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SIN FIN(USA) Limited.
MMB EL BOLEO PROJECT
Quality Plan
Santa Rosalia Plant
Baja Mexico
1October
2012Project Quality plan R Haye
2March
2013Project Quality plan R Haye
3
REV. DATE DESCRIPTION PREPARED BYCHECKED
BY
APPROVED
BY
This quality Plan represents work done by Sin Fin (USA) Limited. The work is based upon the project scope and designinformation as described herein and as provided by the owner. None of the above named parties or individuals shall be
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SIN FINMMB EL BOLEO PROJECT
(USA) LTD.NO: MMB 038-11liable, in negligence or otherwise, for any reliance which may be placed by any other party upon any representations
contained herein.
SIN FIN (USA)
Field QA/QC
Page
1.0 Quality Control Policy 5
1.1 Scope 5
1.2 Purpose 51.3 Laboratory Standards 6
1.4 Test Methods 6
1.5 Operating Procedures 6
1.6 Field Activities 7
1.7 Notification of In-Process Changes 7
2.0 Quality Control Organization 7
2.1 Organizational Definitions 8
2.2 Organizational Responsibility 92.3 Inspector Functions 9
2.4 Certified Individual, Functions 9
2.5 Training of Quality Control Personnel 10
2.6 Training and Qualification of Certified Individuals11
3.0 Contract Review & Design 11
3.1 Minimum Documentation 11
3.2 Document Distribution 11
3.3 Authorized Inspector 123.4 Procedures 13
3.5 Purchasing 13
3.6 Vender Evaluation 14
3.7 Non-Compliant Items/Materials. 14
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4.0 Materials 14
4.1 Receiving Inspection 14
4.2 Resins 15
4.3 Reinforcements 154.4 Curing Agents 16
4.5 Common Additives 17
5.0 In-Process Inspection 18
5.1 Procedures 18
5.2 Resin Mixing 18
5.3 Material Dispersion 19
5.4 Component Fabrication 19
5.5 Assembly 205.6 Nonconformance 21
6.0 Finished Equipment Inspection 24
6.1 Procedures 24
6.2 Pressure Test 25
6.3 Qualification of Secondary Bonders 25
6.4 Access For Authorized Inspector 25
7.0 Records Retention & Control 267.1 Scope 26
7.2 Application 27
7.3 Records Retention 27
7.4 Procedures for Records Handling 27
7.5 Acetone Sensitivity Test 28
7.6 Barcol Hardness Measurement 29
8.0 Lamination Procedure 29
8.1 Surface Prep 308.2 Structural Layer 30
8.3 Interior Layer Corrosion Resistant Barrier 30
8.4 Inspection of Lamination Material 31
9.0 Attachments
9.1 Inspection Checklist 32
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9.2 Barcol/Acetone Sensitivity Test Record 33
9.3 Cut-Out Thickness Check 34
9.4 Mat Reinforcement Log Sheet 35
9.5 Fabric (Woven Roving) Reinforcement Log Sheet 36
9.6 Common Additives Log Sheet 37
9.7 Peel Bond Test Procedure 38
9.8 Peel Test Report Form 39
9.9 Resin Evaluation & Test Procedure 40
9.10 Daily Resin Gel Test 41
9.11 Resin Dispersment Sheet 42
9.12 Non Conformity Correction Report 43-459.13 Inspection Test Plan 46-49
9.14 Quality Assurance & Control Org Chart 50
1.0 Quality Control Policy
1.1 Scope
This manual applies to the installation only of the
fiberglass components at the MMB Santa Rosalia Plant
Baja SUR Mexico. The work scope is for the field fiber
glassing of the CCD THICKENERS, FRP LINERS AND
LAUNDERS and the manufacturing of components.
Purpose
The purposes of the Quality Control Program are to:
1.1.1 Ensure adherence to the rules and requirements of
the Customer through processing of purchase
orders, drawings, specifications, Users Basic
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Requirements Specification (UBRS), and other
documents at the field locations.
1.1.2 Establish an inspection system to monitor thevariability of workmanship, processes and
materials, in order to produce a consistent product.
1.1.3 Establish and monitor the quality requirements
related to the materials and services of vendors of
subcontractors, based on surveillance and
performance analysis.
1.1.4 Provide a system for the detection of defect trends,
and institute corrective measures.
1.2 Laboratory Standards
1.2.1 It shall be the responsibility of the Quality Control
Manager to ensure that all equipment used in
testing is in good working condition.
1.2.2 All testing equipment will be regularly calibrated, in
accordance with recognized national standards.
Where no national standards exist, the basis for
calibration shall be noted.
1.2.3 Items tested with defective testing equipment shall
be considered non-conforming, and shall be retestedafter (re)calibration of the testing equipment.
1.3 Test Methods
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Specific written inspection procedures will be followed,
for all inspection and test operations.
1.4 Operating Procedures.
1.4.1 Parts will be made in accordance with the
conditions specified by the Engineering Manager, as
communicated on the approved shop drawings,
(UBRS), and the inspection requirements check list.
