absa - pressure piping fabrication requirement & qc seminar - selected pages

{ABSA: D0007080.DOC}

PPRREESSSSUURREE PPIIPPIINNGG

FFAABBRRIICCAATTIIOONN RREEQQUUIIRREEMMEENNTTSS

&& QQUUAALLIITTYY CCOONNTTRROOLL

TTRREE PPPP 2008

the pressure equipment safety authority

the pressure equipment

safety authority

PPRREESSSSUURREE PPIIPPIINNGG FFAABBRRIICCAATTIIOONN RREEQQUUIIRREEMMEENNTTSS &&

QQUUAALLIITTYY CCOONNTTRROOLL

CONTENTS

Section: Contents

Rev.: 0

Date: Jan. 1, 2008

PAGE: 1 OF 3

The information provided is for reference only. Decisions must be based upon the original copies of the applicable Regulations, Codes and Standards. {ABSA: D0007080.DOC}

Section

Description

1 Course Introduction: • Purpose • Reference Manual

2 Requirements:

• Safety Codes Act • Pressure Equipment Safety Regulation

- Exemptions-Piping - Design registration of piping over 0.5m3 volume - QMS registration requirements, ‘PP’ Number - Requirements for Pressure Testing and Certification

• Pressure Welders Regulation • CSA B51 (including CRN for Fittings) • ASME Code B31.5, Refrigeration Piping • ASME Code B31.9, Building Services Piping • Z662 and ASME Codes boundaries • CSA B52 Piping, Mechanical Refrigeration Code • ASME B16 Codes, Pipe Flanges & Flanged Fittings • ANSI K61.1, Ammonia Systems Piping • NFPA 58, LPG Systems Piping • NFPA 59, Storage & Handling Piping of LPG at Utility Gas Plants • API 661, Air Cooled Heat Exchanger Piping • Thermal Fluid Heaters Piping

3 ASME B31.3 Process Piping Code:

• Scope • Categories of Piping

4 ASME B31.3 Piping Design Requirements:

• Design Conditions • Design Criteria • Welded and Threaded Joints • Fittings, Valves and Bolting • Pressure Relieving Systems

5 ASME B31.3 Piping Materials Requirements:

• Listed Materials • Unlisted Materials • Unknown Materials • Reclaimed Materials • Nonmetallic Piping • Impact Test Requirements


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QUALITY CONTROL

CONTENTS

Section: Contents

Rev.: 0

Date: Jan. 1, 2008

PAGE: 2 OF 3


Section

Description

6 ASME B31.3 Fabrication, Assembly and Erection Requirements:

• Welding Responsibility, Welders and WPS Qualification • Welding Materials • Preparation for Welding • Fillet, Socket, Seal Welds and Weld Repairs • Preheating and PWHT • Assembly & Erection

7 ASME B31.3 Inspection, Examination and Testing Requirements:

• Responsibility for Inspection • Qualifications of Owner’s Inspector • Examination Required, Extent and Acceptance • Qualifications of Examination Personnel • Examination Procedures, In-Process Examination and Closure Welds • Testing • Comparison Chart-Various Fluid Services and Severe Cyclic Conditions

8 Introduction to ASME B31.1 Power Piping and Inspection

Requirements: • Scope and Jurisdiction of Power Piping Code • Some notable differences between ASME B31.1 and B31.3 Piping • Design Registration, ‘PP’ Stamp and Inspection Requirements • Certification and Records

9 WPS and Welder’s Requirements:

• WPS, Explanation of Essential Variables and Application to production welds • Performance Qualification Card, Explanation of Essential Variables and Application

to production welds

10 Quality Concepts: • Purpose of a Documented QMS • Owner’s/Management’s Responsibilities and Role • QMS Requirements for ASME B31.3, Appendix ‘Q’ • QMS Manual Design, Suitability and ISO System • Planning for Piping Project Realization • Piping Project Design and Development Process • Piping Project Design and Development Inputs/Outputs

11

Quality Management System (QMS) Implementation: • Quality Policy & Objectives • Organization • Owner’s/Management Responsibilities • Contract Review • Piping Design


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QUALITY CONTROL

CONTENTS

Section: Contents

Rev.: 0

Date: Jan. 1, 2008

PAGE: 3 OF 3


Section

Description

• Document & Data Control • Material Control • Piping Construction • Post Weld Heat Treatment (PWHT) • Non Destructive Examination (NDE) • Inspection • Pressure Testing • Calibration of Measuring Devices • Training • Corrective and Preventive Action • Internal Audits

Annex ‘A’ ‘The Pressure News’ articles (an ABSA publication)

Annex ‘B’ Alerts & Information Bulletins issued by ABSA

Annex ‘C’ ASME B31.3 Interpretations

Annex ‘D’ ASME B31.3 Code cases


Course Introduction

Section No.: 1


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COURSE INTRODUCTION

Section: 1

Rev.: 0

Date: Jan. 1, 2008

PAGE: 1 OF 4


Objective

The objective of this course is to provide information to the fabricators and users of Pressure Piping Systems about the requirements of the Safety Codes Act, Regulations, and applicable ASME B31 Codes, and to provide awareness and guidance for the effective implementation of the Quality Management System, thereby, helping to construct safe piping systems.

• Course Materials and Aids: Reference Manual

A copy of the reference manual is provided to each participant. The manual is written as a stand alone document and was designed to provide you with the working knowledge of the overall requirements of the Regulations, applicable ASME Codes and implementation of a QMS for the construction of safe pressure piping systems. Portions of the manual will be reviewed during the delivery of the course. The reference manual includes information that is specific to the piping systems only. The requirements that are general to the pressure equipment but also apply to the pressure piping are included on as needed basis. The information is not complete, but should point you to the relevant sections of the Act, Regulations, Codes and Standards for your review of the overall requirements. The information provided in here is for reference only. The decisions must be based upon the applicable original copies of the Act, Regulations, Codes and Standards.

Sample Project File

A copy of the Sample Project File is also provided to each participant. The file includes documents which are generally found in most well documented project files, and also include recommended practices. The make up of the Project File will vary in accordance with the size and complexity of the project and the needs of the owner. Documentation from the Project file will be reviewed at the conclusion of the review of Quality Elements when applicable. Handouts Some handouts are provided to assist in understanding the application of the requirements or to explain situations.


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COURSE INTRODUCTION

Section: 1

Rev.: 0

Date: Jan. 1, 2008

PAGE: 2 OF 4


Piping Module and RT Room A Piping Module will be used to verify material identifications (Heat Numbers, Color Coding), RT identifications, welders symbols, internal and external inspections per Table 341.3.2 of ASME B31.3 (reinforcements, undercuts, cracks, surface finish, incomplete penetration, suck up) and for conformance to the requirements of the engineering design. An RT room will be utilized for reviewing radiographs and for learning what minimum information must be included in the radiographs and the reports to comply with ASME Section V Code.

• Course Delivery

The training will be delivered in two distinct parts. Part 1 - Requirements: The training program will start with the Section 1 Course Introduction followed by the Section 2 Requirements. The Sections will provide an overview of the training program and information about the requirements of the Safety Codes Act and Regulations. Both Sections will be covered in 3 hrs. Part 2 - Implementation of QMS: Rest of the training program will be delivered using a QMS. The reason is simple; the construction of the pressure piping is done by utilising a QMS. Implementation of a registered QMS is a requirement for obtaining Certificate of Authorization Permit from ABSA. The permit is needed to enable you construct pressure piping in Alberta, however the primary reason of utilizing a QMS is it’s capability to help you produce piping systems that meet the overall requirements of your clients, your standards, regulations and codes on consistent basis. QMS is covered from Section 10 ‘Quality Concepts’ to Section 11 ‘QMS Implementation’. Each element of the QMS Implementation will be covered in detail. During the review of the QMS Quality Elements, materials from Sections 3-9 covering ASME B31.3-2006, ASME B31.1, application of WPS and Performance Qualification Cards, ABSA’s Newsletter articles, ABSA’s Information Bulletins, Alerts, Interpretations and Code Cases of ASMES B31.3 Code will be reviewed as applicable. Only some parts of Sections 3-9 shall be covered. Section 10 Quality Concepts, was developed to provide information and develop basic understanding about quality concepts such as the purpose of a documented QMS, Owners/Managements responsibilities, and the design of a quality manual.


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COURSE INTRODUCTION

Section: 1

Rev.: 0

Date: Jan. 1, 2008

PAGE: 3 OF 4


Section 11 QMS Implementation includes typical quality elements of a documented QMS manual. A typical quality element of the QMS manual will describe:

- Why describe the element in your QMS manual? - What is it? - What are the key activities that should be addressed in the main body of the manual? - How to make reference to the procedures. - What are the current gaps that we discover on day to day basis about the activity?

Subsequent to the review of quality elements, relevant documentation from the Project File will be reviewed. Some examples of the review includes, construction drawings, accurate specification of materials in Requisitions/P.O.’s, review of MTR’s against the requirements of ASME Sec. II, review of CRN documentation for fittings, review of radiographic reports and film, review of PWHT Instruction sheet and chart, correct application of WPS’s and matching WPS’s to the welds, application of Performance Qualification Cards to various sizes of the piping etc. The QMS Manual Elements were developed keeping in sight the principals of ISO 9001:2000, ISO 29001:2003 Standards and those of ISO 10013:01 Guidelines for QMS Documentation.

Nearly 13 hours will be spent in reviewing the implementation of QMS Elements. The duration of the course is 2 days.


Requirements

Safety Codes Act, Regulations, Codes and Standards

Section No.: 2

Objective

To review Pressure Piping requirements of the Safety Codes Act, Regulations and those of the ASME Codes and Standards which have been adopted through the Pressure Equipment Safety Regulations. Only those requirements which are specific to the Pressure Piping systems are included in the manual. The requirements which are general to the pressure equipment may also apply but are not covered in this section.


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REQUIREMENTS Act, Regulations, Codes and Standards Requirements

Section: 2

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Date: Jan. 1, 2008

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Requirements of the Safety Codes Act (Safety Codes Act, Revised Statues of Alberta 2000 Chapter S-1 with amendments in force as of June 1, 2006)

Objective

To review: • Pressure Piping REQUIREMENTS of the Safety Codes Act • Pressure Piping components EXEMPT from the Act

• Application of the Act:

[Safety Codes Act, Application of Act 2(1)] This Act applies to fire protection and applies to the design, manufacture, construction, installation, operation and maintenance of:

(a) Buildings (b) Electrical systems (c) Elevating devices (d) Gas systems (e) Plumbing and private sewage disposal systems, and (f) Pressure equipment

Comment: The requirements of the Act apply to all of the disciplines listed above. Pressure Equipment Safety Regulation (PESR) sets out requirements that apply specifically to pressure equipment. Both the Safety Codes Act and PESR are law in Alberta.

