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Benefit of ASME Standards

- Case Study by APPLUS - AIA

Madrid, April 24th, 2018

Warm Welcome!
Piotr Paluszkiewicz
Regional Technical Manager - Middle East
ASME Authorized Inspector Supervisor
AGENDA

 INTRODUCTION

 ROLE OF THE AIA

 QUALITY SYSTEM

 DUTIES OF THE AI

 WHAT CAN GO WRONG?

 CONCLUSION AND OUTLOOK

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AGENDA

 INTRODUCTION

 ROLE OF THE AIA

 QUALITY SYSTEM

 DUTIES OF THE AI

 WHAT CAN GO WRONG?

 CONCLUSION AND OUTLOOK

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Applus+ at a glance

19,000
Applus+ is one of the world's leading Testing,
Inspection & Certification companies.
employees in 2016
It provides solutions for customers in all types of
industries to ensure that their assets and products
meet quality, health & safety, and environmental
standards and regulations.
1,587
million total
revenue in 2016

70
countries across
all continents

accredited
by major international
organisations

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Global Brands

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Global Map
Industries

Oil and Gas Power Telecom Infrastructure & Aerospace


Building Construction

Mining Other Government & Maritime


Industries Public Organizations

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Services
SERVICES OFFERED

Worldwide Vendor Advanced &


Surveillance & Conventional Non-
Expediting Destructive Testing

Local Third Party Asset Integrity


Inspection & Management
Certification

Supply of Specialized HSE Training & Consultancy


Personnel

Management Systems Lifting Equipment


Certifications Inspection, Certification &
Training
SERVICES
Services OFFERED

Scaffolding Inspection, MEP Commissioning &


Certification & Training HVAC TAB Services

Remote Visual Camera & Rig Inspection &


CCTV Inspection Commissioning

Rope Access Services & Engineering Services


Training

3D Laser Scanning & Trenchless Technology &


As-build Modeling CCTV Inspection
SERVICES
Services OFFERED

UAV Inspection Geotechnical Engineering

Pavement Management Energy Efficiency

Construction Works Electrical Testing &


Consultancy Commissioning

Geotechnical & Structural Telecommunication


Instrumentation and Services
Monitoring
AGENDA

 INTRODUCTION

 ROLE OF THE AIA

 QUALITY SYSTEM

 DUTIES OF THE AI

 WHAT CAN GO WRONG?

 CONCLUSION AND OUTLOOK

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What we ALL have to prevent
from happening...
ROLE OF THE AIA
- Authorized Inspection Agency

AUTHORIZED INSPECTION AGENCY


(as defined in ASME QAI-1)

JURISDICTION INSURANCE COMPANY THIRD PARTY


(e.g. State of OHIO) (USA + CANADA) (e.g. NOTIFIED BODY in EU)

DIFFERENT SCOPES:

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

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ROLE OF THE AIA
- WHAT IS THE LINK BETWEEN ASME AND APPLUS?

Velosi Certification
Services LLC

AUTHORIZED
To be renewed every INSPECTION
3 years AGENCY
(AIA Survey) (AIA-107)

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ROLE OF THE AIA

ASME

CERTIFICATE
AIA JURISDICTION
HOLDER

NATIONAL SHARED ENFORCEMEMNT


BOARD +
SHARED MARK PROTECTION

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ROLE OF THE AIA

THE AIA IS CONSIDERED TO BE THE LINK BETWEEN THE CERTIFICATE

HOLDER AND ASME/NATIONAL BOARD IN THE EVERYDAY BUSINESS.

 Shall have in place a permanent and exclusive SERVICE AGREEMENT with the

Certificate Holder (with some exemptions though!)

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

 Supports Certificate Holders in Preparation for the ASME Audit

 The AI Reviews and accepts the Quality Program

 The AI and AIS joint the ASME Auditor for the “Joint Review” | “Survey” (Audit)

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ROLE OF THE AIA
- WHY APPLUS DECIDED TO BECOME AN AIA?

 A global enterprise follows global clients and global standards

 Prestige, Competency and Recognition as AIA

 Elimination of overhead; own accreditation as AIA since 2016, before


worked through a partner’s shared accreditation

 To better server our clients by extending the Service Lines

 Our Oil & Gas clients prefer ASME Code for their assets

 Better understanding of the requirements and philosophy of the ASME


Code and direct communication link to ASME and the National Board

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FROM THE AMERICAN PERSPECTIVE…

ANSI American National Standards Institute


API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASNT American Society for Nondestructive Testing
ASTM American Society for Testing and Materials
AWS American Welding Society
NACE National Association of Corrosion Engineers
NB National Board of Boiler and Pressure Vessel Inspectors

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AGENDA

 INTRODUCTION

 ROLE OF THE AIA

 QUALITY SYSTEM

 DUTIES OF THE AI

 WHAT CAN GO WRONG?

