Conformity Assessment Dan Cheetham BPV Topics of Interest 2016 Certification 360
BPV Requirements Boiler and Pressure Vessel Requirements (Quality Control Programs, Materials, Examination & Inspection, etc.) Quality Control Programs -Required elements -Auditable -Acceptance
BPV Requirements Materials -Materials produced to an ASTM specification or to an earlier edition of ASME. -Maintaining material ID -Additional requirements per UG-79
BPV Requirements Examination and Inspection -Required examinations -Objective evidence Welding Other Topics
Written Quality System Quality Control Programs -All elements required by the book section (Section I, IV, VIII div. 1 ), must be addressed. -The applicant/manufacturer may choose how to address required element using whatever format or system they want, as long as the system is written and is auditable. Acceptance of Manual revisions. (PG-105.4, HG- 540.6, UG-117(f))
Written Quality System -The applicant/manufacturer may include additional requirements, but anything included must be followed. -All company personnel involved in the system should be assigned a controlled manual or at least have open access to a controlled manual. -Electronic manuals, maintained on a company server, may be used as long as the security of the QC Program is described.
Written Quality System -Sometimes a Team Leader may suggest that something be added to a Manual with good intentions, if it is not required to be addressed in a Manual, it doesn t have to be addressed.
Written Quality System Procedures referenced in a manual must include Procedure name and number, and must be available for review by the JR Team. Common findings: Material Control section does not ensure that only the intended materials are being used.
Written Quality System Manual does not specify who is responsibility Welding section does not require a WPS be available to the welder in the work area Certifications not described Coded marking system not described
Written Quality System Questions?
Materials Material Requirements -Materials produced to an edition of ASTM specification only. (Section IIA and IIB Mandatory Appendix II) -Materials produced to an earlier edition of ASME. -Material marking requirements. -Receiving materials, welding materials. Is the receiving inspection different for plate and pipe, than for welding material? If so, why? Is it not Code material?
Material Requirements -How is material issued? System must ensure that only the intended materials may be used in Code fabrication. (Appendix A-320.4, F-202.4, 10-6) Welding material issuance. -Maintenance of material markings to the original required markings. Is a Coded marking system being used? (PG-77.2, UG-77(a))
Material Requirements -Common problems with materials -Markings not in accordance with the requirements of the material specifications, either not complete from manufacturer or not transferred properly at a supplier. -Coded markings applied by supplier to cut pieces, when the Code only allows coded marking by supplier of formed parts.
Material Requirements -Required certification does not indicate whether or not a formed part has been heat treated. And if cold formed with fiber elongation above 5%, the certification does not indicate what the temperature of the metal was when it was formed. (UG-79(c), UCS-79(d))
Material Requirements Questions?
Examination and Inspection Requirements Examinations and Inspection program -The purpose of a Joint Review is to review the manual and to review the implementation of the manual. The program must be fully implemented during a Joint Review
Examination and Inspection Requirements -Whatever the manual requires must be demonstrated. -If a deficiency is identified, the applicant must implement their program. If a deficiency is identified and fixed without generating the required document, then the system was not implemented. -All identified deficiencies are required to be documented, ie. NCR/CAR
Examination and Inspection Requirements -It is not TL s job to tell an applicant they must write an NCR. The applicant must demonstrate their system. TL s may remind them that they must implement their system.
During a Joint Review Examination and Inspection Requirements -All examinations and inspections must be completed and signed off, before any welding can be demonstrated. Common deficiencies: ITP/Traveler not being signed off before welding demo begins. Welder not following WPS.
Welding -Some common welding deficiencies found at JR s. -Tack welds not being properly examined or documented. -Fit-up examination not being documented. -PQR not addressing all required essential variables. -WPS not addressing all required variables. -WPQ not addressing all required variables or the proper ranges. -Continuity records lacking objective evidence.
Welding -Revisions/changes to PQR s. Must be limited to those described in QW-2002.(c)
Other Topics Other topics -Has ASME a plan to certify material manufacturer? NDE provider? Design organizations? Revised CAP-22. AI s responsibility to verify applicable calculations have been made. U-2(g)
Other Topics CA-1, why only Section I? Usage of AIA Feedback form. Additional buildings, Temporary shops, Name change, relocation
BPV Requirements Questions?