Engineering task and calculation objective
The Pressure Equipment Directive 2014/68/EU requires the manufacturer to subject the pressure equipment to a hazard analysis: all pressure-related hazards must be identified, evaluated and controlled by design, by protective measures or by user information. Module ADZ2 supports the systematic preparation of this hazard analysis within the framework of the German AD 2000 pressure vessel code.
The hazard analysis is a mandatory part of the technical documentation and is reviewed by the notified body during conformity assessment. It documents which essential safety requirements of Annex I of the PED apply to the specific equipment, how they are addressed — for example by strength design to the AD 2000 calculation sheets, by safety valves to Merkblatt A2, or by organizational measures — and which residual hazards must be stated in the operating instructions.
In practice, the hazard analysis is prepared in parallel with the design of a new vessel or piping system and updated whenever the equipment or its service conditions change substantially.
Standard and calculation basis: AD 2000 Z2
Calculation workflow
- Start the documentation and describe the equipment: Via the "Start documentation" entry point, the pressure equipment, its operating parameters (pressure, temperature, fluid) and its intended use are recorded — the basis for evaluating the hazards.
- Identify hazards systematically: Guided by the essential safety requirements of Annex I of the PED, the applicable hazards are worked through: overpressure, impermissible temperatures, corrosion and wastage, fatigue, failure of accessories, hazards during filling and draining, and during inspection and cleaning.
- Assign and evaluate measures: Each identified hazard is assigned the measure taken — by design (e.g. wall thickness sizing to the AD 2000 B series), by safety devices (e.g. safety valve, pressure limiter) or by information (notes in the operating instructions). Requirements that do not apply are excluded with justification.
- Document the hazard analysis: The result is output as a tabular hazard analysis and attached to the technical documentation of the pressure equipment; residual hazards feed into the user information.
Input quantities
| Quantity | Symbol | Unit |
|---|---|---|
| Start Documentation | <1> | - |
Frequently asked questions
Is the hazard analysis under the PED the same as a risk assessment under the German Industrial Safety Ordinance (BetrSichV)?
No. The hazard analysis under the PED is a manufacturer's obligation when placing equipment on the market and considers the pressure-related hazards of the equipment itself. The risk assessment under BetrSichV is an operator's obligation and evaluates the use of the work equipment at the specific installation site, including organizational aspects. The two documents complement each other but do not replace one another.
Must a hazard analysis also be prepared for equipment under Article 4(3) (sound engineering practice)?
Formally, the PED requires the hazard analysis as part of the technical file for equipment in categories I to IV. For equipment below the categories it is not prescribed, but it is recommended as evidence of sound engineering practice — particularly if the equipment is later integrated into an assembly or modified.
What are typical mistakes when preparing the hazard analysis?
Frequently only the strength topics are considered, while requirements such as draining and venting, inspection openings, external corrosion or behaviour under operating errors are overlooked. Also error-prone: blanket "not applicable" statements without justification, and failure to update the analysis after changes to the equipment or the process fluid.