 CONCLUSION AND OUTLOOK

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QUALITY SYSTEM OF THE AIA

EVERY AIA OPERATES IN COMPLAINCE WITH ITS QUALITY SYSTEM


AUDITED BY ASME AND NATIONAL BOARD DEFINING:
 Structure and Roles within the Organisation

 Relationship with Clients

 Training and Qualification of Inspectors

 Duties of the Inspectors and Supervisors

 Auditing of Inspectors and Supervisors

 Continuing Education

 Audits / Joint Reviews / Surveys

 Monitoring of Client’s Quality System

 Independence/ Impartiality & Confidentiality


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QUALITY SYSTEM OF THE AIA

AI DIARY:
 Each Inspection visit shall be documented by the Inspector on the AI Diary

 The entire inspection history is available for review

 The Certificate Holder is responsible for its safe Custody

 No need for Flash Reports, Inspection Reports etc.

 The AI Diary is available for auditing by the Supervisor and for investigations
by National Board and ASME (Peer Review)

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AGENDA

 INTRODUCTION

 ROLE OF THE AIA

 QUALITY SYSTEM

 DUTIES OF THE AI

 WHAT CAN GO WRONG?

 CONCLUSION AND OUTLOOK

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DUTIES OF THE AUTHORIZED INSPECTOR

 Auditing, some of the activities:


 Assistance in establishing a Quality Program at the Certificate Holder
 Attending the (re-) certification audit every 3 years
 Assuring that Quality Program is properly implemented (Monitoring)

 Inspection, some of the activities:


 Reviewing and accepting Inspection Plans
 Reviewing / Verifying Design and Calculations
 Verifying Material identification and certification
 Reviewing Welding Procedures and Welders‘ Qualifications
 Reviewing NDE Procedures and Qualification of Personnel
 Performing visual internal and external inspections
 Witnessing Pressure Tests and Proof Tests
 Signing Data Reports and verifying Nameplates
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AGENDA

 INTRODUCTION

 ROLE OF THE AIA

 QUALITY SYSTEM

 DUTIES OF THE AI

 WHAT CAN GO WRONG?

 CONCLUSION AND OUTLOOK

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WHAT CAN GO WRONG?

INITIAL SITUATION

During a re-certification audit the ASME Auditor finds out that pressure
vessels delivered to the user and inspected by the AI is constructed of
material not permitted by the ASME Code.
Audit Result: failed + further investigation required!

NEXT STEPS
 Investigation with the Manufacturer of all previous jobs  systematic
problem? Potential danger to life and property? Root Cause?
 Notification of User and removal of Nameplates from the vessels
 Investigation by the AIS of the Inspector’s Performance
 Re-Review of the Company required
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WHAT CAN GO WRONG?

INVESTIGATION RESULTS:

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


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

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WHAT CAN GO WRONG?

 Importance of QC System Monitoring activities


 Periodic audits by the AIS are strongly recommended
 Performance Evaluation of the AI shall be conducted annually by the
assigned AIS
 Importance of continuing education of the AI
 Importance of continuous education of the Certificate Holder Staff
 Increasing awareness of all Stakeholders!
 Never look for shortcuts!

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WHAT CAN GO WRONG?

Manufacturer‘s Data Report statement:

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


As such, he/she and his/her AIA may become co-responsible for any
further, damage or loss caused by the inspected equipment.

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AGENDA

 INTRODUCTION

 ROLE OF THE AIA

 QUALITY SYSTEM

 DUTIES OF THE AI

 WHAT CAN GO WRONG?

 CONCLUSION AND OUTLOOK

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CONCLUSION

Why is the ASME Code successful on a global scale?


 Due to its high recognition it opens doors to the new markets
 Equal rules for all Stakeholders regardless of their location:
 Certificate Holders
 Inspection Agencies (AIAs)
 ASME Auditors
 Equality in the Inspection Process
 Universal Conformity Assessment Process
 High Transparency
 Open for feedback and improvements through Committee Work!

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THANK YOU FOR YOUR ATTENTION!

Questions?
I am more than happy to discuss!

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