Water boilers and auxiliary installations - Part 17: Guideline for the involvement of an inspection body independent of the manufacturer

This Technical report gives guidance for the involvement of an inspection body independent of the manufacturer of shell boilers as defined in EN 12952 1.

Wasserrohrkessel und Anlagenkomponenten - Teil 17: Leitfaden für die Einbeziehung einer herstellerunabhängigen Prüforganisation

Chaudieres a tubes d'eau et installations auxiliaires - Partie 17: Guide pour l'implication d'un organisme d'inspection indépendant du fabricant

Vodocevni kotli in pomožne napeljave - 17. del: Smernica za vključevanje kontrolnega organa, neodvisnega od proizvajalca

General Information

Status
Published
Publication Date
31-Oct-2002
Technical Committee
Current Stage
6060 - National Implementation/Publication (Adopted Project)
Start Date
01-Nov-2002
Due Date
01-Nov-2002
Completion Date
01-Nov-2002

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SLOVENSKI STANDARD
SIST CR 12952-17:2002
01-november-2002
Vodocevni kotli in pomožne napeljave - 17. del: Smernica za vključevanje
kontrolnega organa, neodvisnega od proizvajalca

Water boilers and auxiliary installations - Part 17: Guideline for the involvement of an

inspection body independent of the manufacturer

Wasserrohrkessel und Anlagenkomponenten - Teil 17: Leitfaden für die Einbeziehung

einer herstellerunabhängigen Prüforganisation

Chaudieres a tubes d'eau et installations auxiliaires - Partie 17: Guide pour l'implication

d'un organisme d'inspection indépendant du fabricant
Ta slovenski standard je istoveten z: CR 12952-17:2002
ICS:
27.040 Plinske in parne turbine. Gas and steam turbines.
Parni stroji Steam engines
SIST CR 12952-17:2002 en

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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SIST CR 12952-17:2002
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SIST CR 12952-17:2002
CEN REPORT
CR 12952-17
RAPPORT CEN
CEN BERICHT
May 2002
ICS
English version
Water boilers and auxiliary installations - Part 17: Guideline for
the involvement of an inspection body independent of the
manufacturer

Chaudières à tubes d'eau et installations auxiliaires - Partie Wasserrohrkessel und Anlagenkomponenten - Teil 17:

17: Guide pour l'implication d'un organisme d'inspection Leitfaden für die Einbeziehung einer

indépendant du fabricant herstellerunabhängigen Prüforganisation

This CEN Report was approved by CEN on 27 March 2002. It has been drawn up by the Technical Committee CEN/TC 269.

CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,

Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36 B-1050 Brussels

© 2002 CEN All rights of exploitation in any form and by any means reserved Ref. No. CR 12952-17:2002 E

worldwide for CEN national Members.
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SIST CR 12952-17:2002
CR 12952-17:2002 (E)
Contents
page

1 Scope ..............................................................................................................................................................4

2 Normative references ....................................................................................................................................4

3 Guidance.........................................................................................................................................................4

3.1 General............................................................................................................................................................4

3.2 Modules...........................................................................................................................................................4

3.3 Technical complexity.....................................................................................................................................4

4 Conformity assessment activities................................................................................................................5

5 Type examination – Modules B + D and B + F ............................................................................................9

5.1 General............................................................................................................................................................9

5.2 Information for the product type approval schedule .................................................................................9

5.3 Procedure for type examination – for the guidance of the manufacturer..............................................11

5.4 Manufacturing concessions .......................................................................................................................11

6 Design and manufacturing schedule – Modules G and H1 .....................................................................11

6.1 General..........................................................................................................................................................11

6.2 Information for the design and manufacturing schedule ........................................................................11

6.3 Procedure for design appraisal – for the guidance of the manufacturer...............................................12

7 Documentation and marking ......................................................................................................................13

8 Documentation required under the Pressure Equipment Directive .......................................................14

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SIST CR 12952-17:2002
CR 12952-17:2002 (E)
Foreword

This document (CR 12952-17:2002) has been prepared by Technical Committee CEN /TC 269, "Shell and water-

tube boilers" the secretariat of which is held by DIN.