1.4.2 Approved Drawings and the inspection requirements
check list shall be available to the Quality Controlpersonnel.
1.4.3 Procedures shall be prepared and issued, as
specified in section 3 of this manual.
1.5 Field Activities
The field activities performed by SIN FIN (USA) LTD shall
be performed in accordance with the requirements of thisquality control manual. The program responsibilities,
controls, documentation, and authorities shall apply.
1.6 Notification of In-Process Changes
1.6.1 If a change is necessary after the fabrication of an
item has begun, the Engineering Manager shall
issue a written stop work notification to theConstruction/Project Manager and the Quality
Control Manager. The Quality Control Manager shall
remove the item drawing, and the Construction
Manager shall stop work in the area specified by the
Engineering Manager.
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1.6.2 The Engineering Manager shall process the change,
as specified in section 3 of this quality control
manual.
2.0 Quality Control Organization
Responsibility and authority for the implementation of
procedures outlined in this manual shall rest with the
Construction Manager or Project Manager...
The Quality Control Manager shall have the organizational
freedom to identify quality control problems and torecommend solutions. He/She has the responsibility to
report directly to the Construction Manager or Project
Manager matters concerning quality control.
If differences cannot be resolved between Department
Managers and the Quality Control Manager, they shall be
brought to the attention of the Construction Manager or
Project Manager for resolution. In all cases this manual
shall prevail.
2.1 Organizational Definitions
The organization of the quality control department is the
responsibility of the Quality Control Manager. This
section sets forth:
2.1.1 Where Quality Control inspector is referred to, it is
understood to mean the inspector employed by SIN
FIN (USA) LTD.
2.1.2 Where Authorized Inspector is referred to, it is
understood to mean the Inspector mutually agreed
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inspector to ensure conformance to specifications.
Functions include:
a) Review of applicable drawings.b) Inspection of incoming raw materials and
components.
c) Providing Q.C. at various stages of the
fabrication process.
d) Determining product release or rejection.
2.4 Certified Individual, Functions
2.4.1 The Certified Individual shall:
a) Perform an annual audit to verify that SIN FIN
(USA) LTD. Quality Control System is current
and is an effective operation;
b) Verify that the qualifications of the Inspector
and inspectorare in accordance with the SIN
FIN (USA) LTD Quality Control System;c) Verify that corrective actions taken to resolve
nonconformities are in accordance with the
SIN FIN (USA) LTD. Quality Control Program;
d) Verify that the responsibilities and activities of
the Inspectorare in accordance with the
requirements of the Standard;
e) Verify that products are manufactured by
qualified secondary bonders, and
f) Sign the Inspectors Certification on theFabricators Data report and/or the
Fabricators Partial Data Report.
2.5 Training of Quality Control Personnel
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2.5.1 Quality Control personnel shall be provided with
training in the handling of inspection equipment and
tools used by them in the inspection process.
2.5.2 Quality Control personnel shall be provided with
training in the implementing of Quality Control
procedures and the recording, and interpretation of
inspection data.
2.5.3 Quality Control Personnel training shall be
documented in a file maintained by the Q.C.
Manager.
2.6 Training and Qualification of Certified Individuals
2.6.1 Certified Individuals shall be qualified using the
following criteria:
a) A minimum of two years experience with QC
systems in the equipment fabrication industry.This experience need not be direct
employment as QC department personnel.
b) Initial attendance at one internal or external
QC system audit, performed by qualified CI
3.0 Contract Review and design
3.0.1 The Customer job order comes from the Customers
Purchasing Department. The Quality Control
Manager will then prepare a project file.
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3.1 Minimum Documentation
As per agreement of Authorized Inspector
3.2 Document Distribution
3.2.1 Job order documents to be distributed include
(UBRS) drawings, specifications and technical
procedures.
3.2.2 Preliminary design drawings shall be used only forthe following purposes;
a) Review of construction details and
requirements.
b) Preparation of tooling for bonding.
c) Purchase of raw materials.
d) Fabrication of components, on a risk basis,
subject to the express written approval of the
Authorized Inspector.
3.2.3 Fabrication details not shown on design drawings
and details of design drawings, used for purchasing
of subcontracted components, are to be assigned a
sketch number and be placed in the file folder.
3.3 Authorized Inspector
3.3.1 The Authorized Inspector shall be mutually
acceptable to SIN FIN (USA) LTD. and the Customer
(user). This shall be determined during contract
negotiations. If the Authorized Inspector is not
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established by contract, then SIN FIN (USA) LTD.
shall propose a Qualified Authorized Inspector,
and obtain the customers concurrence prior to the
start of fabrication.
3.3.2 Any hold points will be chosen by the Authorized
Inspector prier to work commencing.
3.3.3 The Quality Control Manager shall keep the
Authorized Inspector informed of the work progress
and schedule, for hold point inspections.
