STEP No. 3
Develop a QCSM to meet Annex 2E
2-E.1.1 The Manufacturer shall develop and
maintain a Quality Control System that will
establish that all Code requirements, including
material, design, fabrication, examination (by the
Manufacturer), and inspection of vessels and
vessel parts (by the inspector) will be met.
Provided that Code requirements are suitably
identified, System :
May include provisions for satisfying any
requirements by the Manufacturer or user that
exceed minimum Code requirements
May include provisions for quality control of non-
In such systems, the Manufacturer of vessels and
vessel parts may make changes in parts of the
system that do not affect the Code requirements
without securing acceptance by the Inspector
Shall be one suitable for the Manufacturer’s
circumstances. The necessary scope and detail of
the system shall depend on the complexity of the
work performed and on the size and complexity
of the Manufacturer's organization.
BUY OF ASME CODES LATEST EDITION
SECTION VIII DIVISION 2
SECTION II PARTS A,B,C AND D
BUY OF NBIC BOOKS
PARTS 1,2 AND 3
BUY OF ACCEPTED EDITION OF
REFERENCED STANDARDS AS APPLICABLE
Develop a set of Drawings
and Calculations meeting with
Section VIII Div. 2 requirements.
This is the only requirement on this matter for
Joint Review purposes, that means, Construction
of Mock Up for Joint Review can be constructed
following Section VIII Div. 1.
Develop Special Procedures
in English Language
- Hydrostatic Test Procedure.
- NDE procedures( RT, UT, PT,MT and VT)
- Coded Marking Procedure( Traceability)
Certification of :
AI’s shall recommend Clients that QCSM
must be read it Section by Section with all
personnel involve in Joint Review in order to
be aware of activities , responsibilities and
sharing responsibilities between them.
Prepair documentacion of demonstration:
* Fabrication Drawings
* Bill of Materials
* Materials Requisition including Code Requirements
* P.O.’s without change material requisition requirements
* Traveler Sheet
* WPS’s PQR’s and WPQ’s
* Materials and Welding Maps
Among others the following activities must be done:
-Distribution of QCSM as per QCSM Distribution Log
establish and be sure it is completely understood
- Distribution of Drawings, List of Materials and Materials
Requisition to all departments involve in construction of
Mock up and in accordance with QCSM
- Be sure that Purchase Orders be the same as Materials
requisition establish without any change on it
- Company must search a NDE Agency properly qualified ,
including the level III appointment, reviewing all
documentation ( Procedures and Personnel qualification)
meet Code Requirements.
-Implementing QCSM in shop
-Company must be sure that the following documentation be available in
shop during construction of Mock Up :
-Last revision of Drawing
-Have a copy of the traveler sheet
-Welder’s Continuity Log
-Pressure Parts properly identified with Coded Markings and properly
identified by Q.C. as accepted material
-Welding Filler according with WPS
-Give welders their welder Stamp in order to identify job made by them
-In my personal opinion , A.I must give a brief explanation of handling of
documents below mentioned to the following personnel:
-Production Manager , Production Supervisors and Welders and Fitters ,
-And Q.C. personnel.
Ware house implementation
Among others following activities must be shown
- Set up Code Material Area and Non-Code Material Area
- Set up in warehouse identified areas for:
- Have available a Oven for storage of Welding Material with
attached instructions for Storage handling mainly for electrodes
- Implementing controlled handling of delivering to shop only
materials ( including welding) already accepted by QC
- Have a implementation of Q.C. stickers of accepted,hold
Schedule A.I./AIS visits
Confirm that all steps above
referenced have been met and Client is
ready to Pre Joint Review and Joint
Among others the next are part of A.I. activities:
- Revision of documentation
- Revision, Aceptance and Verification of implementation of
- Set up Hold, Revision and Witness points in Traveler Sheet
to be used during construction of Mock up.
