Materials and welding expertise for semi-finished product manufacturers and pressure equipment production

For manufacturers of steel, stainless steel and non-ferrous semi-finished products as well as pressure equipment: peer review, welding qualification, materials consulting and interface to the notified body – in accordance with PED, AD 2000, ASME and EN 10204.

PED 2014/68/EU AD 2000 ASME Section IX EN 10204 (3.1 / 3.2) Welding qualification Peer Review NoBo interface

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CHALLENGE

Semi-finished products and pressure equipment stand at the start of the value chain – errors here multiply along the entire supply chain.

A PED conformity assessment is due – material specification, welding qualification and the NoBo interface must be coordinated.

A 3.1 or 3.2 material certificate to EN 10204 is required – the requirements differ fundamentally.

A semi-finished product has been the subject of a customer complaint – material defect, heat treatment or processing as the cause?

A welding procedure qualification to AD 2000 or ASME IX is required – the requirements differ from ISO 15614.

PED conformity assessment, initial sample inspection or a complaint about a semi-finished product?

We deliver materials engineering clarity – and take over the interface to the notified body.

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SERVICES

Four core services for semi-finished product manufacturers and pressure equipment production

Welding consulting & welding qualification

Consulting on material selection and joining technology – development and support of welding procedure qualifications in accordance with the applicable codes (PED/AD 2000, ASME IX, ISO 15614).

WPS and WPQR preparation to AD 2000-HP 2/1
Welding procedure qualification to ASME Section IX
Welder qualifications to EN ISO 9606 / ASME IX
Interface to notified body (TÜV, DEKRA, Lloyd’s)
Conformity for pressure equipment and pressure-bearing semi-finished products

AD 2000-HP 2/1 ASME IX ISO 15614

Peer review – independent second check

Independent review of your welding and materials documentation prior to acceptance by customers or the notified body. Errors are found before acceptance – not after.

Peer review of WPS / WPQR / WQR
Review of material specifications and certificates
Review of PED conformity documents
Assessment of initial sample inspections (PPAP / FAI)
Test documentation for regulatory approvals

WPS Review PED docs Initial sample

Materials consulting for semi-finished products

Consulting on material selection, specification and heat treatment of semi-finished products, taking into account further processing at the customer and the relevant codes.

Material specification to EN 10025 / 10028 / 10216
Consulting on heat treatment regimes
Material certificates 2.2 / 3.1 / 3.2 to EN 10204
Suitability assessment for PED categories
Special grades, Z grades, special geometries

EN 10204 EN 10025/10028 PED suitability

Process analysis & complaint handling

Systematic analysis of manufacturing processes and resolution of complaints – from root cause analysis to the interface with the complaining customer.

Complaint analysis: material, heat treatment, geometry
Failure analysis on semi-finished products (cracks, voids, segregations)
Development of procedure and production test concepts
Process optimisation to reduce scrap
Technical clarification with customers and notified body

Complaint 8D report Process analysis

STANDARDS EXPERTISE

Semi-finished product & pressure equipment

PED 2014/68/EU AD 2000 codes of practice ASME Section IX EN 10204 (2.2 / 3.1 / 3.2) DIN EN 13445 (unfired pressure vessels) DIN EN 13480 (piping) DIN EN ISO 15614 DIN EN ISO 3834 EN 10025 / 10028 / 10216

SEMI-FINISHED PRODUCTS & FORMS

Which semi-finished products and forms we cover

LONG & FLAT

Plates, strips, tubes, bars

Material specification and material certificates for rolled and drawn semi-finished products to EN 10025, 10028, 10216 as well as for special grades.

FORMED

Forgings, castings, dished ends

Material and procedure consulting for open-die forged and cast semi-finished products with special requirements for structure, microstructure and cleanliness.

PRESSURE EQUIPMENT

Pressure vessels, piping, torispherical/semi-ellipsoidal ends

PED-compliant design, material selection and welding qualification for pressure equipment of all categories (I-IV) including module assessments.

STAINLESS STEEL & NON-FERROUS METALS

Austenitic, duplex, nickel-base, aluminium

Specific material and welding expertise for corrosion-resistant and high-temperature materials – including special alloys.

HIGH-STRENGTH STEELS

Quenched and tempered and fine-grain structural steels

Consulting for high-strength semi-finished products including heat treatment, hydrogen resistance and controlled processability at the further processor.

SPECIAL MATERIALS

Clad, coated, special grades

Assessment of clad materials, special grades and customer-specific material specifications outside the standard codes.

PRESSURE EQUIPMENT DIRECTIVE 2014/68/EU – THE CORNERSTONES

PED conformity is more than a CE stamp – it is a continuous materials and manufacturing regime.

CATEGORIES I-IV

Which category does your pressure equipment fall into?

The PED category results from pressure, volume and fluid group. It determines module selection, scope of testing and notified body. We assess and document in accordance with the standards – the basis for every further decision.

MATERIALS PER ANNEX I

PED-compliant material selection

Materials for pressure equipment must be approved according to harmonised standards, a European Approval for Materials (EAM) or a PMA. We assess suitability and take over the documentation for the NoBo assessment.

WELDING QUALIFICATION AD 2000-HP

Welding under PED – AD 2000 as the bible

The AD 2000 codes of practice (HP 0, HP 2/1, HP 5/3) govern welding procedure qualifications, welder approval and heat treatment. We develop and document PED-compliant WPS and WPQR.

SUB-SECTOR KNOWLEDGE

Conventional, nuclear or renewable – we know the differences.