3.4 Procedures
3.4.1 Technical procedures that effect the job
requirements shall be prepared by the Engineering
Department, and distributed to appropriate
personnel.
3.5 Purchasing
3.5.1 Purchase orders are prepared by the Purchasing
Department in accordance with a Bill of Materials.
3.5.2 Stock materials, such as resin and reinforcement
materials are detailed on equipment drawings.
These materials are purchased by the Purchasing
department.
3.5.3 If the item to be purchased is a fabricated FRP part,
it shall be furnished with a Partial Data Report and
supporting documents, signed by the sub
contractors Quality Control Manager.
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3.5.4 Purchase order copies supplied to the receiving and
Quality Control departments do not show pricing
information.
3.5.5 The Quality Control department retains all copies of
purchase orders. These are NOT supplied to the
user with the Fabricators Data Report.
3.6 Vendor Evaluation
The Quality Control Manager shall evaluate the Material
Manufacturer by review of material inspections atreceiving. The Quality Control Manager maintains the
records of these evaluations. Since only acceptable
materials are used, the material Manufacturer is
evaluated on each shipment. An annual report of these
evaluations is prepared by the Quality Control Manager
and distributed to appropriate management.
3.7 Non-Compliant Items/Materials.
All items/materials received, that are not in compliance
with the purchasing and contract documents, shall not be
accepted during the receiving inspection process, and
shall not be used in the fabrication process. These
items/materials shall be returned to the Vendor.
4.0 Materials
4.1 Receiving Inspection
All resins, reinforcements, curing agents, purchased and
sub vended items, and common additives shall be
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received and checked under the control of the Quality
Control Manager. The checks shall include:
4.1.1 Check to assure they are the products ordered, bycomparing the items with the purchase order.
4.1.2 Check for proper labeling:
4.1.3 Manufacturers product name.
A) Manufacturers Specific Product
Identification (MSPI)
4.1.4 Verify the receipt of a Manufacturers Certificate ofAnalysis or Certificate of Compliance as applicable
for each lot received, when certificates are
required. Verify that the lot number on the
certificate matches that on the item(s).
4.1.5 Check the packaging for visible damage.
4.1.6 For acceptable items, sign and date the appropriate
receiving documents, and forward to purchasing.
4.1.7 Unacceptable items shall be handled as non-
conforming.
4.2 Resins
The Quality Control Manager prior to use in the
fabrication process shall review the results of the
following inspection and confirm the Material Testreports specify the proper material.
4.2.1 Check for normal color and clarity for the specific
resin type, and that it is free of solids or gelled
particles and contaminants of any type.
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4.2.2 A sample from each resin lot shall be used for
checking specific gravity, viscosity, and room
temperature gel time; that they are within the resin
manufactures specified range of limits. The resultsof these resin analysis shall be compared with the
Resin Manufacturers Certificate of Analysis, and
documented.
4.2.3 Log the lot number and the date received for each
lot, gel time, viscosity and specific gravity.
4.2.4 The storage environment of the resin must be incompliance with the resin manufacturers
recommendations.
4.3 Reinforcements
The results of the following shall be recorded by the
Quality Control Manager on the reinforcement log sheets,
prior to use in the fabrication process.
4.3.1 All reinforcements shall be visually inspected under
suitable overhead lighting, as they are dispersed for
imperfections such as holes, cuts, thin spots,
separation, and for contaminants such as
inclusions, dirt, oil and grease. Dimensions,
weights, and identifying numbers shall be recorded
on Material Reinforcement Log Sheet.
4.3.2 The storage environment of the reinforcement must
be in compliance with the reinforcement
manufacturers recommendations and all material
supplied will be with certified material test report.
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4.4 Curing Agents
The results of the following shall be recorded by the
Quality Control Manager on the Common
Additives/Curing Agents log sheet, prior to use in
the fabrication process.
4.4.1 Check for stratification of material into two or more
phases. In the case of liquids, they shall be free ofsediment or suspended solids.
4.4.2 The curing activity of curing agents shall be tested
generaly in accordance with ASME RTP-1, Appendix
M-3, and Article E.
4.4.3 The storage environment of the curing agent must
be in compliance with the curing agent
manufacturers recommendations.
4.5 Common Additives
The results of the following shall be recorded by the
Quality Control Manager on the Common Additives/Curing
Agents log sheet prior to use in the fabrication process.
4.5.1 Record date received manufacturer, product name,
quantity, and lot number. As additives are used,
record the start use and end use dates.
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4.5.2 The storage environment of common additives must
be in compliance with the additive manufacturers
recommendations.
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5.0 In Process Inspection
5.1 Procedures
5.1.1 The Construction Manager is issued the Approved
for Construction drawings from the Project
Manager, and the Inspection requirements Checklist
from the Quality Control Manager. These
documents, together with the Construction/Project
Managers file, authorize the fabrication process tobegin.
5.1.2 All construction requirements shall be specified on
the drawing, or on a document specified on the
drawings.
