HOW TO CONSTRUCT ASME BOILER BY THAI ASSOCIATION OF BOILOER AND PRESSURE VESSEL

Transcription

1 HOW TO CONSTRUCT ASME BOILER BY THAI ASSOCIATION OF BOILOER AND PRESSURE VESSEL

2 WHAT IS ASME The American Society of Mechanical Engineers set up a committee in 1911 for the purpose of formulating standard rules for the construction of steam boilers and other pressure vessels. This committee is now called The Boiler and Pressure Vessel Committee

3 The Committee s Function To establish rules of safety, relating to pressure integrity, governing the construction of boilers, pressure vessels, transport tanks and nuclear components. Inservice inspection for pressure integrity of nuclear components and transport tanks. Interpret rules when questions arise regarding their intent.

4 CODE REQUIREMENTS AND SCOPE CODE contains mandatory requirements, specific prohibitions and nonmandatory guidance for construction activities. CODE is not a Handbook and cannot replace education, experience, and the use of engineering judgment. Engineering judgment must be consistent with Code philosophy and must never overrule mandatory requirement or specific prohibitions.

5 TECHNOLOGICAL DEVELOPMENT The Boiler and Pressure Vessel Committee meets regularly to consider revisions of the rules, new rules as dictated by Technological Development Code Cases Request for interpretation The action of the Standard Committees becomes effective only after confirmation by letter ballot of the Committees and approval by ASME

6 GLOSSARY AI: Authorized inspector regularly employed by an Authorized Inspection Agency as defined in the Code AIA: Authorized Inspection Agency (ASME Accredited) AIS: Authorized Inspection Supervisor AIA of Record: AIA with whom the Shop has a contract and agreement to perform the inspection services required by the Code.

7 GLOSSARY Code item: Boiler Proper & Boiler External Piping, field assemblies in accordance to the Code COC: Certificate of compliance MDR: Manufacturing Data Report as defined in the ASME Code NCR: Nonconformity Report MTR: Material Test Report

8 GLOSSARY ITP: Inspection and Test Plan MAWP: Maximum Allowable Working Pressure which can also be designated as Design Pressure MDMT: Minimum Design Metal Temperature, the lowest temperature determined by design at MAWP. NDE: Nondestructive Examination

9 GLOSSARY PROCEDURE: A document with step by step instruction describing how action shall be performed in order to produce results in accordance with the specified requirements WPS: Welding Procedure specification PQR: Procedure Qualification Record WPQ: Welder Performance Qualification

10 QUALITY CONTROL MANUAL STATEMENT OF POLICY, AUTHORITY and CERTIFICATION 1. The Management of the SHOP is totally committed to meet all of the requirements of the ASME Boiler and Pressure Vessel Codes and all the quality control system described in this Manual 2. The QA/QC Manager has the authority, sufficient and well defined responsibility, and organizational freedom to identify quality control problem and to initiate, recommend and provide solutions. 3. All Department Managers and their subordinates shall have responsibilities to construct the Code items in accordance with ASME Codes and this Manual

11 QUALITY CONTROL MANUAL The QA/QC Manager shall stop work if further processing would result in a nonconformance to the code items.

12 organization

13 DESIGN, CALCULATION, DRAWING Design and Drawing preparation by Design Engineer Material Requisition preparation by Design Engineer Designs, Drawings, and Material Requisition to be approved by Engineering Manager Submit Designs and Drawings to AI for approval AI verifies, approves, signs off and stamp approval.

14 COMPUTER AIDED DESIGN When CADs are used for Coded items, the Design Engineer is responsible for the input of correct design data. And for the verification of the correct output has been obtained. Engineering Manager shall be responsible for the approval. Review by AI.

15 DESIGN BY OTHERS The Design Engineer review Drawings and Calculations for compliance to the Code and adequate basis for construction or field assembly. Approved by Engineering Manager. Engineering Manager shall be responsible to obtain the necessary documentation of the validity of computer program used for calculation.

16 MATERIAL CONTROL The Design Engineer is responsible to prepare Material Requisition, in accordance with the material specification and the Code requirement, and approved by the Engineering Manager. Purchasing officer prepares the Purchase Order which will be approved by the Managing Director or Authorized personnel

17 MATERIAL RECEIVING INSPECTION Material Controller/QC Inspector shall check that the material is correctly marked in accordance with the Material Specification and prepare Incoming Material Inspection Report. Material Controller transmits Incoming Material Inspection Report to QC Engineer QC Engineer verify MIR and MTR or COC

18 MATERIAL RECEIVING INSPECTION Customer Supplied Material Coded Stamped parts with Partial Data report Welded Consumables Nonconforming materials

19 MATERIAL TRACEABILITY Before cutting Code material into 2 or more pieces where the Original Markings would be lost or destroyed, the entire marking must be transferred for Traceability and verify with QC logo by QC Inspector. Coded Marking System approved by AI may be used where Full Marking is not appropriate. Temporary attachments welded to the pressure part shall be identified with at least P Number.

