Services

Article Index
Services Authority Engineering CE Marking Pressure Equipment Directive (PED) PED Lecturer Notes Basic Mechanical Engineering Detail Mechanical Engineering Procurement Support Explosive Welding All Pages Next to the development and supply of software products, Red-Bag continues to provide the high quality and comprehensive services to support customers to meet their business objectives. The majority of the engineering services are executed by the Red-Bag partner SENS. SENS is Engineering, Design and Consultancy Company in the Petrochemical, Oil and Gas and Machinery industry with home office in Banja Luka, Bosnia and Herzegovina. Due to developed Network Engineering SENS can offer specialized engineering services in a cost effective combination with labor-intensive activities executed in our home office, like:

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Pipe Stress Engineering Services Pressure Equipment Engineering Services PED Consultancy Services 2D Draft Services 3D Solid Modelling Services

authority consultancy and engineering services static equipment and piping basic engineering and software development static equipment and piping design and drafting (ready for fabrication) equipment manufacturing and supporting services

In addition we are exploring the possibility for explosive welding. The explosive welding and cladding is existing technology. The technology has been refined recently for specific purposes. This technology can now be used to weld difficult materials together such as carbon steel with aluminium. Red-Bag will coordinate the research for the required application and supplies the customer with the finished product.

Authority Consultancy Services Red-bag provides you the specialist services to update your existing (or adapt your newly designed facilities yet to be built) to the required authority regulations. Modifications to equipment can be calculated using our equipment basic design group. This gives the

Equipment and Piping Engineering Red-Bag has experienced engineers for the preparation, calculations and basic designs of static equipment and piping components. Red-Bag provides the customers with 30 years of experience in mechanical engineering. This experience is also used

customer the possibility to assess quickly potential cost impacts.

when creating the applicable software tools, (refer to the software pages).

The Authority Engineering services cover the widest possible activities related to: Explosive Cladding and Welding

Permitting Third Party Approvals CE-Marking (including PED)

Red-Bag coordinates for customers the research of explosive welding and the supply of the finished product. Examples of the application are: CS welded to Aluminum for ship building, lining of Copper tubes with Titanium for heat exchangers.

Equipment and Piping Design Red-Bag uses the detail design office for piping, static equipment such as vessels, heat exchangers, columns and tanks. The design office has many years of experience in the industry and has worked already for a wide range of customers. Miscellaneous Services The in-house Red-Bag expertise includes full EPC project execution of projects and revamping petrochemical facilities. Red-Bag is cooperating closely in a network of specialized companies in the industry and can provide full project management services. Red-Bag is flexible and quick to adapt the discipline services to the needs of the customers.

Free Engineering Tools Red-Bag is continuously looking for new services to the benefit of our clients. The purpose of the engineering calculation tools are to be able to quickly check certain data and to be able to make a cost estimate for a pressure vessel or heat exchanger

Authority Engineering and Consultancy services Red-Bag has a very experienced authority consultant available to cope with all aspects of the work involved. The RedBag consultant has over 25 years of experience in the industry. Whether you are the end-user of (Petro-)Chemical plant or a manufacturer of equipment, Red-Bag can assist you in obtaining the required permits, third party approvals and certifications. Authority Engineering and Consultancy covers a wide field of activities which are related to dealing with legal and semilegal requirements. Contacts with authorities and third parties regarding such requirements can be undertaken by RedBag. Authority Engineering activities range from consultancy regarding content and planning of legal requirements through to their implementation in customers project execution. There are three main areas in which the authority engineer in the Netherlands can provide help to his client : Permitting - Preparation of a permitting plan for projects, so that no permit or approval - will be overlooked and can be obtained in time - Assistance in permit or approval application activities Third party approvals - Classification of pressure containing components - Assistance in obtaining approvals for pressure containing components - Assistance in obtaining approvals of civil and steel designs

- Assistance in obtaining approvals for special subjects CE-marking - Overviews of main aspects of CE-marking (including PED) - Practical assistance in achieving compliance with 'essential safety - requirements' - Assistance in preparation of technical files - Reviews of compliance with essential safety requirements, so-called 'risk - analyses'. Activities related to authority requirements but not listed under the groups above can often be developed together with client.

