PED Guide

A PROCESS ENGINEERS GUIDE TO THE
PRESSURE EQUIPMENT DIRECTIVE

Simon Learman
Blackmonk Engineering Ltd

www.blackmonk.co.uk
22nd April 2009

Copyright 2009 Blackmonk Engineering Ltd

www.blackmonk.co.uk
Contents
Contents .......................................................................................................... 2
Preface ............................................................................................................ 3
Introduction ...................................................................................................... 4
Process Engineers & the PED ......................................................................... 4
Determining the Hazard Category.................................................................... 5
Equipment Excluded From the PED ................................................................ 5
Types of Pressure Equipment .......................................................................... 7
Fluid State ........................................................................................................ 8
Fluid Group ...................................................................................................... 9
Classification Charts ...................................................................................... 10
Determine the Maximum Allowable Pressure & Defining Dimension ............. 16
Determine the PED Hazard Category ............................................................ 16
Conformity Assessment ................................................................................. 16
Examples ....................................................................................................... 18
References..................................................................................................... 24
PED Classification Flowchart ......................................................................... 25

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Preface
Thank you for reading this guide. I hope that it will give you a clear
introduction to the Pressure Equipment Directive and be of help to you in your
work.
I would appreciate any feedback you have good or bad. Let me know what
you find useful, what could be improved and what else you would find helpful
in future.
Email: [email protected]
Best regards,
Simon Learman
www.blackmonk.co.uk

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Introduction
The Pressure Equipment Directive (PED) is a European Union Directive
applicable to the design, manufacture and conformity assessment of pressure
equipment and assemblies of pressure equipment with a maximum allowable
pressure greater than 0.5 barg.
The basic purpose of the PED is to ensure that pressure equipment used in
the European Economic Area1 (EEA) is safe. Additionally, because the
requirements of the Directive are common to all states within the EEA, all
equipment complying with the PED may be sold and used anywhere within
the EEA. This promotes the free movement of goods within the EEA.
Within the UK, the Pressure Equipment Regulations 1999 (PER) and
subsequent amendments implement the European Union Pressure Equipment
Directive. Failure to comply with the Pressure Equipment Regulations is
illegal and can result in prosecution and penalties on conviction of a fine,
imprisonment or both.
Process Engineers & the PED

Design of pressure equipment and pressure systems in the process industries
inevitably involves process engineers. Given that all relevant equipment,
plant and systems in the EEA must comply with the PED, it is essential that
process engineers have at least a basic understanding of the requirements of
the Directive.
Essentially, the PED requires the level of hazard of pressure equipment to be
assessed and classified into 1 of 5 categories. The 5 categories are:
SEP (Sound engineering practice)
Category I
Category II
Category III
Category IV
Increasing level of
hazard
The higher the level of hazard, the more extensive the level of quality
assurance required during the design, manufacture and testing of the
equipment.
It is generally the process engineers responsibility to determine the hazard
category of each particular equipment item and system.
The European Economic Area consists of the member states of the European Union plus
Iceland, Norway and Liechtenstein.

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Determining the Hazard Category

In order to classify pressure equipment correctly, the process engineer must
follow the methodology stated in the PED. This methodology is summarised
in the flowchart at the end of this guide.
Once it is determined that the equipment is covered by the PED, the
classification has 6 steps:
1.
2.
3.
4.
5.
Determine the type of pressure equipment being considered

Determine the state of the fluid in the equipment
Determine the hazard group of the fluid in the equipment
Select the appropriate hazard category chart
Determine the maximum allowable pressure and the defining
dimension of the equipment
6. Determine the PED hazard category
Equipment Excluded From the PED

Some equipment is excluded from the Pressure Equipment Directive (and
therefore also the Pressure Equipment Regulations).
Excluded equipment includes:
Pressure equipment and assemblies placed on the market before 29
November 1999
Pressure equipment or assemblies placed on the market on or before
29 May 2002 if they comply with the safety provisions in force in the UK
on 29 November 1999 and do not bear a CE marking (unless required
by another Community Directive or any indication of compliance with
the PED)
Pressure equipment and assemblies as listed below:
1. Pipelines
2. Water supply, distribution and discharge networks
3. Simple pressure vessels (as per Directive 87/404/EEC)
4. Aerosol dispensers
5. Equipment intended for vehicles

