Rev 0 July 18, 2006
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TSSA Sample Refrigeration QC Manual
The ABC Company
Any town
Ontario
A1B 2C3
Quality Control Manual for the Shop and Field Fabrication, Assembly & Repairs of Pressure Piping Systems in accordance with CSA-B51, CSA B52, and ASME B31.5 Refrigeration Piping.
Controlled Manual No ______
Table of Contents / Section iiRev 0 July 18, 2006
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Section /
Title
/ Revisioni / Cover page / 0
ii / Table of Contents / 0
iii / Scope / 0
iv / Statement of Authority / 0
v / Revision Control Record / 0
vi / Organization Chart / 0
1 / Manual Revision Control / 0
2 / Drawings, Design Calculations and Specifications / 0
3 / Material Control / 0
4 / Examination and Inspection / 0
5 / Correction of Nonconformities / 0
6 / Brazing Control / 0
7 / Non-destructive Examination / 0
8 / Heat Treatment / 0
9 / Calibration / 0
10 / Records Retention / 0
11 / The TSSA Inspector / 0
12 / Refrigeration Piping Repairs / 0
13 / Field Work / 0
14 / Sample Forms List / See sect 14
Approved by: / (Company Title) / ______/ Date / ______
Accepted by: / TSSA Representative / ______/ Date / ______
Scope / Section iii
Rev 0 July 18, 2006
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The Company shall hold a valid TSSA Certificate of Authorization to install or repair refrigeration systems greater than 3 tons (11 kW) refrigeration capacity.
This QC Manual provides the requirements to carry out shop and field fabrication of pressure piping in accordance with CSA B51 and the following Codes:
a)CSA B52 Mechanical Refrigeration Code
b)ASME B31.5 Refrigeration Piping
This QC Manual also provides the requirements for shop and field repair of Refrigeration Pressure Piping in accordance with the requirements of CSA-B51 and the following Codes:
a)CSA B52 Mechanical Refrigeration Code
b)ASME B31.5 Refrigeration Piping
c)Other Codes & Standards
The Company shall not engage in the following activities, which are outside the scope of this QC Manual:
a)Fabrication or repairs to Codes not listed above
b)Alterations
c)Repairs of boilers and pressure vessels
d)Welding, heat treatment or Non-destructive examination
These activities may be added into in the scope of the program by revising the QC Manual to include the requirements, in accordance with Section 1 of this Quality Control Manual, and presented to a TSSA Representative for acceptance prior to implementation.
Any subcontracted welding or brazing shall be performed by a Company holding a valid TSSA Certificate of Authorization for the scope of work to be done.
Statement of Authority / Section ivRev 0 July 18, 2006
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This Quality Control Manual contains the organization and system to be used by (insert company name) when performing Code work in accordance with CSA B51, CSA B52 and ASME B31.5 Refrigeration Piping Code and other Codes and Standards.
The Project Manager has the authority and responsibility for enforcing the Quality Control System described, and the organizational freedom to identify Quality Control problems and to initiate, recommend and provide solutions, including the authority to stop work when necessary.
In the event of conflict between the (Company title) and other personnel, problems shall be brought to me for final resolution in accordance with the applicable Code and this Quality Control manual’s requirements.
President / ______/ Date / ______Revision Control Record / Section v
Rev 0 July 18, 2006
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Rev.
/Section
/Description
/Project Manager
Sign & date
/TSSA Representative
Sign & date
Organization Chart / Section viRev 0 July 18, 2006
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ORGANIZATION CHART
Manual Revision Control / Section 1Rev 0 July 18, 2006
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1.0The Project Manager is responsible for the approval, revision, and implementation of this Quality Control Manual.
1.1The Company shall indicate approval and the TSSA Representative shall indicate acceptance of the initial QC Manual by signing & dating the Table of Contents (Section ii).
1.2The Project Manager reviews changes to the CSA and / or ASME Codes and makes any required changes to the QC Manual within six (6) months of change.
1.3Revision of the QC Manual shall be carried out by changing a section or by changing an individual exhibit of the QC Manual. The change is highlighted by bold text in italic font.