The European Standard EN 12952 concerning water-tube boilers and auxiliary installations consists of the following

Parts:
 Part 1: General.
 Part 2: Materials for pressure parts of boilers and accessories.
 Part 3: Design and calculation for pressure parts.
 Part 4: In-service boiler life expectancy calculations.
 Part 5: Workmanship and construction of pressure parts of the boiler.

 Part 6: Inspection during construction, documentation and marking of pressure parts of the boiler.

 Part 7: Requirements for equipment for the boiler.

 Part 8: Requirements for firing systems for liquid and gaseous fuels for the boiler.

 Part 9: Requirements for firing systems for pulverized solid fuels for the boiler.

 Part 10: Requirements for safeguards against excessive pressure.
 Part 11: Requirements for limiting devices of the boiler and accessories.
 Part 12: Requirements for boiler feedwater and boiler water quality.
 Part 13: Requirements for flue gas cleaning systems.
 Part 14: Requirements for flue gas DENOX-systems.
 Part 15: Acceptance tests.

 Part 16: Requirements for grate and fluidized bed firing systems for solid fuels for the boiler.

CR 12952 Part 17: Guideline for the involvement of an inspection body independent of the manufacturer.

Although these Parts can be obtained separately, it should be recognized that the Parts are inter-dependent. As

such, the design and manufacture of water-tube boilers requires the application of more than one Part in order for

the requirements of the standard to be satisfactorily fulfilled.
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SIST CR 12952-17:2002
CR 12952-17:2002 (E)
1 Scope

This Technical report gives guidance for the involvement of an inspection body independent of the manufacturer of

shell boilers as defined in EN 12952-1.
2 Normative references

This CEN Report incorporates, by dated or undated reference, provisions from other publications. These normative

references are cited at the appropriate places in the text and the publications are listed hereafter. For dated refer-

ences, subsequent amendments to or revisions of any of these publications apply to this CEN Report only when

incorporated in it by amendment or revision. For undated references, the latest edition of the publication referred to

applies (including amendments).
EN 10204, Metallic products — Types of inspection documents.
EN 12952-1, Water-tube boilers and auxiliary installations — Part 1: General.

EN 12952-2, Water-tube boilers and auxiliary installations — Part 2: Materials for pressure parts of boilers and

accessories.

EN 12952-6, Water-tube boilers and auxiliary installations — Part 6: Inspection during construction; documentation

and marking of pressure parts of the boiler.
3 Guidance
3.1 General

Depending upon the conformance assessment module chosen by the manufacturer for the design and manufac-

ture of each boiler component and the boiler assembly, the inspection activities will involve, to a greater or lesser

extent, organisations which are independent of the manufacturer. For the guidance of the manufacturer, the

specific involvement of such organisations, known as Responsible Authorities (RA), is described in this CEN report.

For the purpose of this standard, these organizations have been collectively termed RA. A definition of Responsible

Authorities is given in EN 12952-1:2002, 3.6.

The involvement of responsible authorities is recognized by this standard as indicated below:

a) in connection with conformity assessment requirements;
b) arising from the complexity of the technical requirements.
3.2 Modules

Reference to EN 12952-1:2002, Annex A – Guidance in the use of conformity assessment procedures – indicates

that the modules normally applicable to water-tube boilers are B + D or B + F or G or H1. A digest showing the key

requirements of these modules is also given in EN 12952-1.
3.3 Technical complexity

Where the technical requirements are complex and no clearly defined procedure is given in this EN 12952, it is the

convention within the boiler industry for the manufacturer to prepare procedures based on his own experience

proposing how the design/manufacture should proceed. In such cases the proposals are normally submitted to the

RA for appraisal. Such appraisal will normally be completed at the initial design stage, but it is recognized that

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CR 12952-17:2002 (E)

similar proposals may be needed to introduce design modifications and/or to accommodate concessions (devia-

tions) during the manufacturing stage. These latter proposals also form part of the design/type appraisal procedure.

4 Conformity assessment activities

The extent of RA involvement will depend upon the conformity assessment procedure adopted by the manufac-

turer. The assumed involvement of the RA for each appropriate conformance assessment module, in accordance

with Table 4-1 for category IV steam boilers. For category III steam boilers appropriate modules may be chosen.

