must affix its identification number

Draw up a certificate of conformity This certificate must be kept for a period of 10 years
for the test carried out

Manufacturer

The manufacturer or his authorized These documents can be made available on request
representative established within the
European Community must establish
a declaration of conformity

8
Conformity assessment procedure for PE

Conformity assessment procedures


Quality System
Without QA With QA
Mode of
Mass-produced Single unit Mass-produced Single unit
manufacturing

Category I A Internal production control

A1 Internal manufacturing checks D1 E1


Category II
+ monitoring of the final assessment Production QA Product QA

B+E H
B1 + F EC type-examination
Full QA
B + C1 + qa products
Category III EC type-examination
EC design-examination
+ Conformity to type
+ product B1 + D
verification
EC design-examination
+ production QA

B+F B+D H1
G
Category IV EC type-examination EC unit EC type-examination Full QA
+ product verification verification + design examination
+ production QA
+ survey of the
final assessment
9
Conformity assessment procedure for PE

Full quality assurance


Module H Conformity assessment for :
PE up to cat III
Manufacturer

Must implement an approved quality


system for design, manufacture, final
inspection and testing

Must lodge an application for The application must include :


assessment of his quality system  all relevant information concerning the PE
with a NoBo  the documentation concerning the quality system

The QS documentation must contain in particular a description of:


The quality system must ensure  the quality objectives and the organizational structure,
compliance of the PE with the ESR. responsibilities and power of the management with regard to the
quality of the design and to product quality
 the technical design specifications
All the elements, requirements and  the design control and design verification techniques, processes
provisions adopted by the and systematic measures that will be used when designing the PE
manufacturer must be documented (particularly with regard to materials)
 the manufacturing, quality control and quality assurance technique
processes and systematic measures that will be used
 the examinations and tests to be carried out before, during and
after manufacture (and the frequency of these examinations)
 the quality records such as inspection reports and test data,
qualification for permanent joining and NDT
 the means of monitoring the achievement of required PE design and
quality and the effective operation of the QS
10
Conformity assessment procedure for PE

Full quality assurance


Module H Conformity assessment for :
PE up to cat III
Notified Body
Assessment of QS

Must assess the QS to determine The elements of the QS which conform to ISO 9000 are
whether it satisfies the previous presumed to comply with the previous requirements
The auditing team must have at least one member with experience
requirements
of assessing the PE technology concerned

Must notify its approval (or not)


decision to the manufacturer

Surveillance under the responsibility of the NB

Must carry out periodic audits to The NB provides the manufacturer with an audit report
make sure that the manufacturer
maintains and applies the QS

In addition may pay unexpected The need for such additional visits, and the frequency thereof will
be determined on the basis of a visit control system operated by
visits to the manufacturer the NoBo
Manufacturer

Must, for period of 10 years after the The documentation :


last of the PE has been manufactured,  the QS documentation
keep the documentation at disposal  the modifications of the QS
 the decisions and reports from the NoBo
of the national authorities 11
Conformity assessment procedure for PE

Full quality assurance with design examination


Module H1 and special surveillance of the final assessment for :
PE up to cat IV

Requirements
of Module H
Manufacturer
+ Additional requirements

Must lodge an application The application must include :


for examination of the design  the technical design specifications, including standards witch
with the NoBo have been applied
 the necessary supporting evidence for their adequacy

Notified Body

Must examine the application


The EC design-examination must contain :
 the conclusions of the examination
Issue an EC design-examination  the conditions of its validity
 the necessary data for identification of the approved design
certificate  a description of the functioning of the PE or accessories

Final assessment is subject to Increased surveillance : unexpected visits by the NoBo


increased surveillance
12
What is a Nuclear Pressure Equipment ?

 MUST be Pressure Equipment (PS > 0.5 bar )


 Used in Basic Nuclear Facility
 Direct containment of radioactivity
 Release over 370 MBq in case of failure (for T coeff. 1000)

NUCLEAR PRESSURE EQUIPMENT


(NPE)

13
What is a Nuclear Pressure Equipment ?

ITER facility
Field of PE

Field of NPE

Important
Equipment
for safety

14
What is a Nuclear Pressure Equipment ?

Product classification : 2 classification


PRESSURE RADIOACTIVITY
 PS > 0.5 bar (there are exclusions)  Depending on the significance of
 Fluid : gas and liquid the radioactivity emissions possibly
 Level of fluid danger : group 1 or 2 resulting from the failure of NPE
 Pressure and volume or DN

Product classification categories


 N1 Failure not allowed (only for PWR)
 4 Categories : I, II, III and IV
 N2 > 370 GBq
 SEP : Sound Engineering Practice
 370 MBq < N3 < 370 GBq

