Buongiorno! ASME N3 & NQA-1Certification Benefits to D&D Ventures. Dr. Dirk Kölbl. Authorized Inspector Supervisor NQA-1 Lead Auditor

Transcription

1 Buongiorno! ASME N3 & NQA-1Certification Benefits to D&D Ventures Dr. Dirk Kölbl Authorized Inspector Supervisor NQA-1 Lead Auditor Rome March 20th, / 2015

2 Affiliation with ASME Selling Codes Selling Certificate Survey & Audit Accrediting 03-18

3 ASME and the AIA AIA Employs ANIS and ANI Organizes Technical Oversight Holds ASME Accreditation ANIS Represents AIA in Survey QA Manual Acceptance Audits certified companies Audits ANI Oversight of ANI inspection ASME Codes and Standards Certify AIA Certify Manufacturers Perform Surveys & Audits Protect the Mark ANI Independent 3rd Party Inspection Monitoring of QA Program Verify Code Conformance of items! 03-18

4 ASME Certification Programs Introduction Available ASME Certificates N3 Transportation and Storage Containments Why do I need a Certificate? Who is going to certify? What do I need to do? How long does it take? What is it going to cost me? ASME Section III Division 3 NQA-1 Certificate What are the benefits? 03-18

5 ASME Designators Section I Power Boilers S PRT A E M PP V * Power Boilers Boiler Parts Assembly Electrical Boilers Miniature Boilers Power Piping Safety Valves Section IV Heating Boilers H HLW HV Heating Boilers (*cast iron, cast aluminum) Potable Water Heaters Safety Valves Section VIII, Div. 1 Pressure Vessel U PRT UM * UV * UD * Pressure Vessels Pressure Vessel Parts Miniature Vessels Safety Valves Rupture Discs Section VIII, Div. 2 Pressure Vessel U2 PRT Alternative Rules for Pressure Vessels Pressure Vessel Parts Section VIII, Div. 3 Pressure Vessel U3 High Pressure Vessels UV3 * Safety Valves for High Pressure Vessels Section X Fiber-Reinforced Vessels RP Fiber-Reinforced Plastic Pressure Vessels Section XII Transport Tanks T TV * TD * Transport Tanks Safety Valves Rupture Discs National Board Inspection Code R VR * Repairs and Alterations Repair of Safety Valves * = no Authorized Inspector involved and required. Audit by ASME required

6 Nuclear ASME Certificates ASME Code Section III N N3 NPT Nuclear Components Pressure Vessels, Containment, Piping Systems, Tanks, Valves, Pumps. Storage and Transport Containments Nuclear Parts Welded Parts / Appurtenances NV NA NS QSC Nuclear Safety Valves Nuclear Installer Shop and Field Assembly Nuclear Supports, No STAMP! Quality System Certificate Material Organisations ASME Product Certification Mark Designator: N, NA,

7 ASME certified companies ASME Certificate Holders BPV 4812 N Type & QSC

8 ASME Certificate Holders Europe N3 Certificate Number: N-4122 Company Name: Mangiarotti S.p.A. Company Address: Via Timavo, 59 Monfalcone Gorizia Italy 200 U 26 U2 3 U3 6 N 10 NPT 4 NS 2 QSC Scope: Construction of Class TC transportation containments and Class SC storage containments at the above location and with additional Code activities as described in the Quality Program Manual at Zona Industriale, Pannellia 10, Sedegliano (Udine), Italy Authorized date: 12/17/2015 Expiration date: 11/23/2018 TURKEY (118) U 77 U2 2 U3 5 N 1 N3 6 NPT 2 NS 16 QSC

9 ASME Nuclear Accreditation 2017 US N3, 4 INT N-Type, 126 US QSC, 29 US N-Type, 85 INT QSC, 59 INT N3, 5 US NQA-1, 1

10 Why Certification? Why do I need a Certificate? Regulatory Requirement Customer Requirement Competition Reputation & Marketing Who is going to certify? ASME: N, N3, NPT, MO, NQA-1 Customer: NQA-1, 10CFR50 What do I need to do? How long does it take? What is it going to cost me? What are the benefits? 03-18

