Design Verification FAQ

Pressure equipment which contains: - Gases at pressure exceeding 50 kPag - Liquids at pressures exceeding 50 kPag or - Steam Pressure equipment includes boiler, boiler piping, compressor, fired heater, gas turbine, hot water boiler, piping component, pressure fittings, pressure piping, pressure vessel, pump, steam engine, or steam turbine Cranes All powered cranes, including those attached to a vehicle and used for loading and unloading that vehicle. Passenger Ropeways a cableway or ropeway used for conveying in a horizontal or inclined plane person who are on skis, supported by chairs, or in enclosed cars. refer also: https://www.worksafe.govt.nz/dmsdocument/419-health-and-safety-in-employment-pressure-equipment-cranes-and-passenger-ropeways-regulations-1999

Design verification is a comprehensive review of the design of an item of equipment based on detailed fabrication or manufacturing drawings. If the design is approved a design verification certificate is issued and the equipment drawings are stamped by the design verifier. from AS3920, design verification is a documented comprehensive examination and review of a design to evaluate its conformance with specified requirements, and identify any perceived deficiencies. The purpose of design verification is to provide suitable and sufficient checking of the design drawings and other nomination documents to: (a) identify and significant errors or omissions; (b) confirm that the design conforms with good engineering principles; and (c) give a high degree of confidence that the design of pressure equipment is safe and complies with the design standard, applicable laws and the stated purchaser requirements. from NZ's PECPR regulations design verification means verification that the following comply, in every respect related to safety, with the requirements of the appropriate design standards and contain every safety feature that is relevant, whether or not referred to in those standards: (a) designs of equipment, and (b) alterations to designs, affecting the structural strength or safety of equipment, made in the course of manufacture; and (c) designs of a repair or alteration affecting the operational safety of the equipment repaired or altered or any other equipment; and (d) the fabrication inspection requirements specified by the designer

Unlike in Australia, WorkSafe NZ does not maintain a register of pressure equipment designs or pressure equipment items. Each body which issues design verification certificates maintains it’s own register. The inspection body which performs the site inspection once the equipment is installed, issues the certificate of inspection (or operating certificate) and assigns a “Unique Number” to each equipment item. Each inspection body maintains its own register equipment identification numbers ("Unique Number").

Yes We are not aware of any other jurisdiction which requires design verification of piping in the same manner as in NZ (for general pressure piping). This typically involves piping stress analysis being performed using a software program like AutoPIPE. Because overseas inspection bodies are unlikely to have experience performing design verification of pressure piping in this manner, we recommend engaging a NZ based design verifier to provide this service.

The body which issues the design verification certificate must first be recognised (approved) by Work Safe NZ. A register of approved organisations is available at: https://www.worksafe.govt.nz/the-toolshed/registers/recognised-inspection-bodies/ One such organisation is Rhodes Engineering and Design Limited (www.rhodeseng.co.nz) For pressure equipment design verification requirements depend on Hazard Level determined in accordance with standard AS4343. Hazard level A,B,C and D pressure equipment (including piping) requires design verification by an organisation approved by WorkSafe NZ. In-house design verification may be performed for hazard level C and D equipment if the organisation is first approved by WorkSafe NZ (approval is detailed in a "letter of exemption"). Further details are contained in Appendix A of the Appproved Code of Practice for Pressure Equipment (ACOP), https://www.worksafe.govt.nz/assets/dmsassets/zero/2WKS-1-boilers-acop-pressure-equipment.pdf

No, not without supplying detailed drawings for review. You can rest assured that confidentiality of information supplied for design verification will be respected: - For NZ Chartered Professional Engineers, confidentiality of client information is mandated legally under "Chartered Professional Engineers of New Zealand Rules (No 2) 2002" coming into force under the "Chartered Professional Engineers of New Zealand Act 2002" - ISO17020 Inspection Bodies, are required to have legally enforceable commitments to respecting confidentiality of client information - We recommend you ask the design verifier to supply their organisations confidentiality policy for your review. It is the pressure retaining shell and structure which are of interest for design verification. In general, we find that for pressure vessels these components do not contain any significant unique features, and are generally based on designs which are in the public domain, many decades old, and available in handbooks such as Moss, Pressure Vessel Design Manual. Many details, such as nozzle welds, must meet prescriptive code requirements (and match figures in the design code) so can not possibly contain any unique intellectual property. The details required for design verification, such as wall thicknesses and dimensions of members, are also readily available to the end user by measuring the supplied piece of equipment. Even for composite pressure vessels, we find details required such as lay-up and material specifications, are generally readily available from material suppliers, and are generally similar-to those in published papers for design of composite pressure equipment. Details of proprietary internal components, if they do not affect the structural integrity of the equipment, do not generally need to be supplied Just fundamental details such as overall dimensions and mass, details of supports for vessel internals, which are welded to the vessel shell, will be required for design verification.

