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James & Luther, Inc. 7100 Westwind Dr, Suite 130 El Paso, TX 79912 Phone: 915-581-5020

James and Luther, Inc.

QUALITY CONTROL MANUAL

FOR

POWER BOILERS, POWER PIPING, PRESSURE VESSELS & PARTS

CONSTRUCTED IN ACCORDANCE WITH

ASME SECTION I, ASME B31.1 AND

ASME SECTION VIII DIV. 1

&

REPAIRS & ALTERATIONS TO PRESSURE RETAINING ITEMSIN ACCORDANCE WITH THE NATIONAL BOARD INSPECTION CODE

AND JURISDICTIONAL REQUIREMENTS.

AT THIS LOCATION AND ALL FIELD SITES CONTROLLED BY THIS LOCTION

Edition Number 1: July 17, 2014

Revision Number 1: July 17, 2014

CONTROLLED COPY #1

ISSUED TO OFFICE

DATE:

QCM: Date:

AI: Date:

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STATEMENT OF AUTHORITY AND RESPONSIBI LI TY

THIS MANUAL OUTLINES AND DEFINES THE QUALITY CONTROL PROGRAM TO ENSURE THAT

THE COMPANY IS AT ALL TIMES IN COMPLIANCE WITH THE APPLICABLE REQUIREMENTS OF

THE APPLICABLE ASME BOILER AND PRESSURE VESSEL CODE AND THE NATIONAL BOARD

INSPECTION CODE; HEREAFTER REFERRED TO AS THE CODE.

THE PRESIDENT FULLY SUPPORTS THIS QUALITY CONTROL SYSTEM AND GIVES THE

QUALITY CONTROL MANAGER COMPLETE AUTHORITY, RESPONSIBILITY, AND THE

ORGANIZATIONAL FREEDOM TO IDENTIFY QUALITY CONTROL PROBLEMS AND TO PROVIDE

SOLUTIONS. ALL PERSONNEL ARE HEREBY INSTRUCTED TO GIVE FULL COMPLIANCE TO

THIS MANUAL AND THE CODE.

ANY PROBLEMS CONCERNING CODE COMPLIANCE THAT CANNOT BE RESOLVED BY THE

QUALITY CONTROL MANAGER SHALL BE BROUGHT TO THE PRESIDENT FOR FINAL

RESOLUTION WITHOUT COMPROMISE OF THE CODE OR THIS QUALITY CONTROL MANUAL.

___________________________________ ____________________________

PRESIDENT DATE:

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TABLE OF CONTENTS

Section Title

I Title Page

II Statement of Authority and Responsibility

III Table of Contents

IV Organizational Chart

V Abbreviations and Definitions

1 Quality Control Responsibilities

2 Drawings, Calculations, and Specifications

3 Material Control

4 Examination and Inspection

5 Correction of Non-Conformances

6 Welding

7 Non-Destructive Examination

8 Heat Treatment

9 Calibration Testing

10 Record Retention

11 Authorized Inspector

12 Repairs and Alterations

13 Field Sites

14 Exhibits

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ORGANIZATIONAL CHART

PRESIDENT

Engineer Quality Control Manager Purchasing Manager Production Manager

Shop/Field QC Inspector Shop/Field Superintendent

Consultant NDE/HT

Engineer or Sub-Contractors

Customer

Engineer

Responsibility

Communication

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Abbreviations and Definitions

Abbreviations, if used, are defined as follows:

ASME American Society of Mechanical Engineers

ASME CODE American Society of Mechanical Engineers Boiler and Pressure Vessel CodeA.I. Authorized Inspector

A.I.A. ASME Accredited Authorized Inspection Agency

B.O.M. Bill of Material, Exhibit 14.7

C of C Certificate of Compliance

CODE American Society of Mechanical Engineers Boiler and Pressure Vessel Code and /or The National Board Inspection Code

COMPANY Refers to the Organization whose name is as indicated on the title page of THIS

manual and Certificates of Authorization.