For the guidance of the manufacturer, examples of the form that the following certificates may take are given in

clause 7 – Manufacturer's Declaration of Conformity, Responsible Authority's Certificate of Conformity, Responsible

Authority's Surveillance and Inspection Report, Design Examination Certificate and Type Examination Certificate.

Considering the pressures and volumes applicable to water-tube boiler components, Tables 1 to 9 in annex II of the

Pressure Equipment Directive (PED) should be consulted to determine the hazard category. The modules permit-

ted for these hazard categories are included in annex III of the PED.

NOTE A manufacturer can choose to adopt a higher category than indicated by annex II.

The inspection activities given in EN 12952-6:2002, Table 4.5-1are reproduced and supplemented in Table 4-1 with

respect to those activities considered to involve the RA. This indicates where the involvement of the responsible

authority should be additional to that of the manufacturer as a function of the selected conformity assessment

module. It should be noted that for the modules subject to the Type Examination procedure (B + D and B + F), with

the issue of the Type Examination certificate, no further design examination is required for the subsequently

manufactured components. However, surveillance or inspection is required during the manufacturing stage as

indicated in Table 4-1.
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CR 12952-17:2002 (E)

Table 4-1 — Conformity assessment activities showing the involvement of Responsible Authorities

Number Area of activity Inspection operation RA involvement by module
BD F G H1
1 Quality system/product type examination
1.1 Quality system to H1 Assessment of quality system docu- –––– RA
mentation including all modifications
Audit of quality system in operation –––– RA
including all modifications
On going surveillance including all –––– RA
modifications
1.2 Quality system to D Assessment of quality system docu- RA RA – – –
mentation including all modifications
Audit of quality system in operation RA RA – – –
including all modifications
On going surveillance RA RA – – –
1.3 Product type Assessment of product type RA – RA – –
examination
1.4 Type examination Issue type examination certificate – see RA – RA – –
certificate Figure 7-5
Design and general documentation
2.1 Design Check that the design RA – – RA RA
data/calculations
data/calculations conform to:
– technical specifications if applicable
– the requirements of this standard
2.2 Manufacturing Check that drawing information conform RA – – RA RA
drawings to:
– design data and calculations
– technical specifications if applicable
– the requirements of this standard
2.3 Design examination Issue design examination certificate – –––– RA
certificate see Figure 7-2
2.4 Specification for Check that the specification for subcon- RA – RA RA –
subcontracted parts tracted parts conforms to:
– technical specifications if applicable
– manufacturing drawings
– the requirements of this standard
– applicable regulatory requirements
3 Materials
3.1 Material certificates Check that the material can be used RA – RA RA –
Verify that the information on the certi- RA – RA RA –
ficate and results conform to the design
specification
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CR 12952-17:2002 (E)
Number Area of activity Inspection operation RA involvement by module
BD F G H1
3.2 Welding consum- Verify that the consumables to be used RA – RA RA –
ables are in accordance with the design speci-
fication
c c
3.3 Material identifica- Identify the material with the material RA – RA RA –
tion certificates and check the marking at
the boiler manufacturer's works
d d
3.4 Transfer of identifi- Examination of procedure drawn up by RA –RA RA RA
cation marks the boiler manufacturer for the transfer
of marks
c c
Transfer the identification marks – – RA RA –
3.5 Acceptance of sub- Verify that sub-contracted parts conform RA – RA RA –
contracted parts to the boiler manufacturer's specifica-
tion at the sub-contractor's works
4 Fabrication and welding
4.1 Welding procedure Verify that appropriate welding proce- RA RA RA RA RA
specifications dure specifications are available and
that their contents are compatible with
the welding procedure approvals
4.2 Welding procedure Verify that the welding procedures are RA RA RA RA RA
approvals appropriate for the materials and the
field of welding application, and that
they have been approved by a RA
4.3 Welder approval Verify that the welder approvals have RA RA RA RA RA
been approved by a RA and that they
are available and valid