5.1.3 Preliminary activities that may proceed prior to the
issue of Approved for Construction drawings are
identified in 3.4.2.
5.2 Resin Mixing
The resin mixing and dispersion operator, on the Mixing
Data sheet, shall record the following data.
5.2.1 Resin promotion and primary preparation must bedone in the assigned resin mixing area.
5.2.2 Formulas for each particular type of resin mixture
are those recommended by the resin manufacturer
or as predetermined by experience. The
predetermined formulas shall be kept in a log book.
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5.2.3 Resin mixing data shall be completed for each
batch, and recorded on a mixing data sheet withreference to particular Job Number.
5.3 Material Dispersion
5.3.1 Resin shall be dispersed in containers clearly
marked by the resin mixing and dispersion operator,
identifying their contents. Resin type must beentered on the component data sheet for parts
utilizing that resin.
5.3.2 After materials have been fabricated, the identifying
numbers of the materials used in their fabrication,
shall be recorded.
5.4 Component Fabrication
The Quality Control Manager is responsible to have the
following data recorded on the component data sheet
prior to assembly.
5.4.1 The types of materials used in fabrication shall be
recorded, and verified as being correct.
5.4.2 The lamination sequence of a particular component
shall be recorded, and verified as being correct.
5.4.3 Laminate sequences for standard flanges are not
specifically recorded. Structural adequacy is
determined by thickness checks.
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5.5 Assembly
The following inspections shall be done, and the data
shall be recorded by the Quality Control Manager on the
inspection checklist.
5.5.1 All corrosion liners, and repairs to corrosion liners,
shall be inspected on the molds by the Q.C.
Department, prior to continuing the installationprocess. The installation department shall be
immediately notified of the results of these
inspections.
5.5.2 Laminate sequence lay-ups shall be compared with
the drawings, to ensure that all sequence layers are
present and the proper materials are used.
5.5.3 Inspect all equipment nozzles for the following,before installation:
-Corrosion liner quality -Number and size of bolt holes
-Flange and wall thickness -Bolt circle diameter
-Spot facing of flange -Resin in bolt holes
-Flange face drawback -Hub thickness
-Nozzle identification -Hub shear length
5.5.4 Inspect nozzle orientation and layout on allequipment before holes are cut for installation.
5.5.5 Inspect corrosion liners completely for air,
imperfections and inclusions, from the equipment
interior immediately after the parts are removed
from the mold.
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5.5.6 Collect all nozzle cutouts and measure them for
thickness. Confirm that the thicknesses are asspecified and record them on the quality control
report. Retain cutouts for physical properties
testing, as required, & review with the Authorized
Inspector.
5.5.7 Record laminate sequences for both interior and
exterior body welds, when used.
5.5.8 Record resin hardness (Barcol) readings.
5.5.9 Inspect all equipment nozzles after initial
installation (before the nozzle attachment welds are
completed) for the following:
a) Bolt holes straddle major centerlines.
b) Orientation meets specification requirements.
c) Elevation meets specification requirements.
d) Projection meets specification requirements.e) Nozzles are square and level.
5.6 Nonconformance
5.6.1 When a nonconformance is detected, the item shall
be tagged by the Quality Control Inspector and
segregated, when practical. The Quality Control
Inspector notifies the Quality Control Manager andthe Construction/Project Manager, and prepares the
non-conformities correction report, and forwards
the report to the Quality Control Manager. The
detected nonconformance may be cause to reject
items and/or initiate a vendor incident report. The
Vendor Incident Report shall be used for receiving
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inspection on material rejection prior too
acceptance of the material.
5.6.2 The Quality Control Manager may propose the
following dispositions in lieu of forwarding the non-
conformities correction report to the Engineering
Manager.
a) Return to vender
b) Scrap.
c) Repair visual defects (corrosion liner) or
exterior cosmetic defects
5.6.3 For all other dispositions, the report is forwarded to
the Engineering Manager who provides the
disposition. The registered Professional Engineer
(RPE) shall approve all repairs affecting design and
structure.
5.6.4 Dispositions shall be one of the following:
Use as is This is permitted when the item is in full
compliance with the (UBRS) and the
customer order.
Repair The repair shall be fully described on the
Nonconformity report. Only repairs,
which are listed in RTP-1 M7 300, shallbe made. The Authorized Inspector shall
approve the repair. The result of the
repair shall make the part to be in
accordance with the (UBRS) and the
customer order. The Quality Control
Inspector re inspects all repairs.
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Return to vendor Applicable to purchased materials, which
are found to be unacceptable for their
intended use.
Scrap Applicable when the nonconformity is not
repairable or is found to be unacceptable
for its intended use.
Other Other information, not covered by the
above listed categories.
5.6.5 The disposition non conformity report is returned tothe Quality Control Inspector, who causes the
action to be completed. When completed, the
Quality Control Inspector signs and dates the Non
conformity report, to record that the disposition has
been satisfactorily completed. In the case of
repair, the Authorized Inspector also signs and
dates the completed disposition.