• Definitions Related to Pressure Piping: Definition of ‘Pressure Equipment’

[Interpretation 1(1) (y)] “pressure equipment” means a thermal liquid heating system and any containment for any expansible fluid under pressure, including, but not limited to, fittings, boilers, pressure vessels and pressure piping systems, as defined in the regulations;

Comment: Piping in cold water systems or any piping that does not contain expansible fluid (an expansible fluid will flash into vapors upon exposure to atmospheric pressure) is fully exempt from the requirements of the Act. As an exception Piping for Thermal Liquid Heating Systems that contains non expansible fluid is not exempt.


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Section: 2

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Date: Jan. 1, 2008

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Requirements of the Pressure Equipment Safety Regulation (PESR)

(Alberta Regulation 49/2006)

Objective

To review: • Pressure Piping REQUIREMENTS of the Pressure Equipment Safety Regulation for

design, fabrication, installation of Pressure Piping; registration of QMS; application of Codes & Standards; registration of Welding Procedures; pressure testing; certification by the contractor; notification to ABSA upon completion of construction and overpressure protection.

• Pressure Piping EXEMPTIONS from the Pressure Equipment Safety Regulations. • Definitions Related to Pressure Piping:

- Pressure Piping System: [PESR, Interpretation 1(1)(aa)] “pressure piping system” means pipes, tubes, conduits, fittings, gaskets, bolting and other components that make up a system for the conveyance of an expansible fluid under pressure and may also control the flow of that fluid;

- Fittings: [PESR, Interpretation 1(1)(n)] “fitting” means a valve, gauge, regulating or controlling device, flange, pipe fitting or any other appurtenance that is attached to, or forms part of, a boiler, pressure vessel, fired-heater pressure coil, thermal liquid heating system or pressure piping system;

• Requirement for Design, Construction and Manufacturing of Pressure Piping:

A person who designs, constructs, manufactures or imports pressure equipment must ensure that: [PESR, Section 8(a) and 8(d)]

(a) The pressure equipment is designed and constructed to prevent unintentional release

of contained fluid.


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Section: 2

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Date: Jan. 1, 2008

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Interpretations and code cases are not part of the code, and are not automatically adopted for use in Alberta. Use of interpretations and code cases may be accepted on an individual basis upon application to ABSA. Check with an ABSA Safety Codes Officer before attempting to apply interpretations or code cases.

• Requirement for Registration of Pressure Piping Designs: [PESR, Section 14(1)]

The Regulation states that, no person shall

(a) Construct or manufacture for use in Alberta, or (b) Import for use in Alberta

any pressure equipment unless the design of that pressure equipment is registered by the Administrator pursuant to section 40 of the Act and the pressure equipment meets the requirements of this Regulation. Comment: The above requirement for the registration of designs apply to Boilers, Pressure Vessels, Pressure Piping Systems, Fittings, Fired/Unfired Heater Coils or any other pressure equipment required to be registered by the Administrator. The requirement for design registration (CRN) applies regardless of whether the pressure equipment is constructed within Alberta or imported from outside for installation in Alberta.

Registration of pressure piping designs is done by ABSA Design Survey in Edmonton. Be

aware that the registration of a design does not relieve the manufacturer of the responsibility for the design and construction of pressure piping in accordance with the Act, codes and standards.

Importing used pressure piping systems into Alberta is discouraged due to the difficulty in

verifying materials, design and workmanship.

Pressure Piping Design Registration - Requirement for P.Eng. stamp: [PESR, Section 16(2)]

The drawings, specifications and information for registration of a pressure piping system

design must be affixed with the stamp or seal of a professional engineer.

The stamp or seal indicates that the professional engineer (registered anywhere in North America) has verified that the design complies with the applicable code, including pipe stresses and support systems, and that the overpressure protection system complies with this Regulation. The stamp or seal must also be signed and dated.


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Section: 2

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Date: Jan. 1, 2008

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Pressure Piping Registration – AB-96 and AB-31: [PESR, Section 16(h)] Form AB-96 must be completed and submitted by the engineering designer or contractor who

designed the piping system. Form AB-96 should be accompanied by Application Form AB-31. Pressure Piping System Design Submissions: [PESR, Section 16(1)] The submissions for registration of the piping systems must include the items listed in PESR

Section 16(1).

Comment: ABSA may ask for any additional information that is necessary to complete the design review and register the design. Submission of complete information will help prevent delays in design registration. The design surveyor will request any necessary missing information before completing registration.

Pressure Piping System Design Registration ‘PP’ Number (not the ASME stamp): [PESR, Section 19(1)] If the submission for registration of the piping system meets the requirements of the

Regulations, the piping system will be registered by ABSA. The registration will be signified by the stamping and signing of the design documents by ABSA and issuance of a ‘PP’ number to the company.

An example of a Pressure Piping registration number in Alberta:

PP - 110 - E - 72 - P

'PP' indicates Pressure Piping.

This is not the ASME Stamp

'110' indicates a number assigned to the company that owns the facility.

'E' indicates Edmonton, ABSA's Inspection District in which the plant is located. Other letters are C-Calgary, GP-Grand Prairie, R-Red Deer, SP-Saint Paul, FM-Fort McMurray, M-Medicine Hat and L-Lethbridge.

'P' indicates type of plant: R-Refinary O-Oil & Gas Processing & Sulphur Recovery, C-Chemical, Process Plant, Fertilizers P-Petroleum Gathering and Transmission systems, Compressor Stations, H-Heating and Air Conditioning, F-Food Processing, G-Government of Canada, M-Miscellaneous.

'72' refers to the specific facility owned by the company.


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Section: 2

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Date: Jan. 1, 2008

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Comment: Other methods of pressure pipe testing may be permitted by the Administrator. The method of pressure pipe testing must be submitted with design registration information. A pneumatic test requires a detailed test procedure that has been prepared in accordance with the requirements of the QMS. Before testing any pressure piping system, the contractor must inspect the system to ensure that the materials, construction and installation comply with this Regulation. When conducting tests or initial start-ups, all safety precautions should be observed and only essential personnel should be present.

– Requirement for Inspection: For Pressure Piping constructed within Alberta for installation within Alberta, there are no requirements for the inspection of Piping systems by ABSA except for ASME B31.1 Boiler External Piping. All piping must be examined by the manufacturer and inspected by the owner’s inspector.

• Requirement for certification of piping by the contractor upon completion of construction: [PESR, Section 31]

A pressure piping construction and test data report form must be

(a) In a form acceptable to the Administrator, (b) Completed and certified for all pressure piping constructed, and (c) Retained on file by the owner for a period of not less than 5 years.

Despite subsection (1), for piping constructed outside of Alberta, the pressure piping

construction and test data report form must be completed by the person who constructed the piping and must be certified by an inspector acceptable to the Administrator.

Comment:

Section (a) above refers to the completion of ABSA’s ‘Construction Data report for Piping Systems’ AB-83 Form by the contractor. The construction must be certified by the owner's inspector (for process piping the inspector must be qualified per the ASME B31.3 Code, paragraph 340.4). This form must be provided to the owner. If the piping is boiler external piping as defined by ASME B31.1, the AB-83 form must be certified by an ABSA Safety Codes Officer (in Alberta). For Non-boiler external piping, the Form should be endorsed by the owner’s inspector. For code-stamped boiler external piping, the applicable ASME Section I piping data report form must be used. The contractor must provide the piping data report forms to the owner prior to commissioning. Note that the completion of construction declaration may also be required in accordance with


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Section: 2

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Date: Jan. 1, 2008

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PESR Section 32. It is strongly recommended that the piping data report forms (AB-83) be retained for the life of the plant. The paragraph starting with the word ‘Despite’ on the previous page refers to an ABSA ‘Construction Data report for Piping Systems Manufactured Outside Alberta’ AB-83F Form. The form must be certified by a National Board commissioned inspector with an "A" endorsement.

For piping constructed outside of Alberta but within Canada, use ABSA form AB-83F if the piping contractor does not hold a jurisdictional certificate of authorization equivalent to an ABSA certificate of authorization permit and is not permitted to construct such piping without inspection by the jurisdictional inspector. The form must be certified by jurisdictional inspector. ABSA should be contacted prior to the start of construction to establish equivalency. If equivalency is established, the company may use ABSA Form AB-83 provided the manufacturer and owner’s inspector or a jurisdictional inspector certify the construction. If piping is constructed outside of Canada, an ABSA AB-83F Form must be certified by the manufacturer and an A.I. who performed the inspections. The contractor must ensure that Piping Data Reports AB-83/AB-83F are submitted to the owner.

• Notification to ABSA upon completion of construction of Pressure Piping System:

[PESR, Section 32] Before the initial operation of any pressure piping system that requires registration of its

design, the person responsible for its construction must provide the Administrator with a declaration on a form acceptable to the Administrator confirming that the construction was carried out in accordance with this Regulation.

Comment: The above requirement of notification to ABSA upon completion of construction refers to submission of ABSA’s ‘Completion of Construction’ Form AB-81 by the person responsible for the construction of the piping.

An article was published by ABSA in The Pressure News of Sept. 2002, Vol. 7, Issue 3, to clarify requirements for pressure piping systems constructed outside of Alberta. The article may be viewed at Annex ‘A’, p. 4, Article # 3.


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Section: 2

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Date: Jan. 1, 2008

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Requirements of the Pressure Welders Regulation (Pressure Welders Regulation, Alberta Regulation 169/2002)

Objective

To review REQUIREMENTS for the use of Pressure Welders/Machine Welding Operators for welding Pressure Piping systems.

• Requirements for the use of Pressure Welders/Machine Welding Operators for Welding

on Code Piping: [Pressure Welders Regulation, Section 2]

No person shall weld a boiler, pressure vessel, pressure piping system or fitting by any

method, unless the person holds a certificate of competency, including a performance qualification card, that specifically authorizes the person to weld the pressure vessel, boiler, pressure piping system or fitting and authorizes the method used by the person.

