ACCREDITATION OF MANUFACTURERS AND INSTALLERS OF PRESSURE PIPING PARTS AND SYSTEMS TSSA GUIDE FOR SURVEY TEAMS The Technical Standards and Safety Authority Boilers and Pressure Vessels Safety Division 345 Carlingview Drive Toronto, ON M9W 6N9 CANADA August 2016 Rev. 3
INTRODUCTION This guide is prepared for the use of TSSA non-nuclear survey team leaders, members and applicants for TSSA Certificates of Authorization. It is not intended to replace or interpret the requirements of the CSA B-51 Standard or the ASME Boiler and Pressure Vessels Codes, B31.1, B31.3 and B31.5. The checklist does not list all of the detailed requirements of the CSA B-51 and ASME Codes referenced, but rather lists the highlights that the applicant is required to include in the written Quality Control (QC) Manual. In addition, to assist the TSSA survey team, this guide is provided to applicants for TSSA Certificates of Authorization for their use in identifying and verifying the paragraph(s) where their QC Manual addresses all applicable control requirements of the CSA Standard and ASME Codes. The QC Manual must contain the description of the controls necessary for implementing the QC Program but, it is not required to contain all of the programmatic requirements which will be found in the QC Program, such as written procedures. The guide is based upon CSA B-51 and ASME B31.1, B31.3 and B31.5 requirements. The guide is subject to revision by TSSA based on changes made to CSA B-51 and ASME Codes, from time to time, or based on feedback received from users. A survey must cover a QC Manual and its implementation. It is recognized that the scope of work, QC Manual and Manual implementation will vary from one applicant to another, therefore, only those activities to be performed under the scope of an applicant s TSSA Certificate of Authorization are required to be addressed in the QC Manual. TSSA survey teams are advised that this guide may not outline all possible aspects of each survey. The QC Manual need not follow the format of this guide. Questions of possible need for Interpretation raised by survey team members or the applicant shall be submitted to the TSSA Chief Inspector for an answer, and when submitted by the applicant a copy of the inquiry and reply should be provided by the inquirer to the applicant s Inspection Agency and any known involved enforcement authority. HOW TO USE THIS GUIDE Review each checklist item in the checklist against the QC Manual and: 1) Check ( ) the applicable column - Yes, No or N/A (Not Applicable) 2) Note the paragraph number in the QC Program Manual which covers the subject addressed in the column labelled Quality Program. Submit one copy of the completed checklist with one controlled copy of the QC Manual to TSSA Head Office for review, at least one month prior to the scheduled implementation review date. 2 of 11
Company Name: Reviewed by: Date(s): 1. GENERAL QUALITY CONTROL SYSTEMS REQUIREMENTS (a) Is the QC System documented in detail in a QC Manual that addresses all requirements of the applicable Code Section(s) including: Note: a cover sheet that contains the company name and physical address as it will appear on the requested certificate of authorization; The cover sheet may also contain the effective date of the QC Manual, mailing address, phone number or other information desired by the certificate holder or applicant. (ii) a brief description of the products being fabricated and/or work being accomplished under the Code including applicability of QC System to shop activities, field activities or both; (iii) control features to demonstrate Code compliance; (iv) Manual revision control system; is the Manual revision by page or by section, are the controls clearly described; (v) who is responsible for revising the QC Manual (title of person): (vi) who is responsible (title of person) for reviewing ASME Code Addenda and making any required changes to the Manual six (6) months from the Addenda issue date; (vii) provision for review and approval of QC Manual to maintain it current; (viii) provision for submittal of QC Manual revisions to TSSA for acceptance prior to implementation including timely updating of all copies to reflect approved revisions; (b) In the case where the QC Manual exists in more than one language, at least one version is in English and identified as the authoritative version. Note: A glossary of terms is desirable from the standpoint of clarity if abbreviated titles of personnel and control documents are used throughout the QC Manual. This, however, is not mandatory. 2. AUTHORITY AND RESPONSIBILITY (a) The authority and responsibility for QC by management is documented. 3 of 11