1.4Revision of the QC Manual shall be recorded by:
(a)Entering the revision into the revision control record (section v)
(b)Entering the revision number on each page of that section (or sample form)
(c)Entering the revision number in the table of contents (section ii) and / or the Sample forms list (section 14).
1.5All proposed revisions shall be approved by the Company and accepted by the TSSA Representative prior to implementation.
1.6The Company shall indicate approval and the TSSA Representative shall indicate acceptance of the change by signing & dating the Revision Control Record (Section v)
1.7Company personnel shall only use controlled copies of the QC Manual.
1.8A copy of the revised sections shall be distributed to all controlled QC Manual holders for inclusion in their copy. .
1.9If uncontrolled copies of the QC Manual are issued, they shall be current at the time of issue, but shall not be updated as new revisions are issued.
Drawings, Design Calculations and Specifications / Section 2Rev 0 July 18, 2006
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2.0The Project Manager is responsible to generate drawings required for pressure piping.
2.1The Project Manager is responsible to provideany design calculations required by TSSA for the registration of pressure piping.
2.2The Project Manager is responsible to ensure that pressure piping system drawings, and calculations (when required) are submitted to TSSA for P-number registration.
2.3Alternatively, customer supplied drawings and P- number registration may be utilized.
2.4The Project Manager or Company Engineer is also responsible to review drawings produced by the Company or by others to ensure that code compliance can be achieved.
2.5The drawings for pressure piping systems shall contain the following information:
-Code of construction (i.e. ASME B31.5)
-Design pressure and temperature
-Safety valve setting and location (when known)
-Refrigerant name, group number and total weight of charge
-Test pressure
-Material specifications (i.e. ASTM)
-Pipe, tubing and fitting size, schedule, wall thickness, class or rating
-Pipe joining methods (threading, brazing, mechanical, etc.)
2.6Construction of a pressure piping system may commence prior to registration with TSSA provided the Company assumes all risks related to the construction.
Material Control / Section 3Rev 0 July 18, 2006
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3The Project Manager shall ensure that all material is ordered based upon the information specified on the drawing.
3.1The Project Manager shall approve any substitution of material as specified on the registered drawing. Concurrence of the TSSA Inspector is also required.
3.2Purchase Orders (sample form 1) shall include the following information:
(a)Purchase Order Number & date
(b)Material description and specification (ASTM)
(c)Deleted
(d)Fittings (incl. Flexible hoses) require Canadian Registration Number (CRN)
3.3The Foreman is responsible to ensure that pressure piping materials are received, inspected and accepted prior to installation as follows:
(a)Receiving the material by verifying that the material type and quantity received are correct by comparing to the Purchase Order and / or the drawing
(b)Inspecting the material as follows:
- Inspect the material for damages
- Inspect the material for correct material specification, thickness, Class or rating
- Inspect the material for the correct material identification markings
(c)Accepting the material by signing and dating the packing slip
3.4The Foreman and / or (company title) is responsible to ensure that material identification markings are traceable to the original material specification. This may be accomplished by one or more of the following methods:
a)Maintaining the original material identification markings, or
b)Transfer of the original material identification markings, or
c)Recording the original material identification markings on the drawing
3.5Unidentified material that is not traceable to the original material specification is not acceptable for use in pressure piping systems.
3.6The Project Manager or the Foreman is responsible to order brazing material inaccordance with the Brazing Procedure Specification (i.e. AWS Specification & Classification number)
3.7Non-conforming material identified after receiving inspection shall be tagged with a Hold tag (Sample form 5) and processed in accordance with Section 5 of this QC Manual.
Examination and Inspection / Section 4Rev 0 July 18, 2006
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4.0The Project Manager is responsible to ensure that pressure piping is installed in accordance with the drawing and the Code.
4.1The Project Manager is responsible to generate a Checklist (sample form 3) for pressure piping prior to commencement of work.
4.2The Checklist shall be signed and dated by Company personnel as fabrication proceeds.
4.3The Checklist shall also provide space for TSSA hold points, sign off, and dates of any inspections performed by the TSSA Inspector.
4.4The Project Manager is responsible to contact the local TSSA Inspector prior to the start of fabrication of pressure piping.
