Welding Performance Testing Administrators GUIDE FOR ASSESSMENT OF QUALITY CONTROL MANUALS

Transcription

1 BRITISH COLUMBIA SAFETY AUTHORITY Welding Performance Testing Administrators GUIDE FOR ASSESSMENT OF QUALITY CONTROL MANUALS Date: May 1, 2017 Controlled Document: MAN MAN ( ) Page 1 of 10

2 INTRODUCTION This guide is intended for the use of assessment team members for the assessment of welding performance test administrator s conformity assessment programs. It can also be used by applicants for a Certificate of Recognition for the administration of welding performance tests to assist in the development of a conformity assessment program. It is not to be used to replace or interpret the requirements of the Safety Standards Act, the Safety Standards General Regulation and the Power Engineers, Boiler, Pressure Vessel and Refrigeration Safety Regulation, CSA B51or the ASME Codes. The checklist does not list all of the detailed requirements of a conformity assessment program, but rather lists the highlights that the applicant is required to include in the written Quality Control (QC) Manual. To assist the assessment team, this guide is provided to applicants for a Certificate of Recognition for the administration of welding performance tests for their use in identifying and verifying the content of their QC Manual which address all applicable control requirements of their conformity assessment program. The QC Manual must contain the description of the controls necessary for implementing the conformity assessment program but, it is not required to contain all of the detailed programmatic requirements which will be found in the program, such as written procedures. The guide is based upon CSA B51 and ASME Code requirements for welding performance testing. The guide is subject to revision based on changes made to the Act, Regulations, CSA B51 or ASME Code. An assessment will cover both the QC Manual and the conformity assessment program implementation. It is recognized that the scope of work, QC Manual and program implementation will vary from one applicant to another and therefore only those activities to be performed under the scope of an applicant s Certificate of Recognition are required to be addressed in the QC Manual. assessment teams are advised that this guide may not outline all possible aspects of each review. The QC Manual need not follow the format of this guide. HOW TO USE THIS GUIDE Review each checklist item in the checklist against the QC Manual and: 1) Check ( ) the applicable column - Yes or No a. The Corrective Action Required (CAR) column is for use by the reviewer. 2) Note the paragraph number in the QC Manual which covers the subject addressed in the column labeled QC Manual Paragraph Reference. With your application and fee, submit one copy of the completed checklist with one copy of the QC Manual to for review, at least one month prior to the scheduled implementation review date. MAN ( ) Page 2 of 10

3 QC Manual Review Checklist for the Administration of Welding Performance Qualification Tests Name: Address: Contact Person: ITEM 1.0 TITLE PAGE Is the person or organization s name & address shown on the Title page? Is the Edition and Revision # and date of issue shown on the Title page? Is the Manual a controlled or uncontrolled copy? Is the person or company the controlled manual is issued to indicated? Are the Act, Regulations, Codes sections and Standards indicated? APPROVAL AND REVISION HISTORY Is there an approval and acceptance by the person responsible for the QC Program and jurisdiction representative? Is there a listing of the edition and revision number, date and a description of the edition or revision provided? Are the names and signatures of the individuals reviewing and accepting the edition or revision included? Is there a table of contents page listing the contents of the manual by subject, number and revision number of each section? GLOSSARY OF TERMS Is there a listing of the terms and acronyms used in the manual and their meanings SCOPE OF WORK Is there a detailed description of the type of Performance Qualification testing the organization is capable of administrating and intends to carry out? MAN ( ) Page 3 of 10

4 5.0 STATEMENT OF AUTHORITY (on organizations letterhead) 5.1 Is there a statement that all performance qualification tests administered by the organization shall meet the requirements of the Safety Standards Act, Safety Standards General Regulation, Power Engineers, Boiler, Pressure Vessel and Refrigeration Safety Regulation, CSA B51 and ASME codes, as applicable; 5.2 Is the person responsible for the QC Program clearly indicated? 5.3 Does he / she have the freedom to identify QC problems and to initiate and provide solutions? 5.4 Does he / she have the full support of Management? 5.5 Is the responsible person able to stop the performance qualification test if necessary? 5.6 If conflict arises, is it stated that resolution does not contravene the requirements of the QC program, Act, Regulations, Codes or Standards? 5.7 Is there a signature and date by Senior Management official? 6.0 MANUAL CONTROL 6.1 Does the Manual outline whether revisions will be completed by page or by section? 6.2 Are the controls clearly described? 6.3 Does the Manual indicate who is responsible for revising the QC Manual (title of person)? 6.4 Is there a description of the revision control and distribution? 6.5 Is there a provision to ensure the person responsible for the QC program reviews the QC Manual against the latest edition of the Act, Regulations, Codes and Standards to ensure the Manual will be updated to reflect any required changes? 6.6 Does the provision include an interval of when the QC Manual will be reviewed? (example, one time per calendar year) 6.7 Is there a provision for submittal of the QC Manual edition or revision to for acceptance prior to implementation, including timely updating of all copies to reflect approved revisions? 7.0 ORGANIZATION 7.1 Does the QC Manual include an organizational chart? 7.2 Does the organization chart include the title of all personnel and departments that perform functions that can affect the performance qualification testing? MAN ( ) Page 4 of 10

