PRESSURE VESSEL INSPETION AUTHORITIES SABS 0227: 2000 F 41-04 Organisation s SAS No/s. Inspection authority Inspection authority Representative Assessor This report covers the following: Document Review only Implementation on site visit only Document review and Site Visit Other (Specify) omment below on adequacy of how requirements have been addressed, documented and/or implemented. The order of assessment need not follow the order of the checklist. Assessors are expected to know & have the standard, this worksheet is designed as guidance to prompt detailed recording of the process. REFER TO SABS 0227:2000 FOR DETAIL AND FOR LARIFIATION NOTES.. (ompliance =, Non-compliance =, Not applicable = ) LAUSE 4. QUALITY SYSTEM Has the executive management of the inspection authority defined and documented its policy on quality? Does the policy include the inspection authority s objectives and commitment to quality and how it addresses this standard? Is the policy relevant to the goals set by the inspection authority and to the expectations and needs of the customer? Is the policy understood, implemented and maintained throughout all levels within the ispection authority? 5. ORGANISATION 5.1 Independence 5.1.1 Is the inspection authority, its management representative and staff responsible for carrying out the verification of design, manufacture and test on new vessels under pressure, or the verification of design, construction and test on modified or repaired vessels under pressure, the designer, manufacturer, supplier or installer of these vessels or represents the parties engaged in these activities? Inspection authorities shall not become, or have been involved in the design, construction, marketing, representation or maintenance of the vessel under pressure, nor represent the parties engaged in these activities. This independence does not preclude the possibility of exchanges of technical information between the inspection authority and the various parties involved 5.1.2 Does the inspection authority and its staff carry out the verification test with professional integrity and technical competence? Is the inspection body and its staff free from all pressures and inducements (particularly financial) that might influence their judgement of the results of the inspection or verification, especially pressures and 2009-02-27 SAS Page 1 of 14
LAUSE inducements from persons or groups of persons with an interest in the results of the verification? 5.1.3 Is the partiality of the inspection staff guaranteed through management support? 5.1.4 Does the organisation that undertakes the design, inspection and maintenance of (in addition to under taking modifications and repairs) or other activities on vessels under pressure, clearly demonstrate and implement their defined policies for the demarcation and resolution of conflicting interest? 5.2 ONFIDENTIALITY Is the staff of the inspection authority bound to observe confidentiality with regards to all information gained in carrying out their duties, except with regards to the regulatory authority under whose auspices the inspection authority operates? 5.3 MAGEMENT REPRESENTATIVE Does the inspection authority have a management representative who, irrespective of any other responsibilities has the defined authority and responsibility to ensure that the requirements of this standard are implemented and maintained? Table 1 Is the Management Representative s qualification and experience per Table 1 requirements? 5.4 MAGEMENT REVIEW Does the inspection authority s management with executive responsibility review the quality system at define intervals sufficient to ensure the system s continuing suitability and effectiveness in satisfying the requirements of this standard and the companies stated quality policy procedures and objectives? Are records of such reviews kept? 6. FIELD OF ATIVITY 6.1 Is the extent of the service provided by the inspection body documented and is it specific for: a) the regulations in accordance with which the service is being provided; b) the design and manufacturing code (or codes if more than one code is being considered) in accordance with which the inspection services are being rendered; c) the inspection activities carried out, for example design verification, material verification quality for fabrication, NDE and testing verification etc., as applicable to the relevant design and manufacturing code or codes; and d) any other related services pertaining to pressure apparatus that enhance the expertise of the 2009-02-27 SAS Page 2 of 14