MATERIAL CERTIFICATE 3.1

Testing confirmed by the manufacturer

The manufacturer itself certifies that the semi-finished product meets the agreed properties. The prerequisite is testing independent of the quality department.

Standard for most pressure equipment applications
Generally permissible up to PED category III for non-critical applications
Issued by the in-house QA department
Complete documentation of the tests required

MATERIAL CERTIFICATE 3.2

Confirmation by an independent body

In addition to the manufacturer, an independent body (e.g. TÜV, the purchaser’s expert) certifies the testing. The highest level of material certification.

Required for PED category IV and critical applications
Independent testing at the manufacturer or in the test laboratory
Documentation of sampling and testing
We can act as the independent body

PROJECT REFERENCES (ANONYMISED)

From practice – what we have delivered for semi-finished product manufacturers and pressure equipment producers

PRESSURE VESSEL MANUFACTURER

PED conformity assessment for category III pressure vessels

Complete PED conformity assessment for a pressure vessel made of 16Mo3 including WPS preparation, procedure qualification to AD 2000-HP 2/1 and NoBo support.

→ TÜV acceptance without additional requirements, CE marking approved

STEEL SEMI-FINISHED PRODUCT MANUFACTURER

Complaint analysis of void formation in forgings

Failure analysis on rejected forgings made of 42CrMo4 following a void and segregation finding at the customer. Root cause investigation in the melt and heat control.

→ Process adjustment implemented, complaint with customer resolved

STAINLESS STEEL TUBE MANUFACTURER

Welding procedure qualification for duplex piping to ASME IX

Development and support of the welding procedure qualification to ASME Section IX for a duplex pipeline (UNS S31803). 3.2 material certificate with independent testing.

→ Pipeline approved for export to the US market

COLLABORATION

How a collaboration works

Enquiry

A brief description of your concern – semi-finished product, pressure equipment, PED category or complaint.

Initial consultation

Within 24 hours: clarification of the code, the requirements and the NoBo interface.

Processing

Welding qualification, materials consulting, peer review or complaint analysis – at the works or in the laboratory.

Report & acceptance

Complete, standard-compliant documentation – usable for TÜV, ASME auditor or end customer.

WHY TECHNICAL CENTER

What semi-finished product manufacturers and pressure equipment producers value about our work

PED and ASME expertise

We know the Pressure Equipment Directive and ASME Section IX from practice – and translate the codes into concrete WPS, material certificates and audit documents.

Independent body for 3.2 certificates

We can act as the independent body for 3.2 material certificates to EN 10204 – a central element for PED category IV and critical applications.

A complaint as an opportunity, not an annoyance

We carry out complaint analyses in a solution-oriented manner – not only root cause clarification, but technical clarification with the complaining customer.

NoBo interface without friction

We speak the language of TÜV, DEKRA, Lloyd’s and SLV – so that PED conformity assessments run smoothly and cost no delivery time.

TYPICAL OCCASIONS

When semi-finished product manufacturers and pressure equipment producers contact us

A PED conformity assessment with a notified body is due – preparation and interface sought
A welding procedure qualification to AD 2000-HP 2/1 or ASME Section IX is required
A 3.2 material certificate with independent testing is required – we can take over this testing
A semi-finished product has been the subject of a complaint – material defect, heat treatment, manufacturing problem or user error?
Peer review of WPS, WPQR or material specification before an audit or initial sample inspection
A special grade or a non-harmonised material is to be used in a PED-compliant manner – PMA preparation sought

No acute need, but questions about PED, AD 2000 or ASME?

A non-binding initial consultation is possible at any time.

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FREQUENTLY ASKED QUESTIONS

What semi-finished product manufacturers and pressure equipment producers want to know before their first enquiry

What is the difference between material certificate 3.1 and 3.2 to EN 10204?

The 3.1 certificate is issued by the manufacturer itself on the basis of testing independent of production. The 3.2 certificate additionally requires confirmation by an independent body (e.g. TÜV or an expert commissioned by the purchaser). For PED category IV and particularly critical materials, 3.2 is mandatory. We can act as the independent body for 3.2 certificates and take over the sampling and testing at the manufacturer or in the test laboratory.

When do I need AD 2000 and when ASME Section IX?

AD 2000 is a code of practice established in Germany for meeting PED requirements; ASME Section IX applies to the US market and to pressure equipment to the ASME code. For export to the USA or for US clients, ASME is required; within the EU, AD 2000. For dual-listed equipment (EU + US), both qualifications are often needed – we can cover both codes and manage the interfaces between the requirements.

Can you also mediate in complaints raised against our customers?

Yes. Complaint analyses are a central element of our work. We clarify the cause neutrally – whether material defect, heat treatment, manufacturing problem or user error at the customer. On request, we also take over the technical communication with the complaining customer in order to speed up resolution and avoid lengthy disputes.

What is a PMA and when do I need one?

A PMA (Particular Material Appraisal) is a material-specific assessment for non-harmonised materials or special grades under PED. It is required when a material is not listed in a harmonised standard or when a deviation from the standard is intended. We prepare PMA dossiers and support approval by the notified body.

Which PED category applies to my pressure equipment?

The PED category (I to IV) results from pressure, volume and fluid group according to charts 1 to 9 of the Pressure Equipment Directive. The category determines the module for conformity assessment and thus the scope of testing and the involvement of the notified body. We assess your equipment in accordance with the standards and document the classification – the basis for all further steps in the conformity assessment.