ASME

 

 

1.       Quality System

1.1    Q.C manual (Korean & English)

1.2    Q.C procedures (Korean & English)

1.3    Work Instructions, Technical Procedures

 

2.       Design

2.1    For U

- Job spec.

- Calculation sheet

- Drawing

2.2 For S

- Job spec.

- Calculation sheet & Drawing

        2.3 General

          - Computer Program Verification

 

3.       Material control

(Including plates, pipes, flanges and welding material)

3.1    BOM

3.2    M.P.S

3.3    P.O

3.4    RICR

3.5    MTR

3.6    C/P

 

4.       N.D.E.

4.1    Personnel qualification

-          Written practice

-          Level ¥² appointment letter

-          Qualification & certification record

4.2    Equipment calibration

-          Cal. Procedures.

-          Density strip

-          Cal. Record & std. Blocks

 

4.3    Procedures

-          RT, UT, MT, PT

-          Demonstration to AI

 

4.4    Visual Examiner Qualification

-          Procedure

-          Records

 

5.       Welding

5.1    WPS/PQR(test)

5.2    Welder Qualification Record & T.C.W

5.3    Welding map

5.4    Welding material control

-          Procedure

-          Control Room & Baking/Holding Oven

-          Issue slip

5.5    Calibration (hook meter, thermometer, etc.)

 

6.       PWHT

6.1    Procedure & instruction

6.2    T-T chart

6.3    Recorder/thermometer calibration

 

7.       Fabrication

7.1    Traveler

7.2    Inspection and test report-head, etc.

7.3    Work instruction

-          Temporary attachment

-          Repair welding

-          I.T.P(dimensional tolerance, edge prep, etc.)

7.4    Demo. Vessel

-          Shell courses, heads, nozzles shall be finished.

-          Category A,B,C,D shall be demonstrated (welded or fitted)

-          All surfaces shall be clean, free from damage and all joint No. Shall be clearly identified.

-          Edge preparation angle, gap, root face shall be checked preferably by jig plates.

-          RT and other required NDT for joints, temporary attachment removal area

 

8.       Calibration

8.1    Critical dimension measurement

8.2    Material test equipment-tensile, impact machine

8.3    PWHT recorder, censer, controller

8.4    Electric current/voltage meter

8.5    Thermometer-including baking & holding oven

8.6    Pressure gage/dead weight tester

 

9.       Other

9.1    NCR

9.2    Sample MDR

9.3    Field hydro. For A

 

10.    Attentions

10.1                Job no. Shall be appeared on all document

10.2                Do not use white liquid

10.3                Process sequence shall always be considered.

10.4                Document no., revision and page shall be controlled

10.5                Record the measurement instrument No. on reports, if used.

10.6                Each piece of material shall have its I.D on reports, if used.

10.7                Welder I.D, mat1 I.D, report no., NCR No. shall be recorded.

                On each applicable operation of traveler.

10.8                Material spec. shall always be SA-xxx

10.9                Korean version is required for document to be used in the shop.

 

 

 

 

1.       Inspection agreement with HSB(A.I.A).
 
2.       ASME 심사 요청
2.1    신청서 작성 및 발송(ASME Form 사용)
2.2    예치금 송금 및 확인 Letter 발송
2.3    심사 일정 확인
 
3.       Code book  구입
3.1     ASME에 필요한 code book 신청 및 invoice 접수
3.2     Code book 대금 송금
3.3     Code book 접수
 
4.       예비심사(HSB-AIS, AI) 2명, 1~2일
 
5.       본심사(HSB-AI, AIS, ASME Rep.)  -3명, 1박 2일
 
6.       Certificate 및 stamp 수령
          - 심사 후 약 6주 이내
 

 미국기계학회가 발간한 압력용기 및 보일러 설계, 제작, 검사에 관련 된 법규집에 따라 제작업체가 구축한 품질관리 시스템을 ASME, AIA(AIS, AI)가 심사하여 ASME CERTIFICATE를 부여하는 제도..