Activities of AIS during Prejoint Review
-- Make an audit of Quality Program at this time QCSM
must be docummented and implemmented completely
and the Mock up be in process, if possible just like it is
going to show during Joint Review
-- Give Customer recommendations to fix findings found
during PreJoint Review
-- Elaborate Prejoint Review Report and send it to
Customer Representative and A.I. for follow up purposes
Main Requirements to be added during
developing a QCSM to meet Section VIII Div. 2:
Glossary of Terms
Addition of the following nomenclature:
CE Certified Engineer
UDS User’s Design Specification
MFRDR Manufacturer’s Design Report
CE Certified Engineer.
Any Engineer that signs and certifies a User´s Design Specification shall meet one
of the criteria shown below :
a) A Registered Professional Engineer who is registered in one or more of the
states of the United Stated of America or the provinces of Canada and
experienced in pressure vessel design.
b) An Engineer experienced in pressure vessel design that meets all required
qualifications to perform engineering work and any supplemental requirements
stipulated by the user. The Engineer shall identify the location and the licensing
or registering authorities under which he or she has received the authority to
perform engineering work.
c) An Engineer experienced in pressure vessel design who meets all required
qualifications to perform engineering work and any supplemental requirements
stipulated by the user. The Engineer shall be registered in the International
Register of Professional Engineers of the Engineers Mobility Forum.
It is the responsibility of the user or an agent acting on behalf of
the user to provide a certified User’s Design Specification for
each pressure vessel to be constructed in accordance with this
What is User’s Design Specification?
The User’s Design Specification shall contain sufficient detail to
provide a complete basis for design and construction in
accordance with this Division. It is the user's responsibility to
specify, or cause to be specified, the effective Code Edition to be
used for construction.( See paragraph 2.2.2)
2.2.2 USER’S DESIGN SPECIFICATION
22.214.171.124 The User’s Design Specification shall include but not necessarily
be limited to the following:
(a) Installation Site
(2) Jurisdictional authority if applicable
(3) Environmental conditions
(-a) Wind design loads including relevant factors (i.e. design wind
speed, exposure, gust factors)
(-b) Earthquake design loads
(-c) Snow loads
(-d) Lowest one day mean temperature for location
(b) Vessel Identification
(1) Vessel number or identification
(2) Service fluid for proprietary fluids specific properties needed for
design, e.g., gas, liquid, density, etc.
(c) Vessel Configuration and Controlling Dimensions
(1) Outline drawings
(2) Vertical or horizontal
(3) Openings, connections, closures including quantity, type and size,
and location (i.e. elevation and orientation)
(4) Principal component dimensions in sufficient detail so that volume
capacities can be determined
(5) Support method
(d) Design Conditions
(1) Specified design pressure. The specified design pressure is the
design pressure, see paragraph 126.96.36.199(a),required at the top of the vessel
in its operating position. It shall include suitable margins required
above the maximum anticipated operating pressure to ensure proper
operation of the pressure relief devices. The MAWP of the vessel may be
set equal to this specified design pressure. If the actual MAWP of the
vessel is calculated, it shall not be less than the specified design
(2) Design temperature and coincident specified design pressure (see
(3) Minimum Design Metal Temperature (MDMT) and coincident specified
design pressure(see paragraph 188.8.131.52(e)).
(4) Dead loads, live loads and other loads required to perform the load case
combinations required in Parts 4 and 5.
(e) Operating Conditions
(1) Operating pressure
(2) Operating temperature
(3) Fluid transients and flow and sufficient properties for determination of
steady state and transient thermal
gradients across the vessel sections, if applicable (see paragraph 5.5.2)
(f) Design Fatigue Life
(1) Cyclic operating conditions and whether or not a fatigue analysis of the
vessel as required shall be determined in accordance with paragraph 184.108.40.206.
When a fatigue analysis is required, provide information in sufficient detail so
that an analysis of the cyclic operation can be carried out in accordance with
paragraph 5.5. comparable equipment experience.
(2) When a vessel is designed for cyclic conditions, the number of design
cycles per year and the required vessel design life in years shall be stated.
(3) When cyclic operating conditions exist and a fatigue analysis is not
required based on comparable equipment experience, this shall be stated.
The possible harmful effects of the design features listed in 220.127.116.11(a)
(f) shall be evaluated when contemplating comparable equipment
(g) Materials of Construction
(1) Material specification requirements shall be in accordance with one or
more of the following criteria.
