ASME Stamp Does Not Ensure Quality Equipment
Most people believe that an ASME Code Stamp means “High Quality”. It does not.
There are a lot of junk pressure vessels and heat exchangers currently in service with ASME Code Stamps. I see them all the time. I’ve also reviewed enough internal inspections for API 970 Corrosion Control Documents (CCDs) to understand that this junk equipment is the source of many issues in process facilities. Corrosion loves to propagate around poor and incomplete welds. “No Radiography” is specified too often for critical service.
Shouldn’t the Authorized Inspector (AI) catch glaring mistakes? Sure, but many times the AI rubber stamps anything that passes hydrotest. That is why proper Source Inspection is a vital step that Owner/Operators should not skip. In fact, Source Inspection pays for itself by finding issues before hydrostatic testing. It becomes difficult and expensive to fix problems after an Owner/Operator has accepted the equipment into their facility because the fixes usually require an R-Stamp and another hydrotest.
I want to see what the quality control program looks like. I want to see what the non-conformance program looks like. I want to review the detailed calculations and compare them with my own calculations for critical components. Quality shops appreciate these checks because it helps improve quality.
Don’t assume all shops produce high quality equipment. Verify you are getting what you paid for by utilizing Source Inspection.
Integrity Operating Windows (IOWs) Resolve Operator Conflicts
Engineers in most companies have to perform tasks way outside of their official job description. I often find myself working as a mediator helping in conflict resolution situations.
Why does the B Shift Operator run at the exact same equipment at different temperatures and pressures than the A Shift Operator? I can’t tell you why. What I can tell you is that an up-to-date Corrosion Control Document (CCD) with well defined Integrity Operating Windows (IOWs) is all that I need to tell you which operator is correct.
I’ve seen operators ignore visual and audible alarms for high limit switches during their entire shift. Every. Single. Shift. A well defined IOW helps me explain to the operator why equipment should be run under specific conditions. Conflict resolved!