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C10074/UOR-4500/2017/FE/E1 Rev. 0 JOB NO. : C10074/UOR-4500/2017/RF/FE -R1 Dt.30.03.

2018

Draft Annex E
Hazard Analysis

Introduction

The Essential Safety Requirements [ESRs] of Directive 97/23/EC, the Pressure Equipment Directive [PED] place the following obligations
on the manufacturer of the pressure equipment throughout the processes of design, manufacture, conformity assessment, and as
applicable assembly and installation of the pressure equipment, viz.

 To analyse the Hazards in order to identify those which apply to his equipment on account of pressure and then design and construct
the equipment taking into account this analysis.
 To eliminate or reduce these Hazards as far as is reasonably practicable.
 To apply appropriate protection measures against those Hazards that cannot be eliminated.
 To advise the user(s) of the equipment of residual Hazards and indicate whether it is necessary to take appropriate special measures to
reduce the risks art the time of installation and/or use.

The results of the analysis needs be recorded and to be included in the technical documentation which should form part of the submission,
if applicable, to the Notified Body responsible for appraising the design against the ESRs of the PED.

Following is a checklist of typical Hazards which may be applicable to Pressure Equipment. The manufacturer may use the Hazard
checklist as an aide-memoire for eliminating, reducing, specifying protection measures and determining where to apply special
instructions /procedures during construction, test, commissioning, operation and maintenance.

The list of Hazards to be considered outlined in the aide-memoire is not exhaustive, other Hazards may need to be considered by the
manufacturer in certain circumstances.

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C10074/UOR-4500/2017/FE/E1 Rev. 0 JOB NO. : C10074/UOR-4500/2017/RF/FE -R1 Dt.30.03.2018

Manufacturing and Conformity Assessment Considerations

Details PED Comments


Refs. &
Annex I
ESRs
Manufacturing Conformity Assessment

Selection of Conformity Assessment Module


: e.g.
 Ps > 0,5 bar  Art.1-1  Yes
 Exclusions  Art.1-3  No
 Type of Pressure Equipment  Art.1-2 & 3  Flash vessel
 Fluid group 1or 2, or superheated water or  Art.9  Group 1
steam
 Module Risk Category ~ PS.V or PS.DN  Annex II  Category IV
 Module Selection  Annex III  Module “G”
 Application to Notified Body  Annex III  Yes (TUV Nord)

 Procedures / Quality Plans  3.1  As per QAP


 Preparation of components  3.1.1  Manufacturers Procedure
 Permanent joining  3.1.2 / 7.2  Procedure & Personnel qualification as per PED
 Non-destructive testing (NDT)  3.1.3 / 7.2  Inspection and Testing as per EN 1435 / 571-1.
 Heat Treatment  3.1.4  NO
 Traceability  3.1.5 / 7.5  As per QAP / Material Chart
 Final Inspection  3.2.1  As per QAP and ASME, Section VIII, Division 1
 Proof test  3.2.2 / 7.4  Hydrostatic test as per PED requirement
 Inspection of safety devices  3.2.3 / 7.3  NA
 Marking and labeling  3.3  Nameplate on each component as per PED
 Operating Instructions  3.4  Operating instructions attached in Technical documentation
 Materials  4 / 7.5  As per ASME, Section VIII, Division 1 and PED
 Safe Handling  2.8 /  User Operating Manual
2.2.3.c

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C10074/UOR-4500/2017/FE/E1 Rev. 0 JOB NO. : C10074/UOR-4500/2017/RF/FE -R1 Dt.30.03.2018

SourceHazard Pressure Equipment Manufacturers Hazard Analysis Aide-Memoire

Yes / NoRelevant
Hazard Prevention Measures Applied
PED Warnings,
Examples of Hazard and Consequence Annex I Special
ESRs Operating
Eliminat Reduce Protection and/or
e Inspection
Design Considerations Procedures
Internal Chambers and parts of Pressure Equipment
Fluid