11 Containment / Part / Material Component / Containment Design Specification Design Report Fabrication Specification N3 TC SC ISS Part NPT-Certificate Holder Becomes Part of Component No Design Report NPT Material Material Organisation CMTR or COC ASME QSC Certificate NQA-1 Certification of the QA program CONFORMITY

12 Section III Divisions and Subsections DIVISION 1 Metallic Components Subsection NCA General Requirements for Division 1 and Division 2 Subsection NB Class 1 Components DIVISION 2 Code for Concrete Containments DIVISION 3 Containments for Transportation and Storage of Spent Nuclear Fuel and High Level Radioactive Material and Waste Subsection NC Class 2 Components Subsection ND Class 3 Components Subsection NE Class MC Components Subsection NF Supports Subsection NG Core Support Structures Subsection NH Elevated Temperature Service Now Division 5 Appendices Deleted Ed2017 Subsection CC Concrete Containments and Division 2 Appendices Subsection WA General Requirements for Division 3 Subsection WB Class TC Transportation Containments Subsection WC Class TS Storage Containments Ed 2017 Subsection WD CLASS ISS INTERNAL SUPPORT STRUCTURES

13 Structure of Section III GENERAL REQUIREMENTS WA-1000 Scope of Division 3 WA-2000 Design Basis for Containments WA-3000 Responsibilities and Duties WA-4000 Quality Assurance WA-5000 Authorized Inspection WA-7000 Reference Standards WA-8000 Certificates, Nameplates, Certification Mark, and Data Reports WA-9000 Glossary WB-, WC- COMPONENT REQUIREMENTS 1000 Introduction or Scope 2000 Material 3000 Design 4000 Fabrication 5000 Examination 6000 Testing (except WD) 8000 Nameplates, Stamping With Certification Mark, and Reports

14 Storage Containment What does CONFORMITY mean? What kind of CONFORMITY does Section III Division 3 require? Just a brief view Image:

15 Conformity with Material Req ts WC-2320 IMPACT TEST PROCEDURES WC-2321 Types of Tests WC Drop Weight Tests. The drop weight test, when required, shall be performed in accordance with ASTM E208.. WC Charpy V Notch Tests. The Charpy V notch test (Cv), when required, shall be performed in accordance with SA The lateral expansion and absorbed energy, as applicable, and the test temperature, as well as the orientation and location of all tests performed to meet the requirements of WC-2330 shall be reported in the Certified Material Test Report. WC Fracture Toughness Tests. Fracture toughness tests, when required, shall be performed in accordance with ASTM E399. WB Dynamic Tear Test. The dynamic tear tests, when required, shall be performed in accordance with ASTM E604.

16 Conformity with Design Req ts WC-3250 DESIGN OF WELDED CONSTRUCTION WC-3251 Categories WC-3252 Permissible welds WC Joints of Category A. shall be capable of being examined in accordance with WC WC Joints of Category B shall meet the fabrication requirements of WC-4242 and shall be capable of being examined in accordance with WC WC Joints of Category C. shall meet the fabrication requirements of WC-4243 and shall be capable of being examined in accordance with WC Minimum dimensions of the welds and throat thickness shall be as shown in Figure WC or Figure WC ,

17 Even more Design Req ts The minimum thickness of unstayed flat heads, cover plates, and blind flanges shall conform to the requirements given in this Paragraph. Some acceptable types of lat heads and covers are shown in Figures WC , WC , and WC The dimensions are exclusive of extra metal added for corrosion allowance.