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6. Equipment classified no higher than PED Category I for the following:
a. Machinery (Directive 98/37/EC)
b. Lifts (Directive 95/16/EC)
c. Electrical equipment for certain voltages (Directive 73/23/EEC)
d. Medical devices (Directive 93/42/EEC)
e. Burning gaseous fuels (Directive 90/396/EEC)
f. Equipment and protective systems intended for use in potentially
explosive atmospheres (Directive 94/9/EC)
7. Military equipment
8. Nuclear equipment, failure of which may cause an emission of
radioactivity
9. Well control equipment including wellhead (Christmas tree), blowout
preventers (BOP), piping manifolds and upstream equipment
10. Casings and machinery where pressure is not a significant design
factor which may include:
a. Engines (including turbines and internal combustion engines)
b. Steam engines, gas/steam turbines, turbogenerators,
compressors, pumps and actuating devices
11. Blast furnaces and associated equipment
12. Enclosures for high voltage electrical equipment
13. Pressurized pipes for the containment of transmission systems such as
electrical power and telecommunications cables
14. Ships, rockets, aircraft and mobile off-shore units
15. Pressure equipment consisting of a flexible casing e.g. tyres, balls, air
cushions, inflatable craft
16. Exhaust and inlet silencers
17. Bottles or cans for carbonated drinks
18. Vessels designed for transport and distribution of drinks with a
maximum allowable pressure x volume of not more than 500 barg.litres
and a maximum allowable pressure of not more than 7 barg.
19. Equipment covered by the following:
a. ADR (European Agreement concerning the International
Carriage of Dangerous Goods by Road)
b. RID (Regulations concerning the International Carriage of
Dangerous Goods by Rail)
c. IMDG (International Maritime Dangerous Goods Code)
d. ICAO (International Civil Aviation Organization)
20. Radiators and pipes in warm water heating systems

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21. Vessels designed to contain liquids with a gas pressure above the
liquid of not more than 0.5 barg
The detailed list of excluded equipment can be found in Article 1 Section 3 of
the Pressure Equipment Directive:
http://ec.europa.eu/enterprise/pressure_equipment/ped/directive/directive_article1_en.html
Types of Pressure Equipment

The PED defines 6 types of pressure equipment:
1.
2.
3.
4.
5.
6.
Vessel
Steam generator
Piping
Safety accessories
Pressure accessories
Assemblies
The first step in determining the PED category of a particular piece of

equipment is to select the appropriate equipment type from the list.
Definitions of each equipment type are given below.
Vessel
A housing designed and built to contain fluids under pressure. A vessel
includes its direct attachments up to the coupling point connecting it to other
equipment. A vessel may be composed of more than one chamber.
Steam Generator
A steam generator is a particular type of vessel and means fired or otherwise
heated pressure equipment with the risk of overheating intended for
generation of steam or super-heated water at temperatures higher than 110C.
Piping
Piping components intended for the transport of fluids when connected
together for integration into a pressure system. Piping includes a pipe or
system of pipes, tubing, fittings, expansion joints, hoses, or other pressurebearing components as appropriate. Heat exchangers consisting of pipes for
the purpose of cooling or heating air shall be considered as piping.

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Safety Accessories
Safety accessories are devices designed to protect pressure equipment
against the allowable limits being exceeded. Such devices include devices for
direct pressure limitation, such as safety valves and bursting discs, etc, and
limiting devices which either activate the means for correction or provide for
shutdown or shutdown and lock-out, such as pressure switches or
temperature switches, etc.
Pressure Accessories
Pressure accessories are devices with an operational function and having
pressure-bearing housings. Examples of pressure assemblies include valves,
pressure regulators, pressure gauges and filters.
Assemblies
Assemblies are defined as several pieces of pressure equipment assembled
by one manufacturer to constitute an integrated and functional whole.
Examples of assemblies include skid mounted systems, distillation units,
evaporation units and filtering units.
Fluid State
The second step in determining the PED category is to establish whether the
fluid contained within the equipment is gas or liquid.
If the fluid has a vapour pressure at the maximum allowable temperature
of the equipment of greater than 0.5 bar above normal atmospheric pressure
(1013 mbara), it is treated as a gas, otherwise it is treated as a liquid.
Gas
Gases include gases, liquefied gases, gases dissolved under pressure,
vapours and also those liquids whose vapour pressure at the maximum
allowable temperature is greater than 0.5 bar above normal atmospheric
pressure (1013 mbara).
Liquid
Liquids include liquids having a vapour pressure at the maximum allowable
temperature of not more than 0.5 bar above normal atmospheric pressure
(1013 mbara).