HT Heat Treatment

MTR Material Test Report

NBIC National Board Inspection Code

NCR Non-Conformance Report

NDE Non-Destructive Examination

RTRadiographic Examination

UT-Ultrasonic ExaminationMT-Magnetic Particle Examination

PT-Liquid Penetrant Examination

VT-Visual Examination

PQR Procedure Qualification RecordPWHT Post Weld Heat Treatment

QA Quality Assurance

QC Quality Control

QCI Quality Control Inspector

QCM Quality Control Manager

QUALITY CONTROL When indicating a function to be performed shall mean that it is to performed bythe QCM or QCI

SECTION When followed by a roman numeral, shall mean that section of the ASME Boiler

and Pressure Vessel Code

SUPERINTENDENT When used alone, shall indicate shop superintendent or field superintendent, asapplicable

SWPS Standard Welding Procedure Specification

WPQ Welder or Welding Operator Performance Qualification

WPS Welding Procedure Specification

VESSEL All Items to be stamped with the ASME Certification Mark

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2.0 DRAWINGS, CALCULATIONS, AND SPECIFICATIONS

2.1 Drawings, Bill of Materials, Calculations, and Specifications may be prepared by Company

Engineer, Consultant Engineer, or Customer Engineer. When computer programs are used in thedesign, the responsibility for input of correct data and verification of output shall be controlled by a

company engineer. Prior to Code edition becoming mandatory, a company engineer shall perform a

review of the revisions to determine if computer programs are affected. This review and anychanges made to computer programs shall be documented by a company engineer. Hand

calculations to verify output will be provided when requested by the A.I. In either case, all design

documents shall be reviewed for Code compliance by a company engineer and will indicateapproval by signature and date. The Quality Control Manager will indicate his review by signature

and date on the Traveler (Exhibit 14.9). Engineering and the Quality Control managers shall add to

the drawing all required data such as Job No., Unique Serial Number for each vessel or unit, WPS

numbers, Joint design and weld sizes for all joints, NDE Requirements, PWHT Requirements,Hydrostatic Test Pressure, Certification Mark stamping details, and any additional Code

Requirements.

2.2 The Bill of Material (Exhibit 14.7) prepared and approved by a company engineer from designdocuments, shall include all Code ordering requirements for the material to comply with Section II

and to any additional requirements as required by the fabrication code using SA or SB Specification

Designations.

2.3 Any revisions to the above documents shall be reviewed and approved the same as the originals.

2.4 The Quality Control Manager shall maintain the drawings, BOM, calculations, and specifications inthe job file and issue a copy of approved drawings and their revisions to the Shop/Field

Superintendent and a copy of the approved BOM to purchasing. As revisions are issued, the

Quality Control Manager shall recover and destroy all obsolete copies, maintaining one copy

marked VOID in the job file.

2.5 When the Quality Control Manager is unable to physically deliver drawings, BOM, calculations,

specifications, or any other required documentation to the Field Superintendent at the field site, hewill deliver required documents using the Transmittal Form (Exhibit No. 14.6). When received, the

Field Superintendent will issue the new documents, destroy the old documents (if applicable), sign

and date the transmittal form, and return the form to the Quality Control Manager to indicate his

receipt.

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3.0 MATERIAL CONTROL

3.1 Purchasing Manager shall verbally order all code welding material/consumables from data on the

approved B.O.M. or, for welding consumables, by written request of the Superintendent per ASMESpecifications. (See Section 13 for Material purchased in the field)

3.2 No substitution of material is allowed until all affected documents have been revised as describedin this Manual and are approved by Engineering and Quality Control managers and accepted by theA.I.

3.3 All Code material received will be inspected by the Shop/Field Quality Control Inspector forcompliance to the B.O.M. and the Code. This inspection shall include the Quantity, Dimensions,

Code Identification, Physical Defects, Documentation and any Evidence of damage. The results of

this inspection shall be recorded on the B.O.M. Welding consumables shall be inspected Shop/Field

Quality Control Inspector for conformance to the ASME SFA Specification or AWS Classificationincluding Identification Markings and Shipping Damage.

