Understanding EN 10204:2004 Type 3.2 Certification. Working together for a safer world

Transcription

1 Understanding EN 10204:2004 Type 3.2 Certification Working together for a safer world

2 EN 10204:2004 Type 3.2 Certification INTRODUCTION History and Development of the Standard Applicability; Definitions True 3.2 certification v Intent of 3.2 certification Background; Definition; Client classification Common Client Misconceptions Inspection Practicalities What, Why and How we do our Inspections

3 EN 10204:2004 Type 3.2 Certification History of the Standard Originally issued in 1991 derived from DIN Re-issued in 2004 (current version), with reduced No of certificate types seven to four. Certificate types which require independent third-party involvement were called type 3.1c in 1991 version, changed to type 3.2 in 2004 version.

4 EN 10204:2004 Type 3.2 Certification History of the Standard Applicability and definitions Scope (1.1) All metallic products e.g. plates, sheets, bars, forgings, castings. Definition (2.3) Manufacturer organization that manufactures the respective products according to the requirements of the order and to the properties specified in the referenced product specification. Definition (2.5) Product Specification complete detailed technical requirements relevant for the order, stated in written form e.g. referenced regulations, standards or other specifications. Technical Committee responsible for EN comprises mainly representatives of primary steelmakers - hence its focus on primary metallic products. Lloyd s Register (LR) often visit stockists where do they fit in with EN 10204?

5 History of the Standard Purpose of Third-Party Inspection The main purpose of Type 3.2 certification is to independently verify: Material traceability from original cast to despatch to customer. Material properties ensures material is fit for its intended purpose. The Independent Third Party s activity should add value to the material/product. The customer/end user should have assurance that the material is correct and fit for purpose.

6 True 3.2 v intent of 3.2: Background Rise in importance of stockists no longer just steel merchants. Ref:- Intermediate Material Handler LR 3.2 factsheet. Stockists now specialise in selling material into Oil & Gas supply chain Oil & Gas end-users often require third-party inspection/verification of raw materials for critical applications EN Type 3.2 certification Not always economically viable to buy 3.2 certified raw material from primary steelmaker (minimum batch quantity) Industry-driven requirement for Type 3.2 certification of material handled by stockists Can stockists be classified as manufacturers as per EN 10204? If not, how can we certify to Type 3.2 as required by Industry?

7 True 3.2 v intent of 3.2: Definition of Manufacturer LR has adopted the same definition of a manufacturer as stated in NORSOK standard M-650 Qualification of Manufacturers of Special Materials:- party, including sub-contractors, which carry out operations affecting the material properties of the finished product. Clear that Foundries, Forges, Extruders, etc. are manufacturers A stockist depending on their production route could be classed as a manufacturer If a stockist has a production route that is not classed as manufacturing, but LR Surveyors have carried out suitable inspection and witnessing of testing, then certification to the intent of EN Type 3.2 can be endorsed/issued.

8 Is this stockist a manufacturer? Saw Drill Steelmaker Stockist Customer Grind Turn No mechanical property changing operations. Stockist has not manufactured the material certification to the intent of EN

9 Is this stockist a manufacturer? Forge Heat treat Steelmaker Stockist Customer Extrude Wire draw Mechanical property changing operations have been carried out Stockist has manufactured the material certification in accordance with EN Material must be traceable through Stockist s and sub-contractor s operations.

10 Common client misconception #1 If the material has been 3.2 certified at the steelmaker there is nothing else to do. Not necessarily - complicated supply chains lead to potential traceability issues Steelmaker Stockist A Stockist B Customer How can we preserve the material s 3.2 status? Solution Independent Third Party involvement at every stage of supply chain cast transfer.

11 Common client misconception #2 The Independent Third Party can carry out a paperwork review for Type 3.2 certification. Does this verify the material s traceability or properties? Does this add value to the material? No. The Independent Third Party is just acting as an expensive spell-checker.

12 Common client misconception #3 We can ask the Test House to add EN to their Mechanical Test Report. Irrelevant Test House not the manufacturer ref: definition of Type 3.2 certificate in EN Ignores other testing that may be a requirement of product specification (e.g. NDE). Only causes confusion in the industry

13 Inspection practicalities The main purpose of 3.2 certification is to independently verify the material s: Traceability from original cast to despatch to customer Properties to ensure the material is fit for its intended purpose The Independent Third Party s activity should add value to the material/product.

