5.AIA Presentation

ASME BOILER AND
PRESSURE VESSEL
CERTIFICATION
AUTHORIZED INSPECTION AGENCY
“INDEPENDENT INSPECTION &
OVERSIGHT”
BANGKOK, THAILAND
PAUL LANG
1
ASME BOILER AND PRESSURE
VESSEL CERTIFICATION
INTRODUCTION
ROLE OF THE AIA
QUALITY SYSTEM
DUTIES OF THE AI
WHAT CAN GO WRONG?
CONCLUSION AND OUTLOOK
2
AGENDA
 INTRODUCTION
 ACCREDITATION & ROLE OF THE AIA
 QUALITY SYSTEM
 DUTIES OF THE AI
 WHAT CAN GO WRONG?
 CONCLUSION AND OUTLOOK
3
What we ALL have to prevent
from happening...
4
AGENDA
 INTRODUCTION
 QUALITY SYSTEM
5
AUTHORIZED INSPECTION AGENCY

(as defined in ASME QAI-1)
JURISDICTION INSURANCE COMPANY THIRD PARTY

(e.g. State of OHIO) (USA + CANADA) (e.g. NOTIFIED BODY in EU)
DIFFERENT SCOPES:
NEW CONSTRUCTION | IN-SERVICE | REPAIRS AND ALTERATIONS | NUCLEAR | …
6
ASME
CERTIFICATE JURISDICTION
AIA HOLDER
SHARED ENFORCEMEMNT
NATIONAL +
BOARD SHARED MARK PROTECTION
7
THE AIA IS CONSIDERED TO BE THE LINK BETWEEN THE CERTIFICATE
HOLDER AND ASME/NATIONAL BOARD IN THE EVERYDAY BUSINESS.
 Shall have in place a permanent and exclusive SERVICE AGREEMENT with the
Certificate Holder
 Employs Authorized Inspectors (AI) and Supervisors (AIS)
 The AI reviews and accepts the Quality Program
 The AI and AIS join the ASME Auditor for the “Joint Review” | “Survey” (Audit)
8
• ANSI American National Standards Institute
• API American Petroleum Institute
• ASME American Society of Mechanical Engineers
• ASNT American Society for Nondestructive Testing
• ASTM American Society for Testing and Materials
• AWS American Welding Society
• NACE National Association of Corrosion Engineers
• NB National Board of Boiler and Pressure Vessel Inspectors
9
AGENDA
 INTRODUCTION
 QUALITY SYSTEM
10
EVERY AIA OPERATES IN COMPLAINCE WITH ITS QUALITY SYSTEM AUDITED BY
ASME AND NATIONAL BOARD DEFINING:
 Structure and Roles within the Organization
 Relationship with Clients
 Training and Qualification of Inspectors
 Duties of the Inspectors and Supervisors
 Auditing of Inspectors and Supervisors
 Continuing Education
 Audits / Joint Reviews / Surveys
 Monitoring of Client’s Quality System
 Independence/ Impartiality & Confidentiality

11
AGENDA
 INTRODUCTION
 QUALITY SYSTEM
12
 Certification, some of the activities:
 Assistance in establishing a Quality Program at the Certificate Holder,
accepts QA Manual
 Attending the (re-) certification audit every 3 years
 Assuring that Quality Program is properly implemented (Monitoring)
 Inspection, some of the activities:
 Reviewing and accepting Inspection Plans
 Reviewing / Verifying Design Drawings and Calculations
 Verifying Material Identification and Certification
 Reviewing Welding Procedures and Welders‘ Qualifications
 Reviewing NDE Procedures and Qualification of Personnel
 Performing visual internal and external inspections
 Witnessing Pressure Tests and Proof Tests
 Signing Data Reports and verifying Nameplates
13
AGENDA
 INTRODUCTION
 ROLE OF THE AIA
 QUALITY SYSTEM
14
WHAT CAN GO WRONG?
INITIAL SITUATION
During a re-certification audit the ASME Auditor finds out that pressure
vessels delivered to the user and inspected by the AI are constructed of
material not permitted by the ASME Code.
Audit Result: failed + further investigation required!
NEXT STEPS
 Investigation with the Manufacturer of all previous jobs  systematic problem?
Potential danger to life and property? Root Cause?
 Notification of Owner/User and removal of Nameplates from the vessels
 Investigation by the AIS of the Inspector’s Performance (why has he overseen?)
 Re-Review of the Company required
15
15
INVESTIGATION RESULTS:
 5 Pressure Vessels have been evaluated as non-conforming which resulted in