3.4 All Material Test Reports (MTR) shall be reviewed for Code compliance to ASME Section II by the

Quality Control Manager or Shop/Field Quality Control Inspector who will sign and date the MTRwhen acceptable. These MTRs shall become part of the job file and be presented to the A.I. for his

review.

3.5 Code acceptable material will be marked with the job and / or Serial Number and stored in a Code

designated area. If Code acceptable materials are too small to be marked individually, they shall beplaced in a container marked with the job and / or Serial Number and stored in a Code designated

area.

3.6 A Hold Tag (Exhibit 14.12) shall be placed on unacceptable material. A Non-Conformance Report

(Exhibit 14.2) shall be completed by Quality Control for disposition per Manual Section 5. Thismaterial will be segregated form Code Acceptable Material.

3.7 All Code Material will be issued to the Shop/Field Superintendent by Quality Control afterverification that it is acceptable and complies with the applicable Code and the drawings.

Identification may be recorded on the drawing or Traveler (Exhibit 14.9) by the Shop/Field Quality

Control Inspector at time of fit-up examination.

3.8 Material delivered to subcontractors for rolling and / or forming shall be tagged with a metal tag orstamped with the job or Serial Number and any other required identifying number to permit

traceability to MTRs.

3.9 Customer supplied material may be used. If customer supplied material is used, the Quality Control

Manager shall be responsible for obtaining MTRs or certificates of compliance as required, and all

required identification.

3.10 Any additional material testing required shall be identified on the drawings.

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4.0 EXAMINATION AND INSPECTION

4.1 The Quality Control Manager, prior to fabrication, shall prepare the Traveler (Exhibit 14.9.1) for

each Code vessel and present it to the A.I. with the applicable drawings and calculations for hisreview and acceptance and to allow insertion of his required inspection hold points.

4.2 All applicable examination points are mandatory for Quality Control. The A.I.s designated holdpoints may not be passed without his initial and date as acceptable or by obtaining a verbal waiver

of a hold point and documenting such waiver on the Traveler (Exhibit 14.9) indicating the person

who received the waiver and the date.

4.3 When Material Identification Markings are located where they will be removed during fabricationor the material is divided into two or more pieced, the Shop/Field QCI shall transfer the markings or

verify their correct transfer prior to cutting. Alternatively, subject to the acceptance or the A.I., a

documented Coded Marking System traceable to the MTR or to the material specification, when no

MTR is required, may be used.

4.4 The fit up of all weld joints prior to welding shall be examined by the Shop/Field QCI, and when

acceptable, recorded on the Traveler (Exhibit 14.9). At this time the Shop/Field QCI shall record allMaterial Identification as built into the Vessel on the Traveler (Exhibit 14.9) and Drawing.

4.5 The Quality Control Inspector shall monitor all fabrication operations and all non-conformances

shall be handled per Section 5 of this Manual.

4.6 The Hydrostatic test shall be conducted by the Shop/Field Superintendent as specified on the

drawing. The Quality Control Inspector shall witness and accept the Hydrostatic test and notify theA.I. so that he may be present during the test. After acceptance at the Hydrostatic test pressure, the

Quality Control Inspector and the A.I. will make a close visual examination of all weld joints at the

pressure required by the applicable Code. Pressure Gauges used for the Hydrostatic test shall beapproximately twice the pressure but no less than 1 times the test pressure, or more than 4 times

that of the test pressure.

4.7 All repairs to Code Materials shall be referred to the A.I. for his acceptance or the method of repair

prior to performing such repairs.

4.8 The Quality Control Manager is responsible for the Name plate stamping or stamping on the Vessel

or part as specified on the drawing with the review and acceptance of the A.I. They shall record this

on the Traveler (Exhibit 14.9) to verify review of the stamping and its application to the propervessel or part.