4.5The Project Manager shall make available the Checklist (sample form 3), drawings, BPS, BPQ, and any other documentation required by the TSSA Inspector.
4.6Work shall not proceed past the TSSA Inspector hold points until signed off by the TSSA Inspector.
4.7The Project Manager or Foreman shall give the TSSA Inspector sufficient notice in advance of such upcoming hold points to permit the required inspections to be carried out.
4.8Parts and/or workmanship that fail to meet the requirements shall be identified with a hold tag (sample form 5) and processed as per Section 5 of this QC Manual.
4.9The Project Manager or Foreman shall be responsible for performing the final inspection and monitoring the final pressure test and leak test. All repairs shall be completed and accepted prior to the final pressure test being applied.
4.10The Project Manager shall notify the local TSSA Inspector of pressure tests to be conducted on pressure piping.
4.11The Project Manager or Foreman shall examine the Checklist (sample form 3) to ensure that all required examinations and tests have been witnessed and signed off
4.12Refrigerant pressure piping erected on the premises, except piping components that are factory tested, shall be pressure tested and leak tested after installation and before operation in accordance with the Code.
4.13When system components such as compressors, pumps, heat exchangers, valves, gauges, regulators, pipe, tube and fittings, have been pressure tested by the component manufacturer or assembler according to standards or applicable specifications, no further pressure testing, other than leak testing, is required.
4.14All joints to be pressure tested and / or leak tested shall be exposed, unpainted and free of rust, dirt, oil and other foreign materials.
4.15Joints previously tested in a accordance with this Code may be painted and insulated or covered.
4.16All brazing and brazing repairs shall have been completed prior to the final pressure and leak test.
4.17The range of the test gauge should be approximately double the test pressure.
4.18In addition, the test gauge used for pressure testing / leak testing of pressure piping shall be checked for accuracy prior to use by one of the following methods:
(a)The test gauge shall be calibrated (see Section 9) or,
(b)Alternatively, two calibrated gauges mounted on a common manifold may be used for the pressure test. Prior to the application of the specified test pressure, the accuracy of the gauges shall be tested at approximately one-half of the specified test pressure to ensure that the gauges are indicating properly and the readings are within 5% (full scale) of each other. If the two gauges do not give readings within these tolerances, they shall be replaced with other gauges and the accuracy checked again until a properly indicating pair of gauges are in place.
4.19A pressure test and leak test of refrigerant pressure piping shall be conducted as follows:
(a)Piping shall be examined before the pressure is applied to ensure that it is tightly connected.
(b)All items not subject to the pressure test shall be disconnected or isolated by valves, blanks or other suitable means
(c)The Company shall take measures to protect personnel from the potential rupture of piping components during pneumatic testing of systems
(d)The means used to build up the test pressure shall have either a pressure limiting device or a pressure reducing device and a pressure relief device and gauge on the outlet side.
(e)The pressure relief device shall be set above the test pressure but low enough to prevent permanent distortion of any of the piping system components
(f)Testing of refrigeration pressure piping shall be performed with dry Nitrogen or another nonflammable gas.
(g)The high and low sides of each system shall be tested and proven tight at not less than the pressure specified on the registered drawing
(h)For large systems that are not completely visible to the testing operator, the pressure in the system should be gradually increased to one-half of the test pressure, after which the pressure shall be increased in steps of approximately one-tenth of the test pressure until the required test pressure has been reached.
(i)The pressure test shall be continuously maintained for at least two (2) hours
4.20After the pressure test is completed, a leak test shall be performed as follows:
(a)The test pressure for the leak test shall be the lesser of the design pressure or the safety valve set pressure for the leak test.
(b)Examination for leaks shall be by the soap suds test or electronic leak detection or by other methods of equal sensitivity
(c)Examination shall be made of all joints and connections.
(d)The piping system shall show no evidence of leaking
(e)Refrigerant vapour detection methods shall be used when refrigerant is used as the testing medium. Environmental regulations shall be complied with when testing with refrigerants.
4.21The Project Manager shall be responsible for the preparation, review and certification of the Piping Data Report prior to presenting to the TSSA Inspector for acceptance by signing and dating.