5.6.6 The nonconformity report shall record as aminimum:
a) Date of correction
b) Specific location on the equipment
c) Description of the nonconformance
d) Method of correction
e) Name of qualified laminator/secondary bonder
who affected the repairf) Signatures of approvers
5.6.7 The Engineering Manager shall reconcile any
affected design documents, to reflect the current
status.
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6.0 Finished Equipment Inspection
6.1 Procedures
SIN FIN (USA) LTD. shall perform inspection of items
being installed, as necessary to determine that the items
are in compliance with the (UBRS) and the customer
order. These inspections will be done by the Quality
Control Inspector, and recorded on the inspection
requirements checklist. When complete, the Quality
Control Manager shall advise the Authorized Inspector
that the item is complete, and ready for final inspection.The Quality Control Manager prepares the Data Report
and the required supporting documentation. The Quality
Control Manager certifies the data report Certificate of
Compliance. All documents are then presented to the
Authorized Inspector
The Authorized Inspector performs the final inspection of
the item(s) as required. SIN FIN (USA) LTD. shall make
available its applicable inspection reports. TheAuthorized Inspector shall then record the results of
his/her inspections on the SIN FIN (USA) LTD. reports.
When the final inspection has been completed, the
Authorized Inspector shall prepare a brief report
summarizing his/her inspection activities and findings.
He/she then submits a copy of this report to the SIN FIN
(USA) LTD. Quality Control Manager as an attachment to
the Certificate of Compliance. When satisfied that the
item is fabricated within the requirements, the AuthorizedInspector signs and dates the Inspectors Certification,
then returns it to the Quality Control Manager. Once
these actions are completed, and all required testing, is
complete, The Certified Individual then signs and dates
the Contractors Certificate of Compliance, and the
Inspectors Certification.
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6.2 Pressure Test. (NOT APPLICABLE TO CONTRACT)
6.3 Qualification of Secondary Bonders
Secondary Bonders shall be qualified as required by
ASME RTP 1, Appendix M-5 400.This meets or exceeds
the requirements of ASME B-31-3. The Quality Control
Manager shall select the personnel to be qualified and
supply the necessary training. The qualification samples
shall be inspected and tested by the Quality ControlManager. Test results shall be reviewed, and approved
by signature and date, if acceptable. The Quality Control
Manager shall maintain the qualification records. The
Secondary Bonders names are recorded on applicable
reports. The reports shall be available to all parties
involved in the procurement and inspection activities.
Secondary Bonders shall be re-qualified at a three year
frequency, 18 months if inactive, or when the Quality
Control Manager or Certified Individual has cause toquestion their ability to produce quality items.
6.4 Access For Authorized Inspector
6.4.1 The Authorized Inspector shall be allowed access to
areas of the field, where the item is being installed,
at any time during the process.
6.4.2 The Authorized Inspector shall have access at anytime to all documents relating to the design and
quality control of the item being installed.
6.4.3 Access for final inspection to the inside and outside
of the item being installed shall be arranged for the
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Authorized Inspector, at a mutually agreed upon
time.
6.4.4 A clean safe working environment shall be provided
for the Authorized Inspector, with adequate lighting,
scaffolding, and other equipment required for
access to inspect the item being installed.
6.4.5 Adequate safety equipment, such as ventilation
fans, shall be made available for the Authorized
Inspector.
7.0 Records Retention and Controls
7.1 Scope
7.1.1 This procedure shall ensure that the records
retained, are complete and reliable.
7.1.2 Inspection and testing records shall as a minimum,
indicate the nature and number of observations
made. All inspection documentation shall be clearly
identified, indicating the job order number, part
number, part description, or in any manner that will
link the inspection results to a specific part.
7.1.3 Records shall be available for review, as one of the
principal forms of objective evidence of the qualityassurance program at SIN FIN (USA) LTD. office.
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7.2 Application
All records shall reflect the product conformance. The
records shall reflect acceptability of the product, andworkmanship, and what action was taken to correct any
non-conformity.
7.3 Records Retention
All records shall be retained by the quality control
department for a period of not less than five (5) years, or
longer as necessary for compliance of contractualrequirements.
7.4 Procedures for Records Handling
7.4.1 Records shall be identified and filed according to
job order number.
7.4.2 Any items supplied by sub venders shall be recordedby part number, with cross reference to the job
order number.
7.4.3 Records shall form an analysis basis, and
management action regarding the quality assurance
program.
7.5 AcetoneSensitivity Test
Should be applied to any secondary laminate surface,
within the following parameters:
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7.5.1 Perform three (3) tests per joint.
7.5.2 Acetone used for testing must be clean.
7.5.3 Acetone Testing Procedure (Note test location--
elevation and radial location (in degrees--see
drawings for reference) on the Acetone Sensitivity
Report Form).
7.5.4 Apply 5 drops of acetone to a small area of the
laminate surface.
7.5.5 With a clean finger, rub the acetone into the surface
until the liquid evaporates.