4.4 Forming procedures Verify that forming procedures are RA RA RA RA RA
available, where applicable, and their
contents are appropriate to the product
to be formed
4.5 Formed parts Verify that formed parts are in accor- RA – RA RA –
dance with the requirements of the
forming procedures
4.6 Production control Witness removal and marking of RA – RA RA –
test plates, if any production test plates
Verify that any PWHT on production test RA – RA RA –
plates independent of the component
complies with the specific heat treat-
ment applied to the component
Examine NDE reports on production RA – RA RA –
test plates
Confirm identification and marking of RA – RA RA –
test specimens taken from production
test plates for mechanical tests
Witness mechanical tests RA RA RA RA RA
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SIST CR 12952-17:2002
CR 12952-17:2002 (E)
Number Area of activity Inspection operation RA involvement by module
BD F G H1
4.6 Production control Verify that the test information and RA RA RA RA RA
test plates, if any results contained in the manufacturer's
report conform to the requirements of
EN 12952
5 Non-destructive examination of welds
5.1 RA RA RA RA RA
Non-destructive Verify that appropriate non-destructive
examination examination procedures are available
procedures and check the qualification of the
originator
5.2 Non-destructive Verify the validity of the non-destructive RA RA RA RA RA
examination examination operator's qualifications
operator qualifica-
tions
e e
5.3 Non-destructive Scrutinise any radiographs and check RA – RA RA –
examination conformance to the acceptance criteria
operation
Re-check the ultrasonic examination of RA – RA RA –
at least 5 % of the examined drum and
header longitudinal and circumferential
seams after scrutiny of manufacturer's
ultrasonic examination reports
5.4 Non-destructive Verify that the information and results RA RA RA RA RA
examination reports conform to the acceptance criteria
6 Post-weld heat treatment
6.1 PWHT procedures Verify that the post-weld heat treatment RA RA – RA RA
procedures conform to EN 12952
6.2 PWHT records Verify that temperature/time recordings RA RA RA RA RA
conform to the requirements of this
standard
7 Final inspection and marking
7.1 Pre-hydrostatic Dimensional checking, visual examina- RA RA RA RA RA
pressure test tion and identification of accessible
inspection parts after component completion, prior
to hydrostatic pressure test and
application of any covering at the
manufacturer's works, or on site, as
appropriate
7.2 Hydrostatic pressure Witness final hydrostatic test at the RA RA RA RA RA
test manufacturer's works, or on site, as ap-
propriate
7.3 Post-hydrostatic Carry out visual examination on RA RA RA RA RA
pressure test completion of hydrostatic pressure test
inspection
Check marking on nameplate RA RA RA RA RA
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CR 12952-17:2002 (E)
Number Area of activity Inspection operation RA involvement by module
BD F G H1
7.4 Safety devices Check provision of safety equipment RA RA RA RA RA
f f
7.5 Responsible Affix or cause to be affixed identification RA RA RA RA RA
Authority's identifi- number
cation number
7.6 Responsible Issue certificate of conformity – see RA – RA RA –
Authority's certificate Figure 7-4
of conformity
7.7 Responsible Issue report of surveillance and inspec- RA RA – – RA
Authority's report of tion – see Figure 7-5
surveillance and
inspection
7.8 Manufacturer's data Review data dossier for completeness RA RA RA RA RA
dossier

The RA involvement in module D is carried out during periodic, unexpected audits and test.

These requirements apply equally to the initial design stage and to the manufacturing stage when design

modifications/manufacturing concessions are required to be introduced.

This may be delegated to the manufacturer by the RA for materials conforming to certificate 3.1.B of

EN 10204.

This assessment is included in the formal assessment of the manufacturer's quality system.

The extent of radiograph scrutiny will be determined by the RA.

The identification number of the responsible authority who assesses the manufactuer's quality system and, if

different, that of the RA involved during the design, fabrication and final inspection stages concerned with

the component/boiler.
5 Type examination – Modules B + D and B + F
5.1 General

The manufacturer should submit an application for type examination to the responsible authority and enclose the

design and manufacturing schedules in accordance with 5.2. Additionally, a sample of the product should be made

available for examination.

