Asme Awareness Program - 1

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The document discusses the history of boiler and pressure vessel codes in the US and their development to improve safety. It also outlines some of the main ASME codes and requirements for an ASME quality control system.

In the early 20th century, many steam boiler explosions in the US resulted in the development of the first legislation and standards. The ASME formed a committee in 1911 to develop boiler construction standards, publishing the first Boiler Code in 1915.

The main ASME codes discussed are Sections I, II, V, VIII, and IX which relate to power boiler construction, materials, nondestructive examination, pressure vessel rules, and welding qualifications respectively.

ASME AWARENESS

PROGRAM -1
DATE 29-03-2011

BY- GAURAV KHAMKAR

ASME AUDIT

TOPICS

Brief Introduction about ASME AWARNESS


Program

History of Boiler & Pressure Vessel Codes in US

Relevant ASME CODES

ASME - Quality Control System

MFY - ASME & NB STAMP ACCREDITATION

Audit Agenda & Preparation


2

History of Boiler & Pressure


Vessel Codes in US

Duringthe18th&19thcenturies,steambecamemainsourceofpower&
acceleratedIndustrialRevolution.Buttheearly20thcentury,steamboiler
explosioninUSwereoccurringatrateof1perday&claiming2livesper
day.

In1907,after2explosion,StateofMassachusettsenactedfirstlegislation,
dealingwithdesign&constructionofsteamboilers.

In1911,thecouncilofAmericanSocietyofMechanicalEngineers
(ASME)appointedacommitteetoformulatestandardspecificationfor
constructionofsteamboilers.

FirstASMEBoilercodewasissuedonFeb13,1915.NowASMEcodes
areavailablein11Sections.
3

History of Boiler & Pressure


Vessel Codes in US

Thefirstcommitteeconsisted7members&wasassistedby18
membersadvisorycommittee.

TodayASMEisa1,20,000memberorganizationfocusedon
technicaleducation&researchrelatedissues.

ASME CODES
1. I.

Rules for construction of Power Boilers

2. II. Materials
Part A - Ferrous Material Specifications
Part B - Nonferrous Material Specifications
Part C - Specifications for Welding Rods, Electrodes, and
Filler Metals
Part D Properties (Customary), Properties (Metric)
3. V

Nondestructive Examination

4. VIII

Rules for Construction of PRESSURE VESSELS


DIVISION-1
DIVISION-2 Alternative Rules
DIVISION-3 Alternative Rules for Construction of High
Pressure Vessels

5. IX

Welding & Brazing Qualifications.

ASME Quality Control System

The ASME code requires that the Manufacturer operates an


approved

Quality

Control

System,

which

revolves

around

satisfying the rules of the code and has written documentation


covering the company's organization and specifies procedures for
design, material control, manufacture, inspection and testing.

This permits an authorized fabricator to perform inspection


without the involvement of an TPI.

ASME Code requires demonstration or implementation of the


quality control system , It includes

How administrative functions are supporting to quality


control system during design, procurement, fabrication and
testing

knowledge and ability to produce Code compiling product

ASME & NB ACCREDITATION


MFYisAuthorizedStampHolderforfollowing,since15July,
2007
1. SStampFortheconstructionofPowerboilers.
2. UStampFortheconstructionofPressurevessels.
3. RStampForsiterepairworkbyNBBI.
Renewaldueon15July.2011

ASME AUDIT PREPARATION

JOINT REVIEWS OF
QUALITY CONTROL SYSTEM

Joint review is based on Accreditation Procedures set by the


committee .

ASME mandates a joint review of all phases listed below


1. Review of Quality control program
2. Opening meeting
3. Initial tour of facilities
4. Initial meeting with company personnel
5. The implementation review
6. Review of Additions and changes
7. Exit report to management

The joint review team consists of a team leader, and as a minimum, a


representative of the Authorized Inspection Agency.