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Fluid Group
The third step in determining the PED category is to decide whether the fluid
contained within the equipment is classified as a Group 1 fluid or a Group 2
fluid.
Basically, if the fluid is hazardous it is a Group 1 fluid, otherwise it is a Group
2 fluid.
Group 1
Group 1 comprises those fluids classified, according to the EC Directive
on the classification of dangerous substances as:
explosive
extremely flammable
highly flammable
flammable (where the maximum allowable temperature is above
flashpoint)
very toxic
toxic
oxidizing
For more information see http://www.hse.gov.uk/pubns/indg350.pdf
Group 2
Group 2 comprises all other fluids including steam.

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Classification Charts
Once the equipment type, fluid state and fluid group have been determined,
the appropriate classification chart can be selected. This represents the
fourth step in determining the PED category.
There are 9 separate classification charts (also called tables in the PED), one
for each of the possible combinations of equipment type, fluid state and fluid
group.
Equipment Type
Vessel
Vessel
Vessel
Vessel
Steam Generator
Piping
Piping
Piping
Piping
Fluid State
Gas
Gas
Liquid
Liquid
N/A
Gas
Gas
Liquid
Liquid
Fluid Group
1
2
1
2
N/A
1
2
1
2
Chart
1
2
3
4
5
6
7
8
9
The demarcation lines in the classification charts indicate the upper limit for
each PED hazard category.
The charts assign each piece of equipment to a definite category.
Note: over classification of equipment, e.g. declaring it to be category IV when
it is category II, is expressly prohibited.
10

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Chart 1
Chart 2
11

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Chart 3
Chart 4
12

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Chart 5
Chart 6
13

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Chart 7
Chart 8
14

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Chart 9
15

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Determine the Maximum Allowable Pressure &

Defining Dimension
The fifth step in determining the PED category is to determine the maximum
allowable pressure and defining dimension of the equipment.
The maximum allowable pressure is the maximum pressure for which the
equipment has been designed as specified by the manufacturer.
The defining dimension of the equipment is dependent on the equipment type.
For vessels and steam generators, the defining dimension is the equipment
volume expressed in litres.
For piping, the defining dimension is the nominal size of the components
comprising the piping system expressed in millimetres. Typically this is the
nominal pipe diameter.
Determine the PED Hazard Category

The sixth and final step is to read off the PED hazard category from the
appropriate chart using the relevant values of maximum allowable pressure
and defining dimension.
PED Calculator
As an alternative to manually referencing the charts, a calculator is available
at http://www.blackmonk.co.uk/calculators/pressure-equipment-directivecalculator which will automatically determine the PED hazard category given
the equipment type, fluid state and fluid group.
Conformity Assessment
When the PED category has been established for equipment, the conformity
assessment requirements can be defined. In effect, the conformity
assessment is the quality assurance required to validate the design,
manufacture, testing and inspection of the equipment. The higher the
equipment PED category, the higher the level of hazard and therefore the
more extensive the quality assurance requirements are.
The PED category defines the required conformity assessment module.
Where multiple module choices apply, the equipment manufacturer may
select the module(s) best suited to their particular requirement.
16

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PED Category
SEP
I
II
III
IV
Module
Sound engineering practice
A
A1, D1, E1
B1+D, B1+F, B+E, B+C1, H
B+D, B+F, G, H1
Module Definitions
Module
Design Stage
Assessment
Production Stage
Assessment
Sound Engineering Practice
No specific requirements
Technical documentation
Internal production control
A1
Internal production control with

monitoring of the final
assessment
Type examination
B1
Design examination
C1
Monitoring of final assessment
Quality assurance for

production, final inspection and
test
D1

production, final inspection and
test
Quality assurance for final

inspection and test
E1
Quality assurance for final

inspection and test
Product verification
Unit verification
Unit verification
Quality assurance for design

manufacture, final inspection
and test
H1
Quality assurance for design

with design examination

manufacture, final inspection,
test and monitoring of final
assessment
The management of the conformity assessment is generally a quality

assurance or project management responsibility but it is useful for process
engineers to have an overview of the procedure.
17

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Examples
Three examples of determining the PED category for various equipment types
are given below to help with understanding the PED methodology.
Example 1
Determine the PED category of a 50m3 horizontal storage vessel containing
propane with a maximum allowable pressure of 100 barg and a maximum
allowable temperature of 75C.
Solution:
Because the maximum allowable pressure of the equipment is above 0.5 barg
and the equipment is not on the excluded list, the PED will apply. To classify
the equipment remember the 6 steps of the PED classification methodology:
1.
2.
3.
4.
5.