The criteria for type approval should be theedition of EN 12952-6 current on the date when the type approval was

requested or when any subsequent modifications are proposed.
5.2 Information for the product type approval schedule

For each water-tube boiler component, the design and manufacturing schedule should contain:

a) the name of the boiler component manufacturer;
b) technical documentation giving a general description of the type including:

1) the boiler component, giving a clear understanding of its design basis including design calculations. A

general arrangement drawing showing its parts, connection points, any safety equipment such as safety

valves, pressure gauges, thermocouples;
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SIST CR 12952-17:2002
CR 12952-17:2002 (E)
2) the design pressure and test pressure;
3) the design temperature;
4) the intended mode of operation;
5) test reports;
c) the various materials selected:

1) a description of materials for pressure loaded parts; material type and grade should be in accordance with

the requirements of EN 12952-2;

2) a description of materials for non pressure loaded parts welded on to the component; material type should

be in accordance with the requirements of EN 12952-2;
3) the welding consumables in the case of time-dependent design strength values;
d) information for the inspection of welds

1) the weld locations, the weld preparations and, where applicable, the heat treatment requirements;

2) the type and extent of destructive and non-destructive examination;
3) additional tests, where considered necessary;

e) any pertinent details relative to boiler component design and data required in specific cases:

1) the type of heat treatment and, where necessary, the type and extent of associated material tests;

2) the construction sequence schedule if the testing is to be carried out in several steps;

3) additional requirements specified by the purchaser (e.g. extra corrosion/erosion thickness allowance);

4) a low water level for boilers with drums and low flow restrictions for once through boilers;

5) any cyclic and dynamic loading;
6) the location of any welds to be made on the construction site;
7) the design calculation document provided by the manufacturer;

f) additional information for components calculated with time-dependent design strength values:

1) the availability of access for the inspection from the inside and outside of components;

2) the design of components with respect to the possibility of performing additional examinations during op-

eration;

3) the method of recording the operational history of the component with respect to pressure and tempera-

ture;

g) information on safety equipment, e.g. capacity and set pressure of safety valves;

h) information concerning regulatory requirements on the protection of working personnel.

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CR 12952-17:2002 (E)
5.3 Procedure for type examination – for the guidance of the manufacturer
5.3.1 Extent of examination by the Responsible Authority

The RA should confirm that the product type has been designed and manufactured in conformity with EN 12952.

5.3.2 Type examination certificate

The RA should, as a minimum, signify its approval by issuing type examination certificate to the manufacturer. See

Figure 7-3 for an example of such a certificate.
5.4 Manufacturing concessions

During the manufacturing stage there may be a need to accommodate manufacturing concessions (deviations).

The acceptance of such deviations forms part of the type examination process and the type examination proce-

dures are similarly applicable – see EN 12952-1:2001, clause 7. The approval of any manufacturing concessions

should become an addendum to the type examination certificate and be included in the manufacturer's data

dossier.
6 Design and manufacturing schedule – Modules G and H1
6.1 General

The manufacturer should submit an application for design appraisal to the RA and enclose the design and manu-

facturing schedule in accordance with 6.2.

During the manufacturing stage there can be a need to introduce design modifications and/or accommodate

manufacturing concessions (deviations). The acceptance of such deviations forms part of the design appraisal

process and the design appraisal procedures are similarly applicable – see EN 12952-1:2001, clause 7. The

acceptance of any design modifications/manufacturing concessions should become an addendum to the design

appraisal documentation and be included in the manufacturer's data dossier.

NOTE With the RA agreement, water-tube boilers of similar design can be covered by one design and manufacturing

schedule.
6.2 Information for the design and manufacturing schedule

For each water tube boiler, the design and manufacturing schedule should contain:

a) the name or company's name of the boiler plant user;
b) the name and location of the installation;
c) the name of the boiler manufacturer;
d) a document and drawings describing:

1) the water-tube boiler and the pressure parts that permit a clear understanding of the design of the boiler,

its pressure parts and their connections. The general arrangement drawings should show the arrangement

of safety equipment, such as safety valves, pressure gauges, thermocouples;
2) the design pressure and test pressure;
3) the steam or hot water output capacity of the boiler;
4) the design temperatures for each component;
5) the intended mode of operation, e.g. base or peak load.
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SIST CR 12952-17:2002
CR 12952-17:2002 (E)
e) the nature and location of the boiler nameplate or stamp;
f) the various materials selected:

1) a description of materials for pressure-loaded parts, material type and grade according to European Stan-

dards, or in the absence of such reference, trade name and the approved material specification;

2) a description of materials for non-pressure-loaded parts welded on to pressure-loaded parts, abbreviated

name or material number according to European Standards, or in absence of such reference, trade name

and the approved material specification;
3) the welding consumables in the case of time-dependent design strength values;
g) information for the inspection of welds:

1) the weld locations, the weld preparations and where applicable heat treatment requirements;

2) the type and extent of destructive and non-destructive examination;
3) additional tests, where considered necessary;

h) any pertinent details relative to water-tube boiler design, and data required in specific cases:

1) the type of heat treatment and, where necessary, type and extent of associated material tests;

2) the construction sequence schedule if the testing is to be carried out in several steps;

3) additional requirements specified by the purchaser (e.g. extra corrosion/erosion thickness allowance);

4) a low water level for boilers with drums and low flow restrictions for once through boilers;

5) the cyclic and dynamic loading;
6) the location of the welds that will be made on the construction site;
7) the design calculation document provided by the manufacturer;

i) additional information for components calculated with time-dependent design strength values:

1) the availability of access to and inspection of components from the inside and outside of the boiler;

2) the design of the component with respect to the possibility of performing additional examinations during

operation;

3) the method of recording the operational history of the boiler with respect to pressure and temperature;

j) information on safety equipment, e.g. capacity and set pressure of safety valves;

k) information concerning regulatory requirements on protection of working personnel.

6.3 Procedure for design appraisal – for the guidance of the manufacturer
6.3.1 Extent of examination by the Responsible Authority

The examination should cover the water-tube boilers, the economizers, the superheaters located within the circuit

and those that can be isolated from it, the reheaters located in the flue gas path, the pressure expansion vessels,

the desuperheaters and the inter-connecting tubing within the confines of the boiler terminal points. The examina-

tion by the RA should only cover the inter-connecting tubing for which the nominal size (DN) exceeds 32 mm, and

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CR 12952-17:2002 (E)

where, at the same time, the product of maximum allowable working pressure, in bars, and the nominal size, in

mm, exceeds 3 500 bar mm.

Valves and fittings should be included in the design review if the following limits are exceeded:

 Nominal size: 150 mm; and

 for smaller parts: when the product of the maximum allowable working pressure, in bars, and the nominal size,

in mm, exceeds 15 000 bar mm.
NOTE The nominal size relates to the connecting dimension.
6.3.2 Check of design dimensions of water-tube boiler components

A check of the dimensions and thicknesses should be carried out to confirm that the water-tube boiler components

can safely withstand the stresses arising from the operating and test conditions specified.

This check should be carried out by reviewing the design calculation document issued by the manufacturer, or by a

recalculation performed by the RA responsible for the design appraisal.
6.3.3 Design and manufacturing appraisal – Module G
The RA should, as a minimum, signify its approval by the following:

– applying, or causing to be applied, its identification number to each component, or assembly as applicable,

subsequently manufactured in accordance with the technical documentation submitted by the manufacturer;

– the issue of a certificate of conformity. See Figure 7-4 for a typical example of such a certificate.

6.3.4 Design examination certificate – Module H1
The RA should as a minimum, signify its approval by the following:

– applying, or causing to be applied, its identification number to each component, or assembly as applicable,

subsequently manufactured in accordance with the design examination certificate.

– carrying out surveillance during manufacture and final assessment as required and provide the manufacturer

with visit/test reports.
7 Docume
...

SLOVENSKI STANDARD
SIST CR 12952-17:2002
01-november-2002
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Water boilers and auxiliary installations - Part 17: Guideline for the involvement of an

inspection body independent of the manufacturer

Wasserrohrkessel und Anlagenkomponenten - Teil 17: Leitfaden für die Einbeziehung

einer herstellerunabhängigen Prüforganisation
Chaudieres a tube
...

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