1、 Managing competence assurance For personnel undertaking in-service inspection of pressure equipment PUBLICATION 193 Edition 2 Released by IHS. NOT FOR RESALE THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION Managing competence assurance For personnel undertaking in-service inspection of pr
2、essure equipment PUBLICATION 193 Edition 2 Copyright 2013 The Engineering Equipment and Materials Users Association. A company limited by guarantee. Registered in England. Company number 477838. ISBN 978-0-85931-190-8 Imprint reference 02-2013 Registered and Trading Address 63 Mark Lane London EC3R
3、7NQ Telephone: +44 (0)20 7488 0801 Fax: +44 (0)20 7488 3499 E-mail: saleseemua.org Website: www.eemua.org EEMUA Publication 193 Managing competence assurance: pressure equipment EEMUA ii ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION About EEMUA The Engineering Equipment and Materials Users A
4、ssociation is usually known by its initials, EEMUA. EEMUA is governed by a Council of members. This Council is responsible for the policies, financing, membership, and strategy of the Association. Any organisation that is a substantial user or purchaser of engineering products is eligible to apply t
5、o become a member of EEMUA. Membership is subject to the approval of Council. EEMUA Aims EEMUA aims to improve the safety, environmental and operating performance of industrial facilities in the most cost-effective way, pursuing and promoting leadership in industrial asset management by sharing engi
6、neering experiences and expertise, and by the active, enlightened promotion of the distinct interests of users of engineering products. These aims are achieved by various means, including: Providing the organisation within which networking, information sharing and collaboration among users on non-co
7、mpetitive technical matters can take place Influencing the way written regulations are interpreted and applied in practice Promoting and presenting members views, and encouraging the application of good sound engineering practices Developing user guides, specifications, training and competency schem
8、es Facilitating members participation in national and international standards making Influencing relevant national and European legislation and regulation. The income and resources of EEMUA are applied solely towards the promotion of the aims of the Association. No profit is transferred by way of di
9、vidend, bonus or otherwise to members. The work of the Association is mainly carried out by members representatives on EEMUA Technical Committees, Working Groups, and Forums, supported by EEMUA staff. Incorporation, Membership and Other Information For the purposes of conducting its business, EEMUA
10、is incorporated in England and Wales as a company, limited by guarantee, not having share capital. All usual aspects of company management and business administration are dealt with by the EEMUA Executive Director, including policy implementation and leadership of the Executive team (the staff). A l
11、ist of EEMUA publications for sale is given at the end of this Publication. The full list is also on the Associations website, including details of on-line shopping facilities. To enquire about corporate Membership, write to enquirieseemua.org or call +44 (0)20 7488 0801. EEMUA Publication 193 Manag
12、ing competence assurance: pressure equipment EEMUA iii ABOUT THIS PUBLICATION Legal Aspects All rights, title and interest in this Publication belong to EEMUA. All rights are reserved. No part of this Publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any m
13、eans: electronic, mechanical, photocopying, recording or other, without the express prior written agreement of the EEMUA Executive Director. Infringement of copyright is illegal and also reduces the Associations income thereby jeopardising its ability to fund the production of future publications. I
14、t has been assumed in the preparation of this Publication that: the user ensures selection of those parts of its contents appropriate to the intended application; and that such selection and application is correctly carried out by appropriately qualified and competent persons for whose guidance this
15、 Publication has been prepared. EEMUA and the individual members of the Work Group that prepared this EEMUA publication do not, and indeed cannot, make any representation or give any warranty or guarantee in connection with material contained herein. EEMUA and the individual members of the Work Grou
16、p that prepared this EEMUA Publication expressly disclaim any liability or responsibility for damage or loss resulting from the use or reliance on this Publication. Any recommendations contained herein are based on the most authoritative information available at the time of writing and on current go
17、od engineering practice, but it is essential for the user to take account of pertinent subsequent developments and/or legislation. Any person who encounters an inaccuracy or ambiguity when making use of this Publication is asked to notify EEMUA without delay so that the matter may be investigated an
