Communicating Bad News

Chapter-8

procedures

Mirza Safeer AhmadNCNDT-SES Dte.1A written procedure based on the applicable code should be prepared by the organization responsible.Article 9, lists the following elements to be included in a visual examination procedure:How visual examination is to be performedType of surface conditions availableMethod or tools for surface preparation, if anyWhether direct or remote viewing is usedSpecial illumination, instruments, or equipment to be used, if anySequence of performing examination, as applicableData to be tabulated, if anyReport forms to be completed2requirementsThe procedure should also contain or reference a report of the approach used to demonstrate that the examination procedure was adequate (procedure qualification).In general, a fine line, 1/32 in. (0.8 mm) or less in width, or some other artificial flaw located on the surface to be examined or a similar surface is considered satisfactory evidence that the procedure is adequate. To prove the procedure, the line or artificial flaw should be located in the most unfavourable location on the area being examined. It is common to list acceptance criteria for various product forms in the procedure. 3requirementsThe product forms should be specified in order to reduce the number of different visual procedures needed. In any case, substituting equipment with that of a different manufacturer or changing the details of the test parameters may require procedure requalification.The inspector should refer to a copy of the visual test procedure at the test site. A reference standard can be a valuable tool for judging preweld fitup, welding technique and completed weld quality.4requirementsThe conduct of test operations (in-house or contracted) should be performed in accordance with specific instructions from an expert. Specific instructions are typically written as a technical procedure. In many cases, codes and specifications will require that a technical procedure be developed for each individual test. In other cases, the same procedure is used repeatedly.The procedure can take many forms. A procedure may comprise general instructions that address only major aspects of test techniques or a procedure may be written as a step-by-step process requiring a supervisor's or a qualified/certified worker's signature after each step.

5FormatThe following is a typical format for an industrial procedure.The purpose identifies the intent of the procedure.The scope establishes the items, tests and techniques covered and not covered by the procedure.References are specific documents from which criteria are extracted or are documents satisfied by implementation of the procedure.Definitions are needed for terms and abbreviations that are not common knowledge to people who will read the procedure.Statements about personnel requirements address specific requirements to perform tasks in accordance with the procedure issues such as personnel qualification, certification and access clearance.6FormatCalibration requirements and model numbers of qualified equipment must be specified.The test procedure provides a sequential process to be used to conduct test activities.A system performance check is needed before a test. The check might be daily or detailed.Acceptance criteria establish component characteristics that will identify the items suitable for service (initial use or continued service).Reports (records) document specific test techniques, equipment used, personnel, activity, date performed and test results.Attachments may include (if required) items such as report forms, instrument calibration forms, qualified equipment matrix, schedules and others.7FormatOnce the procedure is written, an expert in the subject evaluates it. If the procedure meets requirements, the expert will approve it for use. Some codes and standards also require the procedure to be qualified that is, demonstrated to the satisfaction of a representative of a regulatory body or jurisdictional authority.

8FormatAcceptance criteria for welds will be as designated by the applicable code or specification and will usually include the following discontinuities:CracksIncomplete penetrationCrater pits and cracksArc strikesUndercut (dimension will be specified)Surface porosity (usually defined by a maximum single size or some formula of aggregate amount in a total length of weld)Slag (surface)SpatterBurn-through or melt-through9Acceptance criteriaOverlap and rolloverLack of fillExcessive reinforcementSpecific acceptance criteria can be found in various codes, specifications, and standards. In many cases, they will be specified as part of the contract requirements. Records of inspections or examinations should also include statements indicating part acceptance (if applicable), and include appropriate documentation to support findings. Inspection report forms should be complete, legible, concise, and signed and dated.

10Acceptance criteriaIf corrections are necessary, they should be made with a single line through the entry error, initialed, and dated. All reports, results, and/or drawings, sketches, photos, electronic files, digital video discs (DVD), or videotapes should be listed and retained in accordance with contractual requirements or codes and included with the data sheet.

11Acceptance criteriaRetention and maintenance of recordsThe records and reports shall be retained as identified in IWA-6330, IWA-6340, and IWA-6350 of ASME Sec-XI. The records and reports shall be filed and maintained in a manner that will allow access by the Inspector. The Owner shall provide suitable protection from deterioration and damage for all records and reports, in accordance with the Owners Quality Assurance Program, for the service lifetime of the component or system. Storage shall be at the plant site or at another location that will meet the access and Quality Assurance Program requirements.12DocumentationReproduction, digitization, and microfilming Records and reports shall be either the original or a reproduced, legible copy. Records may be maintained in an electronic (i.e., digital) format using magnetic, optical, or equivalent storage media. Hard-copy records may be digitized. The Owners Quality Assurance Program shall include a system for verifying accuracy and monitoring image legibility, storage, retrievability, and reproduction quality.13DocumentationReproduction, digitization, and microfilming Radiographs may be microfilmed or digitally reproduced. Digital reproduction shall be in accordance with Section V, Article 2, Mandatory Appendix VI, including Supplement A. The Owners Quality Assurance Program shall include a system for monitoring the accuracy of the reproduction process so that the reproduction will provide the same information retrieval capability as the original radiograph. The accuracy of the reproduction process includes the exposure (or multiple exposures for density coverage), focusing, contrast, and resolution. The Quality Assurance Program shall also provide a system for identifying film or reproduction artifacts that might appear as material discontinuities in the reproduction.14DocumentationConstruction recordsRecords designated by the Owner in accordance with NCA-4134.17, the Construction Code, and Owners Requirements, as applicable, shall be retained.

15DocumentationInservice inspection recordsThe Owner shall designate the records to be maintained. Such records shall include the following, as applicable:Record indexPreservice and inservice inspection plans and schedulesPreservice and inservice inspection reportsRecords of flaw acceptance by analytical evaluationRecords of regions in ferritic Class 1 components with modified acceptance standardsNondestructive examination proceduresNondestructive examination recordsPressure test proceduresPressure test records16DocumentationRepair/replacement activity recordsThe following records prepared in performance of a repair/replacement activity shall be retained:Repair/Replacement Program and PlansRecords and reports of repair/replacement activitiesReconciliation documentation NIS-2 FormDocuments certifying repair/replacement activities by contracted Repair/Replacement Organizations.

17DocumentationDATA SHEETSVisual test results are recorded by using forms developed for specific applications. If no form is provided by the customer or regulation, the inspector should develop one that provides the following data:Joint identification and description,Joint inspector's identification,Testing dates, Instrument and equipment identification (may refer to procedure), Procedure identification (and checklist) and Record of the test results.18DocumentationDATA SHEETSIn the record of results, identify all measurements to be recorded, provide space for all recorded measurements with identification, and provide space for recording indications. Through standard recording formats and prepared forms, the inspector and supervisor can determine if all required observations have been made properly.19DocumentationThank You for Your Attention20