18 NQA-1: Design

19 WC-6222 Maximum Permissible Test Pressure The stress limits specified in WC-3218 shall be used in determining the maximum permissible test pressure. In multichamber containments, pressure may be simultaneously applied to the appropriate adjacent chamber to satisfy these stress limits. WC-6223 Hydrostatic Test Pressure Holding Time The hydrostatic test pressure shall be maintained a minimum of 10 minutes prior to initiation of the examination for leakage required by WC WC-6300 PNEUMATIC TESTS WC-6400 TEST GAGES WC-6600 SPECIAL TEST PRESSURE SITUATIONS WC-6700 LEAK TESTING Conformity with Testing Req ts WC-6120 TESTING OF CONTAINMENTS Except for closure welds meeting the requirements of WC-3262 all storage containments shall be hydrostatically (WC-6200), or pneumatically (WC-6300) pressure tested, except as permitted by WC Closure welds made after containments are loaded and meeting the requirements of WC-3262 shall be tested as required by WC WC-6200 HYDROSTATIC TESTS WC-6221 Minimum Hydrostatic Test Pressure The containment shall be hydrostatically tested at not less than 1.25 times Design Pressure.

20 Even Leak Testing Req ts WC-6710 HELIUM LEAK TESTING (a) Helium leak testing of containment welds, other than closure welds of WC-3262, may be substituted for pressure testing if the primary membrane stress due to a hydrostatic (WC- 6200) or pneumatic (WC-6300) test does not exceed the smaller of the one-third of the minimum specified minimum yield strength or one-fifth of the minimum specified tensile strength of the containment material and when specified in the Design Specification. (b) Helium leak testing shall be conducted in accordance with Section V, Article 10, and ANSI N14.5, Leakage Tests on Packages for Shipment.16 Personnel performing leak testing shall be qualified in accordance with Article WC (c) The allowable volumetric leakage rate shall be defined in the Design Specification. WC-6720 CONTAINMENT CLOSURES (a) Closure welds identified in the Design Specification as meeting the requirements of WC-3262, and mechanical closures and seals shall be helium leak tested. (b) Helium leak testing shall be conducted in accordance with Section V, Article 10, and ANS N14.5. Personnel performing helium leak-rate testing shall be qualified in accordance with Article WC (c) The allowable volumetric leakage rate shall be defined in the Design Specification. An acceptable method to determine the maximum, permissible volumetric leakage rate can be found in ANSI N14.5. (d) If a single leak-rate test is conducted, the conversion methods in ANSI N14.5 shall be used to determine if the leakage rates specified in the Design Specification have been met.

21 Conformity with NQA-1 plus NCA-4134 N, NV, NPT, NS, and NA Certificate Holders for Class 1, 2, 3, MC, CS, and CC Construction NCA Organization. The provisions of NQA 1, Requirement 1, shall apply. NCA Quality Assurance Program. (a) The provisions of NQA 1, Requirement 2, shall apply and the system used to meet these requirements shall be described in the Quality Assurance Manual. The Quality Assurance Manual shall also include a statement of policy and authority indicating management support. (b) In lieu of para. 301, Requirement 2, the qualification of nondestructive examination personnel shall be as required by NB/NC/ND/NE/NF/NG/NH (c) The controls used in the Quality Assurance Program shall be documented in the Quality Assurance Manual. The Program need not be in the same format or sequential arrangement as the requirements in this Article, as long as all applicable requirements of this Article have been covered. (d) The Certificate Holder shall be responsible for advising its Authorized Inspection Agency of any changes that are proposed to be made to the Quality Assurance Manual, and shall have acceptance of the ANIS before putting such changes into effect.