(-a) Specification of materials of construction in accordance with Part 3.
(-b) Generic material type (i.e. carbon steel or Type 304 Stainless Steel).
The user shall specify requirements that provide an adequate basis for
selecting materials to be used for the construction of the vessel. The
Manufacturer shall select the appropriate material from Part 3, considering
information provided by the user per paragraph (3).
(2) The user, shall specify the corrosion and/or erosion
(3) The user, when selecting the materials of construction,
shall consider the following:
(-a) Damage mechanisms associated with the service fluid at
design conditions. Informative and non-mandatory
guidance regarding metallurgical phenomena is provided in
Section II, Part D, Appendix A, API RP 571, and WRC Bulletins
488, 489 and 490.
(-b) Minimum Design Metal Temperature and any additional
(-c) The need for specific weld filler material to meet corrosion
resistance requirements, see paragraph 18.104.22.168
(h) Loads and Load Cases
(1) The user shall specify all expected loads and load
case combinations as listed in paragraph 22.214.171.124.
(2) These loading data may be established by:
(-b) Experimental methods
(-c) Actual experience measurement from similar units
(-d) Computer analysis
(-e) Published data
(i) Overpressure Protection
(1) The user shall be responsible for the design,
construction and installation of the overpressure
protection system unless it is delegated to the
Manufacturer. This system shall meet the requirements
of Part 9.
(2) The type of over pressure protection intended for the
vessel shall be documented in the User’s Design
Specification as follows (see paragraph 9.1):
(-a) Type of overpressure protection system (e.g., type of
pressure relief valve, rupture disc, etc.)
(-b) System design (see paragraph 9.7)
(3) The user shall state if jurisdictional acceptance is
required prior to operation of the vessel.
126.96.36.199 Additional Requirements – The user shall state
what additional requirements are appropriate for the
intended vessel service such as:
(a)Additional requirements such as non-destructive
examination, restricted chemistry, or heat treatments
(b) Type of weld joints and the extent of required
(c) Non-mandatory or optional provisions of this Division that
are considered to be mandatory for the subject vessel
(d) Any special requirements for marking and their location
(see paragraph 4.1 and Annex 2-F)
(e) Requirements for seals and/or bolting for closures and
(f) Additional requirements relating to erection loadings
(g) Any agreements which resolve the problems of operation and
maintenance control unique to the particular
(h) Specific additional requirements relating to pressure testing
(1) Fluid properties and test temperature limits
(2) Position of vessel and support/foundation adequacy if field
hydrostatic testing is required
(3) Location: Manufacturer’s facility or on-site
(4) Cleaning and drying
(5) Selection of pressure test method, see paragraph 8.1.1
(6) Application of paints, coatings and linings, see paragraph
188.8.131.52 The User’s Design Specification shall be certified in
accordance with Annex 2-A.
Manufacturer’s Design Report
An individual(s) of Manufacturer Organization often
Engineering Manager,is in responsible charge of the design
and construction of the vessel(s) and shall certify that the
Manufacturer’s Design Report is complete, accurate and in
accordance with the User’s Design Specification, and that all
the requirements of this Division and any additional
requirements needed for adequate design have been met.
Such certification requires the signature(s) of one or more
Engineers with requisite experience and qualifications as
defined below. One or more individuals may sign the
documentation based on information they reviewed, and the
knowledge and belief that the requirements of this Division
have been satisfied.
2.3.3 MANUFACTURER’S DESIGN REPORT
184.108.40.206 The Manufacturer shall provide a Manufacturer’s Design Report that
(a) Final as-built drawings.
(b) The actual material specifications used for each component.
(c) Design calculations and analysis that establish that the design as shown on
the drawings complies with the requirements of this Division for the design
conditions that have been specified in the User’s Design Specification.