Type: e.g. 2.1 / 2.4 / 4


 explosive   N
 extremely flammable  N
 highly flammable  N
 flammable  Y
 very toxic  N
 toxic  N
 oxidising
 N
 harmful
 N
 corrosive
 others – 67/548/EEC
 material compatibility/resistance 2.6  Y Design as per ASME, Sec. VIII, Div.1 with suitable Given in
MOC for process fluid. operation
 filling ratio 2.9  N manual
 venting and drainage 2.5  Y Vent and discharge nozzles provided.
 inspection openings 2.4  Y Content load considered in design
 physical properties – e.g. weight density 2.2  Y
Pressure: e.g.
 heating 2.2  N
 exothermic reaction 5  N
 endothermic reaction 2.2  N Given in
 explosion 2.10  N Operation
 fire 2.11 Manual and
 N
 supply fault 2.12 Control
 N Guidelines
 blocked discharge 2.9
 N - Provision for clearing blockage
 blow back from upstream equipment 2.5 - Charging under atmospheric pressure only
 N
 Resistance – strength - Designed for design conditions
 N
 Stability – buckling 2.2 - Design for design conditions
 N

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Vacuum / external pressure: e.g. 2.2.  Y


 cooling closed valves 2.5 / 2.11  N Design as per ASME, Sec VIII, Div 1 for vacuum
 jacket / limpet coils / panels and External Pressure
Fluid

Temperature: e.g. 2.2.1/.3


 High  over-heating, failure of neighbouring 4.1/ 4.2
equipment/components scale / fouling build-up  Y Design as per ASME, Sec,VIII, Div.1 for high and
 distortion, creep, fracture, embrittlement, low temperature
oxidation etc.
2.2.1/.3  Y Material testing as per PED Annex-I Cl.7.5
 Low  Joule-Thompson effect; leakage, wrong
decanting procedure  embrittlement, brittle 4.1 / 4.2
fracture, loss of ductility etc. 2.9 / 2.10

Flow: e.g.
 Excessive / insufficient, high level carry-over;  N Design as per ASME, Sec.VIII, Div.1
low level  over-heating etc. 2.9/.10/.11  N
 Transient conditions  surge; noise; water 2.2.1/.3  N
hammer etc.  fracture/fatigue 6  N
 Pulsations  reciprocating machines  2.5  N
fracture/fatigue 2.2.1/.3  N
 Cavitation  wear 2.7 / 6
 N
2.2.1/.3
 Erosion  wear  N
4.1
 Abrasion  wear  N
2.7
 Fouling  blockage
Testing Media: e.g.
 Material compatibility/resistance 4  Y MOC as per chemical resistance to testing media.
 Weight density – mass consideration 2 / 3.2.2  Y Content load considered in design
 Venting and draining 2.9  Y Appropriate vent and drain provided.
 Pneumatic  additional considerations 3.2.2 / 7.4  Y
Equipment

Machinery: e.g.
 Stirrers, shakers, percussive device, paddles, 2.2.1/.3  Y Stirrer. Dynamic loads consider in design
pumps;  vibration  fatigue  shock load 
fracture
 Supports  local loads  Y Designed for Seismic load
 Baffles  local loads  fatigue  N
 Material compatibility 4.1/4.2  N
 Means of examination 2.4  Y Adequate opening provided
 Quick opening doors  interlocks 2.3  N

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Accessory supports e.g.

NOT APPLICABLE
 Trays, Downcomers, Deflectors,
 Anti-syphon device, sieves, anti-vortex device 2.9 / 6 c
 Internal pipework
 penetrations  leakage 6
 local loads  fatigue 2.2.1/.3
 Material compatibility 4.1/4.2
 Means of examination 2.4
Equipment

Cyclones; electrostatic devices: e.g.


 Supports 2.2.1/.3

NOT APPLICABLE
 local loads
Electrical charge
 Short Circuit etc.
 material compatibility 4
Penetrations
 leakage 6
 thermal shock 2
 fracture / fatigue
 Means of examination
2.4
Sprays: e.g.
 injection points  N
 steam out 2.2.1/3  N
 vacuum
 high pressure
 material compatibility
Penetrations NOT -
APPLICABLE
 leakage
 thermal shock
 fracture / fatigue
Supports
 local loads Manhole provided
 means of examination 2.4  Y

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C10074/UOR-4500/2017/FE/E1 Rev. 0 JOB NO. : C10074/UOR-4500/2017/RF/FE -R1 Dt.30.03.2018