The ANB acts on behalf


Conformity assessment of the regulator

 N1 : by regulator (ASN)/conformity evaluation procedure (only for PWR)


 N2 and N3 : by ANB/conformity evaluation procedure : same as PED
15
Conformity assessment procedure for NPE

Level N3, Categories I – IV:


- Same conformity procedures as for PE, described in
Order 1999 (PED)

Level N2:
- Cat III, IV – modules for Category IV (for vessel)
- Cat I, II – modules for Cat III or IV

16
Which actors concerned by PE regulation ?

Design, fabrication and


conformity assessment of PE

MANUFACTURER
NOTIFIED
BODY

ORGANE
D’INSPECTION

17
Which actors concerned by NPE regulation ?

Design, fabrication and


conformity assessment of NPE

MANUFACTURER
ACCEPTED
NOTIFIED
BODY

ORGANE
USER/
D’INSPECTION
EXPLOITANT
OPERATOR

18
User

• INSTALLATION, IMPLEMENTATION
USER or
OPERATOR • MONITORING
=
ITER (IO)
• MAINTENANCE and OPERATION

• MONITORING IN SERVICE

Organisation which operate pressure equipment

Organisation having been authorised to build a basic nuclear

facility in which NPE are installed

19
User : what it has to do?

 IO will compile a list of nuclear pressure equipment used in the facility :

 IO will determine and justify the level and category that is given to each
piece of equipment

 IO will provide the manufacturer with a description of all the possible


conditions : normal operating conditions, exceptional conditions, test
conditions and highly improbable conditions. They must be defined in
accordance with the safety report and must take into account the loads for
each set of conditions.

Procurement might have additional requirements (functional,


safety, QA,…)
A specific user inspection procedure might be applied
20
Manufacturer

MANUFACTURER

Organisation who is responsible for design, manufacture


and conformity assessment of the pressure equipment

The manufacturer can do himself the design, the manufacture or


final control.
It can subcontract all or part of theses different steps
Whatever it has really done on the PE or NPE, at the end, it takes
the entire responsibility of a manufacturer.

21
Manufacturer : what it has to do?

 Shall analyse all risks taking into account for each situation

 Must prove that all the Essential Safety Requirements are met

 Must declare the conformity of the PE or NPE

 Provide the operating instructions

 Can subcontract all or part of the design, the manufacture and the final
inspection including pressure test

22
Manufacturer
Exemple of risk analysis
RESULT OF HAZARD ANALYSIS
Manufacturer: Reference:

Date:

If applicable risk reduction by


N° Type of Hazards Applicable Risk Explications
Estimation
(1) (2) By (3) Design Use Comments
Construction Control of Safeguarding Additional Warning against
production (system) precaution remaining risk
process (4) (5)
1 Exceeding of Internal Pressure:
- normal operating conditions
- thermal liquid expansion
- exothermal reactions / run away
2 External Pressure:
- vacuum
- normal operating conditions
- condensing steam / vapour due to
cooling down
3 Ambient temperature

4 Excess of design temperature, due


to:
- margin between operating and
design temperature to small
- exothermal reactions
- to small response time of
temperature sensors
- internal explosion
5 Temperature changes:
- temperature gradient
6 Creep

7 External fire
(pool, jet)
8 Static head of the content under
operating and test conditions

23
Manufacturer
List of essential safety requirements

PED ESSENTIAL SAFETY REQUIREMENTS Codes or Manufacturer COMMENTS


Section Standards procedures
References
1 GENERAL

1.1 Pressure equipment must be designed, manufactured and checked, and if applicable
equipped and installed, in such a way as to ensure its safety when put into service in
accordance with the manufacturer's instructions, or in reasonably foreseeable
conditions
1.2 In choosing the most appropriate solutions, the manufacturer must apply the
principles set out below in the following order
- eliminate or reduce hazards as far as Is reasonably practicable
- apply appropriate protection measures against hazards which cannot be
eliminated
- Where appropriate, inform users of residual hazards and indicate whether it is
necessary to take appropriate special measures to reduce the risks at the lime of
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.
2. DESIGN

2.1 General
The pressure equipment must be properly designed taking all relevant factors Into
account in order to ensure that the equipment will be safe throughout its Intended
life.
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.