18、d appropriate action taken. Consultation and Feedback EEMUA encourages constructive comments on this Publication from both Members of the Association and others. Comments should be sent on the standard feedback form, a copy of which is provided towards the end of this Publication. An electronic vers
19、ion of the feedback form is available from EEMUA - e-mail your request for a copy to enquirieseemua.org, telephone your request to +44 (0)20 7488 0801, or download the form from the EEMUA website at www.eemua.org. Submit comments by e-mail (preferred) or post. Comments are considered by the relevant
20、 EEMUA Technical Committees and may be incorporated in future editions of this Publication. New editions are publicised on the EEMUA website. EEMUA Publication 193 Managing competence assurance: pressure equipment EEMUA iv EEMUA Publication 193 Managing competence assurance: pressure equipment EEMUA
21、 v Contents Abbreviations/Acronyms vii 1. Introduction and Objectives . 1 1.1 Scope . 1 1.2 Objectives . 2 2. Use of this EEMUA Publication 3 2.1 Recommended Use of this EEMUA Publication . 3 2.2 List of Definitions 3 3. Structured Approach to Competence Management . 5 3.1 Evaluations of Inspection
22、Personnel . 5 3.1.1 The Competence Management System Cycle 5 3.1.2 CMS Phases and Principles . 6 3.1.3 Developing and Maintaining the Competence of Individuals 7 3.2 Relevant Qualifications 8 3.3 RG0 Illustrated Process 10 4. Identify the Range of Inspection Activities 11 5. Identify the Competence
23、Required for Each Activity 13 5.1 Personal Attributes of Inspection Personnel 13 5.1.1 Communication Skills 13 5.1.2 Physical Capability 13 5.1.3 Acuity of Senses 13 5.1.4 Ability to Work Alone 14 5.1.5 Ability to Deal with Challenging Clients 14 5.1.6 Writing Skills . 15 5.1.7 Academic and Practica
24、l Training . 15 5.1.8 Inspection Reports and Repair Recommendations . 15 5.2 Technical Competencies . 15 5.2.1 Detection of Defects . 15 5.2.2 Use of Instruments . 16 5.2.3 Evaluation of Defects 16 5.2.4 Decision Making . 21 5.2.5 Inspection Scheme Development, Interpretation and Review 29 5.2.6 Und
25、erpinning Knowledge and Understanding 31 5.2.7 Mechanics of Materials 35 5.2.8 Risk Assessment 39 5.2.9 Failure Mode and Criticality Analysis 39 5.2.10 Limits of their Own Understanding and Capability 40 6. Train and Assess Against the Competence Criteria . 41 6.1 Employ Persons Competent to Underta
26、ke Inspection Tasks . 41 6.2 Ensure Inspection Personnel have the Necessary Personal Attributes, Knowledge, Training and Education 41 6.3 Assess Competence and Ensure Competence of Assessors 41 6.3.1 Certification . 41 6.3.2 Training Records 42 6.3.3 Performance Appraisal Records 42 6.3.4 Observatio
27、n/Demonstration . 42 6.3.5 Direct Questioning 43 7. Authorise Persons for Activities Under Appropriate Supervision 45 8. Monitor Performance of Persons to Re-assess Competence . 47 Appendix A - Typical Job Titles and Roles . 49 A1 (Technical) Management . 49 A2 (Technical) Supervision 49 A3 Inspecto
28、r for Major Systems 50 EEMUA Publication 193 Managing competence assurance: pressure equipment EEMUA vi A4 Support Staff 50 A4.1 Plant Inspector (PI) or Inspector (I) . 50 A4.2 Piping Inspectors and Relief Stream Inspectors . 50 A4.3 Welding Inspectors 51 A4.4 NDT Technicians . 51 Appendix B - Certi
29、fication Schemes 53 B1 UK . 53 B1.1 Scope 53 B1.2 Personnel . 53 B1.3 Training . 53 B1.4 Inspection Methods and Procedures . 54 B1.5 Subcontracting . 54 B2 EU . 54 B3 USA . 54 Appendix C - Examples from RG0 . 55 C1 Example of Type B Inspection Body 55 C1.1 Identification of Competencies 55 C1.2 Trai
30、n and Assess Staff Against Required Competencies . 55 C1.3 Authorisation 56 C1.4 Monitor Performance and Re-assess Competence . 56 C2 Example of Inspection in a Major Hazard Environment 56 C2.1 Identification of Competencies 56 C2.2 Train and Assess Staff Against the Required Competencies 57 C2.3 As
31、sessment 57 C2.4 Authorisation 57 C2.5 Monitor Performance and Reassess Competence 57 Appendix D - Country Specific Legislation 59 D1 Pressure System and Safety legislation . 59 D1.1 Client Safety Training Requirements 60 D1.2 The Pressure Systems Safety Regulations (PSSR) 2000 60 Appendix E - Life
32、Expectancy Data . 63 References and Bibliography 65 References 65 Standards and Recommended Practices . 67 Bibliography 69 Figures Figure 1 Schematic representation of the Phases of the CMS cycle 5 Figure 2 Proposed system for developing/maintaining staff competence 7 Figure 3 Diagrammatic represent
33、ation of competence assessment 10 Tables Table 1 Criteria for Inspection Personnel Qualifications . 8 Table 2 Examples of Inspectors Qualification Criteria 9 Table 3 Example of FMECA Process 40 Table 4 UK and EU Pressure System Legislation . 59 Table 5 Pressure equipment covered/not covered by the P