Heating/cooling: e.g.
 coils / panels  freedom to expand  leakage 2.4 / 2.8  N
 contamination  fire/explosion
 electrical  over-heating  short circuit etc.
 Means of examination 2.4  N

Penetrations
 leakage
MOC suitable for process fluid with relevant
 thermal shock
testing as per PED.
 fracture / fatigue
4.1/4.2  Y
 Material compatibility
Equipment

Linings: e.g.
 Refractory / Brickwork 2.2.1/3

NOT APPLICABLE
 glass / glass reinforced plastic 2.3
 enamel 2.4
 other metal 2.5
 rubber
 freedom to expand 2.2.1/3
 additional loading
 leakage
 material compatibility
 means of examination 2.4

Design Considerations
External parts of Pressure Equipment
Equipment

Mechanical Loads: e.g. 2.2.1/3


 self supports 2.5 / 2.11  Y
 pipework / ductwork 6  Y
 machinery  Y
 access ways  N
 lifting devices  N
 local loads  N
 fracture  N
 fatigue  N Material suitable for process
 material compatibility/resistance 4
 Y

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Thermal Loads: e.g. Heat transfer devices

APPLICABLE
 Fluid heating – panels , limpets etc
 Fired heating – solid, gas, oil Vessel design considered with design
 Electrical heating – immersion, strip temperature
 Nuclear – National Regulations
 thermal stresses 2.2.1/.3
 Material compatibility / resistance 4
Location

Out of Doors: e.g. Indoor Installation


additional loads & considerations
 Wind loads 2.2.1/.3 No Seismic & Wind loads considered
 Blast loads – mining/quarrying

NOT APPLICABLE
 Seismic loads  dynamic mechanical load 
anchoring  vibration etc.
 Fire/explosion: e.g. oil refinery / gas storage
 engulfment  BLEVE*
2.12
 Snow /ice loads  additional mass / wind
2.2.1/.3
area  low temp.  wind chill material
compatibility etc.
 Rain loads  additional mass  drainage 
material compatibility etc.
 Flooding: raised platform anti-buoyancy:
anchors: bunding etc
 Lightening  fire  damage  earthing. 2.2.1/.3  N
 Ambient temperature(s)  N
 Altitude – see also wind load & temperature  N
(process considerations)

Submerged: e.g. deep sea working 2


 external pressure

NOT APPLICABLE
 material compatibility / resistance
Buried: e.g. protection from fire, blast, solar
radiation etc.
 geotechnical effects
 material compatibility / resistance
 Conducted / radiated heat
Mounted on or part of dynamic structure e.g.
tanker vehicle, moving platform
 acceleration forces wind forces 2.3

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C10074/UOR-4500/2017/FE/E1 Rev. 0 JOB NO. : C10074/UOR-4500/2017/RF/FE -R1 Dt.30.03.2018

Protective Devices Pressure Limiting e.g. + vacuum relief 2.9/.10/.11


 Relief Valves  Y Pressure Relief Valves
 Safety Valves  Y Pressure Control Valve Operational
 Bursting discs  N Procedures
 CSPRS* Art 1 – 2.1.3-  Y Pressure Relief & Control Valves provided provided in
 safe discharge  reseating  roll-over Instruction
protection  fire conditions  flaring  Manual
alarms/indicators  supports  type
approvals  N Temperature RTD’s provided suitable interlocks /
Art 1 – 2.1.3--  N alarms recommended in Control Philosophy
Temperature / flame monitoring:
 commensurate response time  N
 lockout / interlocks  N
Flow monitoring:  N Level transmitter provided suitable interlocks /
alarms recommended in Control Philosophy
 level controls  Y
 flow meters  N
 fail safe, self-diagnosis, redundancy  N
Control System

System Type: e.g. Art 1-2.1.3


 Manual  gauges  Y
 Computer Control  SRMCR** devices  Y Suitable gauges, transmitters and switches
 Displays  computer graphics  Y provided along with recommended control
 Alarms / indicators  Y Logic for PLC control by client.
 Appropriate visual recognition  N
 Control room protection  N
 Software failure, hardware failure,  Y


CSPRS = Controlled Safety Pressure Relief System: ** SRMCR = Safety Related Measurement and Control Regulation
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