5 7.3 Does the organization chart show the relationship between each department and indicate the title of those individuals responsible for preparation, implementation, or verification of the Quality System? 7.4 Does the QC Manual define the responsibilities and roles of the individuals? 7.5 Does the QC Manual clearly outline that the individuals shall have the organizational freedom and authority to fulfill those responsibilities? 7.6 Is there access by Quality Control to top Management? 7.7 Are job titles on the organization chart consistent with Manual text? 8.0 PERSONNEL QUALIFICATIONS 8.1 Are the qualifications, knowledge and experience of the person responsible for the QC program indicated? 8.2 Are the qualifications, knowledge and experience of the personnel administering performance qualification testing indicated? 8.3 Are the qualifications, knowledge and experience of personnel performing destructive and non-destructive examinations indicated? 8.4 Are the qualifications, knowledge and experience of any other personnel involved in the quality program indicated? (if applicable) 8.5 Does the QC manual detail the methods for recording and controlling the education, training, qualifications, knowledge and experience for personnel involved in the administering of performance qualification testing? 9.0 DOCUMENT CONTROL 9.1 Is there a position responsible for review and approval of welding or brazing procedures, test forms and test reports? 9.2 Is there a position responsible for documentation revision approval and control? 9.3 Is there a position responsible for completion, certification and distribution of performance qualification records? 9.4 Is there a position responsible for maintaining current editions of codes or other standards? 9.5 Is there a position responsible for maintaining records? 9.6 Are there provisions for what records are to be maintained and for how long records have to be maintained? 10.0 MATERIAL CONTROL 10.1 Is there a position responsible for ordering materials? MAN ( ) Page 5 of 10

6 10.2 Are there provisions to ensure only designated and approved material is ordered? 10.3 Is there a position responsible for review and acceptance of purchase orders prior to issuing? 10.4 Is there a position responsible for material and filler metal receipt and provisions for inspection (dimensional, identification markings an documentation checks)? 10.5 Is there a system for acceptance marking / tagging and subsequent storage identification and traceability? 10.6 Is there a position responsible for the release of accepted material for performance qualification testing including filler metals? 11.0 TESTING CONTROL 11.1 Is there a statement that welding or brazing performance qualification testing shall be carried out in accordance with the Safety Standards Act, the Safety Standards General Regulation, the Power Engineers, Boiler, Pressure Vessel and Refrigeration Safety Regulation, CSA B51 and ASME Section IX and other applicable Codes? 11.2 Is there a position responsible for reviewing the test candidate s qualifications to ensure they are eligible for the test? 11.3 Is there a position responsible for reviewing the Welding or Brazing Procedure Specification and ensure it is registered with prior to testing? 11.4 Does the QC manual include a provision for the issue of test procedures, test coupons and welding consumables? 11.5 Does the QC manual include a provision to verify the calibration of welding machines, electrode holding ovens and other equipment utilized during the testing? 11.6 Is there a provision for handling, storing, distributing and return of filler metal consumables (including heated ovens, dry areas, etc.)? 11.7 Are there provisions for overseeing the testing including joint preparation, fit up, test positions, amperage, voltage, polarity, tack welds, root and fill passes? 11.8 Are there provisions for inspecting the test welds during and after the test to ensure the essential variables and other requirements listed in ASME Section IX are in conformance? (IE deposited F# thickness) 11.9 Is there a provision to positively identifying the test coupons and bend test specimen (IE stamping) prior to removal and completion of bend tests (or radiography)? Is there a provision to describe the preparation requirements of mechanical test specimens? MAN ( ) Page 6 of 10