LAUSE organisation, but are not limited to the requirements of the AT F 41-04 6.2 Does the documentation specify which services and activities are provided in-house and which services, if any are obtained from outside the organisation and on what basis (i.e. design review, IPE s)? 7 QUALITY SYSTEM DOUMENTATION Does the quality system documentation comply with the relevant requirements of SABS ISO 9001or SABS ISO 9002, and does it contains an additional procedure to allow interfacing with those responsible for design in terms of the relevant clause of SABS ISO 9001 or SABS ISO 9002? 8 QUALITY SYSTEM 8.1 GENERAL Has the inspection authority developed and maintained documented procedures for the verification, certification or re-certification of manufactured, modified or repaired vessels under pressure? 8.2 DOUMENTED PROEDURES 8.2.1 Has documented procedures been developed for the following: a) Design and drawing verification; and b) Surveillance of suppliers manufacturing programme. 8.2.2 Does the manufacturing programme include aspects such as the following: a) quality control plan; b) material certification; c) material identification; d) examination of material cut edges and heat e) effected zones; f) verification of weld procedures; g) verification of welders and operators; h) weld preparation and fit up; i) inspection of second side weld preparation; j) acceptance of no-destructive testing (NDT); k) witnessing and evaluation of the mechanical testing of production test welds; l) heat treatment; m) pressure testing; n) final examination; 2009-02-27 SAS Page 3 of 14
LAUSE o) as build verification dimension; p) nameplate and hard stamping; q) acceptance of documentation; and r) certificate of construction or repair or modification 8.3 REERTIFIATION OF VESSELS UNDER PRESSURE Has the inspection authority developed and does it maintain procedures to enable it to rectify a vessel under pressure when any of the following conditions apply: a) unidentified vessels are encounters owing to lost documentation, the unavailability of a name or data plate, unconfirmed history of the vessel or certification by an unrecognised code or country of origin; or b) the vessel under pressure are to be re-rated to operate under different conditions; or c) the vessel under pressure do not conform to the conditions governing approval by the hief Inspector in terms of the Occupational Health and Safety Act, 1993 (Act 85 of 1993), or hief Inspector in terms of the Mine Health and Safety Act, 1996 (Act 29 of 1996) (or both) 8.4 STATUTORY INSPETION Has the inspection authority developed and does it maintain documented procedures for: i) conducting pre-commissioning inspection and tests; ii) iii) to approve changes to statutory inspection and test intervals; and for allowing waivers of hydraulic test, in terms of the regulations on vessels under pressure? 8.5 NON ONFORMATIES AND ORRETIVE ATIONS: (See A.3) (ontract) Has the inspection body developed and does it maintain procedures for handling non-conformities and corrective actions relating to the contract? Does it at least include the following: a) the initiation of reports of non-conformities (if they have not already been initiated) and the transmission thereof to the client and supplier; b) the verification that approved corrective action with regards to the defined non-conformities has been executed by responsible and competent personnel; and c) Instructions for whenever the inspector is unable to resolve any questions concerning compliance with the design and manufacturing code, the 2009-02-27 SAS Page 4 of 14
LAUSE manufacturing procedure, or the provision or implementation of quality assurance. F 41-04 8.6 INTERL AUDIT 8.6.1 8.6.1.1 AUDIT - Has the inspection authority developed and does it maintain procedures for establishing and internal audit programme to carry out planned periodic audits to verify the effectiveness of its own quality system and its compliance with the requirements of this code; - Are there audits of manuals, quality control procedures, inspection plans, other quality related procedures and documentation (for example codes, specifications and their revisions, etc.); and - Audit of the interfaces with suppliers and organisations responsible for manufacture, modification or repairs of vessels under pressure? Does acceptable personnel whom, wherever resource permit, independent of the activity to be audited, carries out the internal audit? Personnel shall not audit their own activities, except where necessary and it can be demonstrated that an effective audit has been done. 8.6.1.2 8.6.1.3 Does the inspection body keep documentary evidence of the audit performed, including the results and an evaluation of the results by the person in charge of the audited area? Does the team that identifies the non- conformities by means of the audit, follow them up and repeat such action until the non-conformity has been corrected? 8.6.2 ORRETIVE ATION (System) 8.6.2.1 8.6.2.2 8.6.2.3 Has the inspection body developed and does it maintain measures for identifying systematic or significant non-conformities in the quality system (discovered by external or internal assessments, or by other means) that require corrective action? Do procedures specify the inspection body s level to which significant non-conformities discovered in the system be communicated? Is records kept of all corrective actions. Does it describe the action and also their results? 8.7 DOUMENTATION ONTROL Has the inspection body develop and does it maintain a system for the control of all contract documentation that include at least: a) procedures for the identification and registration of all documents received and issued; b) procedures for the evaluation of the applicability legibility and completeness of all documents received, and measures for the correction of 2009-02-27 SAS Page 5 of 14