14 Inspection practicalities We ll discuss a generic inspection process applicable for true and intent of 3.2 certification. Additional inspection/witnessing can be done as required by specific customer requirements (Bills of Material; ITPs, etc). All clients are different. Many scenarios can arise. LR Surveyor s experience and collaboration with the client can formulate a suitable work-around where necessary. We adopt a 3-stage inspection process:- 1: Check material s identity and stamp piece/area to be used for mechanical testing Stamp for test 2: Witness/review mechanical and metallurgical testing. 3: Review all client s documentation against product specification, endorse paperwork and inspect/stamp material for release.

15 Inspection Practicalities 1 1: Check material s identity and stamp piece/area to be used for mechanical testing Stamp for test 2: Witness/review mechanical and metallurgical testing. 3: Review all client s documentation against product specification, endorse paperwork and inspect/stamp material for release. Objective is to verify the material s identity look for original, unique identification cast/melt No, serial No, etc. Identification should be traceable within client s facility and back to the melt/cast (if a foundry), or traceable to the original steelmaker s Type 3.1 certificate (stockist, etc). If all is satisfactory, the test material is hard stamped with the Surveyor s personal stamp (initials). This identifies the material to the attending Surveyor at the Test House.

16 Inspection Practicalities 2 1: Check material s identity and stamp piece/area to be used for mechanical testing Stamp for test 2: Witness/review mechanical and metallurgical testing. 3: Review all client s documentation against product specification, endorse paperwork and inspect/stamp material for release. Witness mechanical testing usually carried out at a sub-contract, accredited (ISO 17025) testing facility. All testing equipment will be verified by the attending Surveyor as being within calibration. Testing should be carried out to the client s requirements. Failed tests will be noted on the Test Report. LR s standard policy for 3.2 certification is to witness mechanical testing tensile, impact, hardness, bend, etc. but review metallurgical testing grain size, ferrite count, corrosion test, etc. Ref: LR s 3.2 factsheet

17 Inspection Practicalities 2 1: Check material s identity and stamp piece/area to be used for mechanical testing Stamp for test 2: Witness/review mechanical and metallurgical testing. 3: Review all client s documentation against product specification, endorse paperwork and inspect/stamp material for release. Review client documentation against ALL customer s requirements Product Specification. Includes all processes that affect the material s properties and all processes required by the Product Specification (NDE, etc). Endorse client s paperwork. Inspect material to be despatched (quantity/quality, size, identification) and hard stamp ilrs + personal stamp. If required, LR can issue certification that supplements the client s certification. Includes a scope of survey and conclusion statement that material either conforms to, or is to the intent of EN Type 3.2

18 EN 10204:2004 Type 3.2 Certification Conclusions:- EN Type 3.2 certification provides assurance to the customer that:- The material is fully traceable. The material s properties meet specified requirements. Type 3.2 certified material, carried out by LR, will as a minimum have been subject to the inspection/testing/witness regime described previously. EN Type 3.2 certified material can be used in many applications not just the Oil & Gas industry where a high-level, independent assurance is required.

19 EN 10204:2004 Type 3.2 Certification Further Information:- EN 10204: 2004 Type 3.2 Inspection Certification factsheet. Explains our inspection process in more detail. LR has an extensive global network of qualified and trained Surveyors, capable of inspecting material to EN Type 3.2 and discussing technical queries. Higher concentration of Surveyors in industrial centres to meet client demand Click here to request a quote, ask a question or request a surveyor.

20 David Thompson Senior Surveyor T +44 (0) E david.thompson@lr.org Lloyd s Register 1 Trinity Park, Bickenhill Lane Birmingham B37 7ES Working together for a safer world Lloyd s Register, its affiliates and subsidiaries and their respective officers, employees or agents are, individually and collectively, referred to in this clause as the Lloyd s Register Group. The Lloyd s Register Group assumes no responsibility and shall not be liable to any person for any loss, damage or expense caused by reliance on the information or advice in this document or howsoever provided, unless that person has signed a contract with the relevant Lloyd s Register Group entity for the provision of this information or advice and in that case any responsibility or liability is exclusively on the terms and conditions set out in that contract. 2017, Lloyd s Register. No Part of this document may be reprinted or redistributed without express prior permission of Lloyd s Register.