BPV Certification Form Checklist Accreditation

GUIDE
FOR
ASME REVIEW TEAMS
FOR
REVIEW OF APPLICANTS
FOR
ASME CERTIFICATES OF AUTHORIZATION
{A, M, PP, S, E, H, HLW, U, UM, U2, U3, PRT and T}

The American Society of Mechanical Engineers
Two Park Avenue
New York, NY 10016

BPV‐GUI‐01 Issue 1, Revision 3 ‐ 03‐26‐2018 0 | P a g e

INTRODUCTION

This Guide is prepared for the use of ASME Review Teams. It is not intended to replace or interpret the
requirements of the ASME Boiler and Pressure Vessel Code (B&PVC).

In addition, to assist the ASME Review Team, this Guide will be provided to Applicants for ASME Certificates
of Authorization for their use in cross referencing the paragraphs in their written description of the Quality
Management/{Quality Control ((QC)) Manual} with the applicable control requirements of the Code, and as a
guide as to what is expected for a demonstration of the QC System.

This Guide is based on Section I, Section IV, Sections VIII Divisions 1, 2 and 3, and Section XII of the B&PVC.
The Guide is subject to revision based on changes made in the aforementioned Sections in the B&PVC.

A Review must cover a QC Manual and its implementation. It is recognized that the scope of work, QC Manual,
and Manual implementation will vary from Applicant to Applicant. Therefore, the ASME Review Teams are
advised that all aspects of this Guide may not apply and that this Guide may not outline all possible aspects of
each Review. The Manual need not follow the format of this Guide.

Questions of possible need for Code interpretation raised by Review Teams shall be submitted to the ASME
Director, Accreditation and Certification. When a request for an interpretation is to be submitted by an
Applicant, the Team Leader shall advise the Applicant that all such inquiries must be submitted to the Secretary
of the applicable Boiler and Pressure Vessel Book Section, and that a copy of the inquiry and reply should be
provided by the inquirer to the Applicantʹs Authorized Inspection Agency and cognizant Jurisdiction, if
appropriate.
Suggestions for revisions or clarification to this Guide should be directed to the ASME Director, Accreditation
and Certification.

REVIEW DEMONSTRATION

The purpose of the Review Demonstration is to evaluate the Applicant’s Quality Control System (QCS) and its
implementation. For evaluation of the QCS, the Applicant must demonstrate to current Code rules sufficient
administrative and fabrication functions of the QCS to show that they have the knowledge and ability to produce
the Code items typical of those covered by the QCS. It is expected that fabrication functions be demonstrated
using typical Code work. However they may be demonstrated using current work, a mock‐up, or a combination
of the two. Any current Code work ongoing at the time of the joint review is subject to the Team’s review.

While the Applicant must address each element of the QCS in the Code, the Applicant need only demonstrate
those elements within the intended scope of activities that apply to their program.

Demonstration Item1: An Applicant2 requesting a single Certificate of Authorization (e.g. “A”; “S”; “PP”; “PRT”;
etc.) must demonstrate on an item that will be fabricated for the requested Certificate Designator and scope of
Certificate of Authorization. The demonstration must be an implementation of ALL aspects of the QC System
and is to include a demonstration of actual welding if welding is included in the scope of Code activities. If
computer calculations are to be used, the Applicant shall demonstrate that the computer program has the
capability of producing acceptable calculations.

For Applicants requesting multiple Certificates of Authorization, it is not necessary to have a demonstration
item with design calculations for each Certificate Designator. A demonstration item fabricated to any one of the
requested Certificates may be used as the demonstration item for the implementation portion of the Review. The
Applicant is advised to select a demonstration item based on type of code item normally and most frequently
manufactured. However, please note that if the demonstration item selected does not cover all the Certificates
requested, the applicant will be required to prepare and present to the Review Team design documents for those
Certificate designators not covered by the selected demonstration item.

For example, an Applicant for U and U2 Certificates could demonstrate its QCS on a Section VIII, Div. 1
demonstration item including design. However, since the Section VIII, Div. 1 demonstration item does not cover
the U2 Certificate Designator, the applicant will also be required to prepare and present to the Review Team
design documents for Section VIII, Div. 2 such as, Examination and Inspection plan, Manufacturer’s Design
Report with supporting User Design Specification, Certification of the design documents by an Engineer, as
applicable.

For guidance in the selection of the demonstration item recommended/required based on Certificate Designator
requested, refer to Table 1 below:

1 The demonstration item shall be based on the latest Code Edition in effect at the time a complete Application is received by ASME.
2 This does not apply to an Engineering Contractor under Section I. For an Engineering Contractor Organization under Section I,
without a fabricating facility, a physical demonstration item is not required. However, a design specification must be provided as
well as additional administrative functions to demonstrate compliance with the organization’s QCS.

Table 1
Demonstration & Certificate Coverage Matrix
Demonstration Certificate Coverage
B31.1 [BEP] – Need to show PP
compliance with BEP
Section I PP, S, E, M, U, UM, H, HLW
Section IV H, HLW
Section VIII, Div. 1 PP, S, H, HLW, U, UM, T
Section VIII, Div. 2 Class 1 PP, S, H, HLW, U, UM, T, U2 Class 1
Section VIII, Div. 2 Class 2 PP, S, H, HLW, U, UM, T, U2 Classes 1 & 2
Section VIII, Div. 3 U3
Section XII T

Note: For “PRT” or “A” Certificates, no design calculations are required.
However the applicant shall demonstrate the QCS using a demonstration item
representative of the Certificate scope (e.g. For “PRT” fabrication of a part shall
be demonstrated and for “A” fabrication/assembly of a Section I boiler shall be
demonstrated).

If the demonstration item is based upon current work that is being fabricated to a previous Code edition, the
Applicant shall address changes in the Code that would require different actions in the demonstrations to be in
compliance with the current Code requirements.

QUALITY SYSTEM REVIEW CHECKLIST
Item Quality Element and QC Manual

No. Sub‐elements References
1. GENERAL QUALITY CONTROL SYSTEM REQUIREMENTS

(a) QC System is documented in detail in a QC Manual that addresses all requirements
of the applicable Code Section and includes:

(1) a cover sheet that contains the company name and physical address as it will
appear on the requested Certificate of Authorization;

Note: The cover sheet may also contain the effective date of the QC Manual, mailing
address, phone number or other information desired by the Certificate Holder or
Applicant.

(2) a brief description of the products being fabricated and/or work being
accomplished under the Code including applicability of QC System to shop
activities, field activities or both;

(3) control features to demonstrate Code compliance;

(4) Manual revision control system;

(5) provision for review and approval of QC Manual to ensure it is current;

(6) provision for submittal of QC Manual revisions to the Authorized Inspector
(AI) and T Class 3 for acceptance prior to implementation including timely
updating of all copies to reflect accepted revisions; and

(7) provision for the custody and control of the Certification Mark to prevent
loss or unauthorized use.

(b) In the case where the QC Manual exists in more than one language, at least one
version is in English and identified as the authoritative version.

Note: A glossary of terms is desirable from the standpoint of clarity if abbreviated titles of
personnel and control documents are used throughout the QC Manual. This,
however, is not mandatory.

2. AUTHORITY AND RESPONSIBILITY

(a) The authority and responsibility for QC by management is documented.

Note: In practice, a Statement of Policy and Authority must be signed by a senior
company official responsible for Code activities (e.g., President, Vice President,
Plant Manager, etc.).
BPV‐GUI‐01 Issue 1, Revision 3 – 03‐26‐2018 4 | P a g e


(b) The authority and responsibility of those in charge of the QC System are clearly
established and documented.

(c) Persons performing QC functions have sufficient and well defined responsibility, the
authority, and the organizational freedom to identify quality control problems and to
initiate, recommend and provide solutions.

3. ORGANIZATION

(a) An organization chart showing the relationship between management and
engineering, purchasing, manufacturing, production, field assembling, field
construction, inspection and quality control, as applicable, exists and reflects the
actual organization.

Note: The purpose of this chart is to identify and associate the various organizational
groups with the particular function for which they are responsible. The Code does
not intend to encroach on the Certificate Holderʹs right to establish and, from time to
time, alter whatever form of organization the Certificate Holder considers
appropriate for their Code work.

4. DRAWING, DESIGN CALCULATIONS, AND SPECIFICATION CONTROL

(a) Procedures exist which assure that the latest applicable drawings, design
calculations (design calculations are not required for PRT or certificate scopes with no
design responsibility), specifications and instructions, required by the Code, as well as
authorized changes, are used for manufacture, assembly, examination, inspection
and testing. Procedures include provision for:

(1) review of customer supplied documents for Code compliance;

(2) the preparation, review, approval and distribution of drawings, calculations, and
specifications;

(3) {Applicable to U2 and U3 only} use of the userʹs Certified Design Specification
including authorized changes;

(4) {Applicable to U2 and U3 only}
providing the Manufacturerʹs Certified Design Report including authorized
changes;

(5) {Applicable to U2 and U3 only}
certification of Design Specification and Design Report by an engineer meeting the
criteria defined in Section VIII Div. 2 and/or Div. 3;



(6) {Applicable to T Class 3 only}
provisions for Design Certifying Engineer.

5. MATERIAL CONTROL

(a) Procedures for material control exist to assure that the material received is properly
identified and has documentation, including, as applicable, required material
certifications or material test reports, to satisfy Code requirements as ordered.

(b) The material control system assures that only the intended material is used in Code
construction. For Section XII only, material shall satisfy the applicable modal
appendices requirements.

(c) If substitution of materials is allowed, the applicable procedures for control of this
activity are documented, including designation of the individual authorized to
approve substitutions.

(d) The title of the individual responsible for identifying the need for material test
reports or certificate of compliance is designated.

(e) The title of the individual responsible for performing a receiving inspection of Code
materials is designated.

(f) Information to be provided to the receiving inspector concerning the characteristics
to be checked is documented.

(g) A procedure exists for handling materials that are found to be nonconforming at
receiving inspection.

(h) If further material testing is required to be performed at receiving inspection or
during manufacturing operations, the applicable procedures for control of this
activity are documented.

(i) Measures are established to assure the proper marking, handling and storage of
materials.


6. EXAMINATION AND INSPECTION PROGRAM

(a) Fabrication operations, including examinations and test procedures are described in
sufficient detail to permit the Authorized Inspector (AI) to determine at what stages
specific inspections are to be performed. Specifically:

(1) Provisions for the use of checklists, process sheets, travelers, etc., for listing of
examinations and tests to be performed and for designation of inspection
points;

(2) Such checklists, process sheets, travelers, etc., are made available to the
Authorized Inspector prior to the start of fabrication; and

(3) {Applicable to UIG} A basic production flow diagram exists and includes in‐
plant inspection and check‐off points and means of recording the same.

(b) Material test reports or certificates of compliance, examination reports, test records,
and other fabrication records are available to the Authorized Inspector.

(c) Measures provide for transferring markings to assure traceability is maintained.

(1) If a coded marking system is used, it is documented and acceptable to the
Authorized Inspector.

(d) Measures to ensure that the Authorized Inspector is informed of approaching inspection
points.

(e) AI concurrence is obtained for repairs to material. {Not applicable to T Class 3}

(f) Measures are established to assure that a final inspection is performed to assure all
specified requirements have been met prior to obtaining AIʹs concurrence for
application of the Certification Mark. {Not applicable to T Class 3}

(g) Measures are established to provide for the preparation, certification, and distribution
of the applicable Data Reports.

(h) Measures are established to control field activities, when applicable.

(i) {For operations under UG‐90(c)(2), HG‐515.4(b), or TS‐200.7}
Documented procedures exist and are accepted by the Authorized Inspection Agency
(AIA), Jurisdictional Authority, and ASME Designee.


Note: Procedures should fully describe AI coverage of ASME Code work on all shifts. Also,
percentage of AI time spent inspecting vessels or boilers that may not qualify for
handling under UG‐90(c)(2), HG‐515.4(b), or TS‐200.7 should be addressed.

(j) {Applicable to UIG (Graphite)}

(1) For U (Graphite) pressure vessels hydrostatic tests are conducted as required in
UIG‐99 and there are means of identifying acceptable graphite pressure vessel
parts.

(j) {Applicable to UIG}

(1) Resin or cement mixing procedures are specified; and

(2) Measures are established covering storage, issuance, handling, and disposal or
resins, catalysts, fillers, pigments or cements.

(3) Procedures exist covering:

(i) assembly and fit‐up of the pressure vessel and parts; and

(ii) adhesive‐bonding of components.

(m) {Applicable to E and UM only}

Certified Individual (C.I) qualifications:

i. Is an employee of the Applicant
ii. meets knowledge and training requirements and is qualified and certified by the
Applicant; and
iii. records are available, maintained, certified by the Applicant and contain objective
evidence of the Certified Individual’s qualification.

Measures are established to assure that the Certified Individual performs all required
duties specified in the applicable Code.

Note: For UM, U3, and T Class 3 qualification and duties
for the C.I. shall be in accordance with QAI‐1, Part 8.


7. CORRECTION OF NONCONFORMITIES

(a) A procedure exists for the correction of nonconformities. Where AI involvement is
required by the Code, the procedure is agreed upon with the AI. The procedure
provides for:

(1) identifying those responsible for the resolution of nonconformities;

(2) identifying and controlling further processing of nonconforming items until
final disposition;

(3) documenting the nonconformance and its disposition; and

(4) informing the AI of nonconforming conditions. {Not applicable to T Class 3}

Note: A nonconformity is any condition which does not comply with the applicable rules of
the Code, QC Manual or other specified requirements. Nonconformities must be
corrected before the completed component can be considered to comply with the
Code.

8. WELDING/CEMENTING

(a) Welding/cementing conforms to requirements of Section VIII Div. 1, Section IX and
other Sections of the Code, as applicable to the scope of work.

(b) Those responsible for certifying PQRʹs/CCQ’s, CPQ’s and WPQʹs/CTQ’s are
identified.

(c) WPSʹs/CPS’s are available to the welder/cementing technician in the work area.

(d) Measures assure continued welder/cementing technician qualification in accordance
with Section VIII Div. 1 (UIG‐80(d) or Section IX.

(e) Those responsible for assuring that only qualified welders/cementing technicians are
assigned to perform Code welding or cementing are identified.

(f) Measures provide for the storage and conditioning, as required, of covered electrodes
and conditioning of cements and their ingredients.

(g) Measures are established for the control, issuance and return of welding material or
disposal of cementing material to assure proper materials are used.

(h) Measures are established for removing or inspecting tack welds.


(i) Measures provide for the right, at any time, of the AI to call for and witness tests of the
welding/brazing/cementing procedures and/or call for and witness the ability of
welders, welding operators, braziers or brazing operators, or cementing technicians to
perform their assigned tasks as required by the Code.

(j) Measures provide for a system to identify work completed by each welder/cementing
technician.

9. NONDESTRUCTIVE EXAMINATION

(a) Provisions exist for identifying the appropriate NDE procedures applicable to the
scope of Code work. These provisions assure that:

(1) NDE personnel are qualified in accordance with the applicable Code Section

requirement;

(2) NDE {(UT, MT, PT and VT (UIG)} examinations are performed in accordance
with written procedures when required;

(3) The AI can require demonstration by NDE personnel of an NDE examination or
NDE procedures for cause;

(4) UT reports and RT films, as applicable, are retained in accordance with the

applicable Code requirement; and

(5) NDE equipment is calibrated.

10. HEAT TREATMENT

{Not applicable to UIG}

(a) Controls provided to assure that heat treatment as required by the Code for the scope
of Code work is applied.

(b) Measures are established to assure proper placement of thermocouples and use of
charts.

(c) When heat treatment is subcontracted, measures are established to assure that
procedures are followed and that heat treatment charts are provided.

(d) Means are provided to satisfy for the AI that Code heat treatment requirements are
met, (e.g., review of furnace time‐temperature records or other methods as
appropriate).


11. CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT

(a) A procedure exists for the calibration of examination, measuring and test equipment
used in fulfillment of applicable Code requirements.

(b) Measures are established that assure calibration records are maintained and that
status indicators are used to indicate the current calibration status of equipment.

12. RECORDS RETENTION

(a) Procedures exist for the maintenance of Manufacturerʹs Data Reports, radiographs
and records as required by the applicable Section of the Code.

13. SAMPLE FORMS

(a) Forms used to control functions relative to quality are included within the QC
Manual and their use explained in the text of the QC Manual.

14. AUTHORIZED INSPECTOR (AI)
{Not applicable to T Class 3}

(a) An inspection agreement is established and maintained with an ASME accredited
Authorized Inspection Agency. For Section XII Class 2 this could be a Qualified
Inspection Organization (QIO), as defined in QAI‐1. Part 6.

(1) All required inspections are to be performed by the AIA of Record (the AIA

identified on the application).

(2) Alternatively, when the AIA of Record cannot provide coverage for inspections
at a specific field site the following shall be included in the QC Manual:
(a) Description of how different AIA’s will perform activities under their
Certificate(s) of Authorization;

(b) Ensure the Certificate Holder has a contract or agreement with the AIA
performing the field activities; and

(c) Show evidence that this program has been accepted by the AIA of Record.

(b) A controlled copy of the QC Manual is available to the AI at the plant and all field site
locations controlled by the Code shop where Code activities are being carried out.

(c) The AI has access to all drawings, calculations, specifications, procedures, process
sheets, repair procedures, records, test results, and any other documents as necessary
for the AI to perform their duties.


(d) Provisions exist for providing a liaison between the AI and the
Manufacturer/Installer.

(e) Provisions exist for free access for the AI and the Inspector Supervisor to all areas
involving Code activities.

(f) Provisions exist to assure that all Code required inspections by the AI are performed.

(g) ASME is notified whenever the agreement is cancelled or changed to another
accredited Authorized Inspection Agency

(h) Provisions exist for AIA’s periodic inspection of the E Stamp Holder Code activities
per PEB 18.2.2

(i) Provisions exist for the reviews for UM certification renewal after the first and
second years of each 3 year review cycle to be performed by the Authorized
Inspector Supervisor and report submitted to ASME.

15. CERTIFICATIONS

(a) Provisions exists for written certifications, authorizations and approval that require
written signature and written date.

(b) Provisions exists for certification methods other than written, when used, describing

the controls and safe guards that are employed to ensure the integrity of the
certification, authorization or approval.


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Item Quality Element and QC Manual

Item Quality Element and QC Manual

Item Quality Element and QC Manual

Item Quality Element and QC Manual

Item Quality Element and QC Manual

Item Quality Element and QC Manual

Item Quality Element and QC Manual

Item Quality Element and QC Manual

Item Quality Element and QC Manual

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