(b) The authority and responsibility of those in charge of the QC System are clearly established and documented. (c) Persons performing QC functions have sufficient and well-defined responsibility, the authority and the organizational freedom to identify quality control problems and to initiate, recommend and provide solutions (including stop work orders if further processing would result in non-conformance with the applicable Code section). (d) A Statement of Policy and Authority must be signed by a senior company official responsible for Code activities (e.g.president, Vice President, Plant Manager, etc.). 3. ORGANIZATION (a) An organization chart showing the relationship between management and engineering, purchasing, manufacturing, production, field assembling, field construction, inspection and quality control, as applicable, exists and reflects the actual organization. Note: The purpose of this chart is to identify and associate the various organizational groups with the particular function for which they are responsible. The Code does not intend to encroach on the Certificate Holder s right to establish and, from time to time, alter whatever form of organization the Certificate Holder considers appropriate for Code work. 4. DRAWING, DESIGN CALCULATIONS, AND SPECIFICATION CONTROL (a) Procedures exist which assure that the latest applicable drawings, design calculations, specifications and instructions, required by the Code, as well as authorized changes, are used for manufacture, assembly, examination, inspection and testing. Procedures include provision for: Review of Customer supplied documents for Code Compliance including; who is responsible (title of person) for review and approving customer s calculations, specifications and drawings (as applicable) to ensure Code compliance can be obtained (this approval must be identified by signature and date); (ii) the preparation, review, approval and distribution of customer drawings, calculations, and specifications for manufacture or installation; (iii) who is responsible (title of person) for the design calculations, specifications and drawings produced internally; (iv) who is responsible (title of person) for reviewing and approving drawings and calculations prepared internally to ensure Code compliance to the latest Code of Construction (this approval to be issued by signature and date); 4 of 11
(v) who is responsible for computer aided design calculations and drawings. How is this verified to ensure that the correct output has been obtained; B31.3 (vi) computer program revisions must be made within 6 months of Code Addenda changes. How is this verified to ensure that the revised program is giving the correct output; (vii) who is responsible (title of person) for design registration with the appropriate provincial authority and filing the registered designs upon request. (vii) Who determines which service applies: - severe cyclic conditions - normal fluid service - Category D service - Category M service - Category K service (ix) who ensures branch connections without reinforcement (weldolets, couplings, etc.) are at least Class 2000 and not more than NPS 2 or one fourth the normal size of the pipe run? Category M Service - single welded slip on flanges shall NOT be used - expanded joint flanges shall NOT be used (b) Does the program describe the following controls: ( to (ix) are the responsibility of the Certificate Holder) loads on pipe supporting elements; (ii) supports, anchors and guides; (iii) temperature limitations; (iv) hanger adjustments; (v) hanger spacing; (vi) structural attachments; (vii) requirements for fabricated pipe supports; (viii) boiler external piping; (ix) pressure relief piping; (c) Is non-metallic pipe referenced on the drawing? Have the following conditions been considered for corrosive or other specialized applications: material type and grade; (ii) decrease in tensile strength at slight increase in temperature; (iii) effects of toxicity; (iv) provision of adequate support for flexible pipe (d) Is there a written procedure for bonding? (e) Has the procedure been approved by the applicant? 5. MATERIAL CONTROL (a) Procedures for material control exist and ensure that the material received is properly identified and has documentation including, as applicable, required material certifications or material test reports, to satisfy Code requirements as ordered. 5 of 11
(b) The Material Control System ensures that only the intended material is used in Code construction. Does the program describe the following controls on Material Limitations as referenced in Chapter III: - ASME Code B31.1, paragraph 124; - ASME Code B31.3, Chapter III, paragraph 323; - ASME Code B31.5, Chapter III, paragraph 523. (c) If substitution of materials is allowed, the applicable procedures for control of this activity are documented, including designation of the individual authorized to approve substitutions. (d) The title of the individual responsible for identifying the need for material test reports or certificate of compliance is designated. (e) The title of the individual responsible for performing a receiving inspection of Code materials is designated. (f) Information to be provided to the receiving Inspector concerning the characteristics to be checked is documented. (g) A procedure exists for handling materials that are found to be non-conforming at receiving inspection. (h) If further material testing is required to be performed at receiving inspection or during manufacturing operations, the applicable procedures for