INITIAL TOUR OF FACILITIES


1. Quality Control Manual Review - A joint review commence with the
review of the quality control manual, prior to the opening
meeting.
2. Opening Meeting Finalize Agenda
3. Initial Shop Tour - After the opening meeting, In order to get
familiarize themselves with the applicants facility
. To get first-hand view of the types of products in the plant
. Pinpoint various areas to be visited later
. In some cases, Questionable operations or fabrication practices
may be noted to be tracked in-depth at an appropriate time.
. Review team members talk to with Inspectors, In order to get
insight of company operations that will be helpful during the
review process, and in the initial meeting with the companys
personnel.

10

4. INITIAL MEETING
WITH COMPANY PERSONNEL

To see the type of products produced or work performed, and to


judge if the system described is actually in place throughout the
plant.

To obtain answers regarding company operations not clearly


understood during the manual review.

In the case of new applicants, the Role of Inspectors and


Supervisor must be understood. This should also draw
management attention to the significant importance of their
quality control personnel under an ASME Code program.

Two way communication forum - If Management personnel should


have the opportunity to bring up any questions they may have prior to
the conclusion of the meeting.

11

5. IMPLEMENTATION REVIEW
The starting point and Sequence is a choice of the review team and
company personnel.
1. AVAILABILITY OF LATEST CODE SECTIONS
2. ENGINEERING AND DESIGN
3. PURCHASING FUNCTIONS
4. RECEIVING OF MATERIALS AND PARTS
5. WELDING CONTROL
6. NONDESTRUCTIVE EXAMINATION
7. HEAT TREATMENT
8. CALIBRATION
9. DEMONSTRATION ITEMS

12

5. IMPLEMENTATION REVIEW
ENGINEERING AND DESIGN

If customer provide drawings and calculations, does the


certificate holder review the drawings and calculations
furnished to assure code conformance, and who is responsible for this
activity?

Review calculations & verify compliance

How distribution of Approved drawings are controlled? Are the


latest applicable revisions provided? Is disposal of superseded
documents controlled?

How code materials are specified?

What information is contained in the drawings, or shop prints with


respect to welding, NDE, materials, pressure tests, code edition
and addenda, and minimum design metal temperature?

13

5. IMPLEMENTATION REVIEW
PURCHASING FUNCTIONS

How purchasing information (i.e. materials to procure) conveyed


to Purchase dept ? e.g., material requisitions, bill of materials, or other
means?

does requirements like (material test reports, heat treatment, NDE etc)
specified in purchase order?

What quality control and engineering input is provided?

For cold formed products by a subcontractor, are the


requirements of UCS-79, included in the purchase order and
checked upon receipt ?

14

5. IMPLEMENTATION REVIEW
RECEIVING OF MATERIALS AND PARTS

Who receives materials and parts? What input are required for
Inward Inspection?

How materials and parts are inspected upon receipt? What system
of markings is used for traceability and identification?

Who inspects material test reports for compliance to Material


Specifications, as? Who inspects welding consumable compliance
to Section II C?

How are nonconforming material(s) handled? Who decides?

Requirements of PG-10 and PG-11, or UG-10 and UG-11 are


considered.

Is manufacturers partial data report required and obtained for parts


fabricated by welding?

15

5. IMPLEMENTATION REVIEW
WELDING CONTROL

Who prepares Welding procedures specifications (WPS), procedure


qualification records (PQR) and welder and welding operators
performance qualifications records (WPQR).

How issue and return of covered electrodes are controlled ? Who is


responsible?

Are heated portable ovens provided for covered electrodes?

Is it maintained at temperatures recommended by the electrode


manufacturer?

How these electrodes are protected from moisture absorption?

Are welding consumables marked with SFA or AWS designations?


Filler metal wire traceability to the certificate must be maintained.

How tack welds to pressure-retaining materials are controlled ?

