Guide for Source Inspection and Quality Surveillance of Fixed Equipment PDF

Guide for Source Inspection and Quality Surveillance of Fixed Equipment Foreword This guide has been developed to provide information for source inspectors for the purpose of providing a consistent method of Supplier/Vendor (S/V) quality surveillance for the oil, petrochemical and gas industries. It is intended as a resource for individuals studying to take the API Source Inspector Certification examination. Other references contained herein will also be necessary for individuals to become familiar with in order to pass the examination and to perform satisfactorily in the source inspection job. This study guide is also intended as a draft from which an API Recommended Practice for Source Inspection could eventually be formulated and published utilizing the ANSI standardization process. iii Table of Contents 1 Scope/Purpose................................................................................................................................... 1 2 Introduction......................................................................................................................................... 2 3 References......................................................................................................................................... 2 4 Definitions, Abbreviations and Acronyms........................................................................................... 3 5 Training............................................................................................................................................ 10 5.1 General........................................................................................................................................ 10 6 Source Inspection Management Program........................................................................................ 10 7 Project Specific Source Inspection Planning Activities.................................................................... 11 7.1 General........................................................................................................................................ 11 7.2 Equipment Risk Assessment...................................................................................................... 11 7.3 Development of a Source Inspection Project Plan...................................................................... 13 7.4 Development of Inspection and Test Plans................................................................................ 13 7.5 Selection of an Inspector............................................................................................................. 13 7.6 Coordination of Inspection Events.............................................................................................. 13 7.7 Report Review............................................................................................................................. 13 8 Source Inspection Performance....................................................................................................... 14 8.1 Inspector Conduct and Safety..................................................................................................... 14 8.2 Review of Project Documents..................................................................................................... 14 8.2.1 General.................................................................................................................................... 14 8.2.2 Contractual Agreements......................................................................................................... 14 8.2.3 Engineering Design Documents.............................................................................................. 14 8.2.4 Company and Client Standards.............................................................................................. 15 8.2.5 Industry Codes and Standards................................................................................................ 15 8.2.5.1 General............................................................................................................................ 15 8.2.5.2 API Codes and Standards............................................................................................... 15 8.2.5.3 ASME Codes and Standards.......................................................................................... 16 8.2.5.4 ASNT Standards............................................................................................................. 19 8.2.5.5 AWS Standards and References.................................................................................... 19 8.2.5.6 SSPC Standards............................................................................................................. 20 8.2.6 Welding Procedures and Qualifications.................................................................................. 20 8.2.7 NDE Procedures..................................................................................................................... 20 8.2.8 Project Schedules................................................................................................................... 21 8.3 Performing the Source Inspection............................................................................................... 21 v 8.4 Source Inspection Work Process Scheduled Planning Events................................................... 21 8.4.1 General.................................................................................................................................... 21 8.4.2 Pre-purchase Meeting (Prior to Contract Placement)............................................................. 21 8.4.3 Pre-inspection Meeting (Prior to Start of Fabrication)............................................................. 21 8.5 Report Writing............................................................................................................................. 22 8.6 Nonconformance/Deviations....................................................................................................... 23 8.7 Source Inspection Project Continuous Improvement.................................................................. 23 8.8 Source Inspector Continuous Improvement................................................................................ 24 9 Examination Methods, Tools and Equipment.................................................................................. 24 9.1 General........................................................................................................................................ 24 9.2 Review and Confirmation of Materials of Construction............................................................... 24 9.3 Dimensional Inspections............................................................................................................. 25 9.4 Visual Inspections....................................................................................................................... 25 9.5 Nondestructive Examination (NDE) Techniques......................................................................... 26 9.5.1 General.................................................................................................................................... 26 9.5.2 Penetrant Testing (PT)............................................................................................................ 26 9.5.3 Magnetic Testing (MT)............................................................................................................ 26 9.5.4 Radiographic Testing (RT)...................................................................................................... 26 9.5.5 Ultrasonic Testing (UT)........................................................................................................... 26 9.5.6 Hardness Testing (HT)............................................................................................................ 26 9.5.7 Positive Material Identification (PMI)....................................................................................... 26 9.6 Destructive Testing..................................................................................................................... 26 9.7 Pressure/Leak Testing................................................................................................................ 27 9.7.1 General.................................................................................................................................... 27 9.7.2 Pressure Testing..................................................................................................................... 27 9.8 Performance/Functional Testing................................................................................................. 28 9.9 Surface Preparation/Coatings Inspections.................................................................................. 28 10 Final Acceptance.............................................................................................................................. 28 11 Manufacturing and Fabrication (M&F) Processes............................................................................ 29 11.1 General........................................................................................................................................ 29 11.2 Welding Processes and Welding Defects................................................................................... 30 11.3 Casting........................................................................................................................................ 30 11.4 Forging........................................................................................................................................ 31 11.5 Machining.................................................................................................................................... 31 11.6 Assembly..................................................................................................................................... 32 vi 11.7 Metallurgy Issues Associated with Manufacturing and Fabrication Processes.......................... 