control of this activity are documented. (j) Measures are established to assure the proper marking, handling and storage of materials, including welding materials. Measures describe transfer of marking of materials to be cut into two or more pieces. B31.3 Category M Service - Blanks or blind flanges shall be identified with material, rating and size. 6. EXAMINATION AND INSPECTION PROGRAM (a) Fabrication operations, including examinations test procedures are described in sufficient detail to determine at what stages specific inspections are to be performed. Specifically: provisions for the use of checklists, process sheets, travellers, etc., for listing of examinations and tests to be performed and for designation of inspection points; B31.3 (ii) such checklists, process sheets, travellers, etc., are made available to the Inspector prior to the start of fabrication. Severe Cyclic Conditions - Requires 100% radiography plus MP or LP of socket welds and branch connections that are not radiographed. 6 of 11
Normal Fluid Service - Visual examination of 5% of each welder s work and 100% visual of all longitudinal joints; - RT of 5% of circ and miter groove welds for each welder; - RT of circ seams intersecting long seams must include minimum 1½" of long seam. Category D Service - Visual examinations required to ensure materials, components, joint preparation, alignment, bonding, brazing, welding, bolting, threading and supports are per drawing. Category M Service - Visual examination of all fabrications, threaded and bolted joints required; - RT of 20% of all circumferential butt, miter welds, fabricated laps and branch connections required. Category K Service - Piping or tubing must pass a longitudinal eddy current or UT examination in addition to the material specification; - NDE shall be performed after post weld heat treatment. (b) Examination reports, test records, and other fabrication records are available to the Inspector. (c) Measures provide for transferring markings to assure traceability is maintained. if a coded marking system is used, it is documented and ensures Code compliance. (d) Measures assure that the Inspector is informed of approaching inspection points. (e) Provision is made for repairs to any pressure retaining material. Are the following code related inspection carried out: - fit-up inspections of all welded seams; - fit-up inspections on all nozzles; - dimensional inspections; - material inspections. (f) Measures are established to assure that a final inspection is performed to assure all specified requirements have been met prior to signing of Piping Installation Test Data Reports. (g) Measures are established to provide for the preparation, certification, and distribution of the applicable Reports. (h) Measures are established to control field activities, when applicable. Who is responsible (title of person) for the preparation of the Piping Installation Test Data Report. It will be reviewed for correctness and signed by the individual (title of person) certifying the work on behalf of the company? 7 of 11
2. Who is responsible for contacting the AI. Who will make available to the AI the latest revised drawings, design calculations and all job-related documents for review and designation of Hold Points on the inspection checklist? Who is responsible (title of person) for the preparation of the Piping Installation Test Data Report. It will be reviewed for correctness and signed by the individual (title of person) certifying the work on behalf of the company? 7. CORRECTION OF NON-CONFORMITIES Note: A non-conformity is any condition which does not comply with the applicable rules of the Code, QC Manual or other specified requirements. Non-conformities must be corrected before the completed component can be considered to comply with the Code. (a) Does a procedure exist for the correction of non-conformities. Where Inspector involvement is required by the Code, the procedure is agreed upon with the TSSA Inspector. The procedure provides for: identifying those responsible for the resolution of nonconformities; (ii) identifying and controlling further processing of nonconforming items until final disposition; (iii) documenting the non-conformance and its disposition; and (iv) informing the TSSA Inspector of non-conforming conditions. (v) is the non-conformance addressed on the inspection checklist with QC involvement; (vi) has the final inspection been accepted by the QC Inspector; (vii) when the disposition is USE AS IS, does the disposition involve engineering to ensure an engineering evaluation has been carried out. 8. WELDING (a) Welding conforms to requirements of Section IX and other Sections of the Code, as applicable to the scope of work. (b) Those responsible for certifying PQR s and WPQ s are identified. (c) WPS s are available to the welder in the work area. (d) Measures assure continued welder qualification on an annual basis. (e) Those responsible for assuring that only qualified welders are assigned to perform Code welding are identified. (f) (g) Measures provide for the storage and conditioning, as required of covered electrodes. Measures are established for the control, issuance and return of welding material. 8 of 11