CE marking and regulations CE-Marking, an introduction The CE-marking has been introduced as a measure to remove technical- and non-technical trade barriers between the Member States of the EU on the basis of Article 100 of the EU Treaty. As of 1983, steps have been taken to make this free trade approach more effective by marking products with 'CE' (= "Conformit Europenne"), thus indicating that these products comply with certain requirements regarding safety, health, environment and consumer protection. These requirements are often formulated in the form of 'harmonized' European norms developed from o guideline. The actual implementation of the requirements is the responsibility of designers, manufacturers, traders and users of products, including intermediates such as engineering contractors. Existing and future guidelines for CE-marking A number of guidelines on CE-marking have already been introduced in the member states or will be so in the near future, examples are:

Subject Products for building Simple pressure vessels (such as gas bottles) 'End' equipment for telecommunication Machinery Personal protection equipment Electromagnetic compatibility Gas equipment Low voltage equipment Tools (installations, machines, manual and mechanical equipment) Pressure Equipment Directive
Parties affected by CE-marking The parties affected by the CE-marking requirements include: - Designers of products - Manufacturers of products, both inside and outside the EU - Traders in products, inclusive agents of non-EU manufacturers - Users of products (in some cases)

Valid as of 27 June 1991 1 July 1992 6 November 1992 1 January 1995 1 January 1995 1 January 1996 1 January 1996 1 January 1997 1 January 1997 29 November 1999

Indirectly affected parties are, e.g. suppliers of engineering and/or product services, such as engineering contractors and users of products. However, an engineering contractor may become a directly affected party when a company is a major party in engineering, design and construction of products subject to CE-marking (for example engineering and design of piping systems which may be affected by the Pressure Equipment Directive).

Note: the concept of 'trade' has an extended meaning in relation to CE-marking: it includes selling, making available by renting or leasing, having in stock, offering for sale, rent or lease, delivery, fabrication for own use. Thus, noncommercial ways of making products available are also considered as 'trade' and subject to CE-marking requirements. Standardization It is possible that more than one directive has to be applied. When the product fulfills the essential requirements of all relevant directives, they must be marked or labelled with the designated CE logo. The countries participating in this New Approach must implement the directives into their national legislation and remove conflicting national technical specifications. They must accept that products that fulfill the essential requirements of the directives are introduced on their national market. Additional national specifications can only result from e.g. national traditions and special geographical circumstances. In general the user instructions and safety warnings must be in the national language(s). The CE-marking is only a quality label in as far as the products have to fulfill the official fundamental requirements. Customers may always require a higher quality level. Risk assessment The directives specify for which safety and health aspects a risk assessment has to be performed. The risks that have been determined should be limited as much as possible by adaptations, in sequence of priority, to: design, construction, safety attachments, and quality assessment during or after production. The remaining risks should be covered in adequate user instructions and caution notices, i.e. prescribing the use of personal protective equipment. These instructions must be given in the language of the intended user. European standards Application of European Standards ease proof of conformity but are not mandatory. These harmonized standards are developed by CEN, (general), CENELEC (Electrotechnical products) or ETSI (telecommunication) and can thereafter be translated into national standards with an equal level of safety and health protection. National technical standards that are incompatible with the European standards must be removed. The texts of the standards can be ordered from the official national standardization bodies who are member of the above mentioned European standardization bodies. Certification For many products the conformity of a product to the essential requirements of the directives can be assessed by the company itself. However for products with a high risk, the directive can specify that the design, part or the whole of the quality control during the manufacturing process or each individual product must be certified by an independent test and certification institute (Notified Body or Competent Body). Having followed the correct procedures, the manufacturer has to produce a Declaration of Conformity and in general stamp the CE-marking on the product or on a label firmly attached to it. All documentation related to the certification must be combined into a technical file and kept available for the authorities till 10 years after production of the last product. When the manufacturer is not located in the EU, the importing company will be hold responsible for the correct application of the directives. He must be able to hand the technical files on their request to the authorities within a reasonable time. Products that thus carry the CE-marking can be freely distributed in all countries that are a member of the European Union, moreover in Norway, Iceland and Liechtenstein (EER). The CE-marking is also commonly accepted in Switzerland and the East-European countries.