32 11.7.1 The Structure and Metals.................................................................................................... 32 11.7.2 Physical Properties of Metals.............................................................................................. 32 11.7.3 Mechanical Properties of Metals......................................................................................... 32 11.7.4 Hardness and Hardenability of Metals................................................................................ 32 11.7.5 Weldability of Metals........................................................................................................... 33 11.7.6 Preheating and Postweld Heat Treatment.......................................................................... 33 11.7.6.1 Preheating................................................................................................................... 33 11.7.6.2 Postweld Heat Treatment (PWHT).............................................................................. 33 11.7.6.3 Other Heat Treatments................................................................................................ 34 12 Pressure Vessels............................................................................................................................. 34 12.1 General........................................................................................................................................ 34 12.2 Vessel Methods of Construction................................................................................................. 34 12.3 Vessel Materials of Construction................................................................................................. 34 12.4 Vessel Internal Components....................................................................................................... 36 12.5 Vessel Design and Construction Standards............................................................................... 36 12.6 Dimensional Check of Pressure Vessels.................................................................................... 37 12.7 Heat Exchangers......................................................................................................................... 38 13 Piping............................................................................................................................................... 39 13.1 General........................................................................................................................................ 39 13.2 Valves.......................................................................................................................................... 39 13.3 Flanges........................................................................................................................................ 40 13.4 Fittings......................................................................................................................................... 42 14 Structural Components..................................................................................................................... 42 Annex A....................................................................................................................................................... 44 Annex B …………………………………………………………………………………………………………….45 Annex C ……………………………………………………………………………………………………………..51 vii Guide for Source Inspection and Quality Surveillance of Fixed Equipment 1 Scope/Purpose This study guide covers the process of providing quality surveillance of materials, equipment and fabrications being supplied for use in the oil, petrochemical and gas Industry, including upstream, midstream and downstream segments. This guide may be used as the basis for providing a systematic approach to risk-based source inspection in order to provide confidence that materials and equipment being purchased meet the minimum requirements as specified in the project documents and contractual agreements. The activities outlined in this study guide do not intend to replace the manufacturer’s/fabricator’s own quality system, but rather are meant to guide source inspectors acting on behalf of purchasers to determine whether manufacturers/fabricators own quality systems have functioned appropriately, such that the purchased equipment and materials will meet contractual agreements. This study guide focuses primarily on pressure containing and structural equipment (fixed equipment) including: vessels, columns/towers, heat exchangers, piping, valves, pressure relief devices, tubulars, and associated structural fabrications. This document assumes that suppliers/vendors (S/V) have been pre-qualified by a systematic quality review process of their facilities and quality process to determine if the facility has the ability to meet the requirements of the contractual agreements. That process generally leads to a list of pre-approved S/V’s deemed acceptable to the supply chain management of the purchaser and capable of meeting the requirements of the contract prior to it being placed. S/V’s on such a list will normally have an acceptable quality process already in place that meets the requirements of the contract. The purpose of source inspection in such a case is simply to verify that the S/V quality process is working as it should and to verify that certain vital steps in the inspection and test plan (ITP) have been satisfactorily accomplished prior to fabrication completion and/or shipping. The primary purpose of this study guide is to assist candidates intending to take the API source inspection examination to become certified source inspectors. The study guide outlines the fundamentals of source inspection and may be useful to all personnel conducting such activities to perform their jobs in a competent and ethical manner. For more information on how to apply for Source Inspection Certification, please visit API website at http://www.api.org/certification-programs/icp/programs and follow the work process shown in chart below. Source API website Certification ICP Inspector (www.api.org) select Programs Programs Certification Program The Source Inspector Examination contains 100 multiple-choice questions targeting core knowledge necessary to perform source inspection of fixed equipment. The focus of the exam is on source inspection issues and activities rather than design or engineering knowledge contained in the reference standards. The exam is closed book and administered via computer based testing (CBT). The bulk of the questions address mechanical inspection/surveillance which are typically known by persons who have experience working as source inspectors or persons intending to work as source inspectors who have studied the material in this study guide and the associated reference materials. 1 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT 2 Introduction Like most business processes, the Source Inspection work process follows the Plan–Do–Check–Act circular process first popularized in the 1950’s by Edward Deming. The “Planning” part of source inspection is covered in Sections 6 and 7 of this study guide and involves the source inspection management systems, source inspection project plan and the inspection and test plan (ITP). The “Doing” part is covered in Sections 8 and 9 and involves implementing the ITP, participating in scheduled source inspection work process events, filing nonconformance reports and source inspection report writing. The “Checking” part, covered in Section 8.7, involves looking back at all the source inspection activities that occurred in the Planning and Doing segments to see what went well and what should be improved based on the results of that look-back. And finally the “Act” part (sometimes called the “Adjust” part) covered in Section 8.8 involves implementing all the needed improvements in the “Planning and Doing” process before they are implemented on the next source inspection project. 3 References The most recent editions of these codes, standards or other recommended practices are referenced in this study guide and are the documents from which the SI exam has been developed. API (American Petroleum Institute) RP 572 Inspection Practices for Pressure Vessels RP 577 Welding Inspection and Metallurgy RP 578 Material Verification Program for New and Existing Alloy Piping Systems Std 598 Valve Inspection and Testing ASME (ASME International; formerly known as American Society of Mechanical Engineers) Boiler and Pressure Vessel Code (BPVC)  Section II—Materials, Parts A, B, C, and D  Section V—Nondestructive Examination  Section VIII—Rules for Construction of Pressure Vessels, Divisions 1 and 2  Section IX—Welding and Brazing Qualifications B31.3 Process Piping B16.5 Pipe Flanges and Flanged Fittings ASNT (American Society of Nondestructive Testing) SNT-TC-1A Personnel Qualification and Certification in Nondestructive Testing AWS (American Welding Society) D1.1 Structural Welding Code Welding Inspector Handbook 2 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT Society for Protective Coatings (SSPC) SSPC-PA 2 Procedure for Determining Conformance to Dry Coating Thickness Requirements SSPC Surface Preparation Guide 4 Definitions, Abbreviations and Acronyms For the purposes of this study guide, the following definitions, abbreviations and acronyms apply. Additional definitions which the source inspector needs to know and understand are included in the following documents:  API RP 577, Section 3  API RP 578, Section 3  ASME B31.3, 300.2  ASME BPVC Section VIII, Division 1, Appendix 3  ASME BPVC Section V, Subsection A, Article 1, Appendix 1  ASME BPVC Section V, Subsection B, Article 30, SE-1316  AWS D1.1, Annex K AARH Arithmetic Average Roughness Height (a measure of surface roughness) Annealing Heat Treatment Heating an object to and then holding it at a specified temperature and then cooling at a suitable rate for such purposes as: reducing hardness, improving machinability, facilitating cold working, producing a desired microstructure, or obtaining desired mechanical properties. ANSI American National Standards Institute API American Petroleum Institute ASME ASME International (formerly known as the American Society of Mechanical Engineers) ASNT American Society of Nondestructive Testing ASTM ASTM International (formerly known as the American Society for Testing and Materials) BOK Body of Knowledge (in this case the BOK for the Source Inspector examination) BPVC Boiler and Pressure Vessel Code (published by ASME) C The chemical symbol for carbon which may appear on a MTR. Certification Documented and signed testimony of qualification. Certification generally refers to the confirmation of certain, specified characteristics of a product or confirmation of a person meeting requirements for a specific qualification. 