 

ASME STAMP 

1. 외국 수출 압력용기의 약 80%가 ASME STAMP를 MANADTORY 사항으로 지정(특히 미국 법적 요구사항임)
2. 품질관리 SYSTEM의 획기적인 향상이 기대됨.
3. 영업적인 측면에서 stamp를 미 보유 업체보다 고객에게 제품의 품질에 대한 신뢰성 확보.
 

ASME Stamp Work 관련 절차

1. ASME에 APPLICATION 신청
2. ADVANCE DEPOSIT 입금
3. CODE BOOK 구입
4. MANUAL/ PROCEDURE 작성
5. DEMO WORK(DESIGN/Activity Document 작성/ DEMO VESSEL 제작/ PRE JOINT
6. JOINT REVIEW
 

소요 예산(약 4000만원 소요)

1) ADVANCE DEPOSIT : $8,000(ASME)
2) CERTIFICATES : $1815/CERTIFICA(ASME)
3) STAMP : $181/STAMP(ASME)
4) CODE BOOK : for U & S : Approx : $2500(ASME)
5) Consulting fee : 15,000,000 won
6) NDE Subcontractor : 2,000,000 won
7) Others such as Hotel & meal during Joint Review : 1,000,000 won
8) Demo vessel fabrication : 3,000,000 won

 

소요시간 : ASME DEPOST 후 약 4개월 소요 

 

ASME STAMP를 취득하기 위한 소요 Man Power

(1,4은 외주가능)
1. 설계전문가(압력용기)
2. 용접전문가
3. 품질관리요원
4. NDE 요원

 

ASME Certificate 취득 작업 전 행정사항

1. Application 신청 접수 및 작성
2. Application 송부 to ASME
3. Advance deposit 송금
4. ASME Code Book 구입 : 착수 2개월 후
5. NDE 업체와 용역 계약 : 착수 3개월 후
  

 

PHASE 1_START OFF
Prior to the Phase 1 visit, AIA requests a standard “Pre-Qualification” type document covering shop’s equipment/product lines, etc.. a company organization chart, and a list of “ASME Task Force” members and their individual responsibilities.
 
Kick-Off Meeting
 
Supervisor & Inspector visit and meet with the ASME Task Force.
Guidance is offered regarding:
     Task Force Composition
     Schedule
     Previous experience with shop preparation for initial joint review
     General discussion prior to preparation of QC Manual, Procedures, and demonstration
     Engineering
 
Shop Analysis
 
This is one day examination of shop equipment, Facilities, and present capabilities, in order to determine areas to be addressed by the “ASME Task Force” in order to prepare the shop for Code Work. Possible subcontractor analysis.
 
 
Guidance for QC Manual & Procedure Development
 
AIA will discuss/Provide:
1. List of the code requirement to be addressed in the QC Manual
2. Acceptable welding procedures
3. Checklist for Shop Preparation
4. Discussion of acceptable methods for meeting the checklist items and for QC Manual Preparation based on resources of the shop, product lines, and any subcontractors to be involved.
 
 
PHASE 2_QC Manual/Procedures/Engineering/Training
 
Prior Phase 2, the Task Force should start on the QC Manual, Procedure Preparation, and Demonstration Engineering.
Existing QC Manual would be reviewed and revised if necessary.
 
QC Manual and Procedure Development/ Completion and Training
 
Meeting and Shop Visits are made by Supervisor or Inspector to:
Review progress with Checklist provided by AIA in Phase 1
The Code requirements for a QC Manual together with the particulars of the shop organization, facilities and sub-contractors are integrated to develop a “final draft” QC Manual
Procedure are finalized for Welding, NDE, Calibration etc.. Adjustment is made in shop operation to confirm to such procedures.
Progress with demonstration calculation & drawing is checked.
AIA would take any special procedural questions with the ASME training will be given by Authorized Inspector.
AIA will discuss/Provide:
 
 
PHASE 3_Preparation for Joint Review/Demonstration Vessel Fabrication

During Phase 3, the Task Force and the Authorized Inspector (AI) work together to prepare for the Joint Riview.
 
