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ASME AWARENESS PROGRAM -1 ASME AUDIT1DATE 29-03-2011BY- GAURAV KHAMKAR1TOPICSBrief Introduction about ASME AWARNESS ProgramHistory of Boiler & Pressure Vessel Codes in USRelevant ASME CODESASME - Quality Control SystemMFY - ASME & NB STAMP ACCREDITATIONAudit Agenda & Preparation2During the 18th & 19th centuries, steam became main source of power & accelerated Industrial Revolution. But the early 20th century, steam boiler explosion in US were occurring at rate of 1per day & claiming 2 lives per day.In 1907, after 2 explosion, State of Massachusetts enacted first legislation, dealing with design & construction of steam boilers.In 1911, the council of American Society of Mechanical Engineers (ASME) appointed a committee to formulate standard specification for construction of steam boilers. First ASME Boiler code was issued on Feb 13, 1915 . Now ASME codes are available in 11 Sections.3History of Boiler & Pressure Vessel Codes in US

The first committee consisted 7 members & was assisted by 18 members advisory committee.Today ASME is a 1,20,000 member organization focused on technical education & research related issues.4History of Boiler & Pressure Vessel Codes in US

I. Rules for construction of Power BoilersII. 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)V Nondestructive ExaminationVIII Rules for Construction of PRESSURE VESSELS DIVISION-1 DIVISION-2 Alternative Rules DIVISION-3 Alternative Rules for Construction of High Pressure VesselsIX Welding & Brazing Qualifications.5ASME CODES

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 product6ASME Quality Control SystemMFY is Authorized Stamp Holder for following, since 15 July, 2007S Stamp - For the construction of Power boilers.U Stamp - For the construction of Pressure vessels.R Stamp - For site repair work by NBBI.- Renewal due on 15 July.20117ASME & NB ACCREDITATION

ASME AUDIT PREPARATION88Joint review is based on Accreditation Procedures set by the committee .ASME mandates a joint review of all phases listed below Review of Quality control programOpening meetingInitial tour of facilitiesInitial meeting with company personnelThe implementation reviewReview of Additions and changesExit report to management

The joint review team consists of a team leader, and as a minimum, a representative of the Authorized Inspection Agency.

9JOINT REVIEWS OF QUALITY CONTROL SYSTEM

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 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 plantPinpoint various areas to be visited laterIn 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.

10INITIAL TOUR OF FACILITIES

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.114. INITIAL MEETING WITH COMPANY PERSONNEL

The starting point and Sequence is a choice of the review team and company personnel. AVAILABILITY OF LATEST CODE SECTIONSENGINEERING AND DESIGNPURCHASING FUNCTIONSRECEIVING OF MATERIALS AND PARTSWELDING CONTROLNONDESTRUCTIVE EXAMINATIONHEAT TREATMENT CALIBRATIONDEMONSTRATION ITEMS

125. IMPLEMENTATION REVIEW

ENGINEERING AND DESIGNIf 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?135. IMPLEMENTATION REVIEW

PURCHASING FUNCTIONSHow 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 ? 145. IMPLEMENTATION REVIEW

RECEIVING OF MATERIALS AND PARTSWho 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?155. IMPLEMENTATION REVIEW

WELDING CONTROLWho 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 ?

165. IMPLEMENTATION REVIEW

PTO WELDING CONTROLIs 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)175. IMPLEMENTATION REVIEW

Continued NONDESTRUCTIVE EXAMINATIONReview 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 SNT-TC-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.

185. IMPLEMENTATION REVIEW

PTO NONDESTRUCTIVE EXAMINATIONAre 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?

195. IMPLEMENTATION REVIEW

Continued HEAT TREATMENTIf 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?205. IMPLEMENTATION REVIEW

CALIBRATIONWho 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 SECTIONSThe 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.

215. IMPLEMENTATION REVIEW

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-off 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?

226. DEMONSTRATION ITEMSPTO DEMONSTRATION ITEMSHow 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?236. DEMONSTRATION ITEMSContinued 6.Review of program additions and changes7.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.

24CLOSING MEETING

25THANK YOU25