[Pressure Welders Regulation, Section 2(1)]

Comment: The above requirement refers to the use of certified ‘B’ Pressure Welders or Machine Welding Operators for fabrication of piping systems. The requirements for ‘B’ Pressure Welders and Machine Welding Operators are described in Section 3 of the Pressure Welders Regulations. A person holding temporary ‘C’ Pressure Ticket while in the employ of that organization, may also qualify to weld on pressure piping. Remember, a certified welder cannot weld on any pressure equipment unless he/she is employed by a Certificate of Authorization Permit holder and is knowledgeable of the requirements of the WPS and the QMS. The Certificate of Authorization Permit must be valid and contain authorization for the scope of work. No person shall direct a person to weld a pressure vessel, boiler, pressure piping system or fitting by any method, unless the person who welds holds a certificate of competency, including a performance qualification card, that specifically authorizes that person to weld the pressure vessel, boiler, pressure piping system or fitting and authorizes the method used by that person. [Pressure Welders Regulation, Section 2(2)]


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Section: 2

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Date: Jan. 1, 2008

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Requirements of CSA B51, Boiler, Pressure Vessel, and Pressure Piping Code

(CSA B51-03)

Objective

To review: • Pressure Piping REQUIREMENTS of CSA B51 Code which are in addition to the

requirements of the Regulations • CRN system and requirements • Requirements for Manufacturer’s Data Reports • Requirements for Repair/Alterations and Maintenance of Pressure Piping systems • Requirements for the fabrication and inspection of Pressure Piping • Requirements for CNG station piping • Requirements for testing of Pressure Piping • Requirements for Codes and Standards covering the construction of Pressure Piping

systems • Requirements for inspections • Requirements for the construction of Fired Heaters

CSA B51, Boiler, Pressure Vessel, and Pressure Piping Code have been adopted through Pressure Equipment Safety Regulation, Section 10(a) and therefore is a requirement in Alberta. Some of the requirements for piping systems included in CSA B51-03 are similar to those found in pressure equipment regulations under the Safety Codes Act and may not be repeated here unless there are additional requirements included in the similar CSA clause. If there is a conflict between CSA B51-03 and regulations under the Safety Codes Act, the requirements of the regulations prevail over the code. • Requirements for the Registration of Piping Systems:

(CSA B51-03, Clause 4.1.1) Drawings, specifications, and calculations of designs for all boilers, pressure vessels, fittings

as provided for in Clause 4.2, fired-heater pressure coils, and piping shall be submitted to the regulatory authority. The submission shall identify the substance for which the item is intended. It shall be the responsibility of the users or an agent they designate to determine whether the substance is lethal.

Comment: In Alberta the pressure piping systems are required to be registered with ABSA only when the system’s internal volume exceeds 0.5 m3.


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Section: 2

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Date: Jan. 1, 2008

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CSA’s CRN System for Fittings: Comment: Fittings whose CRN does not include digit ‘2’ or letter ’C’ after the period are not legal for installation in pressure piping systems in Alberta. CRN is generally not stamped on a Fitting (except for PRV’s). The owner or purchaser should ask for documented proof of registration of the design from the supplier at the time of purchase.

0B 4567.1 2 3 4 5 6 7 8 9 0 T Y N C

A 1-5 digit number.

A 'Period' appears after the number.

The Numbers and Letters after the Period, indicate the Province/Territories of Registration. A CRN for Fittings may have one or more digits or letters in any sequence after the ‘period’. First digit indicates where the design was registered first: • 1 means - B.C. (The province in which the

design was first registered). • 2 means – Alberta (for use in Alberta, CRN

must contain digit 2 or letter ‘C’ at any place after the ‘period’)

• 3 means - Saskatchewan • 4 means - Manitoba • 5 means - Ontario • 6 means - Quebec • 7 means - New Brunswick • 8 means - Nova Scotia • 9 means - Prince Edward Island • 0 means - Newfoundland • T means - Northwest Territories • Y means - Yukon Territories • N means - Nunavut • C means - Registration in all of the provinces of Canada

Digit ‘0’ (zero) at the start indicates that it is a Fitting.

‘B’ Indicates Category of Fitting. Table 1 on p.26 of the CSA B51-03 Code describes the categories of Fittings.

An article was published by ABSA in The Pressure News of June 2000, Vol. 5, Issue 2, to alert the industry against the use of unregistered or incompatible fittings. The article may be reviewed at Annex ‘A’, p.11, Article # 9.


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PPRREESSSSUURREE PPIIPPIINNGG FFAABBRRIICCAATTIIOONN RREEQQUUIIRREEMMEENNTTSS AANNDD QQUUAALLIITTYY CCOONNTTRROOLL Jurisdictional Boundaries between ERCB & ABSA

Section: 2 Rev.: 1 Date: March 20, 2008 Page: 32 OF 48


This following diagram is intended to show general code boundaries of some of the piping configurations found in the industry. All of the equipment that is normally found at these plants is not shown. Consult jurisdictional requirements and applicable codes to precisely locate the boundaries. All piping constructed to ASME Codes is subject to the requirements of the Pressure Equipment Safety Regulation and of ABSA.

ASME B31.1 Boiler External Piping; ABSA Jurisdiction

ASME B31.1 Piping; ABSA Jurisdiction

ASME Sec. I Boiler Proper Piping; ABSA Jurisdiction

ASME B31.3 Piping; ABSA Jurisdiction

Z662 Piping; ERCB Jurisdiction

Blowdown

Line Heater

Meter

Inlet Separator

Amine Contactor

Amine Regenerator

Outlet Scrubber

Meter

Flashed vapor to fuel or flare

Reflux Drum

Wellhead Site Meter

Rich AmineFlash Drum

Utilities Plant and a Gas Plant

Wellhead Site with Line heater

Meter

Compressor Station

Compressor

Cooler

Meter

Feedwater

Feedwater Feedwater

Steam Header

Boiler No. 1

Boiler No. 2

Condensate Return

Boiler Room

Chemical FeedDeaerator

Blowdown

Complete ERCB Jurisdiction

ERCB Jurisdiction

ERCB

A

B

ABSA Jurisdiction between points A & B

ABSA Jurisdiction

ERCB Jurisdiction ERCB Jurisdiction

ERCB ABSA Jurisdiction ERCB Jurisdiction

Non-Boiler External Piping may be constructed to ASME B31.3 Code. Wherever double valve is required by the Code, Boiler External Piping extends up to the second valve.


ASME B31.3 Process Piping Code

Scope and Categories of Piping

Section No.: 3

Objective

To provide knowledge about the basic requirements of the code which may be considered essential for all sizes of piping fabrication companies. The Sections cover the scope of the code, categories of piping, design requirements which are useful for construction (Pressure design of components per paragraph 304 and flexibility analysis are not included), materials, fabrication, assembly, inspection, examination and testing requirements. Supplementary requirements for Cat ‘M’ piping, Safeguarding, Precautionary Considerations recommended by the code, and Code ‘Interpretation’ are provided when applicable. No information is provided for Nonmetallic and High Pressure Piping.


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Piping Design Requirements ASME B31.3 Process Piping Code

Section: 3 Rev.: 0 Date: Jan. 1, 2008 PAGE: 1 OF 6


SCOPE (ASME B31.3-2006, Paragraph 300.1)

Objective

To review: • Responsibilities of the Owner, Designer, Manufacturer and Owner’s Inspector • Intent of the code • Scope • What is covered in the code? • Exclusions

Responsibilities: [ASME B31.3-2006, Paragraph 300(b)]

(a) Owner: [ASME B31.3-2006, Paragraph 300(b)(1)]

• The owner is overall responsible for assuring compliance with this code • The owner is responsible for establishing requirements • The owner is responsible for designating fluid categories • The owner is responsible for determining quality system requirements

ASME Interpretation 19-11: Interpretation 19-11 was issued by ASME to clarify responsibilities of the owners in regards to the establishment of design requirements and responsibilities of the designer for addressing those requirements. The interpretation also addresses some other questions and may be found at the back of ASME B31.3-2004 Code, p.I7. The interpretation is also included at the back of this manual and may be viewed at Annex ‘C’, p.13.

(b) Designer: [ASME B31.3-2006, Paragraph 300(b)(2)] The designer is responsible to the owner for assuring that the design meets the requirements of the code and any additional requirements established by the owner.


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CATEGORIES OF PIPING (ASME B31.3-2006, Paragraph 300.2, Definitions, Fluid Service, p.4)

Objective

To review code definitions of various categories of pressure piping and severe cyclic condition.

There are 4 categories of Piping Systems that are based upon the type of fluid handled: 1. Category ‘D’ Piping:

A piping system may be designed and constructed as a Category ‘D’ piping system if all of the following requirements are satisfied:

• The fluid is nonflammable, nontoxic and non damaging to human tissues • Design pressure does not exceed 1035 kPa (150 psi) • The design temperature is from –29°C through 186°C

2. Category ‘M’ Piping:

A piping system should be designed and constructed as Category ‘M’ Piping system if the potential for personnel exposure due to leakage of the fluid is significant and may cause serious irreversible harm to persons.

3. High Pressure Piping:

There are no specified pressure limitations, however ASME B31.3 Chapter IX is generally applied for pressures in excess of Class 2500 (ASME B16.5 designation). The application of Chapter IX is mandatory when specified by the owner.

4. Normal Service:

Piping that is not designated as category ‘D’ or ‘M’ or ‘High Pressure Piping’ is designated as Normal Service piping. Most of the piping systems fall under this category.

Severe Cyclic Condition: Severe Cyclic Condition applies when piping components or joints in which SE (Maximum operating stress range) computed in accordance with code paragraph 319.4.4 exceeds 0.8SA (allowable stress range for displacement stress) and the equivalent number of cycles (N in paragraph 302.3.5) exceeds 7000 or other conditions which the designer determines will produce an equivalent effect.



Piping Design Requirements

Section No.: 4

Objective

To learn requirements for: • 11 Design Conditions that must be considered by the designer • 3 Design Criteria that must be considered by the designer • Welded joints • Threaded joints • Bolting • Pressure relieving systems


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Pressure Piping Design Conditions (ASME B31.3-2006, Paragraph 301)

Objective

To understand the 11 design conditions that must be considered by the designer. The designer must consider the following 11 conditions in the design of the piping: 1. Qualifications of the Designer: (ASME B31.3-2006, Paragraph 301.1) (a) Who is a Designer?

A Designer is a person who is: • In charge of an engineering design of the piping system, and • Is experienced in the use of the Code.