7.5.6 Check the laminate surface for tackiness.
7.5.7 If the laminate feels tacky, note a fail on the test
report. If not, indicate passage by checking OK on
the report.
7.5.8 Sign the report.
7.60 Barcol Hardness Measurement ASTM D 2583
.
Following is a summary of the test method. Refer to the
indicated ASTM for specific instructions on performing
this test.
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7.61 Fill out background information on the Barcol
Hardness Report, including date of test, description of
sample, and the specified Barcol for the test.
7.62 Note and record the areas from which the readings
have been taken (shell interior, bottom interior,
overlays, etc.) in the boxes labeled A through H.
7.63 Check the calibration of the Barcol Impressor with an
aluminum calibration disc before taking any readings.
7.64 Take ten (12) readings from each area listed. Record
each reading in lines 1-12 on the report.
7.65 Discard the lowest and highest readings, and average
the remaining 10 readings.
7.66 Compare the averages for each location to the
specified Barcol for the test.
7.67 Make a note of whether or not they conform. Make any
necessary comments and sign.
8.0 Lamination Procedure
Laminating Construction shall be in accordance with the
tabulated lay-up sequence according to the drawing or
specifications provided by the client.
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8.1 Surface Prep
8.1.1 Surface material must be pre-ground with a 35-50grit sandpaper or equivalent before applying any
structural material
8.1.2 All holes or crevasses shall be filled with resin
paste and left to exotherm and cool before applying
structural lamination
8.2 Structural Layer
8.2.1 Application of the structural layer shall not alter the
corrosion resistant barrier
8.2.2 The first ply of the structural layer of the laminate
shall be 1 or more plies of non-continuous glass
fibers totaling 450 Gram per m comprised of
Chopped Strand Mat and or Woven Roving or as per
owner specification.
8.2.3 Continue layup sequence of plies stated as perdrawing or specification supplied by owner
8.2.4 After each layup sequence is applied allow to
exotherm and cool before next layup sequence
8.3 Interior Layer Corrosion Resistant Barrier
8.3.1 The inner surface layer exposed to the contentsshall be a resin rich layer reinforced with a surface
veil providing a thickness of minimum 0.25 mm
0.50 mm or as per drawing or owner specification.
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8.3.2 After corrosion barrier has reached its peak
exotherm and cooled a resin rich wax coating will
be applied to seal or protect the corrosion barrier.
8.4 Inspection of Lamination Material
8.4.1 All fiber material must be pre inspected and signed
off by quality control before use of product
8.4.2 All resin must have gel test and approved by quality
control before use.
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Attachment 9.1
Inspection Checklist
-
Inspected Item Layout By
(initial/date)Checked By
(initial/date)Verified By
(initial/date)
Proper fit
Pre groundbefore lay-up
Nozzle size &
orientation
Elevation
Material
Lay up sequence
Barcol
Wax coat
Paperwork
completed
ProjectNumber:
CUSTOMER:Customer
Number:Location
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Turnover
Comments:
Attachment 9.2
Barcol/Acetone Sensitivity
Test Record
Component:
1
2
3
4
5
6
78
9
10
11
12
ProjectNumber:
CUSTOMER:CustomerNumber:
EquipmentNumber:
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Average
Note: A minimum of 12 Barcol readings for each component is required for RTP 1 see 6-910
ACETONE SENSITIVITY RECORD
COMPONENT
NUMBER
DATE
RESULT
INITALS
1Attachment 9.3
Cut-Out Thickness Check
Mk Qty Id Service Location DrawingThickness
ActualThickness
ProjectNumber:
CUSTOMER:CustomerNumber:
EquipmentNumber:
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1
1Attachment 9.4
Mat Reinforcement Log Sheet
Mat Manufacturer:
Mat Nomenclature:
Mat Treatment (if given)[Note 1]:
Mat Weight [Note 2]:
Q.C. File No.:
ProjectNumber:
CUSTOMER:CustomerNumber:
EquipmentNumber:
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RollNo.
Reinforcement
ProductionDate
Lot No.[Note
1]
Width Weightof
Sampl
e3
PropertyInspection3
VisualInspectio
n
(if given) (grams) By Date By Date
(3) Inspection Protocol: If no defects have been recorded in the previous 80 rolls,Sample the 1st roll on each skid. If defects are recorded, inspect every roll until 80rolls without defects have been recorded.Complete visual inspection for every roll as used.
Comments on visual and packaging inspection (indicate which roll):
Notes :( 1) Lot, batch, product code, or other label identification. (2)
Manufacturers label weight.
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1Attachment 9.5
1Fabric (Woven Roving) Reinforcement Log Sheet
Fabric Manufacturer:
Fabric Nomenclature:
Fabric Weight:
Fabric Construction:
Roll No.Reinforcem
entProduction
Date
(if given)
Lot No.[Note(1)]
Width
Weight
Gram
s3
Construction3
PropertyInspection
Cols 4,5, and63
VisualInspection
1 2 3 4 5 6 By Date By Date
(3) Inspection Protocol: If no defects have been recorded in the previous 80 rolls,Sample the 1st roll on each skid. If defects are recorded, inspect every roll until 80rolls without defects have been recorded.Complete visual inspection for every roll as used.