22 WA-4000 Records

23 Finally Conformity Certification

24 What do I need to do for N3 Certificate? Contract with an AIA (Inspection Service Agreement) Establish the Scope and Locations - Application to ASME, - Purchase Code Books - Develop QA Manual and Procedures - Implement the QA Program entirely & audit - Qualify Personnel & procedures (Welding, NDE, LA, ITP) - Run a Demo Order (design, purchasing, fabrication, etc) - Demonstration of Material Supply, USM, drop shiment, QMO - ANI shall perform inspections Pre Survey with AIA Final preparation Survey with ASME and AIA (3 Teams, 3-5 days ) days Labour estd. 1d 60d 80d 20d+ 20d+ 0-50d 20d 20d 40d timeline 12 18mo 12 18mo 1.5 years 12 18mo 8 12mo 8 12mo 3 6mo 3 6mo 1 3mo 1 1,5mo

25 Typical ASME Nuclear Survey ASME: AIA: Monday: 1 TL & 2-3 TM, ANIS & ANI QA Manual reading Team 1 QA 2 Software 3 Hardware Tuesday TL & ANIS TM 1 TM 2 & ANI Opening, Shop Tour QAM Opening, Shop Tour, Design Wednesday QAM Procurement, Vendor qualification, NCR, CAR, I&T Personnel, Audit Personnel, Thursday Friday Application Scope Team meeting Exit Meeting Training, Audits, Records Team meeting Exit Meeting Opening, Shop Tour, Welding demo and records NDE, PWHT, Traveler, procedures, Material Receiving and marking, CMTR, Material Supply Calibration, Testing, USM Team meeting Exit Meeting

26 NQA-1 Part 1 Requirements 1 Organization 2 Quality Assurance Program 3 Design Control 4 Procurement Document Control 5 Instructions, Procedures, and Drawings 6 Document Control 7 Control of Purchased Items and Services 8 Identification and Control of Items 9 Control of Processes 10 Inspection 11 Test Control 12 Control of Measuring and Test Equipment 13 Handling, Storage, and Shipping 14 Inspection, Test, and Operating Status 15 Control of Nonconforming Items 16 Corrective Action 17 Quality Assurance Records 18 Audits

27 Definition of QA ASME Code Section III NCA-9000: Quality Assurance (QA): as used in this Section, quality assurance comprises all those planned and systematic actions necessary to provide adequate confidence that all items designed and constructed are in accordance with the rules of this Section. Wisdom from the shopfloor (1) You can not inspect Quality into the Component! ASME NQA-1 quality assurance (QA): all those planned and systematic actions necessary to provide adequate confidence that a structure, system, or component will perform satisfactorily in service. quality assurance record: a completed document that furnishes evidence of the quality of items and/or activities affecting quality. Types of record media may include paper, electronic (magnetic or optical), or specially processed media such as Wisdom from the shopfloor (2) radiographs, photographs, negatives, and microforms. The term record, as used throughout the Standard, is to be interpreted as quality assurance record. You never get what you EXPECT, only what you INSPECT!

28 Quality Assurance Planned and Systematic Actions: Indoctrination, Training, Qualification of Personnel- document! Qualify Equipment and Procedures- document! Qualify Suppliers document! Clear Instructions and Procedures- document! Perform activities according to the Instructions! Perform Inspections and Testings document! Resolve all deviations document! Inspect and test again document! Learn from Problems- document! Audit - document! Prepare records and archive them! Wisdom from the shopfloor (3): When it is not documented, it never happened! Gif:

29 NQA-1 Part 1 Requirements 1 Organization 2 Quality Assurance Program 3 Design Control 4 Procurement Document Control 5 Instructions, Procedures, and Drawings 6 Document Control 7 Control of Purchased Items and Services 8 Identification and Control of Items 9 Control of Processes 10 Inspection 11 Test Control 12 Control of Measuring and Test Equipment 13 Handling, Storage, and Shipping 14 Inspection, Test, and Operating Status 15 Control of Nonconforming Items 16 Corrective Action 17 Quality Assurance Records 18 Audits Written for the Facility Focus: Safety Related Items Must also be applied to Suppliers Customer Audits! NQA-1 Certificate by ASME Audits are required! Scope can be defined! MANDATORY for N-Type Certificates! Great Guidance for D&D!

