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Qual i ty C ontr ol System
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10 Quality Control System The 1960s 1960s was a time time of rapid growth g rowth for the nuclear power indus try. In 1963, 1963, a new ASME Code Code sect ion, Section III, was published to cover construction of nuclear power plant components. One of the features of cons truction un der Section III was a requirement requirement that t hat the t he manufacturer im implem plement ent a q uality ass urance sys tem tem,, a formal formal sys tem of oversight oversight and recor record d keeping keeping as suring that construction takes p la lace ce as intended, that t he right materi material, al, parts, parts, drawings drawings , and procedures are used. The benefi benefits ts of such a s ystem soo n became apparent. apparen t. In 1973, the ASME Boiler and Pressure Vessel Committee (now the BPV Standards Committees) adopted adop ted s im imil ilar ar but less comprehensive an d detail det ailed ed rules for what is called a quality control (QC) (QC) sys tem for for the boiler b oiler and press p ress ure ves sel sections s ections of the Code, Sections I, IV IV, and VIII VIII (and now no w Sections Sections X and XII). XII). In Section I, th ese rules are foun d in PG-1 PG-105 05.4 .4 and Appen A ppendix dix A-30 A-300, 0, both entitled Quality Quality Control System. Each manufacturer is required to hav e a documented doc umented quali qua lity ty control co ntrol syst sy stem em that is fully fully implem implemented ented into its manufactu anufacturi ring ng operations o perations.. It may may be o f interes interes t to n ote that t hat the t he B31.1 B31.1 Power Pipi Piping ng Code has h as n o provisions provis ions for a quality control system that applies to other than boiler external piping, although the governing committee has been cons ider idering ing the idea for many many years. The QC system is intended to control the entire manufacturing process from design to final testing and certification. tifi cation. The s cope o f such sy syst stem emss may vary s ignif ignificantly icantly among among manufacturers , since the compl complex exity ity of the work determines determines th e program required; required; however, ho wever, the ess ential features of th e QC sy st stem em are the s am amee for everyone. everyon e. Each Each manufacturer is free to d eterm etermine ine the lengt h and compl complex exity ity of its Quality Control Manual, maki aking ng it as general or detailed as d esired. It is not a dvisab dvisable le to include detailed practices in the manual that are not actually followed in the shop. Also, when shop practices are revised, the manual must be updated to reflect the reflect t he revisions . Otherwise, Otherwise, the t he Autho A utho ri rized zed Inspect or is likely likely to find no ncon nconform formiti ities, es, which will will cause cons iderable extra extra work before full compl compliance iance with the Code can be d em emons ons trated. Implici Implicitt in the t he Code QC requirem requi rements ents is recognition recognition that each manufacturer manufacturer has its own established practices, and these are acceptwebcache.goog webcache.googleuser leusercontent.com content.com/searc /search?q= h?q=cache:VlIc cache:VlIcq q B-oNk B-oN kQJ:asmedigital QJ:asmedig italcoll coll ection.asme.org/data/Bo ection.asme.org /data/Book oks/85967 s/859674/859 4/859674_ 674_ch10.pd ch10.pdf+&c f+&cd=3&hl= d=3&hl= en&ct…
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able if a documented system can bethat developed control included of the operation in conformance with Code requirements . It is also recognized s ome ofshowing the information in a written description of a quality control sys tem is proprietary, and no distribution is required oth er than to the Au thorized Insp ector. An outline of features to be incorporated into a Section I quality control system is found in the Appendix A-302 paragraphs. These paragraphs are a list of requirements that have proven relatively easy to understand and have worked well. To begin, the authority and responsibility of those performing quality control functions must be established. That is, the manufacturer must assign an individual with the authority and organizational freedom to ident ify qu ality problems and t o recommend an d implement co rrective actions should they be needed. In addition, the written system must include: • The manufactu rer’s o rganization chart, s howing the relations hip between management, engineering, and all other groups involved in the production of Code components, and what the primary responsibility is of each group. The Code does not s pecify how to set up th e
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organization, nor does it prevent the manufacturer from making changes, so long as the resultant organization is ap propriate for doing Code work. • Procedures to control drawings, calculations, and specifications. That is, the manufacturer must have a sys tem to ass ure that current drawings , design calculations, specifications, and instructions are used for the manufacture of Code components. • A system for controlling material used in Code fabrication to as su re that only properly identified and documented material is us ed. • An examination and ins pection p rogram that provides references to nondestructive examination procedures, and personnel qualifications and records needed to comply with the Code. Also required is a system agreed upon with the Authorized Inspector for correcting nonconformities. A nonconformity is any condition that does not comply with the rules of the Code, whether in material, manufacture, or the provision o f all required appurten ances and arrangements. Nonconformities must be corrected before the component can be considered to comply with the Code. • A program to assure that only welding procedures, welding operators, and welders that meet Code requirements are used to produce Code components. This is normally one of the most detailed and important s ections of the QC manual, which desc ribes how qualified welding procedures are maintained and us ed and who within the organization is responsible for them. It also includes details on how welder qualifications are established and maintained. • A s ystem to con trol postweld heat treatment of welded parts and any o ther heat treatment, such as might be required following tube bending or swaging. This system must also provide means by which the Authorized Inspector can verify that the heat treatment was applied. • A system for calibration of examination, measurement, and tes t equipment used in Code co nstruction to ass ure accuracy of such equipment. The Code does not require such calibrations to b e traceable to a national standard s uch as thos e maintained at th e National Institute of Science and Technology (NIST). It merely states that the equipment must be calibrated. • A system of record retention for s uch items as radiographs, nondestructive examination (NDE) reports, and Manufacturer’s Data Reports. • Procedures covering certain other activities of the manufacturer, such as hydrostatic testing. • If a manufacturer intends to sub contract any as pect of Code construction, such as d esign, radiography, or heat treatment, the procedures and controls for the subcon tracting must also b e included in the manufacturer’s quality control system. webcache.googleusercontent.com/search?q=cache:VlIcqB-oNkQJ:asmedigitalcoll ection.asme.org/data/Books/859674/859674_ch10.pdf+&cd=3&hl= en&ct…
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Appendix A-300 concludes with the admonition that the quality control system shall provide for the Authorized Inspector at the manufacturer’s plant to have access to all drawings, calculations, records, procedures, tes t results, and any ot her documents necess ary for him or her to perform the inspections mandated by Section I. The objective is to as sure the quality of the const ruction and compliance with the Code. Note also that the qu ality con trol system may not be changed without obtaining t he concurrence of the A uthorized Inspector. As explained in Chapter 9, under Code Symbol Stamps, one of the con ditions for the issu ance or renewal of a Certificate of Authorization to use one of the ASME Code symbol stamps is that the manufacturer or assembler must have, and demonstrate to a review team, a quality control system intended to assure that all Code requirements will be met. The issu ance b y ASME of a new Certificate o f Auth orization or the required triennial renewal of an existing Certificate o f Auth orization is bas ed on a favorable recommendat ion after a joint review of the written quality control sys tem by the ASME review team.
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