Standard Operating Procedure

QC-101
ASME B31.9 Shop and Field Examination
For

Fabrication and Construction

 SOP # QC-101 Rev.1
Quality Control

Effective Date: Released By: Standard Operating Procedure

08/10/2023 J. Dunne ASME B31.9 Shop and Field Examination

1. PURPOSE

 To establish a standard procedure for Shop & Field Examinations and Testing.
 To ensure ACCO is meeting the expectations of this procedure when an authorized examiner discovers
non-compliant deficiencies they will report to the local QC lead and responsible supervisor to discuss
appropriate resolution. If required, the Construction Leadership Team will be notified to assist with any
further means to resolve non-compliant work activities.
 In the absence of specific written instructions from the client, this SOP shall be used. Client
specifications that limit or exceed those contained in this SOP, shall be agreed to in writing by the
Client and ACCO Engineered Systems.

2. SCOPE

 This procedure outlines code requirements for Examination and Testing of Shop/Field fabrication and
installations of piping systems and components on commercial projects. Examination and testing
criteria are in strict compliance with ASME B31.9, and related ACCO standards.

3. RESPONSIBILITIES

 Examinations, Testing and required documentation will be performed by/or witnessed by ACCO
authorized personnel. These quality control functions are mandatory and require a concerted effort of
shop and field personnel.

 Shop personnel may fulfill examination requirements for shop fabrication and assembly, while field
personnel may fulfill examination and testing requirements for field fabrication and installation.

 Shop and Field Examiners shall have training and experience commensurate with the needs of the
specific examinations. Examination shall be performed by personnel other than personnel performing
the work. Shop and Field Examiners shall be approved by the Regional Quality Control Supervisor
prior to performing examinations.

 ACCO Shop and Field Examiner Log shall be maintained by ACCO QAQC and be kept current.

4. REFERENCES

 ASME Section IX

 ASME B31.9 Building Services

 ASTM B828 Standard Practice for Making Capillary Joints

 ASME B1.20.1 Pipe Threads, General Purpose, Inch

______________________________________________________________________________________
PROPERIETARY AND CONFIDENTIAL
ACCO ENGINEERED SYSTEMS, INC.
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 SOP # QC-101 Rev.1
Quality Control

Effective Date: Released By: Standard Operating Procedure

08/10/2023 J. Dunne ASME B31.9 Shop and Field Examination

 ASTM B828 Standard Practice for Making Capillary Joints by Soldering of Copper and Copper Alloy
Tube and Fittings

 ACCO Pressure Test Report

 ACCO Welding Inspection Checklist

 ACCO Shop and Field Examiner Log

5. PROCEDURES

5.1 Visual Examination – Observation of the portions of materials, components, joints, supports, and other
piping elements that are or can be exposed to view before, during, or after manufacture, fabrication,
assembly, or erection. This examination includes verification of Code and engineering design
requirements for materials and components, dimensions, joint preparation, alignment, joining practices,
supports, assembly, and erection.

5.2 Pressure and Leak Testing

 Hydrostatic Pressure Testing:

Following the application of hydrostatic test pressure for at least 10 min., shop/field personnel shall
examine for leakage of the piping and at all joints and connections. If leaks are found, they shall be
eliminated by tightening, repair, or replacement, as appropriate, and the hydrostatic test repeated until
no leakage is found.
 Pneumatic Pressure Testing:
After the preliminary test, pressure shall be raised in stages of not more than 25% up to full pneumatic
test pressure, allowing time for equalization of strains and detection of major leaks at each stage.
Following the application of test pressure for at least 10 min, the pressure may be reduced to design
pressure and shop/field personnel shall examine for leakage of the piping. Leaks may be detected by
soap bubble, halogen gas, scented gas, test gage monitoring, ultrasonic, or other suitable means. If
leaks are found, pressure shall be vented, appropriate repair or replacement shall be made, and the
pneumatic test repeated until no leakage is found.
 Initial Service Leak Test:
For gases, and steam and condensate service not over 15 psig, and for nontoxic, noncombustible,
nonflammable liquids at pressures not over 100 psig and temperatures not over 200° F, it is permissible
to conduct the system testing with the service fluid.
A preliminary test with air at low pressure may be used. In any event, the piping system shall be
brought up to operating pressure gradually with visual examination at a pressure between one-
half and two-thirds of operating pressure. A final examination shall be made at operating
pressure. If the piping system is free of leaks, it will have met the requirements for service
testing.