4.9 The Certification Mark shall be in the custody and control of the Quality Control Manager and the

Certification Mark may be applied to the Name Plate, Vessel, or Part only with the concurrence of

the A.I. For stamping see Exhibit 14.3.4.10 When internal inspections of a Vessel cannot be made by entering the vessel after the final closure

weld is made, a complete as possible examination shall be made prior to the final closure.

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5.0 CORRECTION OF NON-CONFORMANCES

5.1 A Non-conformance is any condition which does not comply with the Code, this Quality Control

Manual, or customer specifications. There are normally two types of Non-conformances: Those found in material or parts at receiving inspection such as documentation, markings,

dimensions, or physical damage.

Those found on items during fabrication, examination, inspection or final testing.

5.2 When a Non-conformance is discovered, the Shop/Field QCI shall be notified for preparation of a

Non-conformance Report (Exhibit 14.2) and marking of the item or material with the wordHOLD. This HOLD marking may only be removed by the Shop/Field QCI or Quality Control

Manager after correction of the Non-Conformance.

5.3 The Quality Control Manager shall approve the proposed disposition on the Non-conformance

Report after consultation with Engineering, Superintendent, Purchasing, and Customer as required,and then present the approved disposition to the A.I. for his acceptance prior to corrective action

being taken and for the insertion of any hold points

5.4 When the Non-conformance has been resolved to be USE AS IS, the reasons for accepting theNon-conformance is stated by the Quality Control Manager on the Non-conformance Report andsubmitted to the A.I. for his concurrence and acceptance. When any required Revisions to

Drawings, Calculations, or other Manual required documents are made as described in this Manual,

require the same approvals as the Original.

5.5 When the Non-conformance requires rework or repair, the Quality Control Manager prepares therework or repair procedure and presents it to the A.I. for his review, acceptance, and designation of

Hold Points.

5.6 The Shop/Field QCI shall be responsible for all inspection of rework or repair of the Non-

Conformance. When the inspection reveals that the work is acceptable, the Non-conformance report

shall be signed by the Shop/Field QCI with his approval of the final disposition of the Non-Conformance. The A.I. will be notified of the correction of the Non-conformance and presented the

Non-conformance Report for his review and acceptance of the final disposition. The Non-

conformance Report shall be filed in the job file.

5.7 When the Non-conformance requires the rejection of material or items, those items or materials shallbe completely removed from the code work area and clearly marked as to eliminate the possibility

of them being mistakenly used on code work.

5.8 Welding defects determined by NDE are not documented on a Non-conformance Report but, will be

repaired using a WPS specified by engineering or the Quality Control Manager and re-inspected bythe Original NDE (If applicable) used to detect the defects.

5.9 Only the Quality Control Manager or Quality Control Inspector may remove the Hold Tag (Exhibit

14.12) after correction of the Non-conformance. It shall include the verification of the implementedcorrective action by QCM/QCI and AI before removing the Hold Tag (Exhibit 14.12).

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6.0 WELDING

6.1 All Welding procedures, Welders, and Welding Operators shall be qualified and certified to ASME

Section IX with any additional requirements of the Construction Code.

6.2 The Quality Control Manager shall prepare the WPSs which will be revised whena Nonessential

Variable change and will be re-qualified when there is a change in Essential or SupplementaryEssential (When Applicable) Variables.

6.3 The Quality Control Manager shall assign and supervise personnel to perform the Procedure

Qualification Tests. The required welded specimens may be mechanically prepared and tested

either in house or by an acceptable testing Laboratory. Reports of the tests will be reviewed forcode compliance by the Quality Control Manager, who will complete and certify the PQR when

acceptable per the Code.

6.4 The Quality Control Manager or his designee shall supervise welders and welding operators in the

performance of their qualification test. The required welded specimens may be mechanically

prepared and tested either in house or by an acceptable testing laboratory. Reports of the tests will

be reviewed for code compliance by the Quality Control Manager, who will complete and certifythe WPQ Report when acceptable per the Code.

6.5 Copies of WPS, PQR, WPQ, and WOPQ shall be available to the Superintendent, Quality Control

Manager, and the A.I.