(1) Documentation of design-by-rule calculations in Part 4 shall include the
(-a) The name and version of computer software, if applicable
(-b) Loading conditions and boundary conditions used to address the load
cases in the User’s Design Specification
(-c) Material models utilized for all required physical properties (i.e. stress-
strain data, modulus of elasticity, Poisson’s ratio, thermal expansion
coefficient, thermal conductivity, thermal diffusivity), strength parameters
(i.e. yield and tensile strength), and allowable stresses
(-d) Detailed calculations, including results from all of the applicable
steps in the calculations, showing the acceptance criteria utilized to
meet the requirements of this Division.
(-e) A summary of the calculation results
(2) Documentation of design-by-analysis calculations in Part 5 shall
include the following:
(-a) A detailed description of the numerical method used, including the
name and version of computer software, if
(-b) Description of model geometry (including element type for finite
(-c) Loading conditions and boundary conditions used to address the
load cases in the User’s Design Specification
(-d) Material models utilized for all required physical properties (i.e.
modulus of elasticity, Poisson’s ratio, thermal expansion coefficient,
thermal conductivity, thermal diffusivity), strength parameters (i.e.
yield and tensile strength), strain limits, if applicable, and the design
membrane stress intensity per Part 3
(-e) Description of whether material nonlinearity is utilized in
the analysis including a description of the material model (i.e.
stress-strain curve and cyclic stress-strain curve)
(-f) Description of the numerical analysis procedure (i.e. static
analysis, thermal analysis (temperature and stress), buckling
analysis, natural frequency analysis, dynamic analysis) and
whether a geometrically linear or nonlinear option is invoked
(-g) Graphical display of relevant results (i.e. numerical model,
deformed plots, and contour plots of thermal and stress results)
(-h) Method used to validate the numerical model (i.e. mesh
sensitivity review and equilibrium check for finite element
analysis, e.g. check of hoop stress in a component away from
structural discontinuity and a check to ensure that global
equilibrium is achieved between applied loads and reactions at
specified boundary conditions)
(-i) Description of results processing performed to establish
numerical analysis results (i.e. stress linearization method, use of
centroidal or nodal values for stress, strain, and temperature
(-j) A summary of the numerical analysis results showing the
acceptance criteria utilized to meet the requirements of this
(-k) Electronic storage of analysis results including input files and
output files that contain numerical analysis results utilized to
demonstrate compliance with the requirements of this Division
(d) The results of any fatigue analyses according to paragraph 5.5,
(e) Any assumptions used by the Manufacturer to perform the
220.127.116.11 The Manufacturer’s Design Report shall be certified in
accordance with Annex 2-B.
ENGINEERING ADDITIONAL REQUIREMENTS FOR SECTION VIII, DIV. 2
It is the responsibility of the user or an agent acting on behalf of the user to
provide a UDS for each pressure vessel to be constructed in accordance with
Section VIII, Div. 2. The UDS shall contain sufficient detail to provide a complete
basis for design and construction in accordance with Section VIII, Div. 2. It is the
user's responsibility to specify, or cause to specify, the effective Code Edition to be
used for construction of Code Items.
The UDS shall include but not necessarily be limited to the requirements
stated in 18.104.22.168 of Section VIII, Div. 2
The Company is responsible for the structural and pressure retaining
integrity of a vessel or part thereof, as established by conformance with the
requirements of the rules of Section VIII, Div. 2 and the requirements in the UDS.
The Company completing any Item or part marked with ASME Certification
mark and U2 designator has the responsibility to comply with all the applicable
requirements of this Section VIII Div. 2 and, through proper certification, to
ensure that any work by others also complies with the requirements of this
Division. QCM shall certify compliance with these requirements by completing a
Any material substitutions by EM are subject to approval of the
User and communicated to AI for revision of UDS and MFRDR.
A UDS Certified by CE or Professional Engineer shall be
furnished to the EM for review against the requirements of
paragraph 2.2.2 and Annex 2.A of Code, the EM shall be responsible
for verifying that the UDS meets such requirements and for verifying
Code Edition to be used for Construction it’s also specified.
EM is also responsible for preparing the MFRDR which shall
comply with the requirements of paragraph 2.3.3 and Annex 2.B of
Restricted requirements on allowable materials as reflected by
the fatigue curves of paragraph 3.15 of Code must be considered
where a fatigue (Cyclic) analysis is required.
