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Presentacion asme seccion viii division 2 2013


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Presentación para auditoria de certificación ASME sección VIII Div 2 (Estampado U2)

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Presentacion asme seccion viii division 2 2013

  3. 3. STEP 1 Elaborate Applications to : ASME ( caconnect) NATIONAL BOARD (
  4. 4. STEP 2 Have a Contract with HSB GS
  5. 5. STEP No. 3 Develop a QCSM to meet Annex 2E Requirements
  6. 6. ANNEX E 2-E.1 GENERAL 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. .
  7. 7. 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- Code work. 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
  8. 8. 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.
  10. 10. STEP 5 Develop a set of Drawings and Calculations meeting with Section VIII Div. 2 requirements. TIP: 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.
  11. 11. STEP 6 Develop Special Procedures in English Language Among others: - Hydrostatic Test Procedure. - NDE procedures( RT, UT, PT,MT and VT) - Coded Marking Procedure( Traceability) --PWHT procedures
  12. 12. STEP 7 Qualification and Certification of : - WPS’s - PQR’s - WPQ’s
  13. 13. STEP 8 Implementing QCSM Recommendation: 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.
  14. 14. Prepair documentacion of demonstration: Engineering Department * Calculations * Fabrication Drawings * Bill of Materials * Materials Requisition including Code Requirements Purchasing Department * P.O.’s without change material requisition requirements Quality Control * Traveler Sheet * WPS’s PQR’s and WPQ’s * Materials and Welding Maps
  15. 15. 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.
  16. 16. -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 -WPS’s -WPQ’s -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.
  17. 17. 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: Receiving Inspection Accepted Material Holding Material Rejected Material - 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 and rejected
  18. 18. STEP 9 Schedule A.I./AIS visits Purpose: Confirm that all steps above referenced have been met and Client is ready to Pre Joint Review and Joint Review .
  19. 19. Among others the next are part of A.I. activities: - Revision of documentation (calculations,drawings,wps’s,pqr’s,,special procedures,etc.) - Revision, Aceptance and Verification of implementation of QCSM - Set up Hold, Revision and Witness points in Traveler Sheet to be used during construction of Mock up.
  20. 20. 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
  21. 21. 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
  22. 22. 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.
  23. 23. USER RESPONSIBILITIES 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 Division. 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)
  24. 24. 2.2.2 USER’S DESIGN SPECIFICATION The User’s Design Specification shall include but not necessarily be limited to the following: (a) Installation Site (1) Location (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.
  25. 25. (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,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 pressure.
  26. 26. (2) Design temperature and coincident specified design pressure (see paragraph (3) Minimum Design Metal Temperature (MDMT) and coincident specified design pressure(see paragraph (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 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.
  27. 27. (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 through (f) shall be evaluated when contemplating comparable equipment experience. (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).
  28. 28. (2) The user, shall specify the corrosion and/or erosion allowance. (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 toughness requirements. (-c) The need for specific weld filler material to meet corrosion resistance requirements, see paragraph
  29. 29. (h) Loads and Load Cases (1) The user shall specify all expected loads and load case combinations as listed in paragraph (2) These loading data may be established by: (-a) Calculation (-b) Experimental methods (-c) Actual experience measurement from similar units (-d) Computer analysis (-e) Published data (i) Overpressure Protection
  30. 30. (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.
  31. 31. 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 nondestructive examinations (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 covers (f) Additional requirements relating to erection loadings
  32. 32. (g) Any agreements which resolve the problems of operation and maintenance control unique to the particular pressure vessel. (h) Specific additional requirements relating to pressure testing such as: (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 8.1.2(e) The User’s Design Specification shall be certified in accordance with Annex 2-A.
  33. 33. UDS User´s Design Specification.
  34. 34. Manufacturer’s Design Report Who’s responsible? 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.
  35. 35. 2.3.3 MANUFACTURER’S DESIGN REPORT The Manufacturer shall provide a Manufacturer’s Design Report that includes: (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 following: (-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
  36. 36. (-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 applicable (-b) Description of model geometry (including element type for finite element analysis) (-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
  37. 37. (-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)
  38. 38. (-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 results) (-j) A summary of the numerical analysis results showing the acceptance criteria utilized to meet the requirements of this Division (-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, as applicable. (e) Any assumptions used by the Manufacturer to perform the vessel design. The Manufacturer’s Design Report shall be certified in accordance with Annex 2-B.
  39. 39. MFRDR Manufacturer´s Design Report
  40. 40. 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 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 MDR. Continue……..
  41. 41. 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 Code. 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.
  42. 42. UDS, TS and MFRDR must be reviewed by AI prior to start of fabrication. 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. AI AVAILABILITY All documents described in this section shall be available thru the EM for review by the AI.
  43. 43. 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 manufacturer. 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 document. 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 Code requirements.
  44. 44. The BOM for the forming of carbon and low alloy material parts shall specify that certification to paragraph 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 are complied with ASME Section VIII Division 2). 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 by AI. 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.
  45. 45. 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 of ASME Section 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 code.
  46. 46. 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 Code. Removal of temporary attachments shall be in accordance with 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.
  47. 47. 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.
  48. 48. 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.
  49. 49. NON CONFORMITIES CONTROL ADDITIONAL REQUIREMENTS FOR SECTION VIII, DIV. 2 NCR shall be serialized and retained on file by QCM
  50. 50. 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 of Code. Personnel performing and evaluating NDE shall be qualified and certified per 7.3 of Code.
  51. 51. 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.
  52. 52. 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 as applicable: 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.
  53. 53. 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 certifications. 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.
  54. 54. Questions ?