2019 Edition

ASME QC Manual Changes

Narayanan Murugappan
24 October 2019
Suggested QC Manual Changes
● Suggested non-nuclear QC Manual changes due to 2019 Edition ASME BPVC
will be discussed.
● Suggested non-nuclear QC Manual changes due to 2019 Edition NBIC Part-3
will be discussed.
● Changes considered important in my opinion are included here.
● Please note that QC Manual changes are subject to COAs held and scope of
COA held by individual organization.

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 Statement of
Authority and
Responsibility

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Statement of Authority and Responsibility
Addition of Jurisdictional/regulatory authority requirements
● Due to new requirements in NBIC
● Disagreements, which cannot be resolved by the QA/QC Manager, shall be
brought directly to me for resolution, based on jurisdictional/regulatory
requirements, ASME Code requirements, good engineering practice and this
QC Manual.
● The QA/QC Manager is fully supported by the Management and has the
authority, responsibility and organizational freedom to identify QC problems
and report them to XXX, provide their solutions, and verify the implementation
of solution to such problems.

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 Glossary

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Glossary/Definitions
● Add definitions for Certifying Engineer, Designer (For U2 COA)
● Certifying Engineer; an engineer or other technically competent professional
duly accredited and qualified to practice engineering as required by ASME
Section VIII Division-2
● Designer; an individual who is qualified to design pressure vessels in
accordance with the rules of ASME Section VIII Division-2 by demonstrated
knowledge in Code requirements and proficiency in selecting correct design
formulas and appropriate values to be used when preparing the design of a
pressure vessel.

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 Drawing, Design
Calculation and
Specification

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Units of Measurement
● Design Manager is responsible for establishing, specifying units of
measurement to be used in construction and conversion of the
units of measurement using guidelines given in Code (e.g. U-4).
● Design calculations shall be carried out either in US Customary
(psi) or SI units(MPa). Company uses SI units, in general, for
design, however, when required by the jurisdiction or contract, US
Customary units may be used to demonstrate compliance with
design requirements.
● For any single equation, all variables shall be expressed in a
single system of units.
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Units of Measurement
● Data expressed in other units shall be converted to US Customary
or SI units, as applicable, for use in design equations.
● The result obtained from execution of equations or any other
calculations carried out in either U.S. Customary or SI units may
be converted to other units.
● U.S. Customary, SI, or any local customary units may be used to
demonstrate compliance with requirements of construction
except design.

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Drawing, Design Calculation and Specification
● For ASME Section VIII Div-2, the Code Edition used for
construction of Pressure vessel shall be either the edition that is
mandatory on the date the pressure vessel is contracted or a
published edition issued by ASME prior to the contract date,
which is not yet mandatory.
● Add “ Parts ordered by another ASME COA Holder/Vessel
Manufacturer, can be fabricated to the edition governing
construction of the Vessel.”

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Drawing, Design Calculation and Specification
● Parts built for Stock shall be constructed either to the edition that
is mandatory at the time of certification or a published edition
issued by ASME prior to the code certification, which is not yet
mandatory.
● When parts are used from stock, QA/QC Manager shall ensure that
the part fully satisfies all applicable code requirements of the
Code edition used for the construction of the vessel.

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Drawing, Design Calculation and Specification
● Design Engineer prepares the design calculation as per Code. As
an alternative, the design rules of Mandatory Appendix 46 may be
used.
● Where design rules do not exist in ASME Section VIII Division-1,
one of the following three methods shall be used:
– (1) Mandatory Appendix 46 of Div-1.
– (2) proof test in accordance with UG-101.
– (3) other recognized and generally accepted standards or Codes such as
ASME, EN, ISO, national and industry standards or codes using allowable
stress criteria provided in UG-23.

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Drawing, Design Calculation and Specification
● The provisions of U-2(g) shall not be used to justify the use of
materials, joining processes (fabrication), examination,
inspection, testing, certification, and overpressure protection
methods other than those allowed by Division-1.