(b) Qualifications of a Designer:

The qualifications and experience required will depend upon the complexity and criticality of the piping system. The owner’s approval is required if the designer(s) does not meet at least one of the following criteria:

• Completion of an engineering degree requiring at least 4 years of full time study +

5 years of experience in the design of related pressure piping • P.Eng. recognized by local jurisdiction + experience in the design of related

pressure piping • Completion of an engineering associate degree requiring at least 2 years of full

time study + 10 years of experience in the design of related pressure piping. • 15 years of experience in the design of related pressure piping. The experience to

include capabilities to perform design calculations for pressure, sustained and occasional loads and piping flexibility.

Comment:

Piping that is required to be registered with ABSA (when overall internal volume of the piping exceeds 0.5m3), must have it’s design stamped by a P.Eng. P.Eng. may be registered in any province of Canada or in any sate of U.S.A. [PESR, Section 1(2), p.6]


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Pressure Piping Design Criteria (ASME B31.3-2006, Paragraph 302)

Objective

To learn code design criteria that must be considered by the designer. The designer must consider the following 3 Design Criteria: 1. Pressure-Temperature Design Criteria: (ASME B31.3-2006, Paragraph 302.2) (a) Listed Components having Established Ratings:

(ASME B31.3-2006, Paragraph 302.2.1) When the components are designed to the standards listed in Table 326.1 of this code, the design pressure-temperature ratings are acceptable. If responsibility is taken by the owner, the pressure-temperature ratings may be extended using the provisions of the code.

(b) Listed Components not having Specific Ratings: (ASME B31.3-2006, Paragraph 302.2.2) The pressure-temperature rating of some components is based upon straight seamless pipe. Such components shall be rated not more than 87.5% of the nominal thickness, weight or pressure class minus the allowances (corrosion, thread depth).

(c) Unlisted Components: (ASME B31.3-2006, Paragraph 302.2.3)

• Components not listed in Table 326.1 but which conform to published specifications or standards may be used provided:

(1) The designer is satisfied that – The composition – Mechanical properties – Method of manufacturing – Quality control

are comparable to that of listed components.


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Requirements for Flanges, Blanks, Gaskets (ASME B31.3-2006, Paragraph 308) Listed Flanges, Blanks and Gaskets (ASME B31.3-2006, Paragraph 308.1.1) Flanges, Blanks and Gaskets which are constructed in accordance with the ‘Component Standards’ listed in ASME B31.3-2006, Table 326.1 on p.53-54, are permitted for use in Normal Fluid service except as stated elsewhere in paragraph 308. For requirements in regards to Cat. ‘M’, High Pressure and Non-metallic piping, the readers are directed to the Code Chapters specific to those categories. Unlisted Flanges, Blanks and Gaskets (ASME B31.3-2006, Paragraph 307.1.2) Unlisted Flanges, Blanks and Gaskets may be used in accordance with the provisions of paragraph 302.2.3 only. Paragraph 302.2.3 specifies that the designer must verify the composition, mechanical properties, method of manufacture, quality control, the integrity of the components using formulas specified in paragraph 304. Specific Requirements (ASME B31.3-2006, Paragraph 308.2)

• Slip-on Flanges: (ASME B31.3-2006, Paragraph 308.2.1)

(a) A Slip-on Flange must be double welded when the service is:

– Subject to severe erosion, crevice corrosion or cyclic loading. – Flammable, toxic, or damaging to human tissues – At temperature below -101ºC (-150ºF)

(b) Slip-on Flanges should be avoided where many large temperature cycles are expected, particularly if the flanges are not insulated.

ASME Interpretation 19-20: Interpretation 19-20 was issued by ASME to clarify that intermittent welding (stitch) on the back side of the slip-on-flanges is acceptable only when the designer has applied rigorous analysis in accordance with the requirements of ASME B31.3-2006 Code, paragraph 300(c)(3); the analysis is consistent with the design criteria of the code; has documented the calculation; has secured acceptance from the owner and has provided details of design, construction, examination, inspection and testing requirements in the engineering design. The interpretation may be found at the back


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of ASME B31.3-2004 Code, p.I10. The interpretation is also included at the back of this manual and may be viewed at Annex ‘C’, p15.

• Flanges for Severe Cyclic Conditions:

(ASME B31.3-2006, Paragraph 308.2.4) Unless safeguarded, a flange to be used under severe cyclic conditions shall be a Weld Neck Flange conforming to ASME B16.5 or B16.47.

• Gaskets: (ASME B31.3-2006, Paragraph 308.4) Gaskets shall be compatible with the service conditions and selected to assure that the seating load is compatible with the flange rating, strength of flange and bolts. Comment:

• Flanges must be registered with ABSA (listed or unlisted). A CRN is not generally stamped on the flange, however CRN documentation identifiable to the flange must be available to confirm registration and it’s validity.

• Blanks shall be designed to ASME B16.47 and registered with ABSA. • Gaskets are not registered with ABSA.



Fabrication, Assembly and Erection Requirements

Section No.: 6

Objective

To learn requirements for the: • Welding responsibilities, WPS qualification and use of qualified Welders • Weld joint preparation, alignment and spacing • Welding of joints and filler metal • Fillet welds, seal welds and repairs • Preheating and Post Weld Heat Treatment (PWHT) • Assembly and Erection


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Requirements for Welding Responsibility, WPS Qualification and Welders for Process Piping

(ASME B31.3-2006, Paragraph 328)

Objective

To learn requirements for the Welding responsibilities, WPS qualification and use of qualified Welders. Welding Responsibility (ASME B31.3-2006, paragraph 328.1) Each employer:

• Shall be responsible for the welding done by the personnel of his organization • Shall conduct tests to:

- Qualify welding procedures (WPS’s) except as provided for in paragraphs 328.2.2 ‘Procedure Qualifications by Others’

- Qualify and re-qualify welders except as provided for in paragraphs 328.2.3 ‘Performance Qualifications by Others’

- Qualify and re-qualify welding operators except as provided for in paragraphs 328.2.3 ‘Performance Qualifications by Others’

WPS Qualifications (ASME B31.3-2006, paragraph 328.2.1) Qualification Requirements:

(a) Qualifications of: • WPS shall be qualified in accordance with ASME Section IX • Performance qualification of welders and welding operators shall be in accordance

with ASME Section IX except as modified herein. (b) If the base metal is not able to withstand 180° guided bend, a qualifying welded specimen

is required to undergo the same degree of bending within 5°. (c) When Preheat and Heat Treatment are required by the code or the engineering design,

WPS’s shall also be qualified for Preheating and Heat Treatment. (d) When Impact Testing is required by the code or the engineering design, WPS’s shall also

be Impact Tested.


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(e) If consumable inserts, integrally machined equivalents or backing rings are used for producing welded joints, their suitability shall be demonstrated by the WPS except that a WPS qualified without the use of a backing ring is also qualified with backing ring in a single welded butt joint.

(f) To reduce the number of WPS’s: - Materials are grouped in P-Numbers or S-Numbers based upon their composition,

weldability and mechanical properties - P-Numbers or S-Numbers are listed in a separate column in Table A-1 for the

convenience of the users Comment: S-Numbers are a listing of materials which are acceptable for use by the ASME B31 Codes for Pressure Piping but are not included within ASME Boiler and Pressure Vessel Code Material Specification Section II.

- Application of ASME Section IX, QW 420.2 is required by this code Comment: WPS used for the construction of pressure piping systems must be registered with ABSA prior to the start of the construction. WPS qualification shall be in accordance with the requirements of this paragraph and of the ASME Section IX Code. [PESR, Section 18] If pressure piping is constructed outside of Canada, the requirement for registration of the WPS with ABSA (for installation in Alberta) or with the local jurisdiction has not been implemented as referred to in CSA B51-03, Clause 4.4.2. Instead ABSA has relied upon the verifications done by the A.I. who inspected the piping and certified AB-83F form. ASME Interpretation 19-22: Interpretation 19-22 was issued by ASME to clarify that changes to the non-essential variables require revisions to the WPS. ASME B31.3-2006 Code, paragraph 328.2.1 directs the reader to the ASME Section IX Code in regards to the requirements. ASME Section IX-2004, paragraph QW-200.1(c ), ‘Changes to the WPS’, states that the changes to the non-essential variable do not require re-qualification of the WPS, however the changes must be documented by the way of amendment to the WPS or by the use of a new WPS. The interpretation may be found at the back of ASME B31.3-2004 Code, p.I10. The interpretation has been included at the back of this manual and may be viewed at Annex ‘C’, p.16. Comment: In regards to the above interpretation, when any changes to the non-essential variables are done, re-registration of the WPS should be reviewed with ABSA. Depending upon the circumstances such as updating the WPS to the latest Code, re-registration may be required.


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• Branch connections that are inserted through the run pipe shall be inserted as far as the inside surface of the run pipe at all points and shall conform to paragraph 328.4.3(1).

Code Fig. 328.4.4 (c)

• Run opening for branch connections:

– The opening shall not deviate from the required contour by more than the dimension ‘m’

– In no case shall the deviation of the shape cause the root tolerance limits of WPS to exceed

– Weld metal may be added and refinished if necessary for compliance

(d) Spacing: The root spacing shall be within the tolerance limits of the WPS or the engineering design.

≥ 0 mm

Root gap ‘g’ per WPS

Run Pipe

Branch P

ipe

This diagram is a redraw of Code Fig. 328.4.4(c)


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2. Fillet and Socket Welds: (ASME B31.3-2006, Paragraph 328.5.2)

The fillet welds may vary from convex to concave. The size of fillet weld is determined as shown in code Fig. 328.5.2A.

Code Fig. 328.5.2A Fillet Weld Sizes

(a) Typical weld details of Slip-on and Socket Welding Flanges are shown in code Fig. 328.5.2B. Min. welding dimensions for Socket Welding components are shown in code Fig. 328.5.2C or in MSS SP-119.

(Where T = Nominal Wall Thickness of Pipe; Xmin. = The lesser of 1.4T or the thickness of the Hub)

Code Fig. 328.5.2B Slip on Flange installation details


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ASME Interpretation 19-20: Interpretation 19-20 was issued by ASME to clarify that intermittent welding (stitch) on the back side of the slip-on-flanges is acceptable only when the designer has applied rigorous analysis in accordance with the requirements of ASME B31.3-2006 Code, paragraph 300(c)(3), the analysis is consistent with the design criteria of the code, has documented the calculation in the engineering design, has secured acceptance from the owner and has provided details of design, construction, examination, inspection and testing requirements in the engineering documents. The interpretation may be found at the back of ASME B31.3-2004 Code, p.I10. The interpretation is also included at the back of this manual and may be viewed at Annex ‘C’, p15.