30 ISO vs. NQA-1 Example ISO/DIS Competence The organization shall: a) determine the necessary competence and qualification requirements of person(s) doing work under its control that affects the performance and effectiveness of the quality management system and products or services conformity; b) ensure that these persons are competent on the basis of appropriate education, training, or experience; c) where applicable as defined in 7.2.a), take actions to acquire the necessary competence and qualification, and evaluate, on a continuing basis, the competence and qualification of personnel and the effectiveness of the actions taken; ISO Awareness ISO 9001 based The organization shall ensure that persons doing work under the organization s Management control are aware Standard of: a) the nuclear safety Defined and quality Targets policy; b) relevant quality objectives; Customer focus c) their contribution to the effectiveness of the quality management system, including the benefits of improved performance; d) the implications of not conforming with the quality management system requirements. Persons involved in the realization of products or services shall be trained on the importance of their tasks including the possible nuclear safety consequences of errors in 200 INDOCTRINATION AND TRAINING Indoctrination and training shall be commensurate with scope, complexity, importance of the activities, and the education, experience, and proficiency of the person. 201 Indoctrination Personnel performing or managing activities affecting quality shall receive indoctrination in their job responsibilities and authority that includes general criteria, technical objectives, requirements of applicable codes and standards, regulatory NQA-1 commitments, company procedures, and quality Suits ASME Codes&Stds assurance program requirements. Conformity Standard Defined Requirements 202 Training The need for a formal Focus: training Quality program Assurance for personnel performing or managing activities affecting quality shall be determined. Training shall be provided, if needed, to achieve initial proficiency, maintain proficiency, and adapt to changes in technology, methods, or job responsibilities. On-thejob training shall be used if direct hands-on applications or experience is needed to achieve and maintain proficiency.

31 NQA-1 2 QA Program 302 Inspection and Test Personnel The initial capabilities of a candidate shall be determined by an evaluation of the candidate s - education, - experience, inspection: examination or measurement to verify - training, and either whether an item or activity conforms to specified - test results or capability demonstration. requirements. The job performance of inspection inspector: and test personnel a who shall performs be reevaluated inspection at periodic activities intervals to not to exceed 3 yr. Reevaluation shall be verify by conformance to specific requirements. - evidence of continued satisfactory performance or - redetermination of capability in accordance with the requirements of section 200 of this Requirement. If during this evaluation or at any other time, it is determined by the responsible organization that the capabilities of an individual are not in accordance with the qualification requirements specified for the testing: an element of verification for the determination job, that person shall be removed from that activity until such time as the required capability has been of the capability of an item to meet specified requirements demonstrated. by subjecting the item to a set of physical, chemical, Any person who has not performed inspection or testing activities in the qualified environmental, or operating conditions. area for a period of 1 yr shall be reevaluated.

32 NQA-1 3 Design Control Ed Use of Computer Programs Each computer program used for design analysis shall be accepted for use and controlled by applying the applicable requirements of Parts I and II prior to use, or the computer program s results shall be independently verified with the design analysis for each application. The acceptance of controlled computer programs used for design analysis, and verification methods applied to the results of unproven programs, shall meet the following requirements: (a) The computer program, or the verification method applied to the computer program results, shall be shown to produce correct solutions for the applied mathematical model within defined limits for each parameter employed. (b) The applied mathematical model shall be shown to produce a valid solution to the physical problem associated with the particular application.

33 Benefits of ASME Certification International Recognition in over 100 countries Reputation Committee Support Consistent and transparent CONFORMITY Certification Certificate of Competence Certified ASME Quality Assurance System Publication in the ASME database as Authorized Company

34 Containments needed! CONFORMITY needed!.. with Laws.. with Rules.. with Requirements Sources:

35 Got Questions? We have Answers! Dr. Dirk Kölbl, CIS GmbH Consulting Inspection Services Karolingerstr Essen, Germany Tel.: Fax: Karte: Wikipedia