LAUSE documents that do not meet these requirements; c) procedures for the preparation, approval, distribution and cancellation of documents ( both first edition and all subsequent revisions); and d) procedures for the updating of the distribution list, which shall include names, addresses and documentary evidence of the receipt of updated copies, and of their revision, substitution or invalidation 8.8 REORDS Has the inspection body developed and does it maintain procedures for the storage and filing of those documents and registers that give objective evidence of the execution of all activities affecting the quality of the service rendered or of the vessel under pressure. Does the procedure covers at least the following: a) requirements for access to the files, extraction and return of documents, and a list of authorised personnel; b) the files to be used, and the locality, protection and preservation of the documents; c) the category of documents to be filed, their confidentiality and their indexing; and d) retention times, which shall be defined with particular emphasis on the requirements of the regulatory authority. 8.9 ONTROL OF TESTING AND MEASURING EQUIPMENT. Has the inspection body developed and does it maintain procedures for the control of its testing and measuring equipment relating to this standard. Does the procedure cover at least the following: a) requirements for assuring that purchased equipment conforms to specified requirements; and b) the regular calibration of all equipment in accordance with specified requirements, traceable to National Measuring Standards where appropriate. 8.10 PLANNING Has the inspection authority developed and does it maintain procedures for the planning and execution of all inspection and verification activities, including: - the review of quality and quality control plans prepared by the client or supplier or organisation responsible for the manufacture of, modification to or repair of the vessel under pressure; - Ensure during the pre-production review, that all the applicable code and contract quality requirements have been included in the procedure; - All hold and witness points to be supervised by 2009-02-27 SAS Page 6 of 14
LAUSE the inspection authority are determined and defined before any work begins. F 41-04 8.11 STAMP ONTROL Has the inspection authority developed and does it maintain documented procedures for the control and issue of hard and soft stamps to inspectors? Has the inspector completed the relevant documentation by signing (and printing) his name and filing in his registration number? 9. PERSONNEL 9.1 Qualifications, Training And Experience. Does the inspection body use personnel who carry out an activity in terms of this code have: a) the appropriate technical qualifications and certification (See Table 1) for the type of work to be undertaken;(see Annex B) b) a satisfactory knowledge of the requirements of the test they carry out or witness, and adequate experience of such test; c) the ability to draw up the certificates, records and reports required to authenticate the performance of the test; and d) a familiarity with the design and manufacturing codes, standards and specifications to be used for manufacture, or the design, or the installation, or the modification, or the repair ( or any combination of these)? 9.2 ommunication with Personnel Has the inspection body developed and does it maintain procedure for issuing instructions to individual inspectors and for reporting systems to be used? 2009-02-27 SAS Page 7 of 14
TABLE 1 QUALIFIATION REQUIIREMENTS 1 2 3 4 Responsibilities Function Qualification/ertification Experience Design verification Management of all functions of an inspection authority Design Engineer Management Representative Pr.Eng; or Pr. Technologist; or Reg. ert. Eng. University degree*/t4*/ Reg. ert. Eng. Or B Tech; or T4 Ind hemist 4 years pressure vessel design experience with knowledge of the design codes in which service is being rendered 4 years pressure vessel inspection and testing experience with knowledge of the design codes in which service is being rendered. Inspection and verification Inspector #SAQ (IPE) Inspection and testing experience with knowledge of the specific design and manufacturing code of construction in terms of which the service is rendered incorporated in certification Note: The management representative is not authorised to perform IPE functions unless SAQ (IPE) certified. NQF/SAQA and ESA registration will replace the SAQ qualification/certification. Applicable in this context are qualifications in hemical Engineering/ hemistry/ Mechanical Engineering / Metallurgy / Welding Technology/ Material Science. # South African Qualification and ertification ommittee for Inspectors of Pressurized Equipment. 2009-02-27 SAS Page 8 of 14