6.6 The Quality Control Manager shall maintain on file the Welders Qualification Record (Exhibit

14.10) with welder/welding operators qualification listed by process and make a copy available to

the superintendent. The welders qualification record (for evidence of welding process continuity)shall be compiled every 6 months, at a minimum, by the Quality Control Manager to maintain

current Qualification. Welders shall be re-qualified if they do not weld in a specific process for a

period of six months, when there is a change in a performance essential variable, or at any timetheir ability to perform Code Welding is questionable.

6.7 The Superintendent shall assign qualified welders or welding operators to Code welding from theWelders Qualification Record. He shall make the applicable WPS available to the Welder or

Welding Operator as specified on the approved drawing, maintaining supervision and control

throughout production welding.

6.8 All company tack welds shall be made to a qualified WPS. They shall be removed prior to welding

the joint unless welded by a qualified welder in which case, they will be prepared properly for

incorporation into the final weld and inspected for defects by the welder prior to incorporatingthem into the finished weld (if defective they shall be completely removed). Subcontractors tack

welds shall be made using a company WPS or the subcontractors WPS may be used after review

and acceptance by the Quality Control Manager. Subcontractors tack welds shall be removed.

6.9 The Quality Control Manager shall assign each Welder or Welding operator a unique symbol stamp

to identify his welds. All Code welds shall have the welder's symbol stamped adjacent to the weld

at intervals of not more than 3 feet. If stamping is not permitted or in lieu of stamping, theShop/Field QCI shall record the welder's symbol for each weld on the Engineered Drawings.

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6.10 All welding consumables shall be ordered and received as required in the Material Control Section 3

of this Manual. They shall be stored in warm dry areas or heated ovens as recommended by ASME

Section II Part C and/or the welding consumable manufacturers recommendation.

6.11 All Low Hydrogen electrodes, after containers are opened, shall be stored in heated ovens.

6.12 Low Hydrogen electrodes are issued for a maximum of 4 hours use, after which, or at completion of

welding or shift, they are returned to the oven prior to re-issue. Unidentified, damaged or dirtyelectrodes are scrapped.

6.13 The Authorized Inspector may require requalification of a WPS, Welder, or Welding Operator at

any time.

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7.0 NON-DESTRUCTIVE EXAMINATION

7.1 Non-destructive Examination may be subcontracted or performed in house.

7.2 The types of Nondestructive Examination used shall be Radiographic, Ultrasonic, MagneticParticle, Liquid Penetrant, and Visual examinations.

7.3 Subcontract Personnel responsible for performing RT, UT, PT, MT, and VT examination shall be

qualified and certified to their Written Practice, using SNT-TC-1A (Latest Code Accepted Edition

and ADDENDA) as a guideline, and/or the applicable Code.

7.4 The NDE subcontractor's Written Practice shall contain provisions for training, experience,

qualification, and certification. This Written Practice and the certification and examination records

of personnel shall be reviewed and approved by the Quality Control Manager for compliance with

the Code.

7.5 The NDE Subcontract Level III Qualifications and certifications shall be reviewed by the QualityControl Manager who will, upon acceptance, issue a letter of appointment for the Level III to act as

the Company Level III Examiner for RT, UT, MT, PT, and VT.

7.6 When applicable, in house personnel responsible for performing Magnetic Particle or Liquid

Penetrant Examination shall be qualified and certified by the Company in accordance with ASME

CODE and the company qualification and certification requirements.

7.7 When applicable, in house personnel responsible for performing Visual Examination shall be

qualified and certified by the Company in accordance with ASME B31.1, paragraph 136 and the

company qualification and certification requirements.

7.8 All NDE Documentation shall be on file and available to the Authorized Inspector for review.

7.9 Radiograph Film and Interpretation Technique Sheets and other NDE examination records shall be

reviewed and accepted by the Shop/Field QCI prior to making them available to the AuthorizedInspector for review.

7.10 The NDE subcontractorsRadiographic film viewing facilities and density comparing equipment

shall be available for review of film for Code compliance by the Shop/Field QCI and the

Authorized Inspector.

7.11 NDE Procedures (methods and techniques) shall be demonstrated to the satisfaction of theAuthorized Inspector and so documented.

7.12 The Authorized Inspector may request requalification of NDE Procedures or examiners wheneverthere is a reason to question their Code compliance.

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8.0 HEAT TREATMENT

8.1 All PWHT will be performed by an outside contractor either on field site, in shop, or at contractor's

location. Engineering Manager shall prepare and approve the heat treating procedure or review andaccept the subcontractors Heat Treating Procedure which describes the placement of

thermocouples, temperature gradients for heating and cooling, time at temperature, all specialrequirements, and required records.

8.2 The Quality Control Manager shall review and accept the subcontractor's controls equipment and

calibration records to assure Code compliance before placement of an order.

8.3 The subcontractor shall provide the company with records of heat treatment consisting of heat

treatment charts which shall include date, item job and / or serial number, evidence of currentcalibration of recorders, the number, location and method of attachment of thermocouples and shall

be signed and dated by the operator or subcontractors personnel.

8.4 Items to be sent for heat treating shall be tagged with a metal tag or stamped with job and / or serialnumber and any other required identifying numbers. These numbers shall be verified by the

Shop/Field QCI prior to shipment to the outside contractor and upon return to the shop or field.

8.5 The Quality Control Manager shall review heat treatment charts and documentation for compliance

with the procedure and the Code, and indicate this review and acceptance by initials and date.

8.6 The heat treatment chart and documentation shall be submitted to the Authorized Inspector for

review and become part of the Job File.

8.7 Shop/Field QCI shall inspect all returned items for conditions and shipping damage. Unacceptableitems will be handled per Section 5.0 of this manual; acceptance of items will be recorded on the

Traveler (Exhibit 14.9).

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11.0 AUTHORIZED INSPECTOR

11.1 The Authorized Inspector, as defined in the ASME Code, shall have been qualified by a written

examination under the rules of any State of the United States or Province of Canada which hasadopted the Code. He will be employed by an ASME Accredited Authorized Inspection Agency,

as defined by ASME Section I PG-91 & VIII, Div. 1 UG-91 (a)(1), with which the Company has a

current agreement for inspection service.

11.2 The Quality Control Manager or Quality Control Inspector shall act as liaison with the Authorized

Inspector, and shall notify the Authorized Inspector in advance of all Hold Points in sufficient time

for him to perform inspections and of all repairs to materials prior to performing the repairs.

11.3 Where Code work is in progress, whether in shop or field, the Authorized Inspector shall have free

access to perform all required inspections and monitoring, and to those subcontractors facilities andCode material suppliers as he may request.

11.4 The Authorized Inspector shall have free access to all documentation required to performinspections.

11.5 A current controlled copy of the Quality Control Manual shall be made available to the Authorized

Inspector.

11.6 All access given to the Authorized Inspector shall be extended to his supervisor to perform anyrequired audits or reviews.

11.7 Proposed changes to the Quality Control Manual shall be submitted to the Authorized Inspector forreview and acceptance prior to implementation.

11.8 The Quality Control Manager shall furnish the Authorized Inspector with a Traveler (Exhibit 14.9)

prior to any fabrication for review and placement of Hold Points. No work shall proceed beyondthe Authorized Inspector's Hold Points until he accepts them by signature and date OR A VERBAL

WAIVER OF THE HOLD POINT PER PARAGRAPH 4.2 IS OBTAINED.

11.9 The Quality Control Manager shall prepare, certify and submit the appropriate Manufacturer's DataReports to the Authorized Inspector for review for compliance with the applicable Code

requirements. The A.I. will review and sign the Manufacturer's Data Report when he has assured

himself that all Code requirements have been met.

11.10 The Quality Control Manager will assist the Authorized Inspector's Supervisor during his required

audits and the Authorized Inspector while he is monitoring the Quality Control System.

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12.0 REPAIRS AND ALTERATIONS

DEFINITIONS OF SOME TERMS USED IN THIS SECTION

ALTERATION ANY CHANGE IN THE ITEM DESCRIBED ON THE ORIGINAL MANUFACTURERS DATAREPORT WHICH AFFECTS THE PRESSURE CONTAINING CAPABILITY OF THE PRESSURE

RETAINING ITEM. NON- PHYSICAL CHANGES SUCH AS AN INCREASE IN THE MAWP

(INTERNAL OR EXTERNAL), OR DESIGN TEMPERATURE OF A PRESSURE RETAINING ITEM

SHALL BE CONSIDERED AN ALTERATION. A REDUCTION OF THE MDMT SUCH THAT

ADDITIONAL MECHANICAL TESTING IS A REQUIREMENT SHALL BE CONSIDERED AN

ALTERATION.

A.I.A. AN A.I.A. SHALL BE EITHER A JURISDICTION AUTHORITY AS DEFINED IN THE NATIONALBOARD CONSTITUTION OR AN ENTITY THAT IS ACCREDITED BY THE NATIONAL BOARD

MEETING NB369; QUALIFICATION AND DUTIES FOR AUTHORIZED INSPECTION

AGENCIES.

INSPECTOR AN INDIVIDUAL WHO HOLDS A VALID AND CURRENT NATIONAL BOARD COMMISSIONAND EMPLOYED BY AN ACCREDITED IN-SERVICE AUTHORIZED INSPECTION AGENCY.

JURISDICTION A GOVERNMENTAL ENTITY WITH THE POWER, RIGHT, OR AUTHORITY TO INTERPRETAND ENFORCE LAW, RULES, OR ORDINANCES PERTAINING TO BOILERS, PRESSURE

VESSELS, OR OTHER PRI. IT INCLUDES NATIONAL BOARD MEMBERS JURISDICTIONS

DEFINED AS JURISDICTIONAL AUTHORITIES.

REPAIR THE WORK NECESSARY TO RESTORE PRESSURE RETAINING ITEMS TO A SAFE ANDSATISFACTORY OPERATING CONDITION.

RE-RATING SEE ALTERATION

ROUTINE REPAIRS THOSE REPAIRS LISTED AND DEFINED IN THE NBIC AS ACCEPTABLE ROUTINEREPAIRS AND/OR THOSE ACCEPTED BY THE JURISDICTION WHICH HAS CONTROL OVERTHE PRI.

ORIGINAL CODE

OF

CONSTRUCTION

(OCC) - DOCUMENTS PROMULGATED BY RECOGNIZED NATIONAL STANDARDS

WRITING BODIES THAT CONTAIN TECHNICAL REQUIREMENTS FOR CONSTRUCTION OF

PRESSURE RETAINING ITEMS OR EQUIVALENT TO WHICH THE PRESSURE RETAINING

ITEM WAS CERTIFIED BY THE ORIGINAL MANUFACTURER.

NON-CODE ITEM A PRESSURE RETAINING ITEM WHICH WAS NOT DESIGNED OR CONSTRUCTED TO ANYCODE OF CONSTRUCTION OR AN ITEM WHICH WAS DESIGNED IN ACCORDANCE WITH

THE ASME CODE BUT NOT INSPECTED, CERTIFIED, AND STAMPED WITH THE CODE

SYMBOL R.

NBICNATIONAL BOARD INSPECTION CODE

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12.1 This section defines the requirements established for repairs and alterations as defined by the

National Board Inspection Code (NBIC) for Pressure Retaining Vessels

NOTE: When the rules of a jurisdictional authority impose the use of an earlier edition of theNBIC and the following paragraphs are in conflict with those requirements then, the requirements

of the imposed edition shall prevail. (I.E. Routine Repairs, Stamping, NBIC Report Forms, their

preparation, their distribution, etc.)

