What to look for when auditing a pressure vessel fabrication facility

When you’re auditing a pressure vessel fabrication shop, you want to ensure that everything is safe and made well together. At Hongyuan, we know the importance of being vigilant at these sensitive locations. Pressure vessels are giant tanks containing gases or liquids under pressure. If they are not made correctly they can be extremely dangerous. Auditing is a way to identify problems before they get bad. You will examine the equipment, the people who work there and the rules they follow. All of this helps ensure that what we build is safe and endures

What You Should Look for When Auditing Pressure Vessel Fabrication Shops

When you see into any Pressure Vessel plant, the most obvious thing is how clean and organized it looks. A shop that’s a mess spells trouble. You better examine the tools and machines, also; they should be in good condition. Ask about their maintenance schedules. If they are not taking care of their equipment, there may be a sign that they don’t take the safety of their products seriously. Then look at the workers. Are they wearing safety gear? Do they appear to know what they are doing? Training is key. Operators should be licensed, and have experience in both the handling of material but also running machinery efficiently. Insist on seeing evidence of their training records. And it is also critical to determine whether they follow safety rules. For instance, there should be obvious indications about how to stay safely inside the house and emergency exits. They help keep everyone safe. What about the materials with which to form the pressure vessels? They are subject to various quality checks. You can request the material certificates to verify they are using the proper stuff. If they skimp on the materials, the pressure vessel may not withstand much pressure. Finally, verify their inspection records. There should be regular audits and inspections. If a home doesn’t do these, it might be cutting corners. We always put safety and quality above all, so those checks are also to contribute to the safety of everyone,” adds Hongyuan

The Sign of a Good Pressure Vessel Manufacturer

Just how can you tell if a given pressure vessel is constructed well? These are the rules authored by organizations that dictate how things should be built. Ask the facility if they adhere to any particular standards. A couple of popular ones are ASME and API. These organizations establish stringent guidelines to ensure that pressure vessels are safe. You may also want to search for certifications. Facilities with certification have passed tests that demonstrate they’ve reached a standard of high quality. Also during your visit, request to observe their quality control. They ought to have measures up for checking the caliber at every stage of pressure vessel fabrication. For instance, they could carry out tests on materials before beginning to build. You should also find out if they have a mechanism to correct things when bad stuff happens. If they make a mistake, it will be up to them to figure out how to fix it. Quality is about control, not just one time but many. This is helpful in catching any problems early. Finally, have a conversation with the staff about quality. They should be able to articulate how they guarantee that every ship is up to par. Quality is our priority at Hongyuan. We are firm believers that by adhering to the same high standards in our fabrication and quality control, we can construct pressure vessels that are not only safe, but strong

When you're performing an audit on a pressure vessel fabricator you need to consider the welding processes that are employed in producing the manufactured vessel

Welding is integral to building pressure vessels because it binds pieces of metal together to ensure they can safely contain pressure. The first is the type of welding processes an organization uses. Common techniques used for joining vessels involve Shielded Metal Arc Welding (SMAW), Gas Tungsten Arc Welding (GTAW) and Gas Metal Arc Welding (GMAW). Each approach has its own set of pros and cons, so it’s good to know which they are employing. For thin hot workpieces, GTAW provides a high quality weld while for thicker base materials/workpieces or for poor condition workpieces SMAW is more useful. Then, determine if the welders are properly trained and qualified. Highly experienced welders are trained to do their job well, and certifications indicate they have met certain standards. Seek out certifications from groups such as the American Welding Society (AWS). Also, look at the welding process itself. Are the welders following procedure? Are they applying the appropriate settings to machines? There’s a lot that can be learned about the quality of work being performed by watching the welders in action. And also, don't forget to check out that weld quality. This can be accomplished by determining typical defects such as cracks, undercuts and porosity. A good pressure vessel company like Hongyuan will have procedures in place to monitor and test their welds to make sure they are strong, safe. And be sure to consult the welding documents. This would include documentation of WPS and inspection. Making good documentation is the only way that you can demonstrate your facility is doing what they are supposed to do after all

The pressure vessel manufacturers' certifications are also another important area to study un while auditing a pressure vessel fabrication facility

The need for certifications is because they demonstrate that the company has satisfied industry standards in safety and quality. The most significant certification is the ASME( American Society of Mechanical Engineers) certification. This certification shows the plant is qualified to design and construct pressure vessels under stringent codes. A vessel builder that is ASME certified is more likely to build safe and reliable vessels. Beside ASME, be on the hunt for ISO 9001 certification. This certification concerns quality management systems, and that a facility has processes in place to ensure they are consistently making good products. It’s also a good idea to determine if the facility has any other relevant certifications, such as National Board of Boiler and Pressure Vessel Inspectors certification. They also signal that the operation has been looked at by outside auditors, a further assurance. When you look at the certifications, also pay attention to how frequently they are renewed. Certifications must be upgraded periodically so that businesses remain on pace with the most recent standards and best practices. Quality companies such as Hongyuan will not let acquisitions expire. And finally, interview the staff about their training and credentials. The more informed and experienced the personnel, the higher the level of pressure vessels they produce

Lastly, monitor for normal pitfalls which come up in the production of pressure vessels

Knowing these concerns will allow you to spot problems and be more certain that the vessels are safe. One of the most common problems are improper materials used. The pressure vessel materials need to be strong enough to resist that pressure. If cheap or wrong materials are used, you may be seeing failures. Make sure that the facility always properly selects and tests materials. Improper handling and materials storage are another thing to be on the lookout for. When materials are not properly stored, they can become damaged or contaminated in a way that diminishes the integrity of the end product. See if materials are being treated properly and stored orderly and cleanly. Also, keep your eyes on the cleanliness in general of the place that is producing these songs. Dirty or cluttered shop means errors and safety hazards. It is also crucial to keep an eye on quality-control procedures. A responsible plant, such as Hongyuan, will install an stringent standard quality check at different processing level to avoid defective goods produced. Last, look where the teams are in communicating. Mismatches of communication can result in confusion and errors, making it key that everyone is singing from the same hymn sheet at every stage of the production process. Monitoring and recognition of these typical problems can help to ensure that the pressure vessels which are to be manufactured are of safe and high quality