Pressure Equipment Directive The Pressure Equipment Directive (PED, N0.97/23/EC) is one of the 'New Approach' directives of the European Union legislation. It has been adopted by the European Council and European Parliament in May 1997. From 29 November 1999 until 28 May 2002 the manufacturers have the choice between applying the directive or the existing national legislation. From 29 February 2002 the PED will be obligatory throughout the European Union in relation to CE-marking Presentation PED implementation Red-Bag provides services to customers for the implementation of the PED. The services start with a general presentation on PED topics. The main subjects of the presentation are listed below. - What is PED? - Route for implementation - Scope Responsibilities - Methods to comply - Structure - Meaning for manufacturers, end-users and E&C companies - Problem areas

Lecturer introductory notes are on the next page. Useful links Official PED directive site: http://europa.eu.int/.../pressure_equipment/ped/ The New Approach website: http://www.newapproach.org Guide to the implementation of directives based on the New Approach and the Global Approach (.pdf file) European Community: http://europa.eu.int

PED lecturer notes PED is primarily issued to reduce or eliminate trade restrictions caused by local legislation and local interests. Additional considerations include public health and safety of persons, animals [in houses] and goods. PED is an instruction to the legislative bodies in each EU- or EC-country; the text is such that it can be used instead of compilations of 'local' legislation. PED is valid for pressure vessels and pressure piping systems with a design pressure above 0.5 barg. There are a notable number of exceptions, a few of which are shown on later slides. NB, this means, for example, that atmospheric storage tanks are NOT subject to PED PED makes/promotes Europe-wide regulations for pressure vessels based on (preferably) uniform standards and systematics, under the proviso of compliance with minimum requirements for (mainly) safety aspects. NB, in this respect, some 40 points which may be applicable are addressed. PED makes 'manufacturers' responsible for pressure vessels and pressure piping systems design and manufacturing, inclusive of classification, hazard analysis and documentation. There is a classification system based on substance properties (dangerous <> non-dangerous, liquid <> vapour), volume or diameter and design pressure, leading to four categories of non-fired pressure vessels (I IV), one for boilers and three for piping systems (I . III). Supervision and control of certain activities (i.e., design assessments, inspections, quality system reviews) are by independent organizations called Notified Bodies (NBO's). Degree of control depends upon PED-classification. For fired and non-fired pressure vessels the difference with the existing legislative systems seems limited for most ECcountries. The lack of EC-wide applicable standards for engineering, manufacturing and design can be overcome by using the existing standards and to document these properly. - For pressure piping systems the difference with the existing legislative systems is, for some EC-countries, considerable. The role of the engineering contractor for piping systems is extended to that of 'manufacturer'. Several problem areas still exist : - Material standards; existing materials would need re-qualification (?) - Engineering, manufacturing and design standards; about 600 needed and in development - definition of 'manufacturer' is not clear and subject to interpretation - risk coverage for 'manufacturer' to be developed. Mechanical engineering for equipment starts with a process datasheet. From there Red-Bag can provide the services to calculate, design and supply the equipment. The equipment types involve vessels, columns, heat exchangers and other static equipment. Red-Bag has an exclusive cooperation with specialized firms. These firms have 30 years experience with the calculation and design services. Through this arrangement Red-Bag can respond quickly to customer's specific needs and detail requests. Red-Bag is in a unique position to offer both the tools and services for mechanical engineering work. The tools are the required calculation software and related databases for material estimates of static equipment. If a customer prefers not to execute the calculations themselves, in that case Red-Bag can offer to execute the work for you. The mechanical

engineering service completes the basic design for the equipment. This service provides sufficient detail to enables customers to complete a detail cost estimate. The design and material take off is fixed in such detail that lump sum prices can be offered by equipment manufacturers.

Mechanical Engineering Software The software is developed by in-house by engineers and software developers. The developers of the software are experienced engineers who have worked for 30 years in the industry. The software has clear advantages over current available software. The software is a powerful tool which assists the engineer to define and optimize the mechanical design for pressure vessels and heat exchangers. The rules for pressure vessels are implemented in the software according: - Stoomwezen - ASME - TEMA - EJMA - AD Merkbltter - EN Engineering Database Management Database technology is used in the software to manage the equipment data. From the database the information is accessible to be used in other systems. The advantages of using a database approach are: - Efficiency and availability of data - Integrity, sharing of data in the - project team - Quality and validation possibility - One tool for various codes - One tool for various types of - equipment

Heat Exchanger Basic Design One of the software's modules is an automated heat exchanger design package. This package will assist customers to reduce time and cost on heat exchanger design. The typical advantages for this module are: - Quick results of the mechanical - design of the heat exchanger - Ready to use outside dimensions - for design purposes - Ready to use material take off for - shorter and more accurate bidding - As built electronic data available - Cost optimized design Basic Design Services The customer can chose to subcontract the design of equipment. The VES engineers have many years of experience and are the specialists in using the software tools. This ensures the customer of the most efficient execution of the work and also with a high quality output. Reputable customers have used this option already. The customers range from end-users, engineering contractors to manufacturers of equipment. Repeat business has resulted from the high quality of work. The success of the work is also due to the fact that the equipment design is accepted by the authority approval bodies without any significant changes to the design.