3 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT Calibration A comparison between measurements—one of known magnitude or correctness (the standard) compared to the measuring device under test in order to establish the accuracy of a measuring device. Cladding A metal integrally bonded onto another metal (e.g. plate), under high pressure and temperature whose properties are better suited to resist damage from the process fluids than the underlying base metal. Cold Working Plastic deformation (forming, rolling, forging, etc.) of metals below the recrystallization temperature of the metal. Cr The chemical symbol for chromium which may appear on an MTR. Critical Equipment Equipment that has been risk assessed and determined that if it were to fail in service, it would have an unacceptable impact on process safety, environment, or business needs and therefore deserves a higher level of source inspection attention to make sure the equipment being delivered is exactly as specified. Cu The chemical symbol for copper which may appear on a MTR. Destructive Testing Various tests that are performed on metals for the purposes of determining mechanical properties and which involve testing (usually breaking) of sample coupons. Examples of such tests include tensile testing, bend testing and Charpy impact testing. A destructive testing work process involves extracting samples/coupons from components and testing for characteristics that cannot otherwise be determined by nondestructive testing. The work process involves breaking and/or testing coupons/samples to failure, thus usually rendering the component from which the samples were extracted unfit for continued service. Deviation A departure from requirements in the contractual agreements or its referenced PO, engineering design, specified codes, standards or procedures. DFT Dry Film Thickness (of paint and coatings) which is measured by a DFT gauge. Elevation The height of any point on a vessel as shown on a vessel drawing e.g. nozzle, manway, or longitudinal weld as measured from a base plate or other reference line such as the bottom head tangent line. Employer The corporate, public or private entity which employs personnel for wages, salaries, fees or other considerations e.g. the employer of the source inspector. Engineered Equipment Equipment that is custom designed and engineered by the client and/or EPC to perform a project-specific function. Engineered equipment will typically require more source inspection than non-engineered equipment. EPC Engineering/Design/Construction contract company. Examiner A person who performs specified nondestructive examination (NDE) on components and evaluates the results to the applicable acceptance criteria to assess the quality of the component. Typically NDE examiners 4 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT (sometimes called NDE technicians) are qualified to ASNT NDE personnel qualification practices e.g. SNT-TC-IA or CP-189. Fe The chemical symbol for iron which may appear on an MTR. Ferrous Materials Alloys that are iron based, including stainless steels. HAZ Heat Affected Zone, which is the base metal area next to the weld that has had its metal structure affected by the heat of welding. Hot Working Plastic deformation (forming, rolling, forging, etc.) of metals at a temperature above the metal recrystallization temperature. ICP Individual Certification Program (of the API) under which this source inspector certification program is administered. Inspection The evaluation of a component or equipment for compliance with a specific product specification, code, drawing and/or standard specified in the contractual requirements, which may include the measuring, testing or gauging of one or more characteristics specified for the product to determine conformity. Inspection Agency An entity employed to provide competent, qualified and certified source inspection personnel for the purpose of performing source inspection. For example, and inspection agency can be an EPC company, an owner-user, or an inspection service company. Inspection Coordinator Individual who is responsible for the development of the source inspection strategy, coordination of the source inspection visits, and implementation of the source inspection activities on a project. Inspection Waiver Permission to proceed with production/shipment without having a purchaser source inspection representative present for a specific activity. ITP Inspection and Test Plan—A detailed plan (checklist) for the source inspection activities which will guide the source inspector in his/her quality assurance activities at the S/V site with reference to applicable technical information, acceptance criteria and reporting information. The supplier/vendor should also have their own ITP to guide their fabrication personnel and quality assurance personnel in the necessary quality steps and procedures. Lamination A type of discontinuity with separation or weakness generally aligned parallel to the worked surface of a plate material. In a forging it can rise to the surface or occur internally; it is generally associated with forging at too low of a temperature or in plate material may be caused by the tramp elements that have congregated in the center of the plate during rolling. Levelness The position of a surface of a component or structure that is horizontal (within tolerances) with the base plate and at 90 degrees to the vertical plumb line. Nozzle and attachment levelness tolerances are not addressed in ASME BPVC Section VIII, Division 1; however, in the pressure vessel handbook, a ½˚ tolerance is permissible. For levelness checking of a nozzle on a vessel, a level gauge is used. If the bubble is in the middle of the designated lines, the nozzle is level. A level gauge 5 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT would be used for verification and measurement that the angle of a hillside (tangential) nozzle is properly installed relative to the vessel centerline. MAWP Maximum Allowable Working Pressure—The maximum gauge pressure at the top of a pressure vessel allowed by code calculations for a designated temperature. M/F Manufacturer/Fabricator—An organization that has been contracted for and has the primary responsibility for producing the product/equipment items e.g. vessels, exchangers, piping, valves, etc. in conformance with contractual documents. M&F Manufacturing and Fabrication—Refers to the various material working processes that are commonly used to produce a product such as welding, joining, heat treatment, casting, forming, forging, bending, machining, assembly, etc. Mg The chemical symbol for magnesium which may appear on an MTR. Mn The chemical symbol for manganese which may appear on an MTR. Mo The chemical symbol for molybdenum which may appear on an MTR. MSS Manufacturers Standardization Society MT Magnetic Particle Testing (Examination) MTR Material Test Report or Mill Test Report—A document that certifies that a metal/material product is in conformance with the requirements (e.g. chemical and mechanical properties) of a specified industry standard— such as ASTM, ASME, etc. NB National Board Nb The chemical symbol for niobium which may appear on an MTR. NCR Nonconformance Report—A report filled out by the SI detailing an issue that has been discovered to be not in accordance with project contractual agreements such as the PO, engineering design, specified codes, standards or procedures. NDE Map A drawing which identifies specific locations where NDE has been conducted on a product/component. NDE/NDT Nondestructive Examination (the preferred terminology)/Nondestructive Testing (the outdated terminology). A quality process that involves the examination, testing and evaluation of materials, components or assemblies without affecting its functionality e.g. VT, PT, MT, UT, RT. NDT Nondestructive Testing—Means the same as NDE, which is now the preferred terminology. Ni The chemical symbol for nickel which may appear on an MTR. Nonconformance A departure/deviation from project contractual agreements such as the PO, engineering design, specified codes, standards or procedures. 6 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT Non-engineered Equipment Equipment that is designed and fabricated by S/V’s, which includes off- the-shelf items such as valves, fittings, as well as some skid units, instruments, pumps and electrical gear. Such equipment is usually purchased by catalog model numbers, etc. Non-engineered equipment will typically require less source inspection than engineered equipment. Non-ferrous Materials Alloys that are not iron based e.g. nickel and copper based alloys. Normalizing Heat Treatment A heat treating process in which a ferrous material or alloy is heated to a specified temperature above the transformation range of the metal and subsequently cooled in still air at room temperature. Typically normalizing heat treatments will refine the grain size and improve the impact properties of steels. NPS Nominal Pipe Size—A standard for designating pipe sizes (inches) and associated wall thickness (schedule) e.g. the nominal pipe size for a four inch pipe is normally shown as NPS 4. Orientation The orientation of a nozzle or attachment is the number of degrees off from a vertical centerline (a circumferential degree line) of the attachment or nozzle on the plan view of a vessel. For example, orientation of a nozzle or attachment can be checked with a protractor or smart level. Out-of-Roundness A deviation from perfect roundness e.g. ovality in a vessel circumference. ASME BPVC Section VIII, Division 1, UG 80 deals with out of roundness of a vessel shell. The maximum permitted ovality tolerance (Dmax – Dmin) shall not exceed 1% of the nominal diameter of the vessel. P The chemical symbol for phosphorus which may appear on an MTR. PQR Procedure Qualification Record per ASME BPVC Section IX, QW 200.2 Pressure Vessel A container designed to withstand a specified amount of internal or external pressure generally above 15 psig. This definition includes heat exchangers, air-coolers, columns, towers, unfired steam generators (boilers) and other vapor generating vessels. Procedure A document detailing how a work process is to be performed e.g. a welding procedure. Projection A nozzle or attachment projection is the length from the nozzle or the attachment face to the vessel shell centerline. Protractor An instrument for measuring angles, typically in the form of a flat semicircle marked with degrees along the curved edge. PRV/PRD/PSV Pressure Relief Valve/Pressure Relief Device/Pressure Safety Valve PT Penetrant Testing (Examination) QA Quality Assurance—A proactive quality process that aims to prevent defects and refers to a program of planned, systematic and preventative activities implemented in a quality system that is intended to provide a degree of confidence that a product will consistently meet specifications. 7 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT It includes the systematic measurement, comparison with a standard, monitoring of processes and an associated feedback loop that is intended to avoid deviations from specification. QC Quality Control—The specific steps in a QA process that aim to find potential defects in a product before it is released for delivery e.g. VT, PT, RT, UT, dimensional verification, etc. The QA process will specify the particular QC steps necessary during manufacture/fabrication of a product. Qualification Demonstrated skill, demonstrated knowledge, documented training, and documented experience required for personnel to perform the duties of a specific job e.g. a certified source inspector. Quality Surveillance The process of monitoring or observing the inspection activities associated with materials, equipment and/or components for adherence to the specific procedure, product specification, code or standard specified in the contractual requirements. For the purposes of this guide, quality surveillance and source inspection mean the same thing (see definition for source inspection). Quenching Rapid cooling of a heated metal for the purpose of affecting mechanical and/or physical properties. RMS Root Mean Square—A measure of surface finish on flanges. RT Radiographic Testing (Examination) Rust Bloom The term used to describe surface discoloration that occurs on the surface of steel that has been previously blasted e.g. near-white or white metal in preparation for coating. When rust bloom is found, the surface should generally be re-cleaned before coating using the same blast cleaning process. S The chemical symbol for sulfur which may appear on an MTR. SDO Standards Development Organization e.g. API, ASME, ASTM, NACE, MSS, TEMA, etc. SI Source Inspector or Source Inspection SME Subject Matter Expert Solution Anneal Heating an alloy to a specified temperature, holding at the temperature Heat Treatment long enough for one or more elements to reenter into solid solution and then cooling rapidly enough to hold those elements in solid solution. SOR Supplier Observation Reports—Documents filled out by the SI indicating concerns or other factual descriptions of what was noticed during the course of product surveillance, but not necessarily issues that may be considered defects or requiring NCR’s. Source Inspection The process of providing quality surveillance of materials, fabrications and equipment being supplied by supplier/vendor (S/V) or manufacturer/fabricator (M/F) for use in the oil, petrochemical and gas industry, including upstream, midstream and downstream segments. 8 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT Source inspection largely consists of verifying that the S/V’s own quality assurance process is functioning as it should to produce quality products that meet the contractual agreements. Source Inspector Individual responsible for performing the actual source inspection activities at the S/V facilities in accordance with the applicable inspection and test plan (ITP). Specification A document that contains the requirements for the M&F of specific types of equipment and components. SSPC Society for Protective Coatings S/V Supplier/Vendor—The entity which is responsible for the actual manufacturing and fabrication (M&F) of the material, equipment or components and which is responsible for meeting the contractual requirements. TEMA Tubular Exchanger Manufacturers Association Tempering Reheating a hardened metal to a temperature below the transformation range to improve toughness. Ti The chemical symbol for titanium which may appear on an MTR. Tolerance Engineering tolerances refer to the limit (or limits) of specified dimensions, physical properties or other measured values of a component. Training An organized program developed to impart the skills and knowledge necessary for qualification as a source inspector. UT Ultrasonic Testing (Examination), generally for finding component flaws or measuring thicknesses. VT Visual Testing (Examination) Weld Mismatch The deviation from perfect alignment between two pieces of metal welded together. ASME BPVC Section VIII, Division 1 specified tolerances for weld mismatch are in UW-33. It is important for the SI to measure weld mismatch with a welding gauge and to know that the limit for weld mismatch is stringent for a category A weld (Longitudinal joint and circumferential shell to hemispherical head). The concept behind this is that the longitudinal joint bears double the amount of stress, and inspectors should precisely check these joints. Weld Reinforcement The height of the weld cap. The longitudinal joint weld reinforcement limit is more stringent than that for circumferential joints. This is because longitudinal joint bears double stress, and it is required that the stress concentration be minimized. Maximum weld reinforcement is specified in ASME BPVC Section VIII, Division 1. WPQ Welding Performance Qualification Record per ASME BPVC Section IX, QW 301.4 WPS Welding Procedure Specification per ASME BPVC Section IX, QW 200.1 9 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT Websites Useful to the Source Inspector API American Petroleum Institute http://www.api.org ASM American Society for Metals http://www.asminternational.org/portal/site/www/ ASME Formerly known as American Society for http://www.asme.org International Mechanical Engineers ASNT American Society for Nondestructive Testing http://www.asnt.org ASTM Formerly known as American Society for Testing http://www.astm.org International and Materials AWS American Welding Society http://www.aws.org ISA Instrument Society of America http://www.isa.org ISO International Organization for Standardization http://www.iso.org/iso/home.html MSS Manufacturers Standardization Society http://mss-hq.org/Store/index.cfm NDT Resource Nondestructive Testing Resource Center http://www.ndt-ed.org Center NEC National Electric Code http://www.nfpa.org SSPC The Society for Protective Coatings http://www.sspc.org/ Worldsteel Worldsteel Association http://www.steeluniversity.org 5 Training 5.1 General Training and Certification for vendor/source inspection is unique to each organization. This study guide and supporting examination is designed to provide a minimum competency for a Mechanical Fixed Equipment Inspector. 6 Source Inspection Management Program 6.1 Employers or inspection agencies tasked with the responsibility of performing source inspection coordination and/or source inspection activities should develop a management program in order to provide the individuals performing the specific source inspection functions the necessary information to accomplish their duties. These source inspection management programs are generic in nature in that they provide requirements and guidance of source inspection activities on all types of projects that will require source inspection. See Section 7 for the types of source inspection plans that are needed for each specific project. 6.2 Source inspection management programs should cover most of the generic activities identified in this study guide but also include company specific information like:  What activities need to be accomplished  Who is responsible to accomplish each of the activities i.e. personnel titles  The training and competencies required for source inspectors 10 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT  When or how frequently each of the activities will be accomplished  How each of the activities will be accomplished i.e. specific work procedures  Application of acceptance criteria and industry standards 6.3 These management programs may reference many other company specific source inspection procedures, practices and policies with more details that will be needed for specific types of source inspection activities, for example:  How to prepare an overall Source Inspection Plan for an entire project and an Inspection and Test Plan (ITP) for each equipment item  How to conduct an equipment risk assessment in order to determine the level of source inspection activities that will be required  Guidance on the criteria to use for selecting source inspectors to match their skills and training with different types of equipment with different risk levels  Guidance on scheduling and conducting significant source inspection events like the pre- inspection (fabrication kick-off) meeting, the S/V quality coordination meeting, final acceptance testing, etc.  Guidance on SI safety and professional conduct at S/V shops  How to review welding procedures and welder qualification documents  How to review inspection/examination records of the S/V  What inspections should be repeated by the source inspector to verify the results of S/V examinations and tests  How to handle change requests  How to handle deviations and nonconformances  How to write source inspection reports with specific forms to be filled out  What specific steps to take before approving product acceptance, etc.  Interfacing with the jurisdictional authorized inspector 7 Project Specific Source Inspection Planning Activities 7.1 General From the Source Inspection Management Program documents, a Project Specific Inspection Plan should be developed by the inspection coordinator addressing the following activities. 7.2 Equipment Risk Assessment 7.2.1 Effective source inspection for each project begins with a risk-based assessment of the materials and/or equipment to be procured for the project. These risk based assessments are performed to identify the level of effort for source inspection activities during the M&F phase of a project at the S/V facility. Equipment identified as critical equipment will receive more intensive source inspection; while equipment identified as less critical will receive less intensive source inspection and thereby rely more on the S/V quality program. 11 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT 7.2.2 Typically these risk based assessments occur early in the design stages of a project and identify the equipment risks into the following types of categories.  Safety or environmental issues that could occur because of equipment failure to meet specification or failure while in service  Equipment complexity; the more complex the equipment, the higher level of source inspection may be required  Knowledge of S/V history and capabilities to deliver equipment meeting specifications on time i.e. newer S/V with relatively unknown history or capabilities may need closer scrutiny  Potential schedule impact from delivery delays or project construction impact from issues discovered after delivery i.e. long delivery items may require higher level of source inspection  Equipment design maturity level i.e. prototype, unusual or one-of-a-kind type equipment may require higher level of source inspection  Lessons learned from previous projects i.e. has the S/V had problems in the past meeting specifications on time?  Potential economic impact on the project of S/V failure to deliver equipment meeting specifications on time 7.2.3 The risked based assessment team typically consists of individuals from various company groups including: quality, engineering, procurement, construction, project management and source inspection. Input from those who will own and operate the equipment i.e. the client is also beneficial. This collaboration provides input from all parties that may be affected if material or equipment is delivered and installed with unacceptable levels of quality. 7.2.4 The risk assessment process takes into account the probability of failure (POF) of equipment to perform as specified, as well as the potential consequences of failure (COF) to perform in service e.g. safety, environmental and business impact. The ultimate risk associated for each equipment item is then a combination of the POF and COF assessments. 7.2.5 The risk assessment provides the information necessary for the inspection coordinator to specify a level of effort for source inspection of each S/V facilities commensurate with the agreed upon risk level. Typical levels of source inspection effort at the S/V facility commensurate with risk levels may include:  No Source Inspection (lowest risk for equipment failure to meet specifications; rely solely on S/V quality).  Final Source Inspection (final acceptance) only just prior to shipment (lower to medium risk material or equipment; rely primarily on S/V quality with minimum source inspection).  Intermediate Source Inspection level (medium to medium high risk equipment; mixture of reliance on S/V quality with some source inspection activities at the more critical hold points). The number of shop visits may go up or down based on the performance level of the S/V.  Advanced Source Inspection level (higher risk equipment; significant amount of source inspection e.g. weekly to provide higher level of quality assurance). The number of shop visits may go up or down based on the performance level of the S/V. 12 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT  Resident Source Inspection level [highest risk equipment; full time shop inspector(s) assigned, possibly even on all shifts]. 7.3 Development of a Source Inspection Project Plan 7.3.1 A source inspection plan should be developed for projects that have materials or equipment which will be inspected for compliance to the contractual agreements, project specifications, drawings, codes and standards. 7.3.2 The project plan should consist of the project details, list of equipment to be inspected and the project specific details on how the inspection activities will be performed to meet the expected level of quality performance from the S/V and/or the equipment. 7.3.3 The plan should also be based upon the level of risk determined from the risk based assessment performed in the design stage of the project and the appropriate level of effort needed for the surveillance of the S/V that is commensurate with the risk level. 7.4 Development of Inspection and Test Plans 7.4.1 A detailed inspection and test plan (ITP) for each type of equipment to be inspected should be provided. This ITP should be specific to the type of equipment to be inspected, the associated risk level for each piece of equipment and should identify all the inspection activities necessary to be performed by the assigned source inspector. It should also include the appropriate acceptance criteria or reference theretofore. 7.4.2 The source inspector should follow the ITP and ensure that the fabrication and S/V quality activities performed meet the requirements specified in the contractual agreement, referenced project specifications, drawings, applicable codes and/or standards. 7.5 Selection of an Inspector 7.5.1 The source inspection coordinator should review the details of the project plan, location of the S/V and duration of the work and select the appropriate source inspector(s) for the assignment. 7.5.2 The source inspector(s) selected should have the necessary experience, training and qualifications to perform the inspection or surveillance activities referenced in the ITP. 7.6 Coordination of Inspection Events Dates for source inspection scheduled work process events such as the pre-inspection meeting (fabrication kickoff), key inspection events (factory acceptance, performance testing and final inspection) and anticipated shipping date should be identified in advance to allow coordination with other project members involved in the activity. 7.7 Report Review Source inspection reports are important deliverables from the SI to the project team or client. The amount and type should be specified in the ITP. Each inspection report should be reviewed for content, completeness and technical clarity prior to distribution. 13 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT 8 Source Inspection Performance 8.1 Inspector Conduct and Safety 8.1.1 Individuals tasked with the responsibility of performing source inspection activities should conduct themselves professionally while visiting an S/V facility as a representative of their employer and/or purchaser. If any conflict should arise during the inspection activity, the source inspector should notify their supervisor for resolution as soon as possible. It is important that the SI not be confrontational or argumentative regardless of the importance of the issue at hand; but rather simply indicate in objective terms how the SI intends to proceed to resolve the issue. 8.1.2 Safety of the individual performing the source inspection activity is one of the most important aspects of their work. A safety program should be established which identifies specific safety hazards associated with the job. Source Inspectors should be adequately trained and knowledgeable in these safety programs in order to minimize the possibility of injury. The safety program should include:  Potential travel safety issues specific to the job  Potential shop safety issues and hazard recognition  How to handle the observation of unsafe acts in the shop 8.1.3 The SI should observe the safety procedures and policies of the S/V while on their premises or if more stringent, their own company safety requirements. 8.2 Review of Project Documents 8.2.1 General 8.2.1.1 Typical project documents include but are not limited to contractual agreements (purchase orders and/or subcontracts), source ITP, project specifications, engineering or fabrication drawings, applicable codes, references or standards. 8.2.1.2 The source inspectors should familiarize themselves with all project documents and ensure that they have access to the specific edition/version of those documents specified in the contractual agreement at all times during their inspection visits. Prior to commencing the quality surveillance specified in the ITP, the source inspector should confirm that the S/V has the most current documents, drawings, etc. specified in the engineering design. Later editions of industry codes and standards do not apply if the engineering design has specified an earlier edition of a specific standard. Additionally, the source inspector should confirm that that all project documents have been reviewed/approved by the purchaser. 8.2.2 Contractual Agreements The contractual agreements including the purchase order, all specified engineering design documents, specified company standards, and specified industry standards form the basis for the requirements for source inspection of the purchased products. 8.2.3 Engineering Design Documents For engineered equipment, the SI needs to be familiar with the engineering design documents and drawings that are vital to quality of the purchased products. 14 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT 8.2.4 Company and Client Standards The SI needs to be familiar with all company and client standards that are specified in the contractual agreements. These standards typically augment or supplement industry standards for issues not sufficiently well covered in industry standards. All mandatory requirements i.e. “shall/must” statements, included in the company specifications must be met or become an issue for an NCR and handled in accordance with standard purchaser management NCR systems requirements. Other issues contained in the specified standards such as those suggested or recommended i.e. “should” statements which are expectations of the S/V, but not necessarily requirements may become an issue to be reported in Supplier Observation Reports (SOR’s) and handled in accordance with standard purchaser management systems. Company and client standards may cover engineered and non-engineered equipment. 8.2.5 Industry Codes and Standards 8.2.5.1 General The SI needs to be familiar with all industry codes and standards that are specified in the contractual agreements to the extent that requirements and expectations in those codes and standards are part of the contractual agreements and therefore part of the source inspector duties. Those industry codes and standards are typically published by recognized industry standards development organizations (SDO’s), such as those in the following subsections. 8.2.5.2 API Codes and Standards There are a wide variety of API Codes and Standards that may be included in the contractual agreements to specify and control the quality of products for the energy industry. A few of those that the SI should be familiar with and apply when specified are shown in the following subsections; but this list is not all inclusive. Others that are specified in the contractual agreements may be equally important to the quality of the delivered product. The information contained in the following industry standards is generic to a wide variety of products and therefore should be general knowledge to the experienced SI.  API RP 572, Inspection Practices for Pressure Vessels. This RP includes a description of the various types of pressure vessels and the materials and standards for their fabrication. The source inspector should be familiar with Sections 3 and 4 of this RP.  API RP 577, Welding Inspection and Metallurgy. This RP provides guidance for the source inspector on welding fabrication inspection. Issues covered include: welding processes, procedures, welder qualifications, metallurgical affects from welding, inspection techniques, welding terminology and symbols, how to review a welding procedure, and a guide to common filler metals. The source inspector should be thoroughly familiar with the contents of Sections 3 to 10 of this RP.  API RP 578, Material Verification Program for New and Existing Alloy Piping Systems. The purpose of this RP is to provide guidelines for a material and quality system to verify that the nominal composition of piping alloy components is consistent with the material specifications. The primary topics covered include: material verification test methods, evaluation of PMI test results, marking and record keeping. The source inspector should be thoroughly familiar with the contents of this RP except for the sections that focus on material verification for existing systems that are already in operation in a plant.  API Std 598, Valve Inspection and Testing. This standard covers the inspection, examination, and pressure test medium and requirements for various kinds of valves utilized in the energy 15 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT industry. The various kinds of tests and examinations specified in this standard include: shell test, backseat test, low-pressure closure test, high-pressure closure test and visual examination of castings. The SI should look to the appropriate purchasing document and spec sheets for the required characteristics of each valve, such as type, size, materials, rating, trim, etc. The SI should be thoroughly familiar with the contents of API Std 598 whenever specified in contractual agreements. API Std 598 is mostly applied to standard metallic valves (butterfly, gate, globe, ball, etc.) used in ASME B31.1 or B31.3 applications. 8.2.5.3 ASME Codes and Standards There are a wide variety of ASME Codes and Standards that may be included in the contractual agreements to specify equipment fabrication methods and control the quality of products for the energy industry. A few of those that the SI should be familiar with and apply when specified are shown in the following subsections; but this list is not all inclusive. Occasionally there may be other sections of the ASME BPVC that will be specified on different projects in which the SI will be involved.  ASME BPVC Section II—Materials. This section of the BPVC is divided into four parts covering materials for the construction of piping and pressure vessels. o Part A—Ferrous Material Specifications. This part contains the individual specifications for ferrous materials that are allowed in the construction of pressure vessels and piping designed to the ASME BPVC. Part A covers all forms of ferrous material products like wrought, castings, forgings, plates, piping valves, bolting, etc. The issues addressed by each ferrous material specification vary based on the characteristics of the material and final use for which it is intended. Some examples of issues covered include: ordering information, heat treatment, chemical composition, mechanical properties, tests and examinations, dimensions and tolerances and the steel making practice. The source inspector should be familiar with the contents of whichever materials are specified in the contractual agreements. The only three specifications covered in ASME BPVC Section II, Part A that the SI need to be familiar with for purposes of the examination are: — SA-20, General Requirements for Steel Plates — SA-370, Test Methods and Definitions of Mechanical Testing Steel Products — SA-6, Thickness Tolerances for Steel Plate o Part B—Nonferrous Material Specifications. This part contains the individual specifications for nonferrous materials that are allowed in the construction of pressure vessels and piping designed to the ASME BPVC. Part B covers all forms of nonferrous material products like wrought, castings, forgings, plates, piping valves, bolting, etc. allowed for in the construction of ASME BPVC equipment. The types of nonferrous material alloys included in Part B are: aluminum, copper, nickel, titanium, and zirconium. The issues addressed by each nonferrous material specification vary based on the characteristics of the material and final use for which it is intended. Some examples of issues covered include: ordering information, heat treatment, chemical composition, mechanical properties, tests and examinations, dimensions and tolerances and the steel making practice. The source inspector should be familiar with the contents of whichever materials are specified in the contractual agreements. However there will be no specific questions on the core examination out of Part B, but the SI should be familiar with what the standard covers. 16 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT o Part C—Specifications for Welding Rods, Electrodes and Filler Metals. Part C covers material specifications for the manufacture, acceptability, chemical composition, mechanical usability, surfacing, testing, operating characteristics and intended uses of welding rods, electrodes and filler materials. The material specifications are designated by SFA numbers derived from AWS specifications. The source inspector would typically reference these specifications for whichever welding materials are specified in the contractual agreements to ensure that the right materials are being used in fabrication. However there will be no specific questions on the core examination out of Part C, but the SI should be familiar with what the standard covers. o Part D—Materials Properties. Part D provides tables for design stress values, tensile strength, yield strength, and other important chemical and physical properties for all the material specifications contained in Parts A and B. This section is primarily intended for designers of ASME BPVC equipment. As such, there will be no specific questions on the core examinations out of Part D, but the SI should be familiar with what the standard covers.  ASME BPVC Section V—Nondestructive Examination. This section of the BPVC contains requirements and methods for NDE techniques that are specified by other sections of the ASME BPVC and/or contractual agreements. Most of the common methods of NDE are covered in Section V including RT, UT, MT, PT, VT, and LT. Appendix A of Section V presents a listing of common imperfections and damage mechanisms and the NDE methods that are generally capable of detecting them. Section V also provides guidance on methods of evaluating NDE results. The source inspector should be thoroughly familiar with the contents of Section V for whichever NDE method is specified in contractual agreements and/or ITP. For the purposes of SI examination, some of the content covered in ASME BPVC Section V that applicants should focus on include: o All definitions in Subsection A, Article 1, Appendix 1 and Subsection B, Article 30, SE-1316 o Article 1 on General Requirements for NDE o Article 4 on Ultrasonic Examination Methods of Welds o Article 6 on Liquid Penetrant Examination o Article 7 on Magnetic Particle Examination o Article 9 on Visual Examination o Article 10 on Leak Testing o Article 23, Section 797 on UT Thickness Testing  ASME BPVC Section VIII, Division 1—Rules for the Construction of Pressure Vessels. Division 1 contains the requirements, specific prohibitions and non-mandatory guidance for standard design unfired pressure vessel materials, design, fabrication, examination, inspection, testing, certification and pressure relief requirements. Division 1 is divided into three subsections with mandatory and non-mandatory appendices. The source inspector should be thoroughly familiar with the contents of Division 1 with regard to the fabrication, examination, inspection and testing that is specified in contractual agreements and/or ITP. Some of the content covered in ASME BPVC Section VIII, Division 1 that the SI should be familiar with include: o Subsection A covers the general requirements applicable to all pressure vessels. o Subsection B covers specific methods of fabrication of pressure vessels e.g. welding 17 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT o Subsection C covers the various classes of materials used in the fabrication of pressure vessels e.g. steels, alloys, cladding, lining, low temperature materials, etc. For the purposes of SI examination the applicants should focus their attention on the following sections: o All definitions in Appendix 3 o Materials, UG 4 to 15 o Fabrication, UG 75 to 85 o Inspection and Testing, UG 90 to 103 o Marking and Reports, UG 115 to 120 o Welding General, UW 1 to 3 o Welding Materials, UW 5 o Fabrication, UW 26 to 42 o Inspection and Tests, UW 46 to 54 o Marking and Reporting, UW 60 o Postweld Heat Treatment, UCS 56 o Radiographic Examination, UCS 57  ASME BPVC Section VIII, Division 2—Rules for the Construction of Pressure Vessels— Alternative Rules. Division 2 also contains the requirements, specific prohibitions, and non- mandatory guidance for advance designed unfired pressure vessel materials, design, fabrication, examination, inspection, testing, certification and pressure relief. Division 2 is divided into nine parts, each with mandatory and non-mandatory annexes. The source inspector need not be thoroughly familiar with the contents of Division 2 for the core examination, but the SI should be familiar with what the standard covers.  ASME BPVC Section IX—Qualification Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators. Section IX of the ASME BPVC Part QW covers the qualifications of welders, welding operators and the procedures that will be employed during fabrication. The primary subjects covered include: welding general requirements, welding procedure specifications and qualification, and welder performance qualification. Section IX does not cover acceptance criteria for production welds. Section IX also covers fabrication by brazing (Part QB), so the SI inspector should be aware of that section, but will not need to be familiar with it until and unless assigned to a project that specifies brazed construction. The source inspector should be thoroughly familiar with the contents of Section IX Part QW with regard to the WPS, PQR and WPQ that are specified in contractual agreements and/or ITP. For the purposes of SI examination the applicants need to focus their attention on the following sections of ASME BPVC Section IX : o Welding General Requirements QW 100 to 190 o Welding Procedure Qualifications QW 200 to 290 o Welding Performance Qualifications QW 300 to 380 o Welding Data QW 400 to 490 o Standard Welding Procedure Specifications QW 500 to 540 18 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT  ASME B31.3—Process Piping. B31.3 covers the requirements for the fabrication of process piping associated with pressure vessels typically used in the petrochemical industry. It covers design, materials, fabrication, welding, erection, testing, inspection and examination of process piping including flanges, fittings, gaskets, bolting, valves, PRV’s. The source inspector should be familiar with the contents of B31.3 with regard to examination, inspection and testing procedures that are specified in contractual agreements and/or ITP. For the purposes of SI examination some of the content covered in ASME B31.3 that the applicants should be familiar with includes: o Chapter I, Scope and Definitions o Chapter III, Materials o Chapter IV, Standards for Piping Components o Chapter V, Fabrication, Assembly and Erection o Chapter VI, Inspection, Examination and Testing  ASME B16.5—Pipe Flanges and Flanged Fittings. B16.5 covers the requirements for materials, dimensions, tolerances, marking, testing of flanges and flanged fittings, as well as flange bolting and gaskets. B16.5 covers flange class designations for 150, 300, 400, 600, 900, 1500 and 2500 systems for sizes from NPS ½ to NPS 24 made from cast or forged materials. These pressure classes have differing pressure and temperature ratings for different materials of construction. B16.5 also covers blind flanges and reducing flanges. The source inspector would use this standard to verify that flanges and flanged fittings specified in the contractual document have been correctly supplied. For the purposes of the SI examination the applicants should be familiar with the following sections of ASME B16.5: o Chapters 1 to 8, narrative information and associated tables referenced therein 8.2.5.4 ASNT Standards  ASNT SNT-TC-1A. This recommended practice establishes a general framework for a qualification and certification program for NDE technicians. In addition the standard provides recommended educational requirements and training requirements for different test methods. The SI should be thoroughly familiar with this standard, including the duties and responsibilities for each of the 3 levels of NDE qualified technician. 8.2.5.5 AWS Standards and References  The Welding Inspection Handbook. This Handbook provides information to assist welding inspectors and supervisors in the technology and application of visual and nondestructive examination associated with welding. The SI should be thoroughly familiar with the contents of this handbook.  AWS D1.1 Structural Welding Code. This code covers the welding requirements for any type of welded structure made from the commonly used carbon and low-alloy constructional steels. The SI inspector should be familiar with the following sections: o Scope and Application o Requirements for the Welding Inspector o Welding Inspection Operations 19 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT o Inspection Safety Considerations o Preheating and Postweld Heat Treating o Weld and Weld Related Discontinuities o Destructive Testing of Welds o NDE Methods o Qualification of NDE Personnel 8.2.5.6 SSPC Standards  SSPC-PA 2 Coating Applications Standard No. 2, Procedure for Determining Conformance to Dry Coating Thickness Requirements. This standard describes a procedure for determining conformance to a specified dry film thickness (DFT) range on metal substrates using NDE thickness gauges. The SI inspector should be familiar with Sections 1 to 8 of this standard.  SSPC Surface Preparation Guide. This guideline briefly describes the scope of the 7 different SSPC and NACE Surface Preparation Standards with application to source inspection. The source inspector should be familiar with the scope of the 7 standards listed below that are included in this guide, but need not be familiar with the details in the specific standards for examination purposes. o SSPC-SP1—Solvent Cleaning o SSPC-SP3—Power Tool Cleaning o SSPC-SP5 or NACE 1—White Metal Blast Cleaning o SSPC-SP6 or NACE 3—Commercial Blast Cleaning o SSPC-SP7 or NACE 4—Brush-Off Blast Cleaning o SSPC-SP10 or NACE 2—Near-White Blast Cleaning o SSPC-SP11—Power Tool Cleaning to Bare Metal 8.2.6 Welding Procedures and Qualifications For fixed and mechanical equipment and materials, welding procedure qualifications are the responsibility of the S/V while it is the responsibility of the source inspector that they be verified as the ones approved by engineering. Prior to performing welding inspection, the SI should confirm that the version of the WPS in hand has been reviewed and approved by the responsible person e.g. engineer/WPS/PQR SME. The AWS Welding Inspection Handbook, ASME BPVC Section IX, AWS D1.1 and API RP 577 are the appropriate references for knowledge and understanding of WPS/PQR’s. 8.2.7 NDE Procedures Development of NDE procedures are the responsibility of the S/V while it is the responsibility of the source inspector that they be verified as the ones approved for use. Prior to witnessing NDE, the SI should confirm that the version of the NDE procedure in hand has been reviewed and approved by the responsible person e.g. engineer/NDE SME. The AWS Welding Inspection Handbook, ASME BPVC Section V, AWS D1.1 and ASNT SNT-TC-1A are the appropriate references for knowledge and understanding of NDE procedures and required training and certification of NDE technicians. 20 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT 8.2.8 Project Schedules While the responsibility of establishing and monitoring the delivery is not generally in the purview of the SI and the responsibility of meeting the schedule remains with the S/V, the SI may be requested to report on fabrication status or slippage of milestone progress. The SI should notify the inspection coordinator if he/she believes that product quality may be compromised by schedule pressures. 8.3 Performing the Source Inspection 8.3.1 Individuals assigned to perform the source inspection activity must follow the ITP as specified by the purchaser. Visual inspection, welding inspection, dimensional inspections, observing NDE, and all other examinations and tests must be performed in accordance with the source ITP, project specification and applicable code and standards and meet the applicable acceptance criteria. See Section 9 for Examination Methods, Tools and Equipment. 8.3.2 One important step in the source inspection work process is to verify evidence that the S/V personnel conducting the fabrication and quality control steps during fabrication are properly trained, qualified and certified, as specified in the ITP or other contractual documents. This may include verification of such credentials as: S/V quality personnel qualifications per the specified standards, checking welder log books, and NDE technician certifications per the specified standards, such as ASNT SNT TC-1A, EPRI, or API Industry Qualified Examiners. 8.3.3 During the course of M&F, the S/V may propose work process changes that could impact cost, schedule and/or quality. In such cases, the source inspector should request that the S/V propose such changes in writing for review by the purchaser and/or owner-user of the equipment. 8.4 Source Inspection Work Process Scheduled Planning Events 8.4.1 General Typical source inspection scheduled work process events include the following. 8.4.2 Pre-purchase Meeting (Prior to Contract Placement) The source inspector may or may not participate in a pre-purchase meeting. The purpose of such a meeting is to cover some specific design, fabrication, and/or QA/QC requirements expected of the S/V to make sure that their bid does not inadvertently overlook them and result in unanticipated surprises during fabrication and source inspection activities. 8.4.3 Pre-inspection Meeting (Prior to Start of Fabrication) The source inspector assigned to the S/V facility should participate in the pre-inspection meeting. The purpose of this meeting is to ensure that everyone at the S/V who will be involved in manufacturing, fabrication and monitoring the quality of the equipment fully understands specific requirements and details of the job, especially those requirements that may be non-routine or different relative to normal S/V quality surveillance. Advance preparation by the source inspector is important for the pre-inspection meeting to ensure the meeting covers all necessary issues requirements as specified in the contractual agreements and source inspector’s company policy/practices. Those requirements may include review of:  PO and contractual agreements 21 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT  Engineering, technical and material requirements and status  Fabrication schedules  Critical path and long-lead equipment/materials  Quality requirements e.g. ITP, NCR, inspection frequency, etc.  Sub-suppliers and their quality requirements  Special requirements e.g. performance or functional testing requirements  Painting, preservation and tagging  Communication requirements e.g. inspection point notification, report distribution, proposed changes, hold points, schedule impacts, etc.  Shipping and release plan  Final documentation requirements  Recording and reporting any observations, exceptions or deviations These source inspection work process events may also be observed or handled by others besides the source inspector including: project engineering, client representatives or third party inspection agency. 8.5 Report Writing 8.5.1 A key deliverable of source inspection is the progressive inspection reports detailing the documents reviewed, inspection activity performed, observed and/or witnessed during the source inspection visits. The report is normally on a standard format, and follows a consistent approach to reporting as specified by the purchaser. 8.5.2 The source inspector should reference the following minimum information in each report:  Date of visit  Appropriate contract number and key information  Purpose of visit  Action items or areas of concerns  Results of inspection/surveillance  Reference drawings/data used (including drawing numbers) to perform inspection/surveillance  Revisions of referenced drawings/data  Reference to the applicable requirement in the ITP  Identification of nonconforming or deviating items/issues 8.5.3 Photographs are common place in inspection reports as they assist in the description of the inspection results. The SI should request permission from the S/V prior to taking any photographs. Care should be exercised to ensure that an appropriate number of photos are attached as too many can be detrimental to report issuance due to file size. Photos should be dated and labeled with description of 22 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT area of interest or product tag reference so that they can be easily understood by those reading the SI reports. 8.5.4 Reports should be submitted to the inspection coordinator for review of content and technical clarity before they are distributed to the purchaser unless otherwise instructed. 8.6 Nonconformance/Deviations 8.6.1 When deviations to the contractual agreement or its referenced specifications, drawings, codes or standards are identified, the source inspector should identify them as nonconformances. The source inspector should notify the inspection coordinator as soon as practical once a nonconformance has been identified. 8.6.2 Nonconformance reports should reference the following minimum information:  Date of inspection  Contract number and information  Description of nonconforming item and issue  Photo of discrepancy if possible  specification, drawings, codes or standards involved  Impact on the product  S/V recommended disposition of the nonconformance 8.6.3 The source inspector should issue the nonconformance report to the inspection coordinator for review and distribution unless instructed otherwise. 8.6.4 In general, deviations from specifications must be approved by the responsible engineer/technical personnel. 8.6.5 Acceptable disposition of a nonconformance (as approved by the responsible engineer/SME) may include:  Use as is  Rework/repair per original contractual documents or approved repair procedure  Scrap the equipment/component involved and start over 8.6.6 Once the disposition of the nonconformance has been agreed by all appropriate parties and implemented, the source inspector is normally responsible for determining if the nonconforming item currently conforms to the original or revised requirements based on the agreed disposition. It is SI responsibility to verify that NCR disposition has been properly implemented. 8.7 Source Inspection Project Continuous Improvement At the completion of the source inspection activities at an S/V, the source inspector, inspection coordinator, and all others involved in the “planning and doing” processes should review the entire planning and doing part of the “Plan–Do–Check–Adjust” continuous improvement (CI) cycle to determine which activities went well and where improvements/adjustments could/should be made. Determinations 23 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT should be made if improvements are possible and necessary in the source inspection management systems; the source inspection project planning process: the creation and implementation of the ITP; and the implementation of the source inspection work process events. Any such improvements should be documented and made available to source inspection managers and coordinators to implement the improvements. This should include an evaluation of the performance of the S/V. 8.8 Source Inspector Continuous Improvement The source inspector can/should also learn from the continuous improvement cycle how he/she can improve their performance on the job by answering such questions as:  Are there some industry codes and standards that I should be more familiar with?  Are there any safety and/or personal conduct improvements I can make?  Can I improve the way I write the various SI reports?  Do I need to improve my review of project documents before showing up at the S/V site?  Can I improve the way I conducted the pre-fabrication meeting?  Can I improve the timeliness of closing out my part of the source inspection project? 9 Examination Methods, Tools and Equipment 9.1 General This section describes the typical examination methods, tools and equipment with which source inspectors should be familiar during the course of their surveillance at an S/V. Requirements for examinations from the purchaser or references in the contract agreement that may be more stringent than industry codes/standards or the S/V normal procedures should be included in the ITP. 9.2 Review and Confirmation of Materials of Construction 9.2.1 Ensuring that the S/V is using the correct material during the fabrication or manufacturing of the equipment is a critical element of quality surveillance. Typical reviews should consist of the following:  Material Test Reports (MTRs)—The information necessary for the source inspector to know and understand about MTRs is covered in API RP 577, Section 10.8 and ASME BPVC Section II, SA-370.  Any reports e.g. MTR’s that have been modified, corrected, or altered should be cause for immediate rejection as these could indicate the potential for the material or component being counterfeit material. All MTR’s must be legible.  Confirming that the construction materials proposed are the actual materials used during construction is a typical source inspection activity. The source inspector should: o Confirm the correct material type and grade. o Confirm the origin of the material. o Check material size and/or thickness. o Verify traceability of the material to a certifying document. 24 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT o Verify that the material complies with specific chemical and/or mechanical properties as specified in the contractual documents. o Check for evidence of specified heat treatment. o This is typically done by verifying that material grade, type and serial number match the material certifying document. Some S/V’s quality programs as well as purchasers’ have various methods for ensuring that the correct material is used in manufacturing with the use of positive material identification (PMI). The source inspector should be familiar with those methods and ensure compliance. API RP 578 is a good reference document for material verification and positive material identification. 9.2.2 The SI should be aware of the potential for counterfeit materials/documents slipping into the supply chain. Key issues to watch for include, but are not limited to:  Generic documentation which is not product specific  Material or equipment containing minimal or no documentation  Markings or logos that are questionable or obliterated  Items that have inconsistent appearance  Documents that have been altered  Items that lack material traceability or product certification  ASME or ASTM stampings that may have been counterfeited 9.3 Dimensional Inspections 9.3.1 The SI should be proficient in understanding and performing dimensional inspections. Equipment such as tape measures, dial indicators, calipers, protractors, levels are all typical tools that are used for dimensional inspection. See the Welding Inspection Handbook and API RP 577 for further information on SI tools of the trade. 9.3.2 When performing dimensional inspections, the source inspector should be familiar with the dimensional requirements and the allowable tolerances. Actual dimensions should be recorded in the inspection reference drawing. Dimensions which exceed the tolerances should be reported as a nonconformance or deviation. 9.4 Visual Inspections 9.4.1 Adequate lighting is essential when performing visual inspection. The SI must be familiar with the minimum lighting requirements defined by the applicable code, standard or specification. If there is inadequate lighting available during the visual inspection which is not uncommon in some shops, the source inspector must address these concerns with the S/V and inspection coordinator to resolve. Portable lighting such as pen lights, high power flashlights, etc. are common tools that the source inspector may need with him/her in order to perform adequate visual inspection. 9.4.2 Source Inspectors who are performing visual inspections of welding, coatings, etc. should be appropriately trained, qualified and/or certified as required to perform those activities in accordance with the applicable codes or standards including the visual acuity requirements. 25 GUIDE FOR SOURCE INSPECTION AND QUALITY SURVEILLANCE OF FIXED EQUIPMENT 9.5 Nondestructive Examination (NDE) Techniques 9.5.1 General 9.5.1.1 The primary source for the specific NDE techniques to be applied during M&F by the S/V is included in the applicable project specifications. Those documents should reference other appropriate codes/standards for NDE methods such as ASME BPVC Section V and NDE technician qualificati

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