UDS, TS and MFRDR must be reviewed by AI prior to start
Revisions if any, to the UDS, MFRDR, drawings and
calculations shall be handled as described above.
Upon completion of fabrication, EM will provide all
fabrication records to the CE. The MFRDR will be reconciled
against the UDS and if found to be in compliance, the MFRDR
will be certified by the CE.
All documents described in this section shall be available
thru the EM for review by the AI.
MATERIAL CONTROL ADDITIONAL REQUIREMENTS FOR
SECTION VIII DIV. 2
All conflicts between the material specification and the
supplemental requirements stipulated in Part 3 the ASME Section VIII
Division 2 Code, shall be noted on the BOM by the DE, and compliance
with the supplemental requirements shall be certified by the material
If the requirements in a material specification are to be
completed by other than the materials manufacturer, then the DE shall
address on the BOM that supplementary material test reports are
required. QCM receives and review all MTR’s, tests, examination
reports and/or C of C for ensuring compliance and makes them
available to the AI for verification of compliance with the material
specification. If acceptance QCM certifies compliance with
supplemental requirements of Section VIII, Div. 2 by dated initials on
The DE shall specify in the BOM that the certification of materials
shall meet Part 3 paragraph 3.2.6 of the ASME Section VIII Division 2
The BOM for the forming of carbon and low alloy material parts
shall specify that certification to paragraph 22.214.171.124(e) of the ASME
Section VIII Division 2 Code is required.
The DE shall specify on the BOM that material manufacturer´s
identification marking required by the material specification shall not
be stamped on plate material less than 6mm (1/4”) in thickness. (Unless
the requirements of 126.96.36.199 are complied with ASME Section VIII
Substitution of the specified material requires approval of the
User and both the CE responsible for the Certification of the User’s
Specifications and the Manufacturer’s Design Report, and acceptance
The QCM is responsible for providing an as built sketch or
tabulation of materials identifying each piece of material with the MTR
or, if permitted by Code C of C and coded marking which assure
identification of each piece of material during fabrication and
subsequent identification in the completed vessel.
EXAMINATION AND INSPECTION PROGRAM ADDITIONAL
REQUIREMENTS FOR ASME SECTION VIII, DIV. 2
The QCM shall prepare, collect and maintain construction records
and documentation as fabrication progress, (Files of Quality Control).
All materials to be used in constructing a pressure vessel shall be
in accordance with ASME Section VIII Div. 2 Code examined before
fabrication with the purpose of detecting, as far possible, defects that
will affect the safety of the vessel, in accordance with paragraph 188.8.131.52 of
VIII Div. 2 Code.
The QCM is responsible for having examined all cut edges of base
material in accordance with Paragraph 6.1.3 (b) of Code. All welding
shall be subject to in-process examination by Visual Examination at the
fit-up stage and during back gouging.
All weld for pressure retaining parts shall be visually examined by
the QCI who must pass the annual eye test in accordance with
paragraph 7.A.2.2 (b)(1) of ASME Section VIII Div. 2 Code. shall be as
established in paragraphs 7.5.6 and 7.5.7 of ASME Section VIII Div. 2
Weld seams that will be hidden by assembly are given a visually
examination by the QCM from workmanship to final assembly. As per
paragraph 8.2.5 (a) (3) of ASME Section VIII Div. 2 Code.
Forming tolerances shall be maintained in accordance with 6.1.2
and paragraph 4.3.2 & 4.4.4 as applicable, of ASME Sec. VIII Div. 2
Removal of temporary attachments shall be in accordance with
184.108.40.206 of ASME Section VIII Div. 2 Code.
If a fatigue analysis is required for a part of a Code Vessel, then all
of the internal and external surfaces or pressure boundary and
attachment welds for that part shall be examined by wet magnetic
particle method (if ferromagnetic) or by liquid penetrant method (if
non magnetic) after Hydrostatic, unless accessibility prevents
meaningful interpretation and characterization of imperfections. The
acceptance criteria shall be as established in paragraphs 7.5.6 and 7.5.7
of ASME Section VIII Div. 2 code.