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Drawing, Design Calculation and Specification
● For Class 1 vessels: Manufacturer’s Design Report shall be certified
in accordance with Annex 2-B when any of the following is
performed:
– (1)Fatigue analysis
– (2)Use of Part 5 to determine thickness of pressure parts when design rules
are not provided in Part 4
– (3)use of Part 4.8 to design a quick‐actuating closure
– (4)a dynamic seismic analysis
The Manufacturer’s Design Report may be certified by a designer in
accordance with Annex 2-B when none of the conditions of (1) through (4)
applies.
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Drawing, Design Calculation and Specification
● For ASME Section VIII Division-2:
● The QA/QC Manager is responsible to ensure that all personnel
performing and/or evaluating design activities are competent in
the area of design in accordance with the QC Procedure XXXX for
Qualification and Certification of Certifying Engineers and
Designers. The QC Procedure shall meet the requirements of
Annex 2-J of Division-2.

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Drawing, Design Calculation and Specification
● If Computer Software/ Programs are used for design, the Design
Engineer shall verify the accuracy of the Computer software/
Programs for each element used, prior to use by performing
manual calculation or comparing the results against those of
another verified program or by performing solved examples of
ASME PTB-3/ PTB-4 (provided equation used in PTB-3/PTB-4 is
same as that used in the Computer software/ Program). These
results shall be maintained and made available to the AI.

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 Examination
and Inspection
Program

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Examination and Inspection Program
● For Section I and B 31.1 construction, the range of pressure
gauges used in testing shall preferably have dials graduated over
the entire range of about double the intended maximum test
pressure, but in no case less than 1.5 times the pressure nor more
than 4 times that pressure.

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 Welding Control

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Welding Control
● WE shall have a satisfactory level of competence in accordance
with the QC Procedure XXXXXX, wherein competence is defined by
education, experience, or training in ASME Section-IX, company’s
QC program and the scope, complexity, or special nature of the
activities performed by the company.
● QA/QC Manager shall maintain a record containing objective
evidence of the qualifications, training, or experience.

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Welding Control
● When a variable is outside the scope of a WPS (e.g., the variable
applies to a P-Number not included on the WPS) or is addressed
by another variable (e.g., the AWS Classification specifies the filler
metal product form), that variable need not be specifically
addressed on the WPS or PQRs that support the WPS.
● When required by the construction Code, the test plate material
heat-treated condition shall be noted on the PQR and WPS.

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Welding Control
● When required by construction Code, such as ASME Section-I(PW-
38.4, PW-38.8), Preheating band width and conditions for
interruptions in welding shall be defined in the WPS.

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Welding Control

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Welding Control

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Welding Control
● Preparation and testing of the test specimens is performed by an
approved testing laboratory instructed through Testing Request
that is prepared by the Welding Engineer and specifying ASME
Section-IX and construction Code requirements, if any.

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 Non-Destructive
Examination

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Non-Destructive Examination
● The NDE subcontractor shall provide the following documents for
review and verification by QA/QC Manager.
● (1) Written practice in accordance with Code adopted edition of
SNT-TC-1A as amended by Mandatory Appendix III to Article-1 of
ASME Section - V.

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Non-Destructive Examination
● The Subcontractor's NDE procedures for Manual UT, PT and MT
shall be demonstrated to the satisfaction of AI for producing
meaningful results. QA/QC Manager shall certify the
subcontractor's NDE procedures to be in accordance with T-150(a)
or (b) of ASME Code Section V.
● Automated & Semi-automated UT procedures shall be qualified by
demonstration as per T-150(d)and documented on procedure
demonstration record.

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Non-Destructive Examination
● Written radiographic Examination Procedure is not required for
Div-1.
● Additional NDE requirements of ASME Section VIII Div.1 (UW-50)
shall be followed if the item is planned for pneumatic test.
● Before performance of Pneumatic test as per ASME Section VIII
Division1 , the full length of the welds are examined by MT or PT,
………..
– All Welds around openings
– All attachment welds, including welds attaching non-pressure parts, having a
throat thickness greater than ¼” or 6mm.
●
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 Heat Treatment

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Heat Treatment
● Attachments of thermocouples shall be by capacitor discharge
welding method in accordance with QW-289 and QW-389 of ASME
Section-IX. Alternate methods of attachments, if any, as proposed
shall be reviewed and accepted by QM.

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 Calibration

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Calibration
● Densitometer used for determining the density of radiography films
shall be calibrated at least once in 90 days every 3 months using
step tablet or by step wedge calibration films traceable to national
or international standards and verified by the Level II in accordance
with ASME Section V Article 2 T-262.1.