4.22Completed Piping data reports shall be distributed as follows:
(a)Original to TSSA
(b)Copy to owner
(c)Copy to job file
Correction of Nonconformities / Section 5Rev 0 July 18, 2006
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5.0A Non-conformance is any condition that fails to meet the applicable rules of the Code or the requirements of this QC Manual.
5.1When a non-conformance is discovered, the Project Manager or Foreman shall attach a Hold Tag (Sample form 5) to the part.
5.2The Project Manager or Foreman shall be responsible for preparing a Non-conformance Report (NCR) (Sample form 4). This shall be done by entering the description of the non-conformance in section (1) of the NCR.
5.3The Project Manager or Foreman shall be responsible to enter the recommended disposition in section (2) of the NCR. No work shall be allowed to proceed on the item until the disposition has been reviewed and accepted as described below.
5.4The disposition of Non-conformance reports shall be described as follows:
(a)Use-as-is
(b)Repair
(c)Reject
5.5The Project Manager shall be responsible to review and approve the disposition by signing and dating the NCR in section (2).
5.6 Deleted
5.7The NCR shall then be presented to the TSSA Inspector for acceptance of the disposition by signing and dating section (2).
5.8Items dispositioned as reject may be disposed of without further input from the TSSA Inspector.
5.9The Project Manager is responsible to sign and date the NCR in section (3) when the disposition has been completed.
5.10The NCR shall then be presented to the TSSA Inspector for signature & date in section (3). Copies of all non-conformance reports shall be maintained by the Project Manager
5.11The Project Manager or Foreman shall be responsible for removing Hold tags after the NCR report has been completed and signed off.
Brazing Control / Section 6Rev 0 July 18, 2006
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6.0The Project Manager is responsible to ensure that all brazing performed to refrigeration pressure piping meets the requirements of the Code and this QC Manual.
6.1The Project Manager is responsible to ensure the following requirements are complied with in regards to Brazing Procedure Specifications (BPS’s)
(a)Brazing shall be done in accordance with a BPS that has been qualified in accordance with ASME Section IX.
(b)To maintain all documentation and records of BPS’s
(a)To select the BPS’s to be used
(a)Copies of the BPS’s to be used in fabrication are available to the Brazers in the work area.
(b)BPS’s to be used for pressure piping shall be registered with TSSA
(b)To Generate new BPS’s
(c)To revise and / or update the BPS’s
6.2The Project Manager is responsible to ensure the following requirements are complied with when qualifying a new Brazing Procedure Specification (BPS)
(a)The BPS shall list the essential, non-essential and where necessary the supplemental essential variables for the process to be used.
(b)The Project Manager shall conduct the qualification tests for each new BPS to be qualified
(c)Company employees under the full supervision and control of the Company shall braze the test coupons for qualification of Brazing Procedures.
(d)The Project Manager is responsible to document the Brazing variables on the Procedure Qualification Record (PQR). Variables recorded on the PQR shall be the actual variables (including ranges) used during brazing of the test coupon.
(e)When the BPS has been qualified, in accordance with the ASME Code requirements, the results shall be documented on the PQR by the by the Project Manager , who shall date and certify this document on behalf of the Company.
(f)Generate new BPS’s
(c)The local TSSA Inspector shall be notified prior to qualifying a new BPS
(d)To submit copies of a new BPS and PQR to TSSA for registration
6.3The Project Manager is responsible to ensure that the following requirements are complied with in regards to Brazing Performance Qualifications:
(a)Brazers shall be qualified in accordance with ASME Section IX and TSSA requirements
(b)The Brazers shall be under the full supervision and control of the Company.
(c)Brazers shall be qualified to the BPS to be used for the work to be performed
(d)The local TSSA Inspector shall be notified prior to conducting a Brazer test
(e)Each qualified Brazer shall be assigned an identifying number, which shall be used to identify the work done by the Brazer.
(f)The Project Manager or Foreman shall conduct / supervise the Brazing Performance Qualification Tests in accordance with qualified BPS’s.
(g)The Project Manager or Foreman shall be responsible for documenting and certifying the Brazer Performance Qualification (BPQ) form on behalf of the Company.