PTO

16

5. IMPLEMENTATION REVIEW
WELDING CONTROL

Continued

Is there a system available to inform theproduction & other


concern departmentsabout welders qualification
( i.e. his qualified processes,position, progression, with or without
backing, electrode diameter, thickness range, base metal thickness
range, material specification, and the electrode etc)

17

5. IMPLEMENTATION REVIEW
NONDESTRUCTIVE EXAMINATION

Review of written NDE practices and personnel qualification


records. Documentation for various levels of skill regarding
general, specific, and practical examinations and training are
also listed.

Magnetic particle (MT), liquid penetrant (PT), and visual (VT)


examiners required to be certified by the certificate holder on the basis
of certification, skill, annual eye examination.

Is the VT examiner certified in accordance with AWS QC-1, or SNTTC-1A? Is the VT examiner required to have an annual eye
examination?

The Level III examiner may be an employee of the certificate holder or


of a subcontractor.

The letter of appointment, must be on documented accepting the


subcontractors Level III examiner as the certificate holders Level III
examiner.
PTO

18

5. IMPLEMENTATION REVIEW

Continued
NONDESTRUCTIVE EXAMINATION

Are written procedures (UT, MT, PT, and VT) or technique sheets for
RT available to the examiner and the inspector?

Is adequate equipment for film viewing available?

Are interpretation sheets provided along with the RT film?

Is a densitometer or step-wedge film strip available for density


comparison, and is the densitometer and step-wedge calibrated as
required by Section V of the code?

19

5. IMPLEMENTATION REVIEW
HEAT TREATMENT

If heat treatment is subcontracted, the quality control program should


provide adequate controls.

If in-plant or portable equipment is used, a review should be made of


the type of equipment, capacities, whether contact-type
thermocouples are used, calibration and servicing of recording
devices, and their records.

Does written heat treatment procedures provided to the operator?

If subcontracted, are measures provided to assure proper


performance and calibration?

How are materials, parts, or vessels sent out of the plant for
subcontracted heat treatment, and how are they inspected when
returned from the heat treatment subcontractor? Are records
maintained, particularly of material and parts identification?

20

5. IMPLEMENTATION REVIEW
CALIBRATION

Who is responsible for calibration activities? Who accomplishes


calibration requirements?

What is the method used for record keeping?

Is measurement and test equipment identified?


AVAILABILITY OF CODE SECTIONS

The certificate holder or applicant must have the required current


editions, addenda, and divisions of the code sections on hand,

It is recommended that the manufacturer maintain pervious codes


and addenda for those codes used to justify procedures, i.e.,
Sections V and IX.

21

6. DEMONSTRATION ITEMS

The demonstration may be conducted on in-process work, or a


mock-up, plus past job documentation or combination.

The system described in the quality control manual must be


demonstrated.

Are plant facilities and the equipment adequate to fabricate, or


are subcontracting facilities available for these functions?

Does Inspection checklists appropriate for the work being


performed? Do checklists contain steps necessary to assure
required examinations and inspections fulfilled ? Is space provided
for sign-of and date as these activities are completed?

Are fit-up, forming of shells, and welding within an acceptable


tolerance?

How welder or welding operator deployed on Job ?

Does copies of welding procedure specifications or other specific


instructions available to the welder or welding operator in the
work area?
PTO

22

6. DEMONSTRATION ITEMS
DEMONSTRATION ITEMS Continued

How are tack welds treated?


Are they prepared prior to inclusion in the weldment, or are
they removed?
Are tack welds visually examined for defects, and if found
defective are they removed?

Does material identification markings visible and identifiable on


pressure-retaining parts, or are there other means provided for
material traceability?

Does the demonstration includes documentation, as described?

Are welded joints in production clean and free of scale, rust,


oil, etc?

23

CLOSING MEETING
6. Review of program additions and changes
7.

Exit Report To Management - At the conclusion of the review at the


plant or site, a report will be given orally to the applicant concerning
findings, and recommendations to be made by the review team to the
Subcommittee on Boiler and Pressure Vessel Accreditation.

24

THANK YOU

25

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