ANNEX PRESSURE VESSEL INSPETION - SABS 0227: 2000 LAUSE 3 REERTIFIATION OF VESSELS UNDER PRESSURE Has the inspection authority developed and thus it maintain procedures for the re-certification of vessels under pressure that at least ensure that there is a drawing, drawn by a draughtsman, that shows: a) the dimension of the vessel; b) the head shape with the crown and knuckle radii correctly indicated; c) the flange position d) the dimension and orientation of the nozzles e) the minimum measured thickness of the pressure components; and f) the gasket size and material Beside the mandatory re-certification of vessels under pressure, such a vessels shall be ratified when: a) the vessel has to be re-rated to operate at a higher or different duty; b) the nameplate or permanent vessel data has been lost, or c) the vessel has been imported and does not meet the requirements of either the Occupational Health and Safety Act or the Minerals Act. This task assumes that no design information is available. If a certified-as built drawing ids available, information can be taken from the drawing. 3.1 IDENTIFIATION OF MATERIALS 3.1.1 Regarding material identification, is spectroscopic means used to determine the material type, for example carbon steel or alloy steel? In the absence of definite information, is the steel with the lower mechanical properties used for design purposes? 3.1.2 Did the IPE do, obtain or verify the following: a) the dimensional drawing; b) material identification; c) the design data; d) where possible, the condition of the internal and external surfaces; and e) the classification of all welds in terms of the selected code of construction. 3.1.3 Did the IPE pass the information as obtained in 3.1.2 to the design engineer? Did the design engineer: a) hoose a material for design purposes from the 2009-02-27 SAS Page 9 of 14
LAUSE information available? b) Do design calculations to verify that the dimension components meet the requirements of the relevant code; c) Inform the inspector or the customer (or both) of radiographic requirements, or if it is necessary for the design parameters to be changed? d) Issue a design report if all requirements are met; e) Approve the drawing..3.2 DESIGN VERIFIATION Did the IPE, after approval of the design by the design engineer; a) review at least one radiograph per welding process to ascertain construction integrity, and also do any other NDT required by the selected design code; b) Witness the pressure test; c) Issue a certificate of continuance; d) ompile a data dossier; and e) Stamp the nameplate..4 DESIGN AND DRAWING APPROVAL OF VESSEL UNDER PRESSURE.4.1 Did the verification engineer ensure that the clientspecific requirements are included in the drawing?.4.2 Did the inspection authority verify by examination and by the generation of sample calculations, the manufacturer s generated set of calculations? Where computer-based programs are utilised, has the computer program been clearly identified? 4.3 Are all pages of the calculations numbered and authorised? 4.4 Are drawings authorised with their approval status?.5.5.1 IMPLEMENTATION OF AN AGREED-UPON QUALITY ONTROL PLAN. Did the manufacturer generate a quality control plan?.5.2 Has the inspection authority made interventions in the quality control plan and it thus depends on the client and/or code requirements?.6 MATERIAL ERTIFIATION.6.1 Has the inspection authority compared the certification put forward by the manufacturer or the supplier with actual material checking that the cast number or heat 2009-02-27 SAS Page 10 of 14
LAUSE number or batch number matches that on the material? F 41-04.6.2 Has the inspection authority checked that the correct material grade and heat treatment conditions as specified are used?.6.3 Has the inspection authority checked all-mechanical and chemical properties against client requirements or code requirements (or both)?.6.4 Does the signature and number of the IPE and AIA company stamp appear on each certificate?.7 MATERIAL IDENTIFIATION.7.1 Did the IPE inspect the material used in construction to ensure that it bears the identification required by the applicable material specification?.7.2 Did the manufacturer divide the material and transfer the material identification? Did the inspection witness the transfer of the identification of the material for the vessel under pressure, including in the pressure envelope and the material of the first attachment welded to the pressure envelope?.7.3.8.8.1 Did the inspection body ensure that the manufacturer uses acceptable means to maintain traceability to the original marking? EXAMITION OF MATERIAL UT EDGES AND HEAT AFFETED ZONES Has the cut edge been examined before further work was carried