Step 1
The equipment type is a vessel.
Step 2
Propane at the maximum allowable temperature of 75C has a vapour
pressure of 28.5 bara2.
This is greater than 0.5 bar above normal atmospheric pressure of 1013
mbara so the state of the fluid in the equipment is classed as gas.
Step 3
Propane is classified as extremely flammable3 and is therefore a Group 1
fluid.
2
Reference for propane vapour pressure: NIST Webbook

(http://webbook.nist.gov/chemistry/fluid/)
3
Reference for classification: European Commission, European Regulation on the
Classification, Labelling and Packaging of Substances and Mixtures website
(http://ecb.jrc.ec.europa.eu/documents/Classification-Labelling/Table_3-2.doc)
18

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Step 4
The appropriate hazard category chart is Chart 1. This is the chart for a
vessel containing a Group 1 gas.
Step 5
The maximum allowable pressure of the vessel is 100 barg.
The defining dimension of a vessel is volume. The volume of the vessel is
50m3 which is equivalent to 50000 litres.
Step 6
The point corresponding to 100 barg and 50000 litres on Chart 1 is in the
category IV area.
The required PED category for the equipment is category IV.
19

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Example 2
Determine the PED category of 100m of 4 nominal diameter piping
transporting water with a maximum allowable pressure of 20 barg and a
maximum allowable temperature of 50C.
Solution:
1.
2.
3.
4.
5.

Step 1
The equipment type is piping.
Step 2
Water at the maximum allowable temperature of 50C has a vapour pressure
of 0.123 bara4.
This is less than 0.5 bar above normal atmospheric pressure of 1013 mbara
so the state of the fluid in the equipment is classed as liquid.
Step 3
Water is not classified as a dangerous substance and is therefore a Group 2
fluid.
Step 4
The appropriate hazard category chart is Chart 9. This is the chart for piping
containing a Group 2 liquid.
Reference for water vapour pressure: steam tables.
20

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Step 5
The maximum allowable pressure of the piping is 20 barg.
The defining dimension of piping is the nominal size. The nominal size of 4
diameter piping is 100mm.
Step 6
The point corresponding to 20 barg and 100mm on Chart 9 is in the category
SEP area.
The required PED category for the equipment is category SEP.
21

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Example 3
Determine the PED category of a 0.1m3 steam flash drum designed to raise
saturated steam at 10 barg with a maximum allowable pressure of 15 barg
and a maximum allowable temperature of 200C.
Solution:
1.
2.
3.
4.
5.

Step 1
The equipment is designed to raise saturated steam at 10 barg which is
equivalent to a steam temperature of about 184C. The equipment type is
therefore classed as a steam generator as the vessel is designed to raise
steam at temperatures above 110C.
Step 2
The state of the fluid is not applicable to a steam generator.
Step 3
Classification of the fluid group is not required for a steam generator.
However for completeness, steam is not classified as a dangerous substance
and is therefore a Group 2 fluid.
Step 4
The appropriate hazard category chart is Chart 5. This is the chart for a
steam generator.
22

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Step 5
The maximum allowable pressure of the steam generator is 15 barg.
The defining dimension of a steam generator is volume. The volume of the
steam flash drum is 0.1m3 which is equivalent to 100 litres.
Step 6
The point corresponding to 15 barg and 100 litres on Chart 5 is in the category
III area.
The required PED category for the equipment is category III.
23

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References
1. The Pressure Equipment Directive (97/23/EC)
(http://ec.europa.eu/enterprise/pressure_equipment/ped/index_en.html)
2. The Pressure Equipment Regulations 1999
(http://www.opsi.gov.uk/si/si1999/19992001.htm)
3. UK DTI Product Standards Pressure Equipment: Guidance Notes on
the UK Regulations, April 2005
(http://www.berr.gov.uk/files/file11284.pdf)
24
PED Classification Flowchart