Detail mechanical engineering and design Mechanical engineering for equipment starts with a process datasheet. From there Red-Bag can provide the services to calculate, design and supply the equipment. The equipment types involve vessels, columns, heat exchangers and other static equipment. Red-Bag has an exclusive cooperation with specialized firms. These firms have 30 years experience with the calculation and design services. Through this arrangement Red-Bag can respond quickly to customer's specific needs and detail requests. Red-Bag has cooperation agreements with design offices for the detail design services. They have an excellent reputation for executing the design of complex equipment. The customers served are as well engineering contractors as well as manufacturers of equipment. The quality of work has the highest priority and has resulted in repeat business of satisfied customers. We work closely together on a number of projects

Design Services The services consist of preparation of stress calculations, general arrangement drawings and detailed shop drawings for: - heat exchangers - condensers - separators - rod baffle heat exchangers - towers - storage tanks - pressure vessels - reactors - air coolers - etc. The design codes used are for example: - Stoomwezen - ASME Section VIII Div.1 and 2, - AD-Merkbltter (TV) - BS 5500 - API Specs - HEI en TEMA Standards - Lloyds Rules and further user specifications such as Shell, NAM, Linde AG, DOW, UOP, ABB Lummus and Fluor Daniel.

References The design offices have many satisfied customers. Below list represent some of the clients who have been provided the quality services to: ABB LUMMUS FLUOR DANIEL KVAERNER PROCESS SHELL STORK E&C DU PONT NAM BASF TEBODIN DOW CHEMICAL AKZO NOBEL NIOE&C SNAMPROGETTI FOSTER WHEELER STONE & WEBSTER COSTAIN OIL GAS & PROCESS EXXON DSM DELAIR MAERSK MACHINEIMPORT SIMON CARVES TECHNIP LINDE AG SULZER FINA CHIYODA PHILLIPS PETROLEUM AIR-PRODUCTS JACOBS ENGINEERING

Equipment manufacturing and purchasing supporting services The engineering and design work executed by Red-Bag group is done for end-users, engineering contractors and manufacturers. Our engineers have the experience of customer requirements and manufacturer capabilities. Combining these experiences makes our position unique and gives us the capability of providing competitive offers according exactly the customer requirements. Together with Red-Bag, the manufacturers form a strong team. Red-Bag provides in-depth knowledge of the local regulations and norms (such as PED, Stoomwezen, ARAB) and can be the local design office close to the customer. The network of manufacturers combines high quality design and manufacturing with cost effective fabrication of equipment.

The in-house expertise includes full project management services. Red-Bag is a well appreciated partner on a variety of projects. This is based on project execution experience, the engineering capabilities and the software development knowledge.

Explosive Welding Explosive cladding is a well-known technique for large surfaces. The explosive welding technique has been refined during the last few years. In Delft research has been done to understand the mechanism of explosive welding. With this knowledge it is now possible to weld two very different materials together, for instance Copper and Titanium, or Carbon Steel and Aluminum. Red-Bag is supporting this technology and will assist customers to find solutions for their material problems. Find below some material combinations and the possible purposes.

Al-CS

SS-Ag

Cu-Ta

SS-Cu

AL-CS: Example of aluminium with carbon steel. This combination is used for ship building purposes, the top part of the ship will be of lightweight aluminium and the bottom part heavier steel. SS-Ag: Example of Stainless Steel with Silver. A bar of SS is clad with Silver. A wire has been extruded from the clad bar showing a SS wire with a perfect Silver skin. This combination is used when skin conductivity is required for radio frequency receiving. Cu-Ta: Example of Copper with Tantalum. The outside pipe is Copper and the inside clad is Tantalum. This combination could be used in shell and tube heat exchangers where heat transfer and protection against corrosion is important. SS-Cu: Example of Stainless Steel with Copper. The outside pipe is made of SS and the inside is a Copper clad. This combination can be used in the shell and tube heat exchanger industry.

Research at Delft Explosive cladding and welding is already used for some years. The understanding of the technology and the mechanism of explosive welding was still a bit of a mystery. Due to the research in Delft the technology is not a greenfield anymore. However for specific purposes some research is necessary to find the optimum solution. The contact with customers starts usually with some investigation of the design problem and some research. After the solution has been found a specialized fabrication company will fabricate the requested parts.

Results of research Explosive welding configuration:

Determination of optimum welding:

Results of explosive welding: