british columbia safety authority a, a and … b31.1 power piping asme section viii pressure vessels...

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Prepared by: Ed Hurd P.Eng. Provincial Safety Manager, Boilers

Date: July 30, 2012

Controlled Document: MAN-4044-00

BRITISH COLUMBIA SAFETY AUTHORITY

A, AU and AP Contractor Licensing GUIDE FOR APPLICANTS

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ContentsIntroduction ..................................................................................................................... 2

Scope of A, AU and AP Licenses ...................................................................................... 3

Applying for a A, AU or AP License .................................................................................. 3

Application Assessments and Issue of Licenses ............................................................. 5

Outline of Conformity Assessment Program Requirements ............................................ 6

Contractor License To Register Welding Procedures...................................................... 9

Design Registration ....................................................................................................... 10

Requirements for Repairs ............................................................................................. 13

Requirements for Alterations ......................................................................................... 16

Appendix ....................................................................................................................... 21

Introduction The requirements for licensing contractors are established by the Safety Standards Act (the Act) and the Power Engineers, Boiler, Pressure Vessel and Refrigeration Safety Regulation (the Regulation). A person must not do regulated work unless they are licensed by the BC Safety Authority or authorized to do so by a certificate of qualification. Regulated work is the assembly, manufacture, construction, installation operation, testing, maintenance or repair of boilers, boiler systems or plants, pressure vessels, pressure piping or refrigeration systems and equipment. The Regulation further stipulates that a person must have an installation permit to install or alter a boiler and a person must hold a contractor’s license to perform regulated work under an installation permit. There are seven classes of contractors’ license established by section 60 of the Regulation.

(a) for the installation, repair or alteration of pressure retaining equipment such as boilers, pressure vessels and pressure piping:

(i) class "A"

(ii) class "Au"

(iii) class "Ap"

(iv) class "B" - limited capacity boiler, pressure vessel and pressure piping;

(b) for the installation, repair or alteration of refrigeration systems or equipment

- class "REF"

(c) for the servicing, repair or alteration of safety relief valves

- class "SRV"

(d) for the construction of boilers, pressure vessels or fittings

- class "MA" This manual provides policies for the licensing of A, AU and AP contractors and application guidelines for these licenses.

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Scope of A, AU and AP Licenses Class A, AU and AP licenses entitle a contractor to install, repair and alter boilers, pressure vessels and pressure piping systems. The scope of each class is:

Class A – This contractor’s license is for the installation, limited alteration, repair or maintenance of packaged or shop assembled boilers or pressure vessels, and the fabrication, construction, installation, repair, maintenance or alteration of pressure piping. Class A license holders are not authorized to install field assembled boilers or boiler external piping. Field assembled boilers and boiler external piping shall only be installed by an ASME accredited organization. Repair and limited alteration of field assembled boilers and boiler external piping is within the scope of this license. Class Au - This contractor’s license is for the installation, limited alteration, repair or maintenance of pressure vessels, and the fabrication, construction, installation, repair, maintenance or alteration of pressure piping. Class AU license holders are not authorized to install boiler external piping. Boiler external piping shall only be installed by an ASME accredited organization. Class Ap – This contractor’s license is for the fabrication, construction, installation, repair, maintenance or alteration of pressure piping. Class AP license holders are not authorized to install boiler external piping. Boiler external piping shall only be installed by an ASME accredited organization.

Applying for a A, AU or AP License An organization or person may make application to a provincial safety manager to be licensed as an A, AU and AP contractor. The organization or person must provide proof of relevant training, work experience, qualifications and conformity assessment procedures to verify that regulated work will be carried out in accordance with legislative and code requirements. An applicant for a class A, AU or AP licenses must: a) submit a completed form FRM-08110-0 Boiler Contractor License Application and pay

the required fee;

b) submit a Quality Control Manual detailing the scope of work to be performed by the contractor and qualifications of personnel who will carry out the work. The quality control program shall establish a conformity assessment program which will ensure all the requirements of the Act, Regulation, CSA B51 and ASME Boiler, Pressure Vessel and Piping Codes will be met. The program shall be suited to the type and complexity of the work and shall address the required features relative to the scope of work to be performed;

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c) have the current publications of the codes and standards, appropriate to the scope of work to be preformed. As a minimum the applicant shall have the following current publications, which shall be presented at the time of the interview:

i. The Safety Standards Act and Power Engineers, Boiler, Pressure Vessel and

Refrigeration Safety Regulation ii. The CSA-B51 Boiler, Pressure Vessel and Pressure Piping Codes. iii. ASME CSD-1

Depending upon your organization’s scope of work, you shall have current editions of other codes in addition to those listed above. To determine which additional codes apply to your organization’s scope of work, refer to CSA-B51 Code, and CSA-B52 Code. Table 1 lists codes which are required if the scope of work includes boilers, pressure vessels or pressure piping.

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A AU AP

ASME Section I Power Boilers ASME Section II Materials ASME Section II Materials

ASME Section II Materials ASME Section VIII Pressure Vessels

ASME Section IX Welding and Brazing Qualifications

ASME Section IV Heating Boilers


ASME B31.1 Power Piping

ASME Section VIII Pressure Vessels

ASME B31.1 Power Piping ASME B31.3 Chemical & Petroleum Plant Piping


ASME B31.3 Chemical & Petroleum Plant Piping

ASME B31.9 Building Services Piping

ASME B31.1 Power Piping ASME B31.9 Building Services Piping

NBIC – NB23 National Board Inspection Code

ASME B31.3 Chemical & Petroleum Plant Piping


ASME B31.9 Building Services Piping


Table 1 – Codes Applicable to the Scope of A Contractor Licenses

Application Assessments and Issue of Licenses The applicant’s quality control manual will be reviewed by a Boiler Safety Officer and revisions or changes to the manual may be required. After satisfactory completion of the review, a Safety Officer may make assessments of the applicant’s facility, or onsite work procedures to enable the Safety Officer to verify that the quality control program has been established and operates as specified in the quality control manual. The applicant must also demonstrate familiarity with the B.C. Safety Authority’s Boiler and Pressure Vessel Safety Program policies and procedures, the Act, Regulations, and applicable codes and standards. The applicant shall demonstrate sufficient implementation of the conformity assessment program to provide evidence of the licensed organization’s knowledge of welding, nondestructive examination, postweld heat treatment, and other installation, repair or alteration activities is sufficient to perform the scope of work in the quality control manual. The demonstration may be performed using a current installation, repair or alteration work. On successful completion of the review and assessment verifying that the applicant meets the prescribed requirements for licensing the applicant will be issued an A, AU or AP licenses. Failure to comply with the requirements as set out in the Act, Regulation, and applicable codes or standards, may result in the issue of compliance orders, discipline orders, monitory penalties or the suspension of the contractor’s license. The provincial safety manager shall be informed of any address, ownership, organizational or quality control program changes. If a licensed organization is sold the new owner is required to make application for an A, AU or AP license.

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Contractor licenses are renewed annually on the anniversary date provided the contractor continues to meet all prescribed requirements for licensing and pays the required renewal fees. Licensed contractors may be subject to an assessment by the BC Safety Authority, of their conformity assessment program at any time.

Outline of Conformity Assessment Program Requirements The following is a guide which details the required features of a conformity assessment program which shall be detailed in the licensed contractor’s Quality System Manual. As a minimum, each organization shall address the required features relative to the scope of work to be performed. Organizations shall explain their intent, capability and applicability for each required feature outlined in this section. Work may be subcontracted provided controls are clearly defined for maintaining full responsibility for compliance to the Act, Regulation and CSA B51 by the licensed contractor. The “Quality Control Manual” should incorporate the following general requirements:

- bound in a manner that allows for easy revisions and updating - company logo or letterhead on each page - typed name and date after a signature - handwriting not permitted - a copy of the completed “Boiler Contractor’s License Application” form must be included

in the manual - each page must be identified with a page number, total number of pages in the manual

and manual revision number and date The manual should provide clear and simple instructions on the contractor’s policies and procedures for the conformity assessment program. The manual may be brief or detailed depending on the scope of work that the contractor intends to undertake. The following features should be included in the manual:

a) Title Page The name and complete address of the licensed contractor, the class of license, the number assigned to this “controlled” edition, the name of the person or group this controlled copy is issued and the date of issue shall be included on the title page of the manual. b) Contents Page The manual should contain a page listing the contents of the manual by subject, number (if applicable), and revision number of each document. c) Scope of Work The manual shall clearly indicate the scope and type of installations, repairs or alterations the organization is capable of and intends to carry out. The scope should state the capacity of boilers the quality control program covers, if it includes installation, commissioning, and the types of maintenance, repairs or alterations the contractor will carry out. The contractor is authorized to do only work covered in the manual. d) Statement of Authority and Responsibility

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A dated Statement of Authority, signed by an officer of the licensed organization, shall be included in the manual. Further, the Statement of Authority shall include:

i. A statement that all regulated work carried out by the organization shall meet the requirements of the Safety Standards Act, Power Engineers, Boiler, Pressure Vessel and Refrigeration Safety Regulation, CSA B51 and applicable codes or standards;

ii. A statement that if there is a disagreement in the implementation of the Quality System, the matter is to be referred for resolution to a higher authority in the company;

iii. The title of the individual who is responsible for the management of the quality control system to ensure that the quality control system requirements are followed and that the position has the freedom and authority to carry out the responsibility.

e) Manual Control The manual shall include the necessary provisions for revising and issuing documents to keep the manual current. The title of the individual authorized to approve revisions shall be included in the manual. There shall be provisions for signatures of the authorized individual approving changes and revisions must be accepted by the BC Safety Authority prior to issuance of the manual and its implementation. f) Organization An organizational chart shall be included in the manual. It shall include the title of the heads of all departments or divisions that perform functions that can affect the quality of regulated work and it shall show the relationship between each department or division. The manual shall identify the title of those individuals responsible for preparation, implementation, or verification of the conformity assessment program. The responsibilities shall be clearly defined and the individuals shall have the organizational freedom and authority to fulfill those responsibilities. g) Drawings, Design and Specifications The manual shall contain controls to ensure that all design information, applicable drawings, design conditions, design calculations, specifications, design registration and instructions are prepared or obtained, controlled, and interpreted in accordance with the Regulation and applicable codes or standards. h) Installation, Repair and Alteration Methods The manual shall include controls for installations, repairs and alterations, including mechanical assembly procedures, materials, nondestructive examination methods, pre-heat, and postweld heat treatment, as applicable. Special requirements such as mechanical assembly procedures shall be addressed, if applicable. The controls shall include procedures for the giving notice to the BC Safety Authority before commencing any installation, repair or alteration and after completing any installation, repair or alteration. i) Materials The manual shall describe the method used to ensure that only acceptable materials (including welding material) are used for installations, repairs and alterations. The manual shall include a description of how existing material is identified and new material is ordered, verified, and identified. The manual shall identify the title of the individual(s)

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responsible for each function and a brief description of how the function is to be performed. j) Method of Performing Work The manual shall describe the methods for performing and documenting installation, repairs and alterations in sufficient detail to permit a Safety Officer to determine at what stages specific inspections are to be performed. The method of repair must have prior acceptance of a Safety Officer as required by section 86 of the Regulation. Alterations must be registered with the BC Safety Authority in accordance with section 87 of the Regulation. k) Welding, NDE and Heat Treatment The manual shall describe controls for welding, nondestructive examination, and heat treatment. The manual is to indicate the title of the individual(s) responsible for the welding procedure specification (WPS) and its qualification, and the qualification of welders and welding operators. It is essential that only welding procedure specifications and welders or welding operators qualified, as required by the ASME codes or NBIC, be used in the installation, repair or alteration of pressure-retaining items. It is also essential that weld procedures be registered in accordance with CSA B51 section 4.4 and welders or welding operators be approved by the BC Safety Authority in accordance with sections 41 and 42 of the Regulation. WPQ for welders must be administered by an organization holding a Certificate of Recognition and all welders registered with the BCSA by submitting a registration application and a QW 484. The manual shall also describe controls for ensuring that the required WPS or PWP is available to the welder or welding operator prior to welding. Similar responsibility for nondestructive examination and heat treatment shall be described in the manual. Non-destructive testing personnel shall be certified in accordance with CAN/CGSB 48.9712/ISO 9712 as required by CSA B51 section 4.12. l) Examinations and Tests Reference shall be made in the manual for inspections, examinations and tests as required by the codes or standards upon completion of the installation repair or alteration including the pressure testing of pressure components upon completion of the work. A detailed description of the method for conducting the pressure test will be included in this reference

m) Calibration The manual shall describe a system for the calibration of examination, measuring, and test equipment used in the performance of installations, repairs and alterations. n) Acceptance and Inspection of Installations, Repairs or Alterations The manual shall specifically indicate that before any installation, repair or alteration is started, the BC Safety Authority will be informed. Acceptance of repair/alteration methods shall be obtained from a Safety Officer who will make the required inspections and confirm compliance to codes and standards. On completion of work the BC Safety Authority shall be informed that the work was completed in accordance with the Regulations and the applicable forms shall be completed and submitted to the BC Safety Authority and the equipment owner:

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i. Data reports as defined in CSA B51 or NBIC - NB23 ii. FRM-1060-02 Boilers And Pressure Vessels Repair And Alteration

Report; iii. FRM-1329-01 Construction Data Report For Piping Systems

Manufactured Inside British Columbia; or iv. FRM-1330-02 Construction Data Report For Piping Systems

Manufactured Outside British Columbia

o) Inspections The manual shall make provisions for the Safety Officer to have access to all drawings, design calculations, specifications, procedures, process sheets, repair or alteration procedures, test results, and other documents as necessary to ensure compliance with the registered design, codes and standards. A copy of the current manual shall be available to the Safety Officer. p) Report of Repair or Alteration Form The manual shall indicate the title of the individuals responsible for preparing, signing, and presenting the BC Safety Authority report forms to the Safety Officer. The distribution of the report forms shall be described in the manual. q) Exhibits Any forms referenced in the manual shall be included. The form may be a part of the referencing document or included as an appendix. For clarity, the forms may be completed and identified as examples. The name and accepted abbreviations of the licensed contractor shall be included in the manual. r) Construction Code The manual shall include provisions for addressing the requirements that pertain to the specific construction or repair code for the equipment being installed repaired or altered and to ensure individuals performing work have a current knowledge of the Safety Standards Act and Regulations, codes and standards. s) Nonconforming Items There shall be a system acceptable to the Safety Officer for the correction of nonconformities. A nonconformance is any condition that does not comply with the applicable rules of the Act, Regulation, CSA B51, ASME or NBIC codes, or the conformity assessment program. Nonconformance must be corrected or eliminated before the installed, repaired or altered component can be considered in compliance with the legislative or code requirements.

Contractor License To Register Welding Procedures

Any company submitting applications for the registration of welding procedures under their company name must be the holder of a contractor license issued by the BC Safety Authority. The company registering welding procedures should assess what types of pressure retaining components on which welding will be carried out and make application to be licensed as an A, AU and AP contractor depending on the intended scope of work:

Boilers, pressure vessels and pressure piping – A License

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Pressure vessels and pressure piping - AU License Piping only - Ap License

An applicant for a class A, AU or AP license who will only be registering welding procedures and carrying out welding must: a) submit a completed form FRM-0811 Boiler Contractor License Application and pay the

required fee;

b) submit a Quality Control Manual detailing the scope of welding to be performed by the contractor and qualifications of personnel who will carry out the work. The quality control program shall establish a conformity assessment program which will ensure all the requirements of the Act, Regulation, CSA B51 and ASME Boiler, Pressure Vessel and Piping Codes will be met. The program shall be suited to the type and complexity of the work and shall address the required features relative to the scope of work to be performed;

c) have the current publications of the codes and standards for welding. As a minimum the applicant shall have the following current publications, which shall be presented at the time of the interview:

iv. The Safety Standards Act and Power Engineers, Boiler, Pressure Vessel and

Refrigeration Safety Regulation v. The CSA-B51 Boiler, Pressure Vessel and Pressure Piping Codes. vi. ASME Section IX Welding and Brazing Qualifications

The Quality Control Manual for contractors registering welding procedures and carrying out welding need only include the following sections:

a) Title Page b) Contents Page c) Scope of Work d) Statement of Authority and Responsibility e) Manual Control f) Organization i) Materials k) Welding, NDE and Heat Treatment l) Examinations and Tests m) Calibration n) Acceptance and Inspection of Installations, Repairs or Alterations q) Exhibits s) Nonconforming Items

Design Registration

Boilers and Pressure Vessels

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The standards governing the design and construction of boilers and pressure vessels are the ASME Boiler and Pressure Vessel Codes except as otherwise detailed in CSA B51. Sufficient documentation to verify that the design conforms to the applicable ASME code shall be submitted. As a minimum, the following information and documentation shall be submitted:

i. A completed British Columbia CRN application form ii. Design data such as ASME code specification, material specifications, pressure ratings,

temperature iii. ratings and type of service iv. Drawings showing dimensions, construction and welding details of the proposed vessel

design v. ASME code calculations

Registration submissions must be sent to:

BCSA 505 – SIXTH STREET, SUITE 200 NEW WESTMINSTER, B.C. V3L 0E1 Attention: Design Survey

The drawings shall be identified by number and revision and indicate ASME code of construction (edition and addenda), non-destructive examination requirements, maximum allowable working pressure, minimum and maximum design temperatures, service fluid specific gravity, heat treatment, impact testing, corrosion allowance, nozzle locations, reinforcement and dimensions, flange and fitting standards, ASME material specifications, bill of material and nameplate facsimile. All design details and material specifications referenced in the calculations shall be included in the drawing. Conditions such as seismic or wind loadings, which may limit the vessel’s location must be detailed on the drawing. Design calculations shall be to the latest ASME Code edition and addenda unless the submission details the reasons for using an earlier edition or addenda. The calculations shall contain sufficient information to verify that all applicable requirements of the specified ASME code have been complied with. If exemptions from specific code requirements are utilized in the design, the specific code section and subsection permitting the exemption must be identified and supported by an explanation or reason detailing how the exemption applies to the design. The calculations shall show the formulas used and reference the appropriate code section. Where the ASME code does not cover all details of the vessel design and construction, the submission must provide details utilizing recognized engineering practices or proof test results to show that the design method is as safe as those of the applicable ASME code. All UG-22 loadings must be considered in the design and, as a minimum, the submission must have a statement that all UG-22 loadings have been considered. Vessels with an overall length of 20 feet or more must have detailed seismic and support loading calculations. The calculations shall be signed by the person responsible for that function in the manufacturer’s quality control manual. The calculation package shall be numbered and have a method for revision control. The registration submission will be reviewed to verify that all applicable code requirements have been considered in the design and the calculations made. Upon satisfactory review of the registration documentation, the vessel design shall be assigned a Canadian Registration Number (CRN). A design registration letter indicating the CRN, date of registration, manufacturer’s name, description of the vessel, drawing numbers, registration fee and any other pertinent information will be sent to the applicant.

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Piping Pressure piping systems are piping systems containing:

(a) an expansible fluid, or (b) a non-expansible fluid or thermal fluid (fluids other than water or aqueous solutions used for heat transfer) with an operating temperature exceeding 121oC or a working pressure exceeding 1100 kPa. An expansible fluid is any vapour, gas or liquid that will change to a vapour or gas at atmospheric conditions (14.7 psia and 70°F). Pressure piping systems shall be registered in accordance with CSA B51 “Boiler, Pressure Vessel and Pressure Piping Code”.

The following pressure piping systems are exempted from the requirements of the Power Engineers, Boiler, Pressure Vessel and Refrigeration Safety Regulation:

(a) A pressure piping system operating at and with a relief valve or valves set at 103kPa or less. (b) A pressure piping system external to the boiler proper in a low temperature low pressure fluid plant (a plant containing a liquid but not thermal fluids operating at a working pressure of 206 kPa or less and a temperature of 100°C or less).

The standards governing the design and construction of all pressure piping systems including piping that is NPS 3 or less are the ASME Code for Pressure Piping, B31 series. The design of pressure piping that is in a heating plant or NPS 3 or less does not require registration however the piping system must comply with all other requirements of the Regulation and construction code. A heating plant is steam system not exceeding 103 kPa (15 psig) or a hot water system not exceeding 1100 kPa(160 psig) or 1210C (2500F). Design registration is required for all other piping systems greater than NPS 3. Sufficient documentation to verify that the design conforms to the applicable B31 piping code shall be submitted. As a minimum, the following information and documentation shall be submitted:

(a) A completed British Columbia CRN application form (FRM-1171) (b) Design data such as ASME code specification, material specifications, pressure ratings, temperature ratings and type of service (c) Two copies of PI & Ds or schematic drawings showing the specific lines to be registered, and two copies of line lists showing line numbers & sizes, design & test parameters (d) ASME code calculations for expansion, flexibility and support for pipe diameters exceeding NPS 3.

The drawings should be identified by number and revision and indicate ASME code of construction (edition and addenda), non-destructive examination requirements, maximum allowable working pressure, minimum and maximum design temperatures, fluid service, heat treatment, impact testing, corrosion allowance, dimensions, flange, valve and fitting standards, CRNs for boilers, pressure vessels or fittings in the system and ASME material specifications. The drawings and calculations shall contain sufficient information to verify that all applicable requirements of the specified ASME code have been complied with. The calculations shall show the formulas used or reference the code section, which is the source of the appropriate formula. Where computer programs have been used for piping design, a complete program report is not required and only the name of the program utilized, input data and output results should be submitted.

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Upon satisfactory review of the piping system design registration documentation, a design registration letter indicating the British Columbia piping registration number (P number), date of registration, description of the piping system, installation site, drawing numbers, registration fee and any other pertinent information will be sent to the applicant. A separate invoice will be forwarded for the registration fee. No other documents will be stamped or returned to the applicant. Piping systems shall be constructed and installed by a licensed contractor. Prior to construction or installation the contractor shall notify a safety officer of the work. On the completion of construction or installation, the contractor must notify a safety officer that the work is complete and must complete a construction data report for all piping systems. The piping system may be inspected by a safety officer who may witness or require a pressure test report before the piping system is placed in service. For construction data report, the following rules apply:

a) For piping systems manufactured in British Columbia, a Construction Data Report For Piping Systems Manufactured Inside British Columbia (FRM-1329) shall be completed and signed by the manufacturer and by the Safety Officer (BCSA Boiler Safety Officer). b) A partial construction data report shall also be completed for parts of a piping system, such as pipe spools, fabricated at a location other than the piping installation or supplied by another manufacturer. c) All applicable categories indicated by the manufacturer in the construction data report (Shop Construction, Field Construction, Final Data Report or Partial Data Report) shall be signed by a Safety Officer. d) For piping systems manufactured outside of British Columbia a Construction Data Report For Piping Systems Manufactured Outside British Columbia (FRM-1330) shall be completed and signed by the manufacturer and by the Authorized Inspector. e) All applicable piping system construction data reports shall be available for review by the Safety Officer at the installation site.

Fittings

Fittings are valves, gauges, flanges, nozzles or other similar components attached to or forming part of a boiler, pressure vessel or pressure piping system. Fittings shall be registered in accordance with Clause 4.2 of CSA B51 “Boiler, Pressure Vessel, and Pressure Piping Code”. Registration submissions must be sent to the attention of Design Survey. Fittings shall be registered in a category listed in Table 1 of CSA B51 with the exception of Categories A, B, C, and G which are exempted from registration as per Directive No. D-B6 070402 3. Fittings of the same category may be registered collectively. Separate registration of each fitting design in a category is not required.

Requirements for Repairs Definition Of Repair The work necessary to restore a boiler or pressure vessel to a safe and satisfactory operating condition provided there is no deviation from the original design.

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Authorization Repairs to pressure containment items shall not be initiated without the authorization of a Safety Officer, who shall be satisfied that the repair methods are acceptable. The Safety Officer may give prior approval for “Repairs of a Routine Nature”, provided the Safety Officer is satisfied that the repair organization has acceptable procedures covering the repairs. Examples Of Repairs Examples of repairs are:

i. weld repairs or replacement of pressure parts or attachments that have failed in a weld or in the base material;

ii. the addition of welded attachments to pressure parts, such as: a. studs for insulation or refractory lining b. hex steel or expanded metal for refractory lining c. ladder clips d. brackets, having loadings which do not affect the design of the pressure retaining

item to which are attached e. tray support rings

iii. corrosion resistant strip lining or weld overlay; iv. weld buildup of wasted areas: v. replacement of heat exchanger tube sheets in accordance with the original design; vi. replacement of boiler and heat exchanger tubes where welding is involved; vii. in a boiler, a change in the arrangement of tubes in furnace walls, economizer or super

heater sections; viii. replacement of pressure retaining parts identical to those existing on the pressure

retaining item and described on the original Manufacturer’s Data Report such as: a. replacement of furnace floor tubes and / or sidewall tubes in a boiler b. replacement of a shell or head in accordance with the original design c. rewelding a circumferential or longitudinal seam in a shell or head d. replacement of nozzles of a size where reinforcement is not a consideration

ix. installation of new nozzles or openings of such a size that reinforcement is not a consideration (for example, the installation of a 3 NPS nozzle to a shell or head of 3/8 in. or less in thickness or the addition of a 2 NPS nozzle to a shell or head of any thickness);

x. the addition of a nozzle where reinforcement is a consideration may be considered to be a repair provided the nozzle is identical to one in the original design, location in a similar part of the vessel, and not closer than three times its diameter from another nozzle. The addition of such a nozzle shall be restricted by any service requirements;

xi. the installation of a flush patch to a pressure retaining item; xii. the replacement of a shell course in a cylindrical pressure vessel; xiii. welding of gage holes; xiv. welding of wasted or distorted flange faces; xv. replacement of slip-on flanges with weld neck flanges or vice-versa; xvi. seal welding of buttstraps and rivets; xvii. the replacement of a riveted section or part by welding;

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xviii. the repair or replacement of a pressure part with a Code accepted material that has a nominal composition and strength that is equivalent to the original material, and is suitable for the intended service;

xix. replacement of a pressure retaining part with a material of different nominal composition, equal to or greater in allowable stress from that used in the original design, provided the replacement material satisfies the material and design requirements of the original code of construction under which the vessel was built.

Repairs Of A Routine Nature The repairs listed below are examples of repairs which a Safety Officer may give prior approval as “Repairs of a Routine Nature”:

i. weld repair or replacement of tubes or pipes or sections thereof (5) NPS in diameter and under and attachments.

ii. the addition of non-pressure attachment to pressure parts where postweld heat treatment is not required.

iii. weld build-up of wasted areas iv. corrosion resistant weld overlay v. replacement of boiler and heat exchanger tubes where welding is involved; vi. a change in the arrangement of tubes in furnace walls, economizer or superheater

section in a boiler; vii. rewelding or replacing heat exchanger channel partition plates; viii. replacement of nozzles where reinforcement is not a consideration; ix. welding of gage holes; x. replacement of slip-on flanges with weld neck flanges or vice-versa where NDE of the

welding joint is not a requirement of the applicable ASME Code. Repair Method The repair method shall be acceptable to the Safety Officer. Testing Based on the nature and scope of the repair activity, one or a combination of the following examination and test methods shall be applied to repairs and replacement parts used in repairs.

Liquid Pressure Test

Pressure testing of repairs shall meet the following requirements: Pressure tests shall be conducted using water or other liquid medium. 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, as adjusted for temperature. When original test pressure included consideration of corrosion allowance, the test pressure may be further adjusted based on the remaining corrosion allowance.

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During a pressure test, where the test pressure will exceed the set pressure of the pressure relief device, the device shall be removed or gagged as recommended by the device manufacturer. The metal temperature for the pressure test shall be in accordance with the original code of construction, but not less 60o F (15.6o C) unless the owner provides information on the toughness characteristics of the material to indicate the acceptability of a lower test temperature. During close examination the metal temperature shall not exceed 120o F (49o F) unless the owner specified requirements for a higher test temperature and it is acceptable to the Safety Officer. Hold-time for the pressure test shall be a minimum of 10 minutes prior to examination by the Safety Officer. Where the test pressure exceeds the MAWP of the item, the test pressure shall be reduced to MAWP for close examination by the Safety Officer. Hold-time for close examination shall be as necessary for the Safety Officer to conduct the examination. Pneumatic Test A pneumatic test may be conducted for piping systems. Concurrence of the owner shall be obtained in addition to the acceptance of a Safety Officer. The test pressure shall be the minimum required to verify leak tightness integrity of the repair, but shall not exceed the maximum pneumatic test pressure of the original code of construction. Precautionary requirements of the original code of construction shall be followed.

Documentation All repairs shall be documented in the “Repair/Alteration Report Form” as described in the Quality Control Manual.

Requirements for Alterations Definition Of Alteration Any change in the item described on the original Manufacturer’s Data Report which affects the pressure containing capability of the boiler or pressure vessel. Non-physical changes such as an increase in the maximum allowable working pressure (internal or external), or design temperature of a boiler or pressure vessel, shall be considered an alteration. A reduction in minimum temperature, such that additional mechanical tests are required, shall also be considered an alteration. Examples Of Alterations The following are examples of alterations:

i. an increase in the maximum allowable working pressure (internal or external) or

temperature of a pressure retaining item regardless of whether or not a physical change was made to the pressure retaining item;

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ii. a decrease in the minimum temperature such that additional mechanical tests are required;

iii. the addition of new nozzles or openings in a boiler or pressure vessel except those classified as repairs;

iv. a change in the dimensions or contour of a pressure retaining item; v. in a boiler, an increase in the heating surface or steaming capacity such that an increase

in the relieving capacity is required; vi. the addition of a pressurized jacket to a pressure vessel; vii. replacement of a pressure retaining part in a pressure retaining item with a material of

different allowable stress or nominal composition from that used in the original design. viii. the addition of a bracket or an increase in loading on an existing bracket which affects

the design of the pressure retaining item to which it is attached. Design The organization performing alterations shall establish controls used to ensure that all required design information, applicable drawings, design calculations, specifications and instructions are prepared, obtained, controlled and interpreted to provide the basis for an alteration in accordance with the original code of construction. When a Manufacturer’s Data Report is required by the original construction standard, a copy of the original Data Report shall be obtained for use in the design of the alteration. When the original Manufacturer’s Data Report cannot be obtained, agreements on the method of establishing design basis for the alteration shall be obtained from the Safety Officer. All alterations are to be registered with the BCSA. Calculations A set of calculations demonstrating the alteration conforms to code requirements shall be completed prior to the start of any physical work. All design work shall be completed by an organization experienced in the design portion of the standard used for construction of the item. All calculations shall be made available to the Safety Officer. Re-Rating Re-rating of a pressure retaining item by increasing the maximum allowable working pressure (internal or external) or temperature, or decreasing the minimum temperature such that additional mechanical tests are required, is considered to be an alteration. Alterations must be registered with the BCSA. The registration submission for a boiler or pressure vessel that is to be re-rated shall consist of documentation confirming that the vessel’s original construction was in accordance with the appropriate ASME Boiler and Pressure Vessel codes, non-destructive examination results to establish the vessels condition and ASME code calculations verifying that the vessel, in its present condition, is suitable for its intended service. As a minimum, the following information shall be submitted:

i. A completed British Columbia CRN application form. ii. Manufacturers Data Report (MDR).

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iii. Rubbings, copies of vessel markings or name plates showing items such as Canadian Registration Number (CRN), manufacturer’s serial number, National Board Number, Unit ID or BC Unit Identification Number (BC ID).

iv. Maintenance records, periodic inspection reports, and repair/alteration reports if applicable.

v. Internal and external visual inspection reports. vi. A thickness evaluation report, based on an ultrasonic examination, which provides the

actual thicknesses of shells, heads, nozzles, and any other components forming the pressure containment envelope of the vessel. This examination shall be made on a grid, which shall be established based on the size of the vessel. The grid shall be scaled to provide a representative sample of the vessel’s thickness and adequately investigate areas where thinning is suspected.

vii. A report of surface and volumetric non-destructive examinations such as fluorescent magnetic particle, dye penetrant, ultrasonic, radiographic or eddie current carried out on the welds and heat affected zones, bends, thickness, shape transitions or any stress-raiser areas to check for cracking and other defects. These examinations shall be on a grid system, which provides a representative sample of the areas, examined.

viii. A material (metallurgical) soundness evaluation where there is evidence of damage such as corrosion, thinning, dents, cracking or over-heating.

ix. A drawing of the vessel showing design and operating conditions for used vessels or the new conditions for re-rated vessel, material specifications, construction and weld details.

x. Code calculations, based on the vessel’s present condition as determined by the non-destructive examinations, which demonstrate that the vessel is suitable for its intended service conditions and conforms to all ASME code requirements. These calculations shall be based on the original code of construction or the current edition and addenda of the applicable ASME Boiler and Pressure Vessel Code whichever is more stringent. If the vessel does not conform entirely to the ASME code, recognized engineering practices may be used to demonstrate that the vessel can be safely

xi. operated at its intended service conditions. Radiography, any other method of NDE ASME Code Cases or later Code addenda which were not utilized for the vessel’s original design and construction shall not be used to increase welded-joint efficiencies or allowable material stresses to re-rate an existing vessel to a higher Maximum Allowable Working Pressure (MAWP). Upon satisfactory review of the registration documentation, a design registration letter indicating the CRN, date of registration, manufacturer’s name, drawing/revision numbers, registration fee and any other pertinent information will be sent to the applicant. A separate invoice will be forwarded for the registration fee. No other documents will be stamped or returned to the applicant. Registration documents shall be made available for the review of a safety officer. Drawings Drawings shall be prepared to describe the alteration as appropriate. Drawings shall include appropriate information to satisfactorily perform the alteration. Allowable Stresses

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For re-rating or recalculating a new minimum wall thickness for a pressure retaining item using a later edition/addenda of the original code of construction that permits use of higher allowable material stress values than were used in the original construction is not allowed. Examination And Test The integrity of alterations and replacement parts used in alterations shall be verified by examination or test. Examinations and tests to be used shall be subject to acceptance of the Safety Officer. Based on the nature and scope of the alterations activity, one or a combination of the following examination and test methods shall be applied to alterations and replacement parts used in alterations.

Liquid Pressure Test Pressure testing of alterations shall meet the following requirements:

A pressure test as required by the original code of construction shall be conducted. The test pressure shall not exceed 150% of the maximum allowable working pressure (MAWP) stamped on the pressure retaining item, as adjusted for temperature. When the original test pressure included consideration of corrosion allowance, the test pressure may be further adjusted based on the remaining corrosion allowance. The pressure test for replacement parts may be performed at the point of manufacture or point of installation. As an alternative to pressure testing connecting welds may be tested or examined in accordance with the rules for repairs of the National Board Inspection Code NB-23. Connecting welds are defined as welds attaching the replacement part to the pressure retaining item.

During a pressure test, where the test pressure will exceed the set pressure of the pressure relief device, the device shall be removed or gagged as recommended by the device manufacturer. The metal temperature for the pressure test shall be in accordance with the original code of construction, but not less than 60oF (15.6o) unless the owner provides information on the toughness characteristics of the material to indicate the acceptability of a lower test temperature. During close examination the metal temperature shall not exceed 120oF.(49oC). Hold-time for the pressure test shall be a minimum of 10 minutes prior to examination by the Safety Officer. The test pressure shall be reduced to the MAWP for close examination by the Safety Officer. Hold-time for close examination shall be a necessary for the Safety Officer to conduct the examination.

Pneumatic Test

A pneumatic test may be conducted for piping system when contamination of the piping by liquids is possible or when liquid pressure testing is not practicable. Concurrence of

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the owner shall be obtained in addition to Safety Officer approval. Pneumatic test requirements and precautions shall be in accordance with the original code of construction.

Nondestructive Examination

Nondestructive examination (NDE) may be conducted when contamination of the pressure retaining item by liquids is possible or when pressure testing is not practicable. Concurrence of the owner shall be obtained in addition to the Safety Officer. NDE methods used shall be suitable for providing meaningful results.

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Appendix Sample of a Quality Control Manual This guide is intended to assist in the development of a quality control manual for a conformity assurance program for an A, AU or AP contractor’s license. It is not to be used to replace or interpret the requirements of the Safety Standards Act, Safety Standards General Regulation and the Power Engineers, Boiler, Pressure Vessel and Refrigeration Safety Regulation, CSA B51or the ASME Codes. The sample manual may not include all of the requirements for a quality control manual, but rather details the primary aspects that the applicant is required to include in the written Quality Control (QC) Manual. The content and detail in a manual will be dependent on the scope of work, size and complexity of the contractor’s organization. The QC Manual must contain the description of the controls necessary for implementing the conformity assessment program but, it is not required to contain all of the detailed programmatic requirements which will be found in the program, such as written procedures. The manual must describe the actual system in use and cover all responsibilities for the work being performed. When preparing the manual input and support should be obtained from all staff in the contractor’s organization including management, servicing and purchasing. The manual is to be used as a working document for use by company personnel and may also be reviewed by persons outside of the contractor’s organization and therefore it should give a clear understanding of the conformity assessment program for the installation, repair or alteration of pressurized equipment and components. The manual should state the title of persons responsible for each function or procedure. These titles must be the same as those shown on the organizational chart and be consistent throughout the manual. A description of each form, report, tag, or other document used in the conformity assessment program should be provided and the procedures for the use of each document detailed. Exhibits of each document should be added to the manual. The manual should be divided into separate sections for each item or topic in the conformity assessment program.

Name of Company Quality Control Manual

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Facing Page (Manual’s Cover or First Page )

The Facing page must include the contractor’s full company name and address. The title of the manual must be included as well as the revision, control number for the manual and the person to whom the controlled copy is assigned as shown in the example below:

Class A Contractor

Quality Control Manual For

Installation, Repair and Alteration of Boilers

Company Name

Company Address

Controlled Manual No. __________ Assigned To: _Name_ Revision # ____ (Date)


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Approval and Revision History

Rev # Date Description of Revisio 0 Mar. 21, 2012 Initial Issue

Manual Revisions Reviewed by: ____________________ ____________________ Date:______________ Name Signature Manual Revisions Accepted by: ____________________ ____________________ Date:______________ BCSA Safety Officer Signature


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Table of Contents

1. Glossary of Terms

2. Scope of Work

3. Statement of Authority and Responsibility

4. Manual Control

5. Organization

6. Drawings, Design and Specifications

7. Installation, Repair and Alteration Methods

8. Materials

9. Method of Performing Work

10. Welding, NDE and Heat Treatment

11. Examinations and Tests

12. Calibration

13. Acceptance of Repair or Alteration

14. Inspections

15. Report of Repair or Alteration Form

16. Exhibits

17. Construction Code

18. Nonconforming Items


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1. GLOSSARYOF TERMS

“ASME” means American Society of Mechanical Engineers “BCSA” means British Columbia Safety Authority “CGSB” means Canadian General Standards Board “Code” means ASME Boiler and Pressure Vessel Codes “NDE” means Non-Destructive Testing “SO” means British Columbia Safety Authority Safety Officer “WPQ” means Welder Performance Qualification “WPS” means Welding Procedure Specification


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2. Scope of Work Describe the scope and type of installations, repairs or alterations the organization is capable of and intends to carry out:

describe the scope of the activities to be undertaken; installation, repair, or alteration of boilers, pressure vessels and/or piping

describe the code or standards work will conform to list the shop locations; describe the scope of work undertaken at each shop location, and the address of each shop; indicate whether activities are undertaken at shop and/or at field sites; state the title of a person designated to perform QC function at each site, and, the title of a person

who is overall responsible for maintenance and assuring effective implementation of the QMS at all locations.

if a company does not have a shop, and undertakes field activities only, the company shall indicate that the activities undertaken are at field sites controlled from an office address of the company.

This manual describes the procedures that _company name_ will use for the assembly, repair, and limited alteration of packaged boilers, pressure vessels, and pressure piping systems in accordance with Power Engineers, Boiler, Pressure Vessel and Refrigeration Safety Regulation, and ASME Section I, ASME Section IV, ASME Section VIII, ASME B31.1, ASME B31.3, ASME B31.9 and CSA-B51. The installation of new boilers will be limited to external piping only as per ASME Section I at field sites throughout British Columbia. All installation work will be controlled from _ office address of the company. For work beyond the scope of this license or capability of _company name_ qualified contractors will be retained who will work to the requirements of a quality control manual approved by the BC Safety Authority.


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3. Statement of Authority The purpose of this manual is to implement the conformity assessment program to be used by _company name_ for the installation, repair and alteration activities as a Class Contractor in accordance with the Safety Standards Act, Power Engineers, Boiler, Pressure Vessel and Refrigeration Safety Regulation, CSA B-51 and _applicable code name_. The _ name of company position (eg. shop manager) is responsible for the implementation and maintenance of the program and has the authority to ensure compliance with its requirements. Any unresolved problems regarding compliance with this program, jurisdictional or code requirements shall be brought to the attention of _ name of company position for resolution within the jurisdictional, code or this manual’s requirements. _Signature_____________ _________________ name of company position Date


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4. Manual Control This section describes the system for preparing, revising and controlling the distribution of this Quality System Manual. The _ name of company position (eg. quality control manager) is responsible for implementing the conformity assessment program and shall approve this manual as evidenced by the signature and date on the “Approval and Revision History” page. The _ name of company position (eg. quality control manager) shall:

i. Approve all changes to the Quality System Manual, by signature and date on the Revision Summary page.

ii. Ensure that the Revision No. date and page number are shown on each page of the manual. Revised paragraphs will be indicated by a vertical line in each margin alongside the changed paragraph(s).

iii. Issue manual revisions to all persons who are assigned controlled manuals with instructions that superseded pages are to be destroyed.

If additional controlled manuals are issued, the _ name of company position (eg. quality control manager) will keep a list indicating manual numbers and who they are assigned to. Uncontrolled manuals may be issued for information but shall not be used for installation work. "Uncontrolled" shall be indicated on the front page of these manuals. A controlled copy of this manual must be available at all times, on sites where work under this Quality System is being performed. This copy must be made available to the BCSA Boiler Safety Officer upon request.


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5. Organization

President

EngineerShop

Foreman

Welder

Purchasing Agent


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6. Drawings, Design and Specifications All of the engineering functions of design calculations, NDE code requirements, heat treatment requirements and material specifications for a boiler shall be the responsibility of the vendor, (project contractor), his agents, consultants, subcontractors or equipment suppliers. In the event that is _company name_ responsible for the engineering functions, an engineering design consultant will be used. The _ name of company position will assume responsibility for approved drawings, calculations, and specifications. The _ name of company position will review the calculations and specifications for code compliance and indicate acceptance by signing and dating the drawings, calculations, and specifications. Drawings will contain sufficient information, instruction and details to complete the job. As a minimum the drawing or a separate supporting document will contain the following details:

i. Design Conditions ii. Operating and test pressure and temperatures iii. Code Edition and Addenda iv. Bill of Materials including material specifications v. Welding Details-Joint Design vi. Extent of NDE vii. WPS viii. Post Weld Heat Treatment

If required by Regulation designs will be submitted to the BCSA for registration with a C.R.N. or piping registration number. No work shall commence until the design registration has been obtained.


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7. Installation, Repair and Alteration Methods The manual will include detailed procedures for the work that the contractor intends to carryout. These procedures will include, but are not limited to, the selection of the welding procedure, material specifications, nondestructive examination (methods), preheat and postweld heat treatment. The manual will identify the name and title of the individual responsible for the implementation of these procedures. This section defines the responsibility and system for conducting repairs and alterations to pressure equipment. The following shall apply:

i. Repairs and alterations performed by _company name_ on pressure equipment will be completed in accordance with the current the Safety Standards Act, CSA B51, ASME, NBIC and all other applicable codes.

ii. _company name_ registered welding procedures are to be used for the construction of pressure piping and/or the repair of pressure equipment.

Repairs are defined as work necessary to restore pressure equipment to a safe operating condition, provided there is no change from the original design. Alterations are any change in the item described on the original Manufacturer’s Data Report which affects the pressure containing capability of the boiler or pressure vessel. _ name of company position (eg. quality control manager) shall review all procedures and drawings for code and quality assurance compliance prior to start of work. Methods of repairs and alteration must be accepted by a safety officer before starting work. The repair procedure will contain the following as required:

• Equipment or identification numbers • Description and location of repairs • Drawings and line designation table • Engineering calculations • Bill of materials • Registered welding procedure • Non-destructive examination • Hold points for inspection (Fabrication Inspection Report or “Traveler”) • Heat treatment • Pressure test (e.g. hydrostatic test) • BCSA Repair/Alteration Form


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8. Materials The _ name of company position will by means of a Purchase Order (exhibit #1) purchase all welding materials, pipe, tubing, plate, fittings and all appurtenances used in the work to be performed. All the material specifications are to be taken off the approved drawing issued by the_ name of company position . The Purchase Order, as a minimum, will contain the Job #, the material specifications, identify if Material Test Reports or Certificates of Compliance are to be supplied. The purchase order may contain additional information as deemed necessary by the _ name of company position. Substitution of material may not be made without the approval of the _ name of company position. Upon receiving the material the_ name of company position will check the material for obvious defects or any damage that may have occurred while the material was in transit. All material will be checked against the Purchase Order and traced to the Material Test Reports or Certificates of Compliance supplied. If the material is found not to be in compliance with A.S.M.E. Section II code requirements it is to be rejected and a Non-Conformance Report (exhibit #5) issued. When it has been determined that the material meets the requirements of the applicable standard the material will be identified with the job number prior to releasing the material for construction. The job number will also be written on the Material Test Reports or Certificate of Compliance. Any material that is in non-compliance shall be identified and segregated until the non-compliance has been resolved. When material is to be cut to size, the_ name of company position shall transfer the identification markings from the piece containing the original markings prior to cutting or removing from one location to another. Material found not to contain identification marks shall be considered nonconforming and segregated. A copy of the Purchase Order and Material Test Reports and Certificates of Compliance will be retained in the job file.


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9. Method of Performing Work _ name of company position (eg. quality control manager) is responsible to ensure installations, repairs and alterations are conducted to the above requirements and are responsible for completion of the required documentation for code work for the inspection and repair files. _ name of company position (eg. quality control manager) will prepare a repair/alteration procedure and ensure all procedures conform to _ name of company, standard work procedures. All work will be carried out in accordance with the repair/alteration procedures prepared by _ name of company position (eg. quality control manager) Upon completion of the repair/alteration, the Coordinator, Engineering and Maintenance will retain all documentation in the vessel file for a minimum of 7 years. All documentation is subject to audit by the BCSA.


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10. Welding, NDE and Heat Treatment Welding All the welding performed by _ name of company in the repair, alteration, and installation of packaged boilers, pressure vessels, or pressure piping systems shall be in accordance with the Power Engineers, Boiler, Pressure Vessel and Refrigeration Safety Regulation. _ name of company procedures are considered to be the BCSA PWP series or WPS prepared by name of company. _ name of company position (eg. quality control manager) will maintain control and custody of the procedures. _ name of company position (eg. quality control manager) will ensure that all welders are qualified to weld the work they are assigned within the range qualified for the essential variables in the WPQ. The welder’s log book will be the continuity record for our shop and field sites. _ name of company position (eg. quality control manager) will assign and maintain a record of identifying symbols assigned to each welder. The symbol will be unique to each welder and will be used to identify all welds performed by that welder. All welds performed will be traceable to a particular welder, either by an identifying symbol or a weld map. For each job the _ name of company position (eg. quality control manager) will maintain a weld map containing the welds performed by or sub-contracted welders. The weld map will be retained in the permanent job file. All consumables used in the welding process shall be ordered and received in accordance with the materials section of this manual. All electrodes shall be stored and handles in accordance with the manufacturers recommendations. name of company position (eg. quality control manager) will assume responsibility of ensuring that the welders are registered with the BCSA and are welding within the limits of the assigned procedure. name of company position (eg. quality control manager) will review the job requirements and after checking the welders log book will assign the appropriate weld procedure. Non-Destructive Testing name of company position (eg. quality control manager) shall determine all NDE requirements. name of company will sub-contract all required NDE to organizations who meet ASME code requirements. name of company position (eg. quality control manager) shall review the NDE sub-contractors Quality Control Manual to ensure that personnel performing the NDE are qualified in accordance with CGSB requirements. Visual examination of welds shall be conducted by the name of company position (eg. quality control manager). The NDE sub-contractor shall have procedures to calibrate equipment.


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Heat Treatment name of company position (eg. quality control manager) shall determine all heat treatment requirements. name of company Will sub-contract all heat treating requirements to organizations qualified to perform this type of service. name of company position (eg. quality control manager) shall review the procedures put forth by the sub-contractor to ensure that the requirements conform to ASME code requirements. The heat treatment procedures shall include but is not limited to the following:

i. Joint identification ii. Material type and thickness iii. Time and temperature at starting iv. Time and temperature at start of hold time v. Time and temperature at end of hold time vi. Time and temperature at end of power cut off vii. Operators name and the date

A transferable heat treatment record shall be maintained and recorded.


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11. Examinations and Tests Examinations and testing after the completion of installation, repair or alteration work shall be in accordance with the ASME codes. name of company position (eg. quality control manager) shall determine all examination and test requirements. Hydrostatic Testing name of company position (eg. quality control manager) is responsible for performing the hydrostatic tests, and when required, arrange to have the test witnessed by a safety officer. 13.2 There shall be provisions for the implementation and subsequent use of pressure relief valves, suitable for the test pressure, in all hydrostatic testing. The range of pressure test will be from 90% to a maximum of 150% of the maximum allowable working pressure. In determining the test pressure consideration shall be made for in service equipment regarding age, corrosion, and duty. New equipment shall be tested after installation and prior to operation in accordance with the applicable ASME code. name of company position (eg. quality control manager) will ensure the PRV’s are calibrated, in good working order, and are installed in such a manner as to relieve the system should the test exceed the maximum test pressure. The temperature of the test medium shall be that of the applicable code. The test pressure shall not be applied until the system and the pressurizing medium are approximately at the same temperature. The test medium temperature will be between 40o F and 120o F. A chart recorder with a range of the scale suitable for the test pressure such that when at test pressure, the indicator needle is in mid range of the chart recorders maximum calibrated range, shall be used to record the test pressure and temperature. name of company position (eg. quality control manager) shall record the serial number or identifying number of the pressure gauge, the test pressure, the length of time of the test, and the test results on the hydrostatic test report which will then become part of the


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12. Calibration name of company position (eg. quality control manager) is responsible to ensure that all test gauges are in good working order and have not exceeded the calibration due date. All pressure test gauges shall be under the control and custody of name of company position (eg. quality control manager) who will ensure that they are stored in such a manner that the potential of physical damage is minimized. name of company position (eg. quality control manager) will ensure that the pressure test gauges are marked with a system that is traceable to a written record of each calibration for each gauge. The record will contain the date of calibration, gauge serial number, and the authorized calibration agent. All test gauges shall be calibrated once a year as a minimum. Gauge will be checked prior to every use for up to date calibration. Any gauges whose accuracy is suspect, defective, or damaged will be removed for servicing or be discarded. All calibration or repairs will be sub-contracted to a qualified agency who will calibrate the gauges to a nationally recognized standard.


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13. Acceptance of Repair or Alteration Prior to the commencement of any work name of company position (eg. quality control manager) shall notify a safety officer and detail the repair or alteration procedure. The safety officer shall have the opportunity to select inspection hold points on the traveler which lists the sequence of operations necessary to perform the job. All work reports will be available to the safety officer in the job file before the traveler is signed off by the safety officer.


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14. Inspections

The safety officer shall be notified when work has reached an inspection hold points on the traveler. Work shall not proceed beyond the hold point until the safety officer has completed an inspection or authorized the work to proceed without an inspection.

15. On completion of the installation, repair or alteration the construction data report or repair/alteration report shall be completed and made available for review by the safety officer.


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15. Report of Repair or Alteration All repair and alterations shall be recorded on form FRM 1060-02 Boiler and Pressure Vessel Repair and Alteration Report. Piping installations shall be recorded on form FRM 1329-01 CONSTRUCTION DATA REPORT FOR PIPING SYSTEMS Manufactured Inside British Columbia. name of company position (eg. quality control manager) is responsible for the maintenance of a permanent job file. This file shall contain the appropriate Purchase Order, Bills of Material, approved drawings, specifications, Material Test Reports, Certificates of Compliance, Manufacturers Data Report, Repair / Alteration Report and any other documentation pertinent to the job such as a Construction Data Report. All job files will be, made available to the S.O. The job file shall be retained for a minimum of 7 years.


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16. Exhibits

LIST OF EXHIBITS Exhibit 1) Purchase Order Page __ Exhibit 2) Traveler Page __ Exhibit 3) Non-Conformance Report Page __ Exhibit 4) Construction Data Report Page __ Exhibit 5 Repair / Alteration Report Page __ Include a copy of each form.


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Exhibit 5 – Repair Alteration Report


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17. Construction Codes

As a condition of this license the name of company position (eg. quality control manager) shall produce upon request from a safety officer or BCSA auditor any of the following codes and standards:

i. Power Engineers, Boiler, Pressure Vessel and Refrigeration Safety Regulation ii. CSA B51 iii. ASME B31.1 iv. ASME B31.3 v. ASME B31.9 vi. ASME Sect. I vii. ASME Sect. II viii. ASME Sect. VIII ix. ASME Sect. IX x. ASME Sect. IV xi. NBIC – NB23


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18. Nonconforming Items A non-conformity is any condition which does not meet the requirements of this Quality Control Manual, Regulations or codes. This includes physical non-conformities found during receiving of materials, those found during fabrication and final testing, and it also includes errors and omissions in the form of documentation. When it has been determined that a non-conformity exists, the items shall be marked hold and identified and segregated from the production area until resolution. In respect to non-conformities with material the material will be rejected and discarded, returned to the supplier, repaired and used, subject to the acceptance of a safety officer or used as is, subject to the acceptance of a safety officer. It is the responsibility of all employees to identify non-conformities. name of company position (eg. quality control manager) shall document and record all non-conformities on a nonconformance report which will be placed in the permanent job file. All non-conformities shall be resolved to the satisfaction of a safety officer.

british columbia safety authority a, a and … b31.1 power piping asme section viii pressure vessels...

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