20 INSPECTION and EXAMINATION Inspection and Test Plan During construction, Code items are controlled using Inspection and Test Plan (ITP) based on Approved Drawings. List the sequence of fabrication, examination and inspection. QA/QC Manager shall review and approve the ITP and present it to AI to assign his designated Inspection Points.

21 INSPECTION and TEST PLAN GLOSSARY H: Hold Point, No work may proceed beyond this point until AI has accepted it. W: Witness Point, No work may proceed beyond this point until AI has accepted or has given his permission to waive this point. R: Review Point: would cover the review of documents and records, and must be finished prior to the Final Inspection of the Code item.

22 FINAL INSPECTION Final Inspection must be performed together with AI before Hydrostatic Test or Pneumatic Test. Actual dimensions and material markings are recorded during Final Inspection by QC Inspector. When a Code item is not provided an opening or access to inspect inside, a Hold Point for QC Inspector and AI will be set on ITP.

23 HYDROSTATIC TEST QA/QC Manager shall assure that AI has been notified sufficiently in advance of the Test. Water temperature shall not be less than 70 F (20 C) The test pressure should be gradually increased to not less than 1.5 MAWP, closed examination is not required at this stage. Reduce pressure to MAWP for closed examination. No part shall be subject to membrane stress >90% of its yield strength (0.2% offset)

24 NONCONFORMITY (NC) DEFINITION: Any condition which does not comply with the applicable rules of the Code, the Quality Control Manual or other specific requirements. All NCs must be corrected before the complete Code item can be considered to comply with the Code. IDENTIFICATION: QC Inspector will identify by applying a HOLD Tag or Sticker or marking.

25 CORRECTION OF NC QA/QC Manager is responsible for approval disposition of all NCRs. QA/QC Manager may convene a meeting with Production Manager or Engineering Manager. The disposition agreement shall be recorded on the NCR and signed by the meeting members.

26 CORRECTION OF NC USE AS IS : There will be no need for any correction, revision of drawing, calculation, or related documents may be required. REPAIR/REWORK : Repaired Procedure shall be created and approved by QA/QC Manager and AI. REJECT : The item has to be removed from the work area and tagged or marked Reject

27 WELDING WPS: is prepared by Welding Engineer including all variables required for the process by ASME Code Section IX and intended range of production welding. Test welds are made under his supervision and all variables shall be recorded by QC Inspector. Welding Engineer verifies Test Results, then prepares and certifies PQR. WPS and PQR shall be reviewed and approved by QA/QC Manager and submitted to AI for review.

28 WELDER QUALIFICATION Qualified as per ASME Section IX and the applicable Code Section. Under supervision of Welding Engineer. Welding Engineer verifies Test Result, prepares and certifies Welder Performance Qualification (WPQ) or WOPQ WPQ and WOPQ are reviewed and approved by QA/QC Manager and reviewed by AI.

29 PRODUCTION WELDING Weld Map to be prepared by Welding Engineer showing at least Joint numbers and Joint details. Welding Engineer assigns WPS to each Joint. Welders and Welding Operator will be assigned to welding joints according to their Qualifications. NDE Schedule to be prepared by QC Inspector, performed by Qualified QC Inspectors or Third Party.

30 NONDESTRUCTIVE EXAMINATION NDE PROCEDURES: All NDE Procedures shall be submitted to AI for review. All NDE Procedures shall be qualified by demonstration to the satisfaction of AI by NDE Personnel Level III in accordance with Section V, paragraph T 150 and the Code. NDE personnel records including list of NDE personnel are available for review by AI.

31 HEAT TREATMENT POST WELD HEAT TREATMENT: Shall be performed in accordance with PWHT Work Instruction prepared by Welding Engineer and approved by QA/QC Manager. Shall describe the placement and method of attachment for thermocouple, temperature gradients for heating and cooling, support locations, time temperature record, etc. to be submitted to AI for review.

32 PWHT TIME TEMPERATURE RECORD Procedure & Revision Order number Date of Heat Treatment Code item or Part number and Job number Identification of thermocouples Signature of Welding Engineer and Operator Type of thermocouples/time Recorder and validity of the calibration

33 RECORD RETENTION QA/QC Manager shall be responsible for the safe keeping of all records related to Code work performed at Shop and at field sites. As per Nonmandatory Appendix A The Manufacturer shall have a system for the maintenance of radiographic and Manufacturer s Data Reports for 5 years. (10 years per Thai Law) QA/QC Manager shall maintain National Board Number Log and registered at NB within 60 days after signature of AI

34 WATER TUBE BOILER

35 STANDARD AND CODE CERTIFICATES Lloyd s Register certificate

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42 MATERIAL TRACEABILITY Original marks Transferred marks

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