______________________________________________________________________________________
PROPERIETARY AND CONFIDENTIAL
ACCO ENGINEERED SYSTEMS, INC.
Page 3 of 5
 SOP # QC-101 Rev.1
Quality Control

Effective Date: Released By: Standard Operating Procedure

08/10/2023 J. Dunne ASME B31.9 Shop and Field Examination

6. EXAMINATION

Perform random Visual Examinations of the various stages and elements of the fabrication and
installation process in accordance with section 5.1 above.
Perform Leak Testing of each installation in accordance with section 5.2 above and document each test.

7. Welded Fabrication

 Perform random material verification along with random fit-up examination.

 Perform weld examination and when required, document on Welding Inspection Checklist. Upload
checklist on to project Box folder.
 Acceptance Criteria - Girth and Groove Welds
Cracks - None Permitted
Lack of Fusion - The length of unfused areas shall not be more than 20% of the circumference of the
pipe, or of the total length of the weld, and not more than 25% in any 6 inches of weld.
Incomplete Penetration - The total joint penetration shall not be less than the thickness of the thinner of
the components being joined, except that incomplete root penetration is acceptable if it does not exceed
the lesser of 1∕32” or 20% of the required thickness, and its extent is not more than 25% in any 6” of
weld.
Undercut and Reinforcement - Undercut shall not exceed the lesser of 1/32” or 12-1/2% of wall
thickness. Thickness of weld reinforcement shall not exceed 3/16”.
Concave Root - Concavity of the root surface shall not reduce the total thickness of the joint, including
reinforcement, to less than the thickness of the thinner of the components being joined.
Excess Root Penetration - The excess shall not exceed the lesser of 1/8” or 5% of the inside diameter of
the pipe.
Weld Surfaces - There shall be no overlaps or abrupt ridges and valleys.

 Fillet, Socket & Seal Welds – Same as above for Cracks, Lack of Fusion, Undercut, and Weld
Surfaces.

8. Grooved and Rolled Fabrication – Verify groove & depth is per manufacture specifications.

9. Threaded Joints - There shall be no severe chipping or tearing of visible threads. No more than six
and no fewer than two threads shall be visible after makeup of the joint.

10. Flanged Joints - The flange faces shall be parallel with in 1 degree. Nuts and bolts shall be fully
engaged.

11. Flared, Flare-Less, and Compression Joints - There shall be no cracks in flare or tube ends. Tube ends
shall be cut square and be free of distortion or grooves that would hinder assembly or sealing. Negligible
force shall be required to align ends.

______________________________________________________________________________________
PROPERIETARY AND CONFIDENTIAL
ACCO ENGINEERED SYSTEMS, INC.
Page 4 of 5
 SOP # QC-101 Rev.1
Quality Control

Effective Date: Released By: Standard Operating Procedure

08/10/2023 J. Dunne ASME B31.9 Shop and Field Examination

12. Copper Fabrication & Installation - Brazed and Soldered Joints – Verify materials, flux, solder &
brazing rod meets the job specifications and ACCO’s submittals. Verify all Copper Installers have been
CAT Trained.
o Acceptance Criteria: Penetration of filler metal inside the pipe shall not exceed 100% of the
wall thickness.
o There shall be no visible unfilled joint space.
o There shall be no visible evidence of excessive over-heating.

12.1 Copper Fabrication & Installation - Mechanical Press – Verify materials meets the job
specifications and ACCO’s submittals. Installers must be CAT Trained and have their Press
Certification.
 Be sure tube ends are square cut, de-burred, and clean prior to joining.
 Randomly verify insertion depth is being marked along with completion mark.
 Properly support tubing before heating to maintain alignment. Perform final examination. Document
results on the Daily Inspection Report. Imperfections in mechanical and proprietary joints shall be
within the limitations established by the manufacturer.

13. Solvent-Cemented, Adhesive, and Heat-Fusion Joints – Verify primer / cement are not expired, and
have been properly stored.
 Pipe ends must be cut square, de-burred and prepped per manufacturer instructions.
 Piping and valves must be properly supported. Internal protrusion shall not exceed 50% of wall
thickness for solvent-cemented and 25% for adhesive and heat-fusion joints.
 There shall be no visible unfilled or un-bonded areas.
 Excess cement/adhesive shall be wiped clean.

14. Document Control

 Verify Copper Logs and Pressure Test Reports are properly filled out and are being turned into
Warranty.
 When needed: Provide WPS & WPQ’s for special inspections.

End of Section

______________________________________________________________________________________
PROPERIETARY AND CONFIDENTIAL
ACCO ENGINEERED SYSTEMS, INC.
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