Comments on visual and packaging inspection (indicate which roll):
ProjectNumber:
CUSTOMER:CustomerNumber:
EquipmentNumber:
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Notes:(1) Lot, batch, product code, or other label identification.
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1Attachment 9.6
1
Common Additives Log Sheet
Manufacturer: Raw Materials Inspection Inspector Date
As Received
Product Name:
Lot Number:
Additive Purpose:
Manufacturer: Raw Materials Inspection Inspector Date
As Received
Product Name:
Lot Number:
Additive Purpose: Catalyst
Manufacturer: Raw Materials Inspection Inspector Date
As Received
Product Name: I
Lot Number:
Additive Purpose:
Manufacturer: Raw Materials Inspection Inspector Date
As Received
ProjectNumber:
MMB 038-11
CUSTOMER: MMB El Boleo MiningCustomerNumber:
EquipmentNumber:
CCD 01
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Lot Number:
Additive Purpose:
Attachment 9.7 Peel Bond Test Procedure
.
General Method for Performing Peel Test
A Peel Bond Test is performed to test secondary bondingperformance. It should also be run prior to the start of work toverify proper application technique.
1: First the area to be bonded is properly prepared by grindingwith a 16 or 24 grit disk. This removes any paraffinatedresin/concrete laitance or contaminants. Or in the case of themoulded surfaces, it roughens the surface and exposes glassfibers.
2: A piece of Mylar is taped over 1/2 of the area to be tested.Next a laminate is prepared consisting of 3 layers of 450 GramChopped Strand Matt cut to 150mm x 300mm along with a properamount of resin and catalyst.
3: The glass is wet out and applied over the test area being carefulto center the laminate over the prepared area and the Mylar area,i.e., 150mm x 150mm over the Mylar and 150mm x 150mm over theprepared area.
4: After the laminate has properly cured, the laminate is removedby lifting along the no bond (Mylar) side and pulling the laminatefree from the test area.
5: If the laminate pops free from the test area with little or no fiberstearing, it has failed the test. The prepared area needs to beinspected to see if it was ground properly to the right profile andto see if all contaminants have been removed.
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6: If the laminate tears loose exposing numerous fibers along thissubstrate, the test show that a proper bond has been achieved.
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1Attachment 9.8
Peel Test Report
Location Accepted Rejected Comments
Inspectors Name ____________________ Date:_____________________________
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Attachment 9.9
Resin Evaluation & Test Procedure ASTM D2471
Following is a summary of the test method. Refer to the
indicated ASTM for specific instructions on performing
this test.
Gel Time:
Gel time is defined as the timer interval between the
mixing of a resin with catalyst and promoter, and the
point where the mixture becomes unworkable due to
gelation. Gel time tests follow this procedure:
1. Make a note of all information on the resin to be
tested, including type of resin, resin manufacturer, date
of manufacture, batch and drum numbers, and date of
test. If required, note type of promotion and type of
catalyst, including percent used in the test. Also, if
required, include temperature at time of test.
2. Set gel time counter to zero.
3. a. When using a Gel Timer, weigh and place 100g
sample of resin in a paper cup, measure and add an
appropriate amount of catalyst and mix for at least one
minute.
b. When using a Hot Pot Gel Timer, set the thermostat
at the desired test temperature (usually 20 deg. C to 25
deg. C). Weight and place a 100g resin sample in an
aluminum gel cap. Measure and add an appropriate
amount of catalyst and mix for at least one minute.
4. Place the sample in the gel timer.
5. Insert a wire utensil and stir.
6. When the resin gels, note the time shown on the
counter and record it on the Resin Evaluation & Test Log.
7. Record comments, if any, and sign the log.
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1Attachment 9.10
Resin Dispersement Sheet
Project Number MMB 038/11
Customer MMB El Boleo Mining
Equipment Number CCD 01
1Manufacturer: Ashland Chemicals Q.C. contact:
Resin: Derakane 411-350 VE Address:
Spindle No.: Telephone No.:
Emergency telephone
No.:
Date Lot No.
Gel Time @25oc
(min)
Viscosity
@25oc (cps)
Specific Gravity
@25oc VisualExamination
Manufacturers
Specification
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1Attachment 9.11
Daily Resin Gel Test
Resin Type: Derakane 411/350 VE
Catalyst Used: _Norox 922H (Red) __
Additives Amount
Mass
% Comments
D 411/350 1000 gram 100%
Cobalt (6%) 20 ml 2%
BYK A 515 1.5 ml 0.15%
2.4p (Acetyl Acetone) 0.2 ml 0.02%
MEKP ( Norox) To be added for Gel test.