Manufacturer and AIA is providing QC and Engineering Personnel Training ABS Group is providing AIA guidance this process. The Authorized Inspector Supervisor (AIS) could also make a visit about midway through Phase 3 if Manufacturer so request, although AIA would not propose this unless considered necessary after the Phase 2 visit.
 
The Inspector is checking the demonstration vessel fabrication and Manufacturer’s record keeping and procedure implementation.
 
New question raised during this period may be referred by the AI to AIS for answer at or before the Pre-Joint Review.
1. List of the code requirement to be addressed in the QC Manual
2. Acceptable welding procedures
3. Checklist for Shop Preparation

 
 
Phase 4_PRE-JOINT REVIEW 

The AIS or AI would conduct a Pre-Joint Review, similar to the review to be performed by ASME and AIA for obtaining the Certificates of Authorization. This review should be 2 to 4 weeks before the Joint Review.
 
An extra visit will be made by the Inspector after the Pre Joint Review to recheck any needed corrections.
During Phase 3, the Task Force and the Authorized Inspector (AI) work together to prepare for the Joint Riview.
 
Manufacturer and AIA is providing QC and Engineering Personnel Training ABS Group is providing AIA guidance this process. The Authorized Inspector Supervisor (AIS) could also make a visit about midway through Phase 3 if Manufacturer so request, although AIA would not propose this unless considered necessary after the Phase 2 visit.
 
The Inspector is checking the demonstration vessel fabrication and Manufacturer’s record keeping and procedure implementation.
 
New question raised during this period may be referred by the AI to AIS for answer at or before the Pre-Joint Review.
1. List of the code requirement to be addressed in the QC Manual
2. Acceptable welding procedures
3. Checklist for Shop Preparation

 
 
Phase 5_Joint Review

Schedule : To be set by ASME
 
Authorized Inspector Supervisor (AIS) and Authorized Inspector (AI) attend with the representative from ASME for period of 2 days.
 
1. ASME 인정 요청서(Application) Fax 발송, 접수, 작성 송부(To ASME) – 약 2주 소요
2. 예치금 및 인정서 비용 송금 : US $ 1,815 (인정서 당, 인Ⅴ정서 2개인 경우(1,815*2=$3,630)
3. ASME Code Book : Section ¥± Part A, B, C, D – Material
4. Section ¥´ – NDE
5. Section ¥• , Div. 1 – Pressure Vessel
6. Section ¥¸ - Welding
7. ASME QC Manual and Procedures 작성
8. ASME 인정 심사 시는 필히 DEMO VESSEL을 제작하여 심사를 받아야 함. 귀사의 ASME QC MANUAL이 ASME Code에서 요구하는 사항의 만족여부 Check, ASME 작업 관련 직원들의 ASME CODE BOOK 이해도 CHECK, 귀사에서 귀사의 ASME QC MANUAL 및 Code Book에 따라 DEMO VESSEL 제작 과정을 통하여 ASME CODE 제품 제작 능력 CHECK 하는 것이 심사의 가장 핵심임.
9. (설계에서 DEMO 용 ITEM을 선정 일반적인 설계업무와 같이 도면 작성, 계산서 작성, POS/POR 및 설계 사항 준비)
10. 자재 담당 부서 – 설계부서에서 작성된 POS/POR에 준하여 PO 발행
11. 자재 입고 및 QC 수입 검사실시 및 서류 작성 – Manual 및 Procedure에 따름
12. 비파괴 업무는 주로 외주 처리하므로, 외주 처리에 필요한 계약 및 서류 작성(비파괴 업체에서 잘 숙지하고 있음)
13. Demo Vessel 제작 시 필요한 WPS, PQR 및 용접사 자격 등 용접 관련 각종 서류 준비
14. Demo Vessel 제작 – 작성된 Manual 및 Procedures에 따라 제작 및 서류 작성 측정 장비 교정 및 MANUAL 및 Procedure에 따라 서류 작성
15. 기타 필요한 서류 준비
16. Pre-Joint Review : AIA에서 AI 및 AIS가 사전 점검(2일간)
17. Joint Review – ASME Team Leader / AIS / AI – (2일간) 심사 일정은 ASME에서 정함.