out to ensure that they are free from laminations and free from cracks cause by shearing as required by the relevant code of practice or the client?.8.2 Has the prepared edges been examined to ensure that there is no burnt metal, notches, slag inclusions, scale or flaw as required by the relevant code or client?.9 APPROVAL OF WELD PROEDURES.9.1 Did the inspection authority review and accept or reject previous approved welding procedures for specific applications?.9.2 Did the inspection body certify or witness (or both) proposed welding procedures, including any mechanical testing that might be required?.10 APPROVAL OF WELDERS AND OPERATORS.10.1 In the case of existing welder performance records, did the inspection authority review the documentation to ensure that the validation of the certificate is current?.10.2 In the case of new welders performance records, did the inspection authority: 2009-02-27 SAS Page 11 of 14
LAUSE a) check the welder s identification document and obtain the stamp number; b) ensure that the supplied WPS is approved; c) ensure that the test pieces and consumables are in accordance with the WPS and that the stamp test pieces bear the inspection stamp; d) monitor welding of the test piece to ensure that it is welded in accordance with the WPS and position qualification requirements; e) reviewed the NDT result or witness the mechanical test (or both), as applicable; and f) produce or endorse welder performance certificates..11 WELD PREPARATION AND FIT-UP.11.1 Where required by the relevant code or client, does the IPE visually check weld dimensions and fit-ups for alignment and tolerances as permitted in the manufacturing code, against approved drawings together with the WPS?.11.2.12 Does the IPE verify (where required) that the disposition of tack welds is in accordance with the WPS? INSPETION OF SEOND SIDE WELD PREPARATION Does the inspection authority ensure that the minimum requirements of the relevant code are met with regards to second side weld preparation?.13.13.1 AEPTAE OF NON-DESTRUTIVE TESTING (NDT) Does the inspection authority review and, where relevant, accept NDT procedures and the calibration of equipment, and verify that examination have been performed by suitably qualified personnel in compliance with the appropriate standards, codes, specifications and drawings. Is a record of such verification maintained?.13.2.14.14.1 Does the inspection authority verify the radiographic films, UT,MPT,LPT and hardness testing in sufficient numbers to ensure compliance with the specifies acceptance levels? WITNESSING AND EVALUATING MEHANIAL TESTING OF PRODUTION WELDS Does the inspection authority identify production test plates?.14.2 Does the inspection authority witness mechanical testing and verify the results? 2009-02-27 SAS Page 12 of 14
LAUSE.15 HEAT TREATMENT F 41-04 Does the inspection authority ensure that the heat treatments have been performed correctly to the specified procedures and do they endorse the records?.16 PRESSURE TESTING.16.1 Does the inspection authority witness the pressure test to the requirements of the relevant code or of the client?.16.2 In the case of a hydraulic test, does the inspection authority verify that the vessel has been fully vented to remove all air and gases?.16.3 Does the inspection authority verify the calibration status of the test gauge?.16.4 Where the amount of set is to be recorded, does the inspection authority not the circumference before, during and after testing? 16.5 Does the inspection authority witness that the vessel is gradually taken up to the correct test pressure, in accordance with the drawing, specification or statutory requirement? 16.6 After the specified test period, and the slow release of pressure and the vessel vented, and does the inspection authority ensure that the pressure gauge return to zero? 16.7 Did the inspection authority endorsed the pressure test certificate?.17 FIL EXAMITION.17.1 Does the inspection authority inspect the vessel internally (where possible) and externally and, preferably, before and after testing?.17.2 Does the inspection authority ensure that any safety critical dimension of the item being inspected conform to the dimensions shown on the approved drawing?.18 AS-BUILT VERIFIATION DIMENSIONS Does the inspection authority verify and stamp the asbuilt drawings?.19 MEPLATE Does the inspection authority: a) ensure that the details that appear on the nameplate are legible and correspond with those noted on the approved drawing and regulation; 2009-02-27 SAS Page 13 of 14
LAUSE b) Verify that the nameplate has been attached in the position and manner specified on the approved drawing; c) Verify hard stamping direct onto the vessel where this is required by the relevant code; and d) Affix a hard stamp to the nameplate or the vessel, as required. Additional / General omments This space may also be used to expand on comments in specific sections Signed : Technical / Lead Assessor Date 2009-02-27 SAS Page 14 of 14