Extent of design verification (for NZ), for pressure equipment is outlined in the ACOPs: https://www.worksafe.govt.nz/assets/dmsassets/zero/2WKS-1-boilers-acop-pressure-equipment.pdf https://worksafe.govt.nz/dmsdocument/1571-acop-the-design-safe-operation-maintenance-and-service-of-boilers This includes: (a) Suitability of materials for service (b) Adequacy of all pressure parts for design operating conditions including the effect of pressure, temperature, externally applied loads and local environmental conditions such as seismic disturbances and wind, snow and ice (c) Manufacturing and testing requirements including the inspection and test plan; (d) Specifications for flanges, valves and fittings (e) Transportation and erection plans and procedures (f) Equipment design life including the procedure to be followed when the end of any finite life is reached; (g) Equipment supports not covered by CPEng certificates (typically supporting structure not welded to equipment and foundations) and (h) Where appropriate any other aspects of design affecting safety. Per the regulations (PECPR), design and design verification must take into account the nature of the New Zealand seismic environment.

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Yes

Inspection Bodes outside of New Zealand and Australia can perform design verification for NZ if recognised by WorkSafe NZ. Also PED certificates may be accepted. In both cases the certificate issued by the overseas Inspection Body may cover some, but not all of the requirements. In that case design verification will also be required by a local Inspection Body (in NZ or Australia). Under the PECPR Design Verifiers in New Zealand and Australia must hold a relevant certificate of competence (this requirement does not apply to inspection bodies outside of Australia and New Zealand). Inspection Bodies outside of Australia and New Zealand perform design conformity assessment under regulations in the country which they are located (such as the Europe’s Pressure Equipment Directive, PED). The extent of design verification for New Zealand is covered in the approved codes of practice. This includes considering the nature of the New Zealand seismic environment. In contrast inspection bodies accredited to perform design conformity assessment under the PED are not required to have knowledge and experience in local requirements relevant to New Zealand and Australia. So certificates of design conformity issued by Inspection Bodies outside of Australia and New Zealand may address some, but not all requirements for design verification in NZ. For example, design for pressure containment is likely to be covered by a certificate issued by an Inspection Body accredited under the PED, but consideration of seismic design, piping loads imposed on equipment in an earthquake, and piping resistance to earthquake actions in accordance with local standards may not be. In general, we recommend design verifiers hold a relevant certificate of competence which demonstrates knowledge and experience in local requirements. Engineers Australia and New Zealand Engineering, both maintain registers of competence for Pressure Equipment Design Verifiers.

Here’s our view of the typical requirements for imported pressure equipment: 1. Design verification certificate for equipment items (from WorkSafe NZ recognised body) 2. Design verification certificate for piping (from WorkSafe NZ recognised body) 3. Fabrication Inspection, performed by WorkSafe NZ recognised inspection body, while the equipment is being manufactured see A6 of ACOP). The primary documents are a. The ITP with appropriate points signed off by the inspector b. Manufacturer’s Data Report (Form) from Appendix D of the ACOP, signed by the manufacturer and the inspector c. Manufacturer’s Data Book, containing material certificates, welding documents (WPS, PQR, Welder qualification records, weld maps, etc), NDE reports, pressure test report (including chart), completed and signed ITP, as built drawings, etc 4. Once the equipment is installed on site, it must be inspected by a local (WorkSafe NZ recognised) inspection body, and an inspection certificate is issued. 5. Supporting structures, and foundations must be certified by a NZ CPEng. This usually takes the form of a PS1 (design producer statement), or PS2 (design review producer statement). Sometimes a PS4 construction monitoring producer statement may also be required, but this would only be at the clients request or to satisfy the territorial authority (the local council) for building code compliance. An Australian CPEng could also do this, if they register in NZ with Engineering NZ as a CPEng, under the mutual recognition agreement. (4) is critical, because at that point the local inspector will review all the manufacturing documents (and could identify fabrication issues). So we recommend discussing with the local inspector as soon as possible, preferably before any manufacturing commences. It is the certificate of inspection (sometimes called an operating certificate) issued by the local inspector which is the key document to the equipment being able to be operated legally in NZ.

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