Code Fig. 328.5.2C Socket Welding details

ASME Interpretation 20-01: Interpretation 20-01 was issued by ASME to clarify when 1/16˝ gap is required and how you may verify it. The interpretation may be found at the back of ASME B31.3-2006 Code, p.I-3. A copy of the interpretation is included at the back of this manual and may be viewed at Annex ‘C’, p.2.


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Requirements for Assembly & Erection of Process Piping


Objective

To learn requirements for the assembly and erection of piping.

Assembly and Erection (ASME B31.3-2006, Paragraph 335)

(a) Alignment (ASME B31.3-2006, Paragraph 335.1)

• Piping Distortions:

Distortion of piping to bring it into alignment for joint assembly which creates detrimental strain is prohibited.

• Cold Spring:

– Before assembling any joints to be cold sprung, guides, supports and anchors shall be examined to assure free movement.

– Gap/overlap shall be checked prior to the assembly against the drawing and checked if necessary.

– Heating shall not be used to help close the gap because it defeats the purpose of cold springing.

• Flanged Joints:

Before bolting up,

– Flange faces shall be aligned to the design plane within 1 mm in 200mm (1/16 in./ft) measured across any diameter.

– Flange bolt holes shall be aligned within 3 mm (⅛″) maximum offset.


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Additional Requirements when applicable: Piping for Category ‘M’ Fluid Service: Alignment: In addition to requirements of paragraph 335.1, any bending or forming required for alignment and fit up shall be heat treated if required by paragraph 332.4. (ASME B31.3-2006, Paragraph M335.1.1)

ASME Interpretation 17-25: Interpretation 17-25 was issued by ASME to clarify that alignment tolerances for the installation of the flanges apply to each individual flange and not to total misalignment between mating flanges. The interpretation may be found in the ASME B31.3 Interpretations Vol. 20, p.210. The interpretation is also included at the back of this manual and may be viewed at Annex ‘C’, p22.

Flanged faces shall be aligned to the design plane within 1mm in 200 mm (1/16˝/ft) measured across any diameter. For example if D = 200 mm then ‘m’ must not be greater than 1 mm measured across any diameter. [ASME B31.3-2006, Paragraph 335.1(c)]

D

mFlange bolt holes shall be aligned within 3 mm (⅛˝) maximum offset. [ASME B31.3-2006, Paragraph 335.1(c)]

90º



Inspection, Examination and Testing Requirements

Section No.: 7

Objective

To learn requirements for the: • Responsibilities for Inspection of piping • Qualifications of Owner’s Inspector • Types and extent of NDE required (such as Visual, RT) • Qualifications of NDE personnel • NDE examination procedures, definitions of NDE techniques and In-Process examination • Pressure Testing of the piping and records of tests


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Requirements for Responsibility for Inspection of Process Piping


Objective

To learn requirements for the responsibilities for inspection of piping. 1. General:

(ASME B31.3-2006, Paragraph 340.1) The code distinguishes between Examination and Inspection.

• Inspection refers to functions performed for the owner or by the owner’s inspector or the inspector’s delegate.

• Examination is defined in paragraph 341.1 and states that ‘Examination applies to quality control functions performed by the manufacturer, fabricator or erector’.

2. Responsibility for Inspection:

(ASME B31.3-2006, Paragraph 340.2) It is the owner’s responsibility exercised through the owner’s inspector, to verify that:

• All required examinations and testing have been completed, and • To inspect the piping to the extent necessary to be satisfied that it conforms to all

applicable examination requirements of the code and engineering design.

An article was published by ABSA in The Pressure News of December 2000, Vol. 5, Issue 4, to inform the owners about their responsibilities for the inspection of pressure piping to ensure that the piping meets the requirements of the engineering design and the code. The article may be reviewed at Annex ‘A’, p.18, Article # 15.


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Requirements for Examination of Process Piping (ASME B31.3-2006, Paragraph 341)

Objective

To learn requirements for the types and extent of NDE required (such as Visual, RT). 1. General:

(ASME B31.3-2006, Paragraph 341.1) • Examination applies to quality control functions performed by the manufacturer, fabricator

or erector. • Examiner refers to a person who performs quality control examinations.

2. Responsibility for Examination:

(ASME B31.3-2006, Paragraph 341.2) Inspection does not relieve the manufacturer, fabricator or the erector of the responsibility for: (a) providing:

• Materials, and • Components, and • Workmanship

in accordance with the requirements of this code and of the engineering design. (b) Performing all required examinations, and (c) Preparing suitable records of examinations and tests for the inspector’s use.

3. Examination Requirements:

(ASME B31.3-2006, Paragraph 341.3)

(a) General: (ASME B31.3-2006, Paragraph 341.3.1)

• Prior to initial operation:

- Each piping installation, including components and workmanship shall be examined in accordance with the requirements of paragraph 341.

- The type and extent of the additional examination required by the engineering design and acceptance criteria shall be specified.


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- Acceptance criteria as required for the original work.

(d) Progressive Sampling for Examination (Weld repairs):

(ASME B31.3-2006, Paragraph 341.3.4) When required spot or random examination reveals a defect:

(a) 2 additional samples of the same kind welded/bonded by the same welder/bonder/operator shall be subject to the same type of examination; and

(b) If the examination per (a) above is acceptable, the defective item shall be repaired/replaced and reexamined as specified in paragraph 341.3.3 and all items represented by the 2 additional samples shall be accepted; and

(c) If any of the 2 additional samples examined per (a) above reveal any defect, 2 further samples of the same kind shall be examined for each defective item found; and

(d) If the examination per (c) above is acceptable, the defective item shall be repaired/replaced and reexamined as specified in paragraph 341.3.3 and all items represented by the additional samples shall be accepted; but

(e) If any of the items examined per (c) above reveal any defect, all items represented by the progressive sampling shall be either:

• Repaired/replaced and reexamined; or • Fully examined and repaired/replaced, and reexamined as necessary.

Comment: The above requirement applies to repairs [Defect 2 Tracers (defect) 2 more Tracers (defect) Entire Lot]

ASME Interpretation 18-01: Interpretation 18-01 was issued by ASME to clarify that if a welding operator’s weld is rejected and the repair is made by another welding operator, it is still required to be examined, and that the 2 tracers be shot at the same time as the repair weld. The interpretation may be found in the ASME B31.3 Interpretations Vol. 20, p.215. The interpretation is included at the back of this manual and may be viewed at Annex ‘C’, p.18.

Comment: The interpretation 18-01 applies to both welders and machine welding

operators. The interpretation refers to welding operator only because that is how the question was asked.


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In process examination in accordance with paragraph 344.7 may be substituted if specified in the engineering design or specifically authorized by the inspector for all or part of the RT/UT on a weld-for-weld basis. Comment:

• 5% RT is the requirement that is normally applied by the industry (vs the UT or In-Process examination). The work of each welder and welding operator should be included and it does not mean 5% RT for each welder/welding operator.

• Coverage of intersections and longitudinal joints: The key wording in paragraph 341.4.1(b)(1) is "at least the adjacent 1½″...", where the word adjacent means "positioned next to, lying near, or adjoining". Therefore, the radiography to be completed is 1½″ from the edge of the weld.

Brazed joints: • At least 5% of the brazed joints shall be examined by in process examination in

accordance with paragraph 344.7 • Work of each brazer shall be included in the examination

Additional Requirements when applicable: Piping for Category ‘M’ Fluid Service: Extent of Required Examination - Other Examination:

• The random RT/UT requirements of paragraph 341.4.1(b)(1) apply except that at least 20% of circ. butt welds, miter welds, fabricated laps and branch connection welds comparable to code Figs. 328.5.4E and 328.5.5 sketches (d) and (e) shall be examined.

At least 38 mm (1½″) on each side of the intersecting joints must be covered by NDE.

38 mm (1½″) 38 mm (1½″)

Circ w

eldLongitudinal weld

Longitudinal weld


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(2) Not required in P3, 4, 5 or 10A materials when the throat thickness is 13 mm (½″) or less regardless of base metal thickness provided: • That the recommended preheat is applied • Specified min. tensile strength of the base metal is less than 490 MPa (71 ksi)

(3) Not required:

• For ferritic steels when welds are made with filler metal which does not air harden.

• Austenitic welds may be used to join ferritic materials if service conditions such as:

- Differential thermal expansion - Corrosion

will not adversely effect the weldment.

(c) Heating and Cooling: (ASME B31.3-2006, Paragraph 331.1.4)

The heating method shall provide for: • Required metal temperature • Temperature uniformity • Temperature control

The heating method may include:

• Enclosed furnace • Local flame heating • Electric resistance • Electric induction • Exothermic chemical reaction

The cooling method shall provide for:

• Required/desired cooling rate The Cooling method (rate of cooling) may include cooling:

• In furnace • In air • By application of local heat or insulation • By any other suitable means

Comment: No heating rate is specified by ASME B31.3-2006 Code for PWHT. Cooling rate is specified only for P10I, P11A SG 1, P11A SG 2 and P62 materials (please review


Introduction to ASME B31.1 Power Piping and Inspection

Requirements

Section No.: 8

Objective

To learn about:

• Application of ASME B31.1 Power Piping code • Scope of the code • Boiler External piping, PP stamp • Owner’s and ABSA’s Inspection Requirements • Some notable differences between ASME B31.1 Power Piping and ASME B31.3

Process Piping


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Introduction to ASME B31.1 Piping and Inspection Requirements

ASME B31.1 Power Piping Code



Introduction to ASME B31.1 Piping and Inspection Requirements

(ASME B31.1-2004, Addenda 2006) Introduction (ASME B31.1-2004, Addenda 2006, Introduction)

• ASME B31.1 Power Piping is typically found in:

– Electric power generating stations – Industrial plants – Institutional plants – Geothermal heating systems – Central and district Heating & Cooling systems

• Responsibility for the selection of a Code:

It is the Owner’s responsibility to select the Code Section that most nearly applies to a proposed piping installation. The owner must consider the following factors when applying the Code section:

– Limitation of the Code section – Jurisdictional requirements – Applicability of other Codes and Standards

All applicable requirements of the Code section shall be met. For some installations, more than one code section may apply to different parts of the installation. The owner is responsible for imposing requirements supplementary to those of the selected Code section, if necessary, to assure a safe piping system for the proposed installation.