the removal of Nameplates
 No Periodic Audits performed since last Joint Review
 No performance evaluation of the AI performed
 No monitoring of the Quality Control System performed
 Poor Code knowledge of the Company Staff
 Continuous violations of the Quality Control System e.g. one single
inspection visit per vessel, missing internal inspections, blank inspection
points on the Inspection and Test Plan, missing entries in the AI Diary…
16
INVESTIGATION RESULTS:
 Importance of QC System Monitoring activities

 Periodic audits by the AIS are a necessity
 Performance Evaluation of the AI shall be conducted annually by the
assigned AIS
 Importance of continuing education of the AI
 Importance of continuous education of the Certificate Holder Team
 Increasing awareness of all Stakeholders!
 Never look for shortcuts!
17
WHAT CAN GO WRONG?
Manufacturer‘s Data Report statement:
The Inspector is considered to be an “Expert“ in pressure equipment.

As such, he/she and his/her AIA may come under scrutiny,
investigation, and subject to suspension or withdrawal of thier ASME
Accreditation.
18
AGENDA
 INTRODUCTION
 ROLE OF THE AIA
 QUALITY SYSTEM
19
Why is the ASME Code successful on a global scale?
 Due to its high recognition it opens doors to the new markets
 Equal rules for all Stakeholders regardless of their location:
 Certificate Holders
 Inspection Agencies (AIAs)
 ASME Auditors
 Equality in the Inspection Process
 Universal Conformity Assessment Process
 High Transparency
 Open for feedback and improvements through Committee Work!
20
20
And last but not least…

1. EMBRACE THE CONFORMITY ASSESSMENT PROCESS
2. DEMONSTRATE FULL COMMITMENT
3. MAKE A DIFFERENCE
4. EXCEED EXPECTATIONS!
21
Its the Mark that Sets You Apart.
The Gold Standard
ASME And You!
22

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ASME BOILER AND

ROLE OF THE AIA

WHAT CAN GO WRONG?

CONCLUSION AND OUTLOOK

 ACCREDITATION & ROLE OF THE AIA

 WHAT CAN GO WRONG?

 CONCLUSION AND OUTLOOK

 ACCREDITATION & ROLE OF THE AIA

 WHAT CAN GO WRONG?

 CONCLUSION AND OUTLOOK

AUTHORIZED INSPECTION AGENCY

JURISDICTION INSURANCE COMPANY THIRD PARTY

NEW CONSTRUCTION | IN-SERVICE | REPAIRS AND ALTERATIONS | NUCLEAR | …

THE AIA IS CONSIDERED TO BE THE LINK BETWEEN THE CERTIFICATE

HOLDER AND ASME/NATIONAL BOARD IN THE EVERYDAY BUSINESS.

 Employs Authorized Inspectors (AI) and Supervisors (AIS)

 The AI reviews and accepts the Quality Program

 ACCREDITATION & ROLE OF THE AIA

 WHAT CAN GO WRONG?

 CONCLUSION AND OUTLOOK

 Relationship with Clients

 Training and Qualification of Inspectors

 Duties of the Inspectors and Supervisors

 Auditing of Inspectors and Supervisors

 Audits / Joint Reviews / Surveys

 Monitoring of Client’s Quality System

 Independence/ Impartiality & Confidentiality

 ACCREDITATION & ROLE OF THE AIA

 WHAT CAN GO WRONG?

 CONCLUSION AND OUTLOOK

 ROLE OF THE AIA

 WHAT CAN GO WRONG?

 CONCLUSION AND OUTLOOK

 5 Pressure Vessels have been evaluated as non-conforming which resulted in

 Importance of QC System Monitoring activities

Manufacturer‘s Data Report statement:

The Inspector is considered to be an “Expert“ in pressure equipment.

 ROLE OF THE AIA

 WHAT CAN GO WRONG?

 CONCLUSION AND OUTLOOK

And last but not least…

Its the Mark that Sets You Apart.

The Gold Standard

ASME And You!

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