Is the maximum
allowable pressure >
0.5 barg?
NO
PED does not

apply
YES
PED does not

apply
YES
Is the equipment
excluded from PED?
(See Article 1 of PED)
NO
Determine type of
pressure
equipment
Vessel
Steam Generator
Fluid State?
GAS
Fluid Group?
GROUP 1
Chart 1
GAS
Fluid Group?
Chart 3
Fluid State?
LIQUID
GROUP 2 GROUP 1
Chart 2
Piping
Fluid Group?
GROUP 2
GROUP 1
Chart 4
Chart 5
Chart 6
Determine maximum allowable pressure in barg and equipment volume in

litres
LIQUID
Chart 7
Chart 8
Pressure
Accessories
Manufactured for specific

equipment?
Is equipment volume or
nominal size more
appropriate?
YES
Classified the
same as the
protected
equipment
Fluid Group?
GROUP 2 GROUP 1
Safety
Accessories
Assemblies
Assess each
item in the
assembly
according to its
PED category
NO
Choose a
module from
Category IV
Volume more
appropriate
Nominal size
more
appropriate
Volume &
nominal size
equally
appropriate
GROUP 2
Go to
X
Chart 9
Go to
Y
Compare PED
category
determined
from X to that
from Y and
select the
higher
category
Assess the integration of the components of

the assembly against sections 2.3
(Provisions to ensure safe handling and
operation), 2.8 (Assemblies), and 2.9
(Provisions for filling and discharge) of the
Essential Safety Requirements section of
the Pressure Equipment Regulations as
determined by the highest category
applicable to the items concerned other than
that applicable to any safety accessories
Assess the protection of the assembly

against exceeding the permissible operating
limits referred to in sections 2.10 (Protection
against exceeding the allowable limits of
pressure equipment) and 3.2.3 (Inspection
of safety devices) of the Essential Safety
Requirements section of the Pressure
Equipment Regulations at the level of the
highest category applicable to the items to
be protected
Determine maximum allowable pressure in barg and

nominal size of piping in millimetres
Use the appropriate chart to determine the PED category
Choose the required module for the PED category
PED Category
Module
SEP
I
II
III
IV
Sound engineering practice

A
`
A1, D1, E1
B1+D, B1+F, B+E, B+C1, H
B+D, B+F, G, H1
Blackmonk Engineering
www.blackmonk.co.uk
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A PROCESS ENGINEERS GUIDE TO THE

PRESSURE EQUIPMENT DIRECTIVE

Blackmonk Engineering Ltd

22nd April 2009

Blackmonk Engineering Ltd

Blackmonk Engineering Ltd

Blackmonk Engineering Ltd

Process Engineers & the PED

Blackmonk Engineering Ltd

Determining the Hazard Category

Determine the type of pressure equipment being considered

Equipment Excluded From the PED

Blackmonk Engineering Ltd

Blackmonk Engineering Ltd

Types of Pressure Equipment

The first step in determining the PED category of a particular piece of

Blackmonk Engineering Ltd

Blackmonk Engineering Ltd

Blackmonk Engineering Ltd

Blackmonk Engineering Ltd

Blackmonk Engineering Ltd

Blackmonk Engineering Ltd

Blackmonk Engineering Ltd

Blackmonk Engineering Ltd

Blackmonk Engineering Ltd

Determine the Maximum Allowable Pressure &

Determine the PED Hazard Category

Blackmonk Engineering Ltd

Sound Engineering Practice

Internal production control

Internal production control with

Monitoring of final assessment

Quality assurance for

Quality assurance for

Quality assurance for final

Quality assurance for final

Quality assurance for design

Quality assurance for

Quality assurance for design

Quality assurance for

The management of the conformity assessment is generally a quality

Blackmonk Engineering Ltd

Determine the type of pressure equipment being considered

Reference for propane vapour pressure: NIST Webbook

Blackmonk Engineering Ltd

The required PED category for the equipment is category IV.

Blackmonk Engineering Ltd

Determine the type of pressure equipment being considered

Reference for water vapour pressure: steam tables.

Blackmonk Engineering Ltd

The required PED category for the equipment is category SEP.

Blackmonk Engineering Ltd

Determine the type of pressure equipment being considered

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The required PED category for the equipment is category III.

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PED Classification Flowchart

PED does not

PED does not