(h) Measures are established for removing or inspecting tack welds. (j) Measures provide for a system to identify work completed by each welder. Measures provide for the right of the TSSA Inspector to require re-qualification of a welder or procedure for cause. Measures provide for a system to identify work completed by each welder (e.g. permanent markings on piping, weld maps, etc.) B31.3 When welders are qualified by others: - Who ensures that welders are qualified by bend tests NOT by radiography? - Who ensures that GTAW or SMAW are the only permitted processes? Category M Service - Split backing rings are NOT permitted. - Socket weld joints over NPS 2" are NOT permitted - Soldered and bolted joints are NOT permitted Category K Service - Backing rings are NOT permitted - All procedures shall be qualified with impact testing. - No seal welding is permitted 9. NON-DESTRUCTIVE EXAMINATION (a) For B31.1 Piping Systems, Have the requirements of paragraph 136.4 been considered for RT, UT, PT, MT and visual examination? (ii) Have the mandatory minimum requirements of Table 136.4 been addressed? (iii) Have the requirements of Table 136.4.1 been addressed (weld imperfections indicated by various types of examination)? (b) For B31.3 Piping Systems, Note: Have the requirements of paragraph 341.4 (extent of requirement examination) been addressed in the manual? The following qualification of personnel for visual examination shall be addressed: For B31.1 - Paragraph 136.1 (a) to (e) For B31.3 - Paragraph 344.2.1 (c) Provisions exist for identifying the appropriate NDE procedures applicable to the scope of Code work. These provisions assure that: NDE personnel are qualified in accordance with the applicable Code Section requirement; 9 of 11
(ii) NDE (UT, RT, MT and PT) examinations are performed in accordance with written procedures when required; (iii) UT reports and RT films, as applicable, are retained in accordance with the applicable Code requirement; (iv) NDE equipment is calibrated; (v) to meet Canadian jurisdictional requirements does the QC Manual address the requirements for the Qualification and Certification of Non-Destructive Testing Personnel, CAN / CGSB - 48.9712. (d) How is extent of NDE determined based on fluid service? (e) How is this information transferred to the inspection checklist? 10.0 HEAT TREATMENT (a) Controls provided to assure that heat treatment as required by the Code for the scope of Code work is applied. (b) Measures are established to assure proper placement of thermocouples and the use of charts. (c) When heat treatment is subcontracted, measures are established to assure that procedures are followed and that heat treatment charts are provided. (d) Means are provided to ensure that Code heat treatment requirements are met, (e.g. review of furnace timetemperature records or other methods as appropriate) and signed off by QC personnel. 11.0 CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT (a) A procedure exists for the calibration of examination, measuring and test equipment used in fulfilment of applicable Code requirements. (b) Measures are established that assure calibration records are maintained and that status indicators are used to indicate the current calibration status of equipment. 12.0 13.0 RECORDS RETENTION (a) Procedures exist for the maintenance of Piping Installation Test Data Reports, Radiographs and records required by the applicable Section of the Code. SAMPLE FORMS (a) Forms used to control functions relative to quality are included within the QC Manual and their use explained in the text of the QC Manual. (b) Sample forms are subject to the same revision controls as the rest of the QC Manual. 14.0 TSSA INSPECTOR (a) A controlled copy of the QC Manual is available to the TSSA Inspector at the plant or construction site where Code activities are being carried out. 10 of 11
(b) The TSSA Inspector has access to all drawings, calculations, specifications, procedures, process sheets, repair procedures, records, test results, and any other documents necessary for the Inspector to perform his duties. (c) Provisions exist for providing a liaison between the TSSA Inspector and the Certificate Holder. (d) Provisions exist for free access for the TSSA Inspector and the Inspector Supervisor to all areas involving Code activities. REVIEW DEMONSTRATION Note: A demonstration or implementation of the QC System during the joint review should include the administrative functions to support the QC System and the manufacturing, fabrication and testing of product necessary to indicate knowledge and ability to produce the component/parts covered by the Scope of the system. The demonstration may be conducted on in-process work, a mock-up to current Code rules, or combination thereof, and a review of past job documentation. Where Code work is in progress, the demonstration shall include the administrative and construction functions for the products and orders, which are being processed to meet Code requirements. 11 of 11