The pressure test shall be in accordance with a pressure test
procedure, prepared and approved by the QCM, which shall be in
accordance with 8.2 or 8.3 of the ASME Section VIII Div. 2 Code.
The test method and the upper test pressure limit shall be
referenced on the drawings by the DE. Pressure test procedure
must be submitted to AI for review.
The required markings for Code Vessel of paragraph 2.F.1 of
the ASME Sec. VIII Div. 2 Code shall be applied on a Nameplate
or shall be stamped with low stress type stamps directly on the
Item, located on an area designated as a low stress area by the DE
in the MFRDR.
The ASME Certification Mark with U2 designator shall be
applied by the QCM only with the approval of the AI and after
the hydrostatic test and all other required inspection and
testing has been satisfactorily completed.
The MFRDR shall be prepared by EM and submitted to CE
for review for accuracy and signed by him prior to being
presented to the AI for his review and signature. The name of
the Company’s Certified Engineer shall be on the MFRDR. The
QCM shall be responsible for routing the MFRDR to the
customer, the appropriate enforcement authority in the
jurisdiction in which the Code Vessel is to be installed where
required by law and National Board as applicable. The QCM
shall also be responsible for retention of the Company’s copy of
the Manufacturer’s Data Report.
NON CONFORMITIES CONTROL ADDITIONAL
REQUIREMENTS FOR SECTION VIII, DIV. 2
NCR shall be serialized and retained on file by
NON-DESTRUCTIVE EXAMINATION ADDITIONAL
REQUIREMENTS FOR SECTION VIII, DIV. 2
All finished welds shall be subject to nondestructive Examination
depending on Examination Group selected in paragraph 7.4.2 and the
Joint Category and weld type as defined in paragraph 4.2 of Code.
All welding shall be subject to in process examination by QCI,
making visual examination at the fit up stage and during back gouging
in accordance with paragraph 220.127.116.11 of Code.
Personnel performing and evaluating NDE shall be qualified and
certified per 7.3 of Code.
CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT
ADDITIONAL REQUIREMENTS FOR SECTION VIII, DIV. 2
All gages shall be calibrated against a standard
deadweight tester or a calibrated master gage at
least every 6 months or at any time there is a
reason to believe that they are in error.
RECORDS RETENTION ADDITIONAL REQUIREMENTS FOR ASME
Section VIII Div. 2 items:
a) User’s Design Specification
b) Manufacturer’s Design Report
c) Manufacturer’s Data Report
d) Manufacturer’s Construction Records and Partial Data Reports.
An Index of the Construction Record Files shall consist of the following as a minimum
1) Tabulated list of all material used for fabrication with Materials Certifications and
Material Test Reports, and a record of any repairs to pressure retaining material that
require a radiographic examination by the rules of this Div. 2. The record of the repairs
shall include the location of the repair, examination results, and the repair procedures.
2) Fabrication information including all heat treatment requirements, forming and
rolling procedure when prepared, an inspection and test plan identifying all inspection
points required by the user, and signed inspection reports.
3) List of any subcontracted services or parts, if applicable.
4) Pressure Parts documentation and certifications.
5) Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR),
weld map and welder or welding operator qualification test results.
6) Record of all heat treatments including post weld heat treatment (these records may
be either the actual heat treatment charts or a certified summary description of heat
treatment time and temperature).
7) Results of production test plates, if applicable.
8) NDE procedures, records of procedure demonstrations, and records of personnel
9) All reports stating the results of inspection, nondestructive examinations and testing
including radiographic examination, ultrasonic examination, magnetic particle
examination, liquid dye penetrant examination and hardness tests.
10)All non-conformance reports including resolution and a detailed description of any
repairs including repair procedures, a sketch, photo, or drawing indicating the location
and size of the repaired area.
11) Charts or other records of required hydrostatic, pneumatic, or other tests. Test logs
shall include the test date, testing fluid, duration of the test, temperature of the test
fluid, and test pressure.
12) Dimensional drawings of the as-built condition.
The Company shall maintain a complete set of radiographs until the signing of
the Manufacturer’s Data Report, and furnish upon request to the user and, upon
request to the AI.