understanding en 10204:2004 type 3.2 certification · pdf filemelt/cast (if a foundry), or...

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Understanding EN 10204:2004 Type 3.2 Certification

Lloyd’s Register – Understanding EN 10204:2004 Type 3.2 Certification

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



• History of the Standard

• Originally issued in 1991 – derived from DIN50049.

• 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.



• 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 10204 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?


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.


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 10204 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?

http://www.lr.org/en/services/en-10204-type-3-2-certification.aspx


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 10204 Type 3.2 can be endorsed/issued.


Is this stockist a manufacturer?

• No “mechanical property changing” operations.

• Stockist has not “manufactured” the material – certification “to the intent of “ EN 10204 3.2

Steelmaker Stockist Customer

Saw Drill

Grind Turn


Is this stockist a manufacturer?

• Mechanical property changing operations have been carried out

• Stockist has “manufactured” the material – certification “in accordance with“ EN 10204 3.2

• Material must be traceable through Stockist’s and sub-contractor’s operations.

Steelmaker Stockist Customer

Forge Heat treat

Extrude Wire draw


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

• How can we preserve the material’s 3.2 status?

Solution – Independent Third Party involvement at every stage of supply chain – cast transfer.

Steelmaker Stockist A Stockist B Customer



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”.



We can ask the Test House to add “EN 10204 3.2” to their Mechanical Test Report.

• Irrelevant – Test House not the manufacturer – ref: definition of Type 3.2

certificate in EN 10204.

• Ignores other testing that may be a requirement of product specification (e.g. NDE).

• Only causes confusion in the industry


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.


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:-

Check material’s identity and

stamp piece/area to be used for

mechanical testing – “Stamp

for test”

Stage 1:

Witness/review mechanical and

metallurgical testing.

Stage 2:

Review all client’s documentation

against “product specification”,

endorse paperwork and inspect/stamp material for

release.

Stage 3:


Inspection Practicalities – Stage 1

• 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.

Check material’s identity and stamp

piece/area to be used for

mechanical testing – “Stamp for test”

Stage 1:



Stage 2:




release.

Stage 3:



• 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




Stage 1:



Stage 2:




release.

Stage 3:




• 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 10204 Type 3.2




Stage 1:



Stage 2:




release.

Stage 3:



• Conclusions:-

• EN 10204 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 10204 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.



• 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 10204 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.


http://www.lr.org/en/manufacturing/quick-request-form.aspx

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.

David Thompson Senior Surveyor T +44 (0)7768 175713 E [email protected] Lloyd’s Register 1 Trinity Park, Bickenhill Lane Birmingham B37 7ES

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understanding en 10204:2004 type 3.2 certification · pdf filemelt/cast (if a foundry), or...

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