Conformity Assessment

Dan Cheetham BPV Requirements

4/12/16

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

Examination and Inspection

•  -Required examinations

•  -Objective evidence

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! The AIA representative or the applicant has a right to know where the requirement is in the Code, before agreeing to add it to the Manual.

Written Quality System

•  -Any 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.

•  Manual does not specify who is responsibility

•  Welding section does not require a WPS be available to the welder in the work

area

•  Certifications are not described

•  Coded marking system not described

Written Quality System

Questions?

Material Requirements

•  Materials •  -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. •  -Maintaining 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 the program requires a Nonconformance Report (Or whatever it is called in your system) be issued, then that is what has to occur. If a deficiency is identified and fixed without generating the required document, then the system was not implemented.

•  -It is not up to the Team to remind the applicant to generate the appropriate document.

Examination and Inspection Requirements

•  -AIA’s, remind your clients of this before the Joint Review.

•  -Team Leaders, it is not your job to tell the applicant they must write an NCR! Let the applicant demonstrate their system, if they don’t, then report they did not implement the system. You can remind them that they must implement their system, whatever it say, they must do.

Examination and Inspection Requirements

•  -All examinations and inspections must be completed and signed off, before any welding can be demonstrated.

•  Common deficiencies: •  ITP not being signed off before welding demo begins. •  Fit-up and tack weld examination not being performed. •  Welder not following WPS.

Other Topics

Other topics •  -Has ASME a plan to certify material

manufacturer? NDE provider? Design organizations?

•  -Will ASME acknowledge other than English editions of the Code book?

•  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?