24
Notified Body
for PE only

NOTIFIED • In charge of conformity


BODY assessment of the PE

Technical organisation approved in an EU state, either for approval


and monitoring of the manufacturer’s quality assurance system or
for direct product inspection

25
Accepted Notified Body
for NPE only

ACCEPTED • In charge of conformity


NOTIFIED assessment of the NPE
BODY

Technical organisation approved in an EU state, either for approval


and monitoring of the manufacturer’s quality assurance system or
for direct product inspection
For NPE assessment Notified Body must by accepted by the
French Nuclear Authority (ASN)

26
Notified Body or Accepted Notified Body :
what it has to do?

 Control the compliance with the Essential Safety Requirement

Depending on category and level


 Check the risk analysis (hazard analysis)
 Check design (calculation note, …)
 Perform stage inspection during manufacture
 Monitor final inspection and test
 Approve welding procedures and welder qualifications
 Approve NDT personnel
 Approve Materials

27
NB or ANB
Check the risk analysis
The NB or ANB checks that risk analysis issued by the manufacturer is
complete.

This verification takes into account the essential safety requirements, the
radiation protection requirements corresponding to the technical
specification given by the user.

The NB or ANB checks the risk analysis :


• The list of dangerous phenomena identified in the risk analysis
• The design and manufacture solutions found for suppress or reduce
the dangerous phenomena,
• If dangerous phenomena cannot be suppress, the adapted protection
solutions,
• The operating instructions for the information of the user.

28
NB or ANB
Check the calculation note

The NB or ANB checks the calculation note :


• Conformity of the input data regarding the foreseeable conditions and
loads for each set of conditions given by the user
• Verification that the calculation method used :
• is able to integrate all the applicable requirements due to the
loading conditions
• is used in a correct way and is adapted to the objective
• is used with correct technical means (Computer, knowledge of
engineer, …)
• The coherence of output data.
It is possible for NB or ANB to perform his own calculation .

29
NB or ANB
Approve welding procedures and welders

« …For PE, permanent joining of components which


contribute to the pressure resistance of equipment and
components which are directly attached to them must be
ESR carried out by suitable qualified personnel according to
Appendix 1 suitable operating procedure … »
Decree 99

« …For PE cat II, III, IV , permanent joining procedure and


personnel must be approved by a competent third party
which, may be :
- a Notified Body
- a Third Party Organization

To carry out these approvals the third party must perform


examinations and tests as set out in the appropriate
harmonized standards or equivalent examinations and tests
or equivalent examinations and tests.… »

30
NB or ANB
Approve welding procedures and welders
 New procedures of permanents joining (Guideline CLAP Nbr147)

The NB or TP organization must approve the permanent joining procedure


after it is sure that reference documents or specifications are available

31
NB or ANB
Approve welding procedures and welders
 New procedures of permanents joining (Guideline CLAP Nbr78)

The NB or TP organization must perform the qualification of welds, as


required by the applicable standard and examinations and tests

32
NB or ANB
Approve welding procedures and welders
 Existing procedures of permanents joining (Guideline CLAP Nbr36)

The NB or TP organization must approve the permanent joining procedure

33
NB or ANB
Approve welding procedures and welders
 Existing procedures of permanents joining

Methodology

Step 1 Conformity with the ESR of decree 99

Step 2 Conformity with the ESR of NPE order N2, N3

Step 3 Conformity with harmonized standard e.g. ISO NF EN


15614-1

This is not required for PE

34
NB or ANB
Approve welding procedures and welders
 Existing procedures of permanents joining

Methodology

Step 3 Conformity with harmonized standard e.g. ISO NF EN


15614-1

Harmonized Requirements of
Standard standard used for the
Requirements previous qualification
(ISO NF EN 15614-1 (e.g. RCC-M)
for example)
Comparison:
 Evaluation of difference between the 2 standards
 Result (perhaps some complementary tests have to be perform)
35
ANB
Approve welding procedures and welders
ATTESTATION D'APPROBATION
DE MODE OPERATOIRE D'ASSEMBLAGE PERMANENT
PERMANENT JOINT PROCEDURE APPROBATION RECORD

N° AP - SE - 07 - xxxx
Fabricant : ....................................................................................................................................
Manufacturer
....................................................................................................................................

APAVE Approbation Référence QMO_AP


PJ_PQ N° : ....................................................................................................................................

Document de référence
record for permanent Reference standard : ....................................................................................................................................

Complétée par : ....................................................................................................................................


assemblies Supplemented by ....................................................................................................................................
....................................................................................................................................
Essai complémentaire éventuel réalisé en présence de : ............................................................................
Supplementary test performed in the presence of

Lieu du soudage : ............................................................ Date du soudage : ........................


Place of welding Date of welding

Apave Groupe – Organisme Notifié n° 0060


Apave Sudeurope – Agence

certifie que ce mode opératoire de soudage satisfaisant les exigences essentielles de sécurité définies :
 au paragraphe 3.1.2 de l’annexe 1 du décret 99/1046 du 13 décembre 1999
aux annexes 1 2 3 de l’AM 12 décembre 2005 correspondant aux Niveaux N1 - N2 - N3
certifies that this welding procedure qualification assessed to safety essential requirements stated by :
the decret 99/1046 appendix 1 §3.1.2. dated 1999 December 13th
to appendix 1 2 3 of AM 12/12/2005 according to Level N1 – Level N2 – Level N3

Attestation établie le : ..............................................................