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Calibration
● The magnetizing power of yokes shall be verified prior to use each
day the yoke is used. Each yoke shall have its lifting power checked
at the maximum pole spacing, with contact similar to what will be
used during the examination.

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 Record
Retention

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Record Retention
● RT and UT Reports
– NDE Interpretation Reports
● Hydrostatic Test Records
– Pressure Test Records

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Record Retention
● If Records are maintained in electronic soft copy, description on
how it is retained is required.
– Scanned copy of records
– Legible
– Access restrictions for deletion and no modifications
– Location of storage defined and back-up arrangements
– Sub-divided
– Indexed and book marked

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Record Retention
– For R COA
– Continuity records for a welder, welding operator, bonder, or cementing
technician shall be maintained for a minimum of 5 years.

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 Repairs and
Alterations

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Repairs and Alterations
● Scope of Repair/Alteration is to be addressed
– Shop or field metallic repairs and alterations to pressure retaining items
Pressure vessels to ASME Section VIII Div-1, PD 5500, Boilers to ASME Section-I
and piping to B31 Codes when required by the owner, user, jurisdiction or AIA
responsible for in-service inspection of the unit, are made in accordance with
the applicable requirements of the NBIC and this Manual, and jurisdictional
requirements, if applicable.

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Repairs and Alterations

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Repairs and Alterations
– All examination and tests required during and after repairs or alterations shall
be identified on the Repair procedure and ITP/QCP.
– Exclusive use of VT as examination for repair is not followed by the Company.

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Repairs and Alterations
– When alternative welding methods without PWHT is planned to be used
• in highly stressed areas,
• if service conditions are conducive to stress corrosion cracking,
• if materials are subject to hydrogen embrittlement, or
• are operating at temperatures in the creep range, or
• if the alternative is being considered for “on-stream” repairs or “hot tapping” on
piping systems,
then, competent technical advice is required.
This Technical advice shall be recorded in the R-Form.

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Repairs and Alterations

– In this case, concurrence of Owner shall be recorded in R-Form.

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Repairs and Alterations

– Similarly, if Pressure test is waived, it shall be recorded in R-2 Form.

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Repairs and Alterations

– Ensure R-Form Log has the above details.

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Repairs and Alterations

– The test pressure shall be the minimum required to verify the leak tightness
integrity of the repair, but not more than 150% of the maximum allowable
working pressure (MAWP) stamped on the pressure-retaining items test
pressure allowed by the original Code of construction, as adjusted for
temperature.

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Repairs and Alterations
– Routine Repair
– Routine repairs are repairs for which the requirements for in-process
involvement by the Inspector and stamping by the “R” Certificate Holder may
be waived as determined appropriate by the Jurisdiction and the Inspector.

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 Exhibits

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Exhibits
– Filled up exhibits after initial review
– Name plate Exhibits for Div-1 & Div-2 to be revised.

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Summary
– Mandatory changes
• Statement of Authority & Responsibility
• Addition of Definitions in Glossary for VIII Div-2 COA Holders
• Changes due to Units of Measurement
• Changes due to VIII Div-2 Edition requirements for sub-contracted parts
• U-2(g) requirements
• VIII Div-2 Class-1 vessel MDER Certification requirements
• Certifying Engineer/Designer competence requirements
• Pressure Gauge range for Section-I
• Competence of welding supervisory personnel
• Variables and construction Code requirements to be addressed in WPS

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Summary
– Mandatory changes
• NDE Written Practice, RT Procedure and UW-50 requirements
• Densitometer calibration frequency & MT Yoke lifting power check
• Records retention
• Repair & Alteration scope, VT examiner requirement, details to be recorded in R-
Form, maximum test pressure, routine repair
• VIII Div-1 and Div-2 exhibits

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Summary
– Recommended changes
• Parts built for Stock & used from Stock- Edition requirements
• Software validation- requirement to verify formulae
• Introduction of PQR testing request
• Reference to QW-289 and QW-389 for Capacitor Discharge welding
• Description of how soft copies of QC Records are retained
• Filled up exhibits for renewal joint review

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 Thank you
Please contact:
Narayanan Murugappan
ASME Authorized Inspector Supervisor
Lloyds Register EMEA
Dubai office
Narayanan.murugappan@lr.org

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