• The Code section includes:

– References to acceptable material specifications

Comment: Not all materials are suitable for Boiler External Piping. In ASME B31.1-2006 Power Piping Code wherever ‘(1)’ appears in the ‘Notes’ column in Tables A-1 to A-9 (p98 to p187), the material is not permitted for Boiler External Piping. – References to component standards – Requirements for design of components and assemblies, including pipe supports


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PPRREESSSSUURREE PPIIPPIINNGG FFAABBRRIICCAATTIIOONN RREEQQUUIIRREEMMEENNTTSS && QQUUAALLIITTYY CCOONNTTRROOLL

ASME B31.1 Power Piping Scope Modified Fig. 100.1.2(B), ASME B31.1- 2004

Section: 8 Rev.: 0 Date: Jan. 1, 2008 PAGE: 5 OF 10 D0008673.DOC

Nonboiler External Piping

Constructed to

Applicable ASME B31

Code • B31.1 for

Utilities Plant. • B31.3 for

Process Plant.

Blow Off - Single and multiple installations

Boiler Proper: All construction must be per ASME Section I. ABSA inspections mandatory.

Boiler External Piping: All piping must be designed and constructed in accordance with the requirements of ASME B31.1; inspected and certified per ASME Section I. ABSA inspections mandatoryNonboiler External Piping: Constructed per ASME B31.1 or B31.3 as applicable. No ABSA inspections.

Note 1: BEP extends through one or more valves depending on the installation. See Fig. 100.1.2(B) in ASME B31.1 or Fig. PG-58.3.1 in ASME Section I.

Superheater

Reheater

Economizer

Boiler Steam Drum

Boiler Water Drum

Boiler Tubes

Boiler Proper (Blue) Constructed to ASME Section I

Boiler External

Piping (Red)Constructed

to ASME B31.1

Boiler External

Piping (Red) Constructed

to ASME B31.1

All construction within these boundaries must be inspected by ABSA

All drums and Headers are constructed to ASME Section I

Drain

Drain

Drain

Vent

Vent

Vent

Nonboiler External Piping

Constructed to

Applicable ASME B31

Code • B31.1 for

Utilities Plant. • B31.3 for

Process Plant.

Control Devices 122.1.6

Vent

Vent

Drain

Drain

Feedwater system(See Note 1)

Main Steam(See Note 1

Blow down

Level Indicator

Vents and Instrumentation

122.6.2

Steam outlet (See Note 1)

Cold Reheat

Hot Reheat


WPS and Welder’s Requirements

Section No.: 9

Objective

To understand and apply the information provided in a: • WPS • Performance Qualification Card


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PPRREESSSSUURREE PPIIPPIINNGG FFAABBRRIICCAATTIIOONN RREEQQUUIIRREEMMEENNTTSS AANNDD QQUUAALLIITTYY CCOONNTTRROOLL WPS, Explanation of Variables and Application to Production Welds

Section: 9 Rev.: 0 Date: Jan. 1, 2008 Page: 3 OF 7

{ABSA: D0010303.DOC .1}

• This chart is for reference only and is based upon ASME Section IX-2007 Edition. For future use, decisions must be confirmed against the latest edition of ASME Section IX Code and current Regulations. • Welding outside the limits/tolerances specified in the WPS or the Welding Data (Article IV) for Essential Variables and Supplementary Essential Variables may have detrimental effect on the mechanical properties

such as strength, toughness and ductility of the weld and shall render the production joint(s) unacceptable. • *Changes to Non-Essential Variables do not require re-qualification of the WPS, but changes may have a detrimental effects on the weld and therefore must be accepted by engineering prior to the start of welding. • Changes beyond those specified in the engineering design/drawings but within the limits specified by the WPS or Welding Data (Article IV), must be accepted by engineering prior to start of welding.

A change from one welding process to another welding process is an essential variable and require re-qualification (QW-401) WPS

Explanation of Variables and Application to Production Welds

QW-482 Suggested format for Welding Procedure Specification (WPS) (See QW-200.1, Section IX, ASME Boiler and Pressure Vessel Code)

Information in green was filled in to illustrate application Company Name: XYZ Piping Fabrication Ltd. By: Materials Testing Ltd. WPS No.: XYZ-WPS-12 Date: Dec. 12, 2003 Supporting PQR No(s): XYZ-PQR-4 & 6.Rev. No.: 1 Date: March 23, 2006

QW-253 Welding Variables Procedure Specifications (WPS)

Shielded Metal-Arc Welding (SMAW) Legend: + Addition; - Deletion; > Increase/Greater than ; < Decrease/Less than; Uphill; Downhill; Forehand; Backhand; Ø Change; ± Addition/Deletion; T = Base metal thickness; t = weld deposit;

Welding Process(s): SMAW Type(s): Manual

Paragraph Brief of Variables

Essential Sup. Essential

Non Essential

Welding Data Article IV

Application to Production Welds

JOINTS (QW-402) Joint Design: All Groove and Fillet designs per construction drawing. Backing (Yes): (No): Backing Material (Type): Retainers not used

.1 Ø Groove Design

X QW-402.1: A change in the type of groove (Vee-groove, U-groove, Single-bevel, Double-bevel, etc.)

*The code permits change in the type of groove only. Inclusion of a new grove design will require revision to WPS or to the engineering design. Change in dimensions beyond those permitted by the engineering design and by this code shall render the production weld unacceptable.

Metal Nonfusing Metal Nonmetallic Other Sketches, production drawings, weld symbols or written description should show the general arrangement of the parts to be welded. Where

.4 - Backing X QW-402.4: The deletion of the backing in single welded groove welds. Double welded groove welds are considered welding with backing.

*If backing was used during the qualification of the PQR, but no backing was specified in the WPS, no re-qualification of the WPS is required provided the change has been addressed in the WPS and accepted by engineering.

applicable, the root spacing and the details of weld groove may be specified. (At the option of the manufacturer sketches may be attached to illustrate joint

.10 Ø Root Spacing

X QW-402.10: A change in the specified root spacing.

*Root spacing may be adjusted beyond that specified in the WPS provided the change has been accepted by engineering.

Design, weld layers and bead sequence, e.g., for notch toughness procedures, for multiple process procedures, etc.)

QW-402 Joints

.11 ± Retainers X QW-402.11: The addition or deletion of nonmetallic retainers or nonfusing metal retainers.

*The addition or deletion of nonmetallic retainers or nonfusing metal retainers. May be specified in the WPS.

BASE METALS (QW-403) P-No.: 1 Group No.: 1 & 2. to P-No.: 1 Group No.: 1 & 2. OR

.5 Ø Group No. X QW-403.5: This variable applies only when impact testing is required. • Welding procedure shall be qualified

using one of the material conditions specified in QW-403.5.

If impact testing is required, Group No. becomes essential and no substitution is permitted. Review QW-403.5 for details.

Specification Type and Grade: to Specification Type and Grade: OR

.6 T Limits impact

X QW-403.6: This variable applies only when impact testing is required. • The min. base metal thickness is the

thickness of the test coupon T or ⅝″ whichever is less. When T is < ¼″, the min. thickness qualified is ½T.

• If impact testing is required, Min. base metal T is specified in QW-403.6.

• If impact testing is not required Min. and Max. T values are specified in QW-451.1

Chem. Analysis and Mech. Prop.: N/A to Chem. Analysis and Mech. Prop.: N/A .8 Ø T Qualified

X QW-403.8: A change in base metal thickness beyond the range qualified in QW-451, except as otherwise permitted by QW-202.4(b).

This is an essential variable, therefore welding beyond the maximum base metal thickness limits specified in QW-451 shall render the production weld unacceptable.

Thickness Range - Base Metal: 2.7mm to 19.1mm (0.108″to ¾″) inclusive.

QW-403 Base Metal

.9 t Pass > ½″ X QW-403.9: For single/multi pass welding in which any pass is > ½″ t, an increase in base metal thickness beyond 1.1 times that of the qualification test coupon.

Re-qualification is required if any weld pass is > ½″.

Automatic, Manual, Machine, or Semi-Auto.

Refer to both backing and retainers

Provincial Registration


Quality Concepts

Section No.: 10

Objective

To understand the Quality Concepts: • Purpose of a QMS • Owner’s/Management’s Responsibilities and Roles • QMS requirements of the Piping codes • QMS manual design, suitability to company’s operations and ISO Standards • Planning for Piping Construction Project • Piping Project Design and Development Process • Piping Project Design and Development ‘Inputs/Outputs’


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Quality Concepts



Quality Concepts

Objective The objective of this section is to understand some of the quality concepts for developing

understanding in regards to the purpose, responsibilities, design of an effective quality manual and planning for piping construction projects.

• Purpose of a documented QMS:

A quality management system (QMS) as applied to the pressure equipment is a system that outlines the policies and procedures necessary for constructing safe pressure equipment, meets the needs and specifications consistently, is capable of improving and controlling the quality processes, and as a result leads to improved safety and business performance. Customers require products with characteristics that satisfy their needs and expectations. These needs and expectations which also meet the safety requirements of the Regulations are expressed in product specifications and collectively referred to as ‘requirements’. These ‘requirements’ may be specified contractually by the customer or may be determined by the organization itself. Customer ultimately determines the acceptability of the product. Customer needs and expectations tend to change and the organizations are driven to continually improve their products and processes. A documented QMS assist the organizations in meeting the above challenges and provide with tools to help them analyze overall requirements, define the processes that contribute to the provision of the product and keep those processes under control. A documented QMS can provide the framework for continual improvement to enhance the satisfaction of customers and meet the statutory requirements. It provides confidence to the organization; the customers and the Regulations that it can provide safe piping systems that consistently fulfill requirements.

How to do it:

The organization should assign responsibilities for the development and implementation of the QMS to a qualified member of the management team. The person is generally known as the Management Rep./QC Manager and has other responsibilities as well within the organization. The person selected by the management should have awareness of quality concepts, have knowledge of the developmental process and have sufficient authority to request resources and


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Piping Project Design and Development Process

Section: 10 Rev.: 0 Date: Jan. 1, 2008 PAGE: 8 OF 9.


The Piping Project Design and Development process should be undertaken in the initial stages and before the start of construction. The process is based upon the guidelines of ISO 9001:2000 Standard (Section 7.3 Design and development). The process is applicable to the design & development of a ‘product’ which may include piping design, processes, procedures, development of flowcharts, work instructions and services no matter how small or large a project may be. The application will vary with the size and complexity of the project. The process is designed to assist the manufacturers meet the overall requirements of the client, regulations, codes, standards and any other statutory requirements that may apply to the project.