Certificate issued on

ORGANISME D'EXAMEN
Examining body
Signature :
Représentant autorisé: ........................................................ Visa
Authorized representative

Autre observation (si besoin)


Other remark (as necessary) ...............................................................................................................................
...........................................................................................................................................................................
...........................................................................................................................................................................
...........................................................................................................................................................................
...........................................................................................................................................................................
........................................................................................................................................................................... 36
ANB
Approve materials
 Materials used for PE must comply with the ESR of PED (decree 99)
 Materials used for NPE must comply with the ESR of PED (decree 99)
and the additional requirements of NPE order

The 2 possible ways to demonstrate this conformity :

 Use materials from an European harmonized standard (i.e. EN 10028)


supplemented by :

 respect of the radiation protection requirements

 respect of the additional requirements for N2 NPE

 Use materials with particular material appraisal

This is not required for PE

37
ANB
Approve materials
 Inspection documents (Guideline CLAP Nbr12)

38
ANB
Approve materials
 Inspection documents (Guideline CLAP Nbr12)

39
ANB
Approve materials
 Main pressure bearing parts ? (Guideline CLAP Nbr88)

40
ANB
Approve materials
 Particular material appraisal

For PE NoBo approves material :


• Conformity with the ESR of decree 99
• Verification of the compatibility with other material of the PE
• Verification of the compatibility with the fluid inside PE

For NPE NoBo approves material :


• Conformity with the radiation protection requirements
• Conformity with ESR of NPE order N2

41
ANB
Approve materials
 Essential Safety Requirements for materials from decree 99 (PED)

Particular case A% > 14%


KV > 27J at T > 20°C and
of steel
T° > the lowest scheduled operating temperature

 Essential Safety Requirements for materials from NPE order, 2005

For N3 - the same as in PED ,

For N2: Ferritic steel: A% > 14%, KV > 27J at T - 0°C

Austenitic steel: A% > 25%, KV > 60J at T - 20°C

Bolts: A% > 12%, KV > 40 J at T - 0°C


If A% < 14%, reduction of area > 0.45

42
ANB
Approve materials
 Radiation protection requirements about material from NPE order

The choice must be decided while taking into account:

⃝ their possible activation

⃝ The dumping of corrosive products can, due to an


activation, require measures of protection against radiation
while in operation.

43
ANB
Pressure Equipment Directive 97/23/EC
Approve materials
191, rue de Vaugirard - 75738 PARIS Cedex 15 - Tél. 01 45 66 99 44 - Fax 01 45 67 90 47 - www.apave.com

Pressure Equipment Directive 97/23/EC


Particular Materials Appraisal Particular Materials Appraisal

Material Designation: Material Designation:


Original Specification and Issue: Specific Requirements Checklist:

for use in the following applications: Properties Requirements Specification and / Comments
or
Equipment Details Comments Test Methods
Vessel: Drawing: : Ductility: Carbon steel 14% min
Piping: Type:
Pressure Accessory: Issue: Toughness: Carbon steel 27J @ 20 °C
Safety Accessory:
or T min = °C
Assembly:
Strength: Re/20°C: :
Fluid
Rm/20°C:
Gas:
Liquid: Re/t:

Group 1: Rm/t:

Group 2: Hardness:
Steam: Chemical Composition: Elements: :
Category: I
II Others:
III IV Dimensions Limits:

Operating Conditions Heat Treatments:

Details Comment Joint properties: As parent material min


Maximal Allowable Pressure bar
Allowable Temperature Range °C To Formability:

And where relevant X Non-destructive Tests:


Corrosion
Erosion Creep data:
Ageing
Formability Particular Applications:
Joinability (Weldability)

The above material has been appraised for compliance with the essential requirements of the
Directive 97/23/EC for the above application and has been granted a Particular Material Appraisal Conditions
subject to the conditions listed.
In addition to the requirements of the above specification each batch of material used in this application shall be
Revisions to the parent specification, by the issuing authority, are to be reviewed by the manufacturer,
and where applicable advised to the notified body, and may result in invalidation of this Particular
covered by a certificate of specific material control as evidence of conformity with the following requirements:
Material Appraisal.

PMA number: Appraisal issue: Appraiser: PMA number: Appraisal issue: : Appraiser:
Company References: Signature Company References: Signature

44
Summary

ITER has various types of pressure and nuclear pressure


equipment

The French regulation applies and request in some


conditions the control of an Notified Body

List of NPE, classification and justification is the


responsibility of IO

IO will provide at the next PT Leaders meeting the general


rules for organization (who is manufacturer)

Most of the requested activity/control/assessment are


needed to insure quality of ITER components

45