Gel Test
TimeofTest
% ofCatalyst
CatalystMass
ResinMass
RelativeHumidity
AmbientTemp
GelTime
InspectorsInitials
1.25% 1.25ml.
100 Gr.
Project
Number:MMB 038/11
CUSTOMER: MMB El Boleo MiningCustomerNumber:EquipmentNumber:
CCD 01
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Inspectors Name ____________________ Date:_____________________________
Attachment 9.12
Nonconformity Correction Report (Page 1 of 2)
Project Number:
Customer:
Customer PO Number:
Equipment Number:
Sequence No.: Initiation Date:
Description of equipment
Work area or responsible laminator(s) or secondary bonder(s):
Description of nonconformity (i.e. size, type, location, etc.):
Identified by: Date:
Method of repair or corrective action (Use back of form if necessary. If other attachments,sketches, or drawings are required, they must be referenced here and attached),
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Check off approvals required (see ASME RTP-1, Appendix M-7 for stamped equipment):
Registered Professional Design Engineer Date
: Fabricators Engineering Manager Date
:
Inspector Date:
Fabricators Quality Control Manager Date
:
Other Date
Project Number:
Customer:
Customer PO Number:Equipment Number:
Nonconformity Correction Report (Page 2 of 2)
CorrectiveWorkdoneby:
Name Title Employee
No.
Supervisorssignature:
Date completed:
Required quality control inspections and approvals (check off approvals required):
Inspector Date
:
Fabricators Quality Control Manager Date
:
Other Date
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:
Date
:
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Attachment 9.13Project Number:
Customer:
Customer PO Number:
Equipment Number:
Receiving Inspection / Material Verification x 1Verify all resin and additives received comply topurchase orders x Standard 1
Verify all glass received complies to purchase orders x 1
Unacceptable material is reported to purchasing x 1 Purchasing to mark non conforming material as: use as
is, rework, or return to vendor x1
Lamination Process Inspection x
Resin inspection as per field order x 1
Fiberglass inspection as per field order x 1
Resin Additives inspection as per field order x 1Final cure Thickness Dimensions, Appearance, BarcolHardness x 1
Component inspection (covers, flanged nozzles,
bosses, gussets, ribs, stiffeners, etc. X 3Submit Report x
Assembly Inspection x
Production layouts for flanged nozzles, fittings,manholes, vents, filling ports prior to bonding sub-assemblies, Assembly fixtures, leveling devices, Drill
jigs properly oriented, Locating pins and stops usedproperly.
x 3
Sanding (applies to all sanded parts /areas) x
Smooth surface, Critical wall thicknesses aremaintained after sanding, Areas requiring secondarybonding are completely sanded, Air bubbles have beensanded through are repaired
x 1
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Drilling x
Drill patterns to match drawings, Jigs to matchdrawings, Resin wipe all holes, Exposed fibers are
sealed, Check size, Check location, Check number,Check orientation x
1
Trimming x
Trimmed to correct dimensional lines, Check fordelamination where trimmed, Resin wipe trimmededges are wiped to seal exposed fiber
x 1
Hydrostatic Testing (if required) 2
Check pressure to meet specification 2
Check vacuum to meet specification 2
Log time test begins 2
Log time test ends 2
Check Hourly: 2
Liquid level 2
Pressure Gauge 2
Submit Report 2
Manway Covers and Fittings x 3
Top Center Manway Covers, Smooth inner surface, Noentrapped air or dry spots, Hole pattern, Edge distance x 1
Sidewall Manway Covers, Smooth inner surface, Boltpattern, O.D. Trimming, Thickness, No entrapped air ordry spots
x 1
Molded Fittings x Tie down brackets smooth, no dry spots, internal voidsor delamination x 3
Fittings not meeting the above criteria may besubmitted for rework. x 3
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Purchased Parts x
Reinforced Plastic Sub Assemblies x
Threaded assemblies have clean threads
x
Nipples, elbows, flange faces have no cracks, airpockets or damage of any kind, Ends are cut squareand smooth
x
Sub-Assemblies x Dimensions and angles meet engineering drawings,specifications and tolerances x
Mating joints are fully and firmly seated, Evidence offiller squeeze out around circumference of joint x
Cut edges are sanded and resin coated x Excess filler is removed from outside and inside
assembly x
Resin fillers are smooth, even and fully cured, no tackyor soft spots x
Acceptable sub-assemblies marked OK,Unacceptable sub-assemblies marked REJECTED,Unacceptable sub-assemblies removed for rework ordisposal
x
Tank Bottoms x
Material requirements are verified to drawing x Inspect surface preparation prior to application x
Exterior surface has no protrusions above 1/8 x Seams and overlays are blended to form a smooth anduniform transition area x
No voids or delaminations between liner and structurallaminate larger than visual inspection criteria. x
Pits are filled prior to bottom installation x
Submit Report x
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Attachment 9.14
George White
Project Manager
Robert Haye
QA/QC(Manager)
TBDField QAManager
TBDQC Inspector