Prepare Plan 1

Determine Inputs 2

Determine Outputs 3

Review 4

Verify 5

Validate 6

Control Changes

7 The Quality Plan should include determination of construction stages; review, verification and validation that is appropriate for each stage and assignment of responsibilities. The following and other activities as applicable to the construction of the piping system should be considered before the start of construction: • Design and development stages:

During the planning phase, the organization should establish procedures for design and development of the project, and where appropriate, include the following: - identification, scope and objectives. - sequential and parallel work sch. - timing, frequency of activities. - evaluation of safety, performance and

dependability of the product. - methods of measurement, testing and

acceptance criteria. • Review, verification and validation that

are appropriate to each stage: Design and development plans should be integrated with any other plans and verification or validation procedures related to the product, and these plans should be updated as necessary.

• The responsibilities and authority for

design and development: The organization should clearly assign responsibilities for specific leadership and other design and development work functions to qualified personnel. The personnel in these functions should have access to information and resources needed to complete the work.

• Functional and performance requirements:

Functional and performance requirements such as the ability of the piping system to deliver the product from point ‘A’ to ‘B’ under specified conditions, ability to perform under specified environment and any other design conditions that may have been set by the owner. • Applicable statutory and regulatory

requirements: Inputs shall include the specification of: - applicable construction Codes such as ASME B31.3, B31.1.

- SCA & Regulations and requirements such as ABSA Certificate of Authorization Permit for construction, use of certified ‘B’ Pressure Welders, registration of design with ABSA etc.

- any other statutory requirements such as safety and environmental that may be applicable.

• Information derived from previous similar designs: When dealing with piping systems that had been constructed before, it may be possible to use some of the construction information such as design details, materials information, requirement for personnel, equipment etc. for the project inputs.

• Other requirements essential for the realization of the project:

Other requirements may include owner’s specifications, manufacturer’s standards, pipe size, type & grade of materials, max. pressure, max. and min. temperatures, turn over package etc.

Outputs shall be provided in a form that may enable verification against the inputs and shall be approved prior to start of the job. Outputs shall: • Meet the inputs: All requirements of the client, Act & Regulations and any

other specifications must be met. Some examples of outputs may be: - Has the QMS been developed and registered with

ABSA and Certificate of Authorization Permit received?

- Has the design been completed in accordance with the overall requirements and registered with ABSA?

- Software required identified? - Has the preparation of procedures needed for

construction been completed or is on track? - Has the arrangements for training been done or in is

in process as planned? - Has the WPS’s been developed and registered with

ABSA etc.? • Provide appropriate information for purchasing

and construction: - Generally upon completion of piping system design,

the material specifications should be known (output of the design) and used for purchasing.

- Upon completion of the design, the construction stages may be identified and outputs specified.

• Specify the acceptance criteria: Acceptance criteria should be identified. For code construction of piping some of the acceptance criteria such as for welding quality acceptance may be found in applicable code of construction such as ASME B31.3. Acceptance criteria specified by the client and others that is over and above the code requirements should be identified as input and output.

• Specify characteristics of the piping system for safe use:

Specify characteristics of the piping system for safe use. An example may be that the piping designed for non-sour service is not suitable for sour service. Max. design pressure and max. and min. temperature conditions should not be exceeded.

At suitable stages systematic reviews of the design and development should be performed in accordance with the planned arrangements to: • Evaluate the ability of the

results of the design to meet the overall requirements: Checks may be done at various stages to confirm if the: - design and development

outputs satisfy the specified requirements.

- proper design codes are being used and materials are appropriate.

- required procedures are being developed for use at specified stages.

- training arrangements are being done.

- computer software was validated etc.

- project development is happening on time.

• Identify any problems and corrective action: Any problems discovered must be corrected. Some examples of problems discovered may be discovery of wrong use of materials, fittings, nozzles orientation, dimensions etc.

Verifications shall be performed in accordance with the planned arrangements to ensure that the output have met the input requirements. Verify: • if the piping

design outputs have met the inputs at each completed stage of design and development.

• if materials meet the requirements of the design and if the design and development process is progressing at the desired rate.

• the completion of other checks as necessary to assure overall acceptability of the piping system.

Validation should be performed in accordance with the planned arrangements to ensure that the piping system is capable of meeting the requirements specified for the application or intended use. Validation may be performed by the owner upon operation of the piping system to evaluate if it is performing to the requirements and that it has served the purpose for which it was intended. Any discrepancies discovered should be used to correct the inputs for the future piping designs.

Any changes to the design of the project shall be controlled. The changes shall be reviewed, verified, validated and approved for implementation. The effects of changes shall be evaluated at stages. Some of the non-conformances with the requirements may be traced back to the changes that were not controlled and construction continued in accordance with the obsolete designs, drawings and documents. The manufacturer must ensure that any changes to the documents and project activities are communicated, and that the obsolete instructions, drawings or documents are effectively removed from the use areas.


QMS Implementation

Section No.: 11

Objective

To learn implementation of the QMS: - Quality Policy & Objectives - Organization - Owner’s/Management’s Responsibilities - Contract Review - Piping Design - Document & Data Control - Material Control - Piping Construction - Post Weld Heat Treatment (PWHT) - Non Destructive Examination (NDE) - Inspection - Pressure Testing - Calibration of Measuring Devices - Training - Corrective and Preventive Action - Internal Audits


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QMS Implementation



Owner’s/Management’s Responsibilities

Why Describe Owner’s/Management’s Responsibilities in your QMS Manual To ensure that top management takes a leading and visible role in defining, implementing, administering and improving the QMS with the goal of meeting all requirements. What is it? Leadership, commitment and the active involvement of the owner and/or the top management are essential for developing, maintaining and implementing an effective and efficient quality management system. Top management should:

• Lead the organization by example in order to develop trust with its people • Communicate the direction and values of the organization • Participate in improvement initiatives • Obtain feedback • Create an environment that encourages the involvement and development of the people

Key activities that should be addressed in your QMS manual: Owner and/or the top management should:

• Appoint a member from its management team to act as a Management Representative who, irrespective of other responsibilities, shall have defined authority for:

- Ensuring that a quality management system is established, implemented and maintained in accordance with company’s policies.

- Reporting on the status of the quality system to the top management on a regular basis. • Communicate to the organization the importance of meeting customer’s statutory and

regulatory requirements • Establish a quality policy • Ensure that quality objectives are established at appropriate levels of the organization • Conduct management reviews of the QMS • Assure availability of competent resources

Current Gaps:

• Owner’s and/or the top management’s responsibilities not described in the quality manual • Responsibilities not described adequately • Responsibilities not carried out effectively


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QMS Implementation



Piping Design

Why Describe Piping Design Process in your QMS Manual

Whether the piping system design is undertaken in-house, contracted out or is supplied to you by the owner; design process will help you to make certain that the piping system you manufacture meets all the specified design requirements set by the owner, Regulations and the applicable ASME B31 code(s). What is it? The manufacturer should establish and maintain documented procedures for piping design control and the coordination of those activities. This section should describe the system for ensuring that piping systems are designed in accordance with the requirements of the company, Regulations, and that the design addresses the service conditions and other process related requirements needed to prevent unintentional release of fluid. Key activities that should be addressed in your QMS manual: Responsibilities for the implementation of the Design Control activities should be defined and understanding confirmed. 1. If the piping design is undertaken in-house, ensure that:

• The design inputs and outputs are identified prior to the start of the design activity. • The design requirements such as the operating conditions, the service requirements

and other information needed to facilitate the safe design, construction, and inspection of the piping system are identified and documented.

• The personnel assigned to engineer the piping systems are competent and meet the piping design, code knowledge and qualification requirements of the company, and of the applicable ASME B31 Code. Piping system designs that are over 0.5m3 internal volume must be stamped by a P.Eng.

• The piping design documents – (specifications, drawings, P & ID’s, Process Flow Diagrams, calculations, etc.) are prepared, verified and approved.

• The design documents provide information about code of construction (including Edition), proper material specifications, design pressure, maximum and minimum design temperatures, ASME B31.3 category for process piping, type and extent of NDE required, hydro test pressure and medium, Pre Heat and PWHT treatment requirements, WPS and dimensions.


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QMS Implementation



- Exercise - Piping Design

Project File: Review the following documents from the Project File: • DBM: Review purpose, contents and in particular sections 2.1, 3.2, 3.4, 4.1 and 6.1 for Piping

Design requirements • Design calculations document • Registration of design with ABSA, AB-96, AB-31 • Registered Drawing(s)


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QMS Implementation



Material Control

Why Describe Material Control Process in your QMS Manual To make certain that the materials are purchased in accordance with the specifications, materials supplied by the owners meet the requirements, is inspected on receipt to assure conformance, stored and that it remains identifiable until processed.

What is it? The manufacturer should establish and maintain documented procedures for material control activities such as purchasing, receiving and storage to assure conformance with the requirements of the owner, your QMS and the Act. Key activities that should be addressed in your QMS manual: Responsibilities for the implementation of the Material Control activities should be defined and understanding confirmed.

• Evaluation and selection of suppliers: − Define the process used for selecting suppliers based on their ability to supply

materials (piping, fittings and other materials used for the fabrication of piping) and services such as NDE, PWHT, Impact testing, and Calibration in accordance with the requirements of the engineering design, QMS and the Act. Criteria for selection, evaluation and re-evaluation of suppliers shall be established. Records of evaluation results and any necessary changes to vendor approval arising from the evaluation shall be maintained.

− Maintain a current approved vendors list that is available to and used by all personnel involved with purchasing activities.

• Purchasing:

The manufacturer should ensure that purchased materials conform to the specified purchase requirements. The following key activities should be controlled through documented procedures:

− Quality System Certification requirements when purchasing the services of piping manufacturers

− Material specifications and other required information such as type, class, grade of materials and the applicable issues of the Codes and Standards to which the product must comply


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QMS Implementation



- Exercise - Material Control

When one group is reviewing the Project file, the other group should do Piping Module exercise. Project File: Review the following documentation from the Project File:

• Engineering design/drawings/owner supplied Piping Specifications to establish quantity, type, class and grade of materials required for construction

• Requisition and P.O.: Discuss accurate specification of materials, requirements such as MTR’s, CRN documentation and other requirements on the P.O.

• Verification of the validity of CRN documents • Verification of MTR’s against materials, ASME Section II. • Verification of Material Receiving Reports

Piping Module: Conduct ‘Receiving’ inspection of the piping components and verify:

• If the materials are identifiable. Materials may be colour coded, marked with heat numbers, manufacturer’s symbols, name plates etc.

• that the materials are not damaged. • at least 8 heat numbers against the P.O.