7 11.11 Is there a position responsible for reviewing test results, recording and certifying the results on the performance qualification record? Are there provisions for the control, storage and period of retention of passed/failed test coupon? 12.0 NON-DESTRUCTIVE EXAMINATION 12.1 Is there a position responsible for the requesting of all nondestructive examinations? 12.2 Does the QC manual include a procedure to outline whether nondestructive examinations will be performed in-house or are they performed by a sub-contractor employing personnel qualified to CGSB? 12.3 Does the QC manual include a position responsible for the review and acceptance of the written NDE procedures certified by a CGSB Level III Examiner? 12.4 Is there a procedure to appoint the CGSB Level III Examiner in writing? 12.5 Is there a procedure for the review, acceptance, documenting and controlling of NDE personnel qualifications? 12.6 For radiography, does the QC Manual include a provision for maintaining a calibrated density strip and/or calibrated densitometer for use by the COR or sub-contractor? 12.7 Is there a provision for traceability of radiographs to weld coupons? 12.8 Is there a position responsible for review and acceptance of NDE reports and radiographic film? 12.9 Are there provisions for the maintenance of NDE records and periods for record retention? 13.0 HEAT TREATMENT 13.1 Does a statement exist whether heat treatment is in-house or subcontracted? 13.2 Is there a position responsible for approving and accepting of heat treatment procedures in accordance with material specification and/or referenced standards? 13.3 Are there provisions for identification and traceability of weld coupons being heat treated and acceptance of time/temperature charts by the organizations representatives? 13.4 Are there provisions for the maintenance of heat treating records and period for record retention? MAN ( ) Page 7 of 10

8 14.0 CALIBRATION OF TEST EQUIPMENT 14.1 Is there a position responsible for control of equipment used during the administration of performance qualification testing and record keeping? 14.2 Is there a provision to describe and control the equipment used during the administration of performance qualification testing? (IE: welding machines, electrode ovens, measuring equipment for material receiving, NDE equipment etc) 14.3 Is there a description of how items are identified and the frequency of calibration is recorded (e.g. stickers, cards, logs, etc.)? 15.0 REPORTS AND RECORDS 15.1 Does the manual indicate the title of the individuals responsible for preparing, competing and signing the performance qualification test forms? 15.2 Does the manual indicate who the completed performance qualification records shall be distributed to? 15.3 Does the manual indicate the length of time records shall be retained? 16.0 NON-CONFORMITIES 16.1 Are there provisions for indentifying, documenting and resolving nonconformities? 16.2 Is there a position responsible for the disposition and resolution of nonconformities? 16.3 Is there a position responsible for corrective action initiation and documentation? 16.4 Are there provisions for indentifying, documenting and resolving nonconformities? 16.5 Is there a position responsible for record retention of nonconformance reports? 17.0 INTERNAL AUDITS 17.1 Are there provisions for the periodic review of the conformity assessment program? 17.2 Is there a system for implementing improvements to the conformity assessment program based on the findings of a periodic review? 17.3 Is there a position responsible for conducting periodic reviews and implementing improvements? 17.4 Is there a system for reporting and recording the results of the reviews? MAN ( ) Page 8 of 10

9 17.5 Are there provisions for review by the of the organization s policies, procedures, documentation, records and test facilities? 18.0 REVIEW AND APPEAL 18.1 Is there a system for the resolution of complaints by test candidates? 18.2 Is there a position responsible for receiving, reviewing and replying to complaints? 18.3 Are there provisions for appeal of the complaint review to more senior management positions? 18.4 Is there a system for recording the results of the reviews? 19.0 DOCUMENT COMPLETION 19.1 Are all Manual references provided and complete? 19.2 When this Checklist is completed by the applicant, has a written reference or comment been provided against each Item (Form is not acceptable without completion of 19.1 and 19.2)? MAN ( ) Page 9 of 10

10 MAN-4017 Revision History Revision Revision Date Revision history Revised by /03/02 New release Ed Hurd /05/01 Added Scope of Work item, removed reference to SNT TC 1A, aligned order of items with MAN guide, replaced N/A column with Corrective Action Required (CAR) column. Larry Malmgren Approval This document has been approved for adequacy by: Tony Scholl May 1, 2017 Safety Manager, Boilers and Pressure Vessels MAN ( ) Page 10 of 10