34、SSR . 61 Table 6 Life expectancy for plastics 63 EEMUA Publication 193 Managing competence assurance: pressure equipment EEMUA vii Abbreviations/Acronyms ACoP Approved Code of Practice ALARP As low as is reasonably practicable AUT Automated ultrasonic testing BIS Department of Business, Innovation a
35、nd Skills, UK CAF Compressed asbestos fibre CDGTPER Carriage of Dangerous Goods and Use of Transportable Pressure Equipment Regulations CE Conformit Europene CMS Competence management system COMAH Control of major accident hazards DPI Dye Penetrant Inspection DTI Department of Trade and Industry (no
36、w BIS), UK EMAT Electromagnetic acoustic transducer testing EtOH Ethanol EU European Union FMECA Failure mode and criticality analysis FSA Fitness for service analysis GMAW Gas metal arc welding GRP Glass reinforced plastic GTAW Gas tungsten arc welding GW Guided wave testing HAZOP Hazard and operab
37、ility study H and S Health and Safety HSE Health and Safety Executive IB Inspection body IE Inspection engineer IRIS Internal Rotary Inspection System IS Inspection surveyor IT Information Technology IVI Internal visual inspection LOLER Lifting Operations and Lifting Equipment Regulations MAG Metal
38、active gas welding MeOH Methanol MIG Metal inert gas welding MMA Manual metal arc welding MPI Magnetic Particle Inspection MsS Magnetostrictive sensor MT Magnetic particle inspection NB Notified body NDE Non-destructive examination NDT Non-destructive testing NII Non-intrusive inspection NPSH Net Po
39、sitive Suction Head NVQ National Vocational Qualification PAUT Phased array ultrasonic testing EEMUA Publication 193 Managing competence assurance: pressure equipment EEMUA viii PEC Pulsed eddy current PED Pressure Equipment Directive PER Pressure Equipment Regulations PFEER Prevention of Fire and E
40、xplosion and Emergency Response Regulations PQR Procedure Qualification Record PRA Process risk assessments PSSR Pressure Systems Safety Regulations PSR Pipelines Safety Regulations PT Dye penetrant inspection PTFE Polytetrafluoroethylene PWHT Post weld heat treatment QC Quality control QRA Quantifi
41、ed risk assessment RBI Risk based inspection RLA Remnant life assessment RCA Root cause analysis RT Radiographic testing SAW Submerged arc welding SEP Sound engineering practice SHE Safety, Health And Environment SLOFEC Saturated Low Frequency Eddy Current (Trademark - KontrollTecknik GmbH) SMAW Shi
42、elded metal arc welding SPVD Simple Pressure Vessels Directive SS Stainless steel TIG Tungsten inert gas welding TOFD Time of flight diffraction UI User Inspectorate UKAS United Kingdom Accreditation Service UT Ultrasonic testing WPQR Welding Procedure Qualification Record WPS Welding Procedure Spec
43、ifications WSE Written scheme of examination EEMUA Publication 193 Managing competence assurance: pressure equipment EEMUA 1 1. Introduction and Objectives EEMUA Publication 1931is a recommended practice for Inspection Bodies (IBs) operating in the process, energy and related industries, whose prima
44、ry responsibility is for pressure equipment. This is the revised Second Edition which incorporates changes in practice and legislation since first publication in 1998 as EEMUA Recommendations for the Training, Development, and Competency Assessment of Inspection Personnel. It presents a structured t
45、raining, development and competency assessment process for inspection personnel. EEMUA developed this Publication in response to: The increasing emphasis on the competency of individuals, for example during assessment of IBs under the accreditation process and also the general requirement to ensure
46、competency as a part of safety management. The development of API certification schemes for inspectors. A changing relationship between IBs and inspection contractors. 1.1 Scope Demonstration of the competence both of IBs and the individuals directly or indirectly employed in them is important in en
47、suring adherence to legislation and its supporting standards, especially in the EU. The criteria for IBs are already defined, for example in the International standard ISO/IEC 17020(39)and by the United Kingdom Accreditation Service (UKAS). UKAS accredits IBs to the Standard ISO 17020. The structure
48、 of this EEMUA Publication is such that it respects the requirements of UKAS RG0(2). This EEMUA Publication is limited to in-service inspection of industrial pressure equipment which is taken to mean all inspections excluding new build and commissioning. The types of equipment covered (see Appendix
49、D Country Specific Legislation) includes all equipment covered by: PSSR; pressure equipment subject to the COMAH Regulations; Pipeline Regulations; PFEER (offshore); transportable pressure equipment; and above ground tanks metal and plastic. It excludes: subsea equipment; new equipment subject to the PER; and below ground/buried tanks. EEMUA Publication 193 is designed to be an authoritative statement of competency criteria for inspection personnel. 1Contains public sector informat