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QMS Implementation



Non Destructive Examination (NDE)

Why Describe NDE in your QMS Manual

NDE such as RT, UT, and MT may be required by ASME B31 Codes. The process for controlling the NDE activities, defining responsibilities and qualifications of personnel, verification and certification of reports, radiographs may be described in the manual for assuring consistent application of the procedures.

What is it? The manufacturer should establish and maintain documented procedures for NDE and the coordination of those activities. This section should describe the system for ensuring that the NDE Procedures meet the requirements of the company, Regulations, the engineering design ASME Section V, the code of construction (such as ASME B31.3, ASME B31.1), and that the procedures are implemented by qualified personnel and the conformance is verified by the manufacturer. Key activities that should be addressed in your QMS manual: Responsibilities for the implementation of the NDE procedures should be defined and understanding confirmed. The following key activities should be addressed: Ensure that the:

• NDE required for the piping is specified in the drawings or engineering specification documents available to the manufacturer

• Qualified NDE sub contractors have written procedures that meet the requirements of the current Regulations, ASME Section V and the applicable ASME B31 code of construction. Work performance of the NDE sub contractor should be verified by the manufacturer and acceptance documented.

• Qualified NDE sub contractors employ certified NDE technicians for the applicable NDE techniques. All examinations must be performed under the supervision of a CGSB/ASNT Level II or III technicians.

• NDE interpretations are done by CGSB/ SNT-TC-IA Level II or III technicians • Sub contractor employs a CGSB/SNT-TC-IA Level III technician to resolve interpretation

issues, provide training and certify staff • Written instructions for performing NDE are provided to the sub contractor and

understanding confirmed • Welding joints requiring NDE are identified and documented


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QMS Implementation



- Exercise - NDE

When one group is reviewing the Project file, the other group should do Piping Module and RT room exercises. Project File: Review in the following documents from the Project File:

• Drawings and/or engineering documents to determine if the NDE requirements are specified and are correct (including the Fluid service)

• the construction drawing and determine the number of joints to be radiographed. Ensure that the RT requirements of the construction drawing are complied with and that the work of all of the welders is covered.

• Review the Radiographic Reports completed by the NDE company and verify if all of the joints identified were radiographed. Review and confirm if the report was completed correctly, meet the requirements of the ASME Section V code, signed of by CGSB/ASNT Level II technician minimum. Use ‘Radiograph Review Form’ (ABSA document 53155.DOC) included in the Project File at p4. of Section 10 NDE to verify the Radiographic Reports completed by the NDE company.

• Determine if the report was reviewed and accepted by the manufacturer Piping Module: Conduct inspection and verify if the welded joints marked for RT are identified. RT Room: Review the radiographic film using a viewer and verify if all of the information included in the ‘Radiography Film Review’ chart (ABSA document 53220.DOC) could be verified. The chart is included in the Project File at p5. of Section 10 NDE.


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QMS Implementation



Inspection

Why Describe Inspection in your QMS Manual

To assure that the piping conforms to all of the specified requirements at each construction stage; to identify nonconforming product at the earliest possible stage, and to facilitate corrective action.

What is it? The manufacturer should demonstrate that Inspection Procedures are in operation to ensure that piping conforms to the specified requirements at all stages of construction. Inspections requirements should be identified for:

• Materials received from the owner and suppliers • Piping fabrication packages (partial) received from subcontractors • Construction activities at the manufacturer shop and field sites • Finished product to assure overall conformance to the requirements prior to the release of

the piping to the owner Key activities that should be addressed in your QMS manual: Responsibilities for the development and implementation of the Inspection procedures and the overall inspection program should be defined in the QMS manual. The manufacturer should assure that:

• The QMS inspection requirements and associated procedures are available and understood by the personnel responsible who are taking part in any construction activities.

• The materials received from the owner(s) and supplier(s) meet the specified requirements, and that the materials are not released for processing until such inspections are successfully conducted.

• The ‘partial’ piping packages received from the subcontractors are inspected prior to release for further processing. All partial piping packages received from manufacturers within Alberta must be accompanied by ‘Partial AB-83’ forms.

• Piping packages received from manufacturers outside Alberta are accompanied by ‘AB-83F’ forms.

• The Inspection activities are defined for various stages of construction and are conducted in accordance with the procedures at the shop and field sites. The owner’s inspector shall be informed of the construction project and owner’s inspections completed in accordance with the requirements of the applicable ASME B31 Code.


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QMS Implementation



- Exercise - Inspection

When one group is reviewing the Project file, the other group should do Piping Module exercise. Project File: Review the following documentation from the Project File.

• Review ITP Piping Module: Conduct visual inspection (internal and external) using Table 341.3.2 of ASME B31.3-2006, p70 or an acceptance criteria that is more stringent than the Code and specified in the engineering design to verify:

• That the defects such as cracks, lack of fusion, incomplete penetration, undercuts, surface porosity, surface finish, suck up, weld reinforcement and alignments are with the specified limits.

• If the construction, materials and dimensions are those specified in the construction drawings.


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QMS Implementation



Pressure Testing

Why Describe Pressure Testing in your QMS Manual

A Pressure Test is a significant activity that must be performed safely upon completion of all code work such as PWHT, NDE, mechanical assembly and welding. To assure the safety of the pressure tests, the QMS should address the activity, procedures documented, personnel trained, tests completed safely and records maintained.

What is it? The manufacturer should establish and maintain documented procedures for Pressure Testing of piping and the coordination of those activities. This section should describe the system for ensuring that piping systems are pressure tested safely in accordance with the requirements of the engineering design, Regulations, and that the personnel responsible for testing are trained to prevent failures during the test. Key activities that should be addressed in your QMS manual: The manufacturer should plan the pressure test of the completed piping and assure that it is safely accomplished. Responsibilities for the completion of the pressure test should be defined and understanding confirmed. The key pressure test activities that should be addressed in the QMS manual are as follows: Assuring that:

• A documented procedure is in practice and is understood by all the personnel involved in the pressure test

• The procedure is effective and meets the requirements of the engineering design and the code of construction

• The procedure is complied with • The pressure gauges used are calibrated and of proper range • The piping is protected from over pressure • The pressure test areas are secure and safe for the personnel around • The required inspections are carried out by qualified personnel • The pressure test records are maintained per the requirements of the procedure • For ASME B31.1 Boiler External Piping, prior arrangements are made for the SCO to

inspect and witness the pressure test


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QMS Implementation



- Exercise - Pressure Testing

Project File: Review the following documentation from the Project File.

• Pressure Test control sheet • Completion of AB-83 • Completion of AB-81


Annex ‘A’

Selected Pressure Piping Articles from ‘The Pressure News’

The Pressure News is a publication of ABSA. The newsletter is issued quarterly in March, June, September and December of each year. This newsletter provides current information and events regarding pressure equipment safety. ‘The Pressure News’ can be accessed at http://www.absa.ca/newsletter/default.aspx.


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Annex ‘A’

Annex: A Rev.: 0 Date: Jan. 1, 2008 PAGE: 12 OF 27


Article # 10 The following article was published by ABSA in The Pressure News of Sept. 1998, Vol. 3, Issue 3, to clarify situations when altered fittings should be re-registered. Cutting 90º elbow to accommodate 80º change or boring schedule 80 to schedule 40, are not considered alterations requiring re-registration. The intent is valid to date.


Annex ‘B’

Selected ‘Information Bulletins & Alerts’ related to the Pressure Piping

Alerts are safety warnings issued to the public or a specific group of people involved with pressure equipment. Usually an incident or accident has happened. Lessons learned from the incident or accident are passed to the public through Information Bulletins as Alerts. The Information Bulletins and Alerts are issued by ABSA and may be accessed at ABSA’s website at http://www.absa.ca/IBIndex/default.aspx


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Annex ‘B’

Annex: B Rev.: 0 Date: Jan. 1, 2008 PAGE: 8 OF 8


Information Bulletin No. IB07-002 The following Information Bulletin was issued by ABSA in connection with the timing of radiographic testing of the piping. The information is valid to date.


Annex ‘C’

Selected Interpretations by ASME related to the Pressure Piping

ASME issues written replies to the inquiries concerning interpretations of technical aspects of the Code. An interpretation applies to the edition or addenda stated in the interpretation itself, or, if none is stated, to the latest published edition and addenda at the time it is issued. Subsequent revisions to the rules may supersede the reply. An ‘interpretation’ is not part of the code. Should you contemplate the use of an ‘interpretation’ in Alberta, you must contact a Safety Codes Officer of your nearest ABSA office to ensure that the use of the ‘interpretation’ is acceptable. Latest ‘Interpretations’ are included at the back of the ASME B31 Codes. Past ‘interpretations’ are published by ASME and may be obtained from ASME at http://cstools.asme.org


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Annex ‘C’

Annex: C Rev.: 0 Date: Jan. 1, 2008 PAGE: 18 OF 27


Interpretation 18-01

Interpretation 18-01 was issued by ASME to clarify that if a weld done by a welding operator is rejected and if the repair is done by another welding operator, it is still required to be examined, and that 2 tracers may be shot at the same time the repaired weld is radiographed. The interpretation may be found in the ASME B31.3 Interpretations Vol. 20, p.215. The interpretation quotes 1999 Code and was issued in 2000, however the intent is valid to date.

Comment: The interpretation 18-01 applies to both welders and machine welding operators.


Annex ‘D’

Recent Code Cases published by ASME related to the Pressure Piping

A Code Case is the prescribed form of reply when study indicates that the Code wording needs clarification, or when the reply modifies existing requirements of the Code or grants permission to use new materials or alternative constructions. A Case is published as part of a Case supplement. A Case is normally issued for a limited period. If at the end of that period it is incorporated into the Code, or if no further use of its provisions is anticipated, it is allowed to expire. Otherwise, it is renewed for a limited period of time.

Manufacturers and users of piping components are cautioned against making use of cases that are less restrictive than former requirements without first having confirmed that the cases were accepted by the proper authorities in the jurisdiction where the component is to be installed. A Code Case is not part of the code. Should you contemplate the use of a Code Case in Alberta, in addition to following all of the requirements of the Code Case, you must contact a Safety Codes Officer of your nearest ABSA office to ensure that the use of the Code Case is acceptable. The Code Cases are published on the ASME website and may be purchased directly from ASME at http://cstools.asme.org

absa - pressure piping fabrication requirement & qc seminar - selected pages

Documents

piping materials requirements

piping design requirements

asme b31

piping design registration

process piping code

fittings asme code b31

testing requirements

welders requirements