12.2 Repairs and alterations to ASME Code items shall be carried out in accordance with the

requirements of the NBIC, this Quality Control Manual, and Jurisdictional requirements (whenapplicable) and shall conform to the applicable ASME Code.

Repairs and alterations to Non-Code items shall be carried out in accordance with the

requirements of the NBIC, this Quality Control Manual, and Jurisdictional requirements (whenapplicable) and shall conform, insofar as possible, to the current mandatory Edition of the most

applicable ASME Code provided the Company has the concurrence of the Inspector and the

jurisdiction where the pressure retaining item is installed.

Routine Repairsshall be carried out on ASME Code items only. Routine Repairs to ASME Code

items shall be carried out in accordance with the requirements of the NBIC, this Quality Control

Manual, and Jurisdictional requirements (when applicable) and shall conform to the applicableASME Code; however, the requirement for in-process involvement of the Inspector and stamping

are waived provided all of the following conditions are met:

The Company shall verify, to the satisfaction of the Inspector, that routine repairs are

acceptable to the jurisdiction. Prior approval for routine repairs shall be obtained from the Inspector.

Routine repairs shall be documented on a Form R-1 with a statement In Remarks:

Routine Repair.

12.3 The Quality Control Manager shall assume overall responsibility for the performance of repairs andalterations and for originating the construction procedures necessary to direct the course of the

work.

12.4 The method of repair or alteration shall be made available to the Authorized Inspection Agency

(A.I.A) responsible for the in-service inspection of the item or the A.I.A of record.

The QCM shall prepare and make available to the Inspector a proposed Repair Plan (Exhibit

14.8) for the method and extent of repairs or alterations. If applicable, drawings andcalculations shall also be made available.

Under no circumstances shall work be started without authorization of the Inspector. The

Inspector making the acceptance inspection should be the same Inspector who authorized

the repair or alteration, but, in all cases, shall be an employee of the same organization as

that of the Inspector that authorized the repair or alteration.

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12.10 When a repair or alteration requires the removal of that part of the item bearing the original

Certification Mark, the Inspector shall witness, subject to the approval of the Jurisdiction, the

making of a

Facsimile of the stamping, the obliteration of the old stamping, and the transfer of such stamping tothe new item. When the stamping is on a nameplate, the Inspector shall witness the transfer of the

nameplate to the new location.

Any relocation is to be reported on the applicable NBIC Report Form. All re-stamping shall be

done in accordance with the original Code of Construction, and as noted in the NBIC.

12.11 The QCM shall be responsible for the custody and use of the National Board R Repair Symbol

stamp. REPAIR, ALTERATION, or RE-RATING stamping or nameplate information, size,

location, and attachment (nameplates) shall conform to the requirements of the NBIC and will only

be applied with the concurrence of the Inspector.

12.12 A copy of the original Manufacturers Data Report for the item being altered or re-rated shall be

required and attached to the completed Form R-2. When this is not possible, agreements on the

method of establishing design basis for the alteration shall be obtained from the Inspector and thejurisdiction.

12.13 The QCM or his/her designee shall initiate the applicable NBIC Report Form and sign theapplicable Certification before presenting it, together with all supporting documentation, to the

Inspector for review and signature.

Distribution of the applicable NBIC Report Forms is the responsibility of the Company and shallbe performed by the QCM as follows:

REPAIRS - Legible copies of the form R-1, together with all required attachments, shall be

distributed to the owner or user, the Inspector, the AIA responsible for the in-service inspectionof the item, and the Jurisdiction (if required). The Form R-1 may beregistered with the National

Board in accordance with the NBIC.

ALTERATIONS AND RE-RATINGS - Legible copies of the form R-2, together with all

required attachments, shall be distributed to the Inspector, the A.I.A responsible for the in-service

inspection of the pressure retaining item, the owner or user, and the Jurisdiction (if required).

If the item is registered with the National Board, the Form R-2 shall be registered with the

National Board in accordance with the NBIC.

If the item is not registered with the National Board, the Form R-2 may be registered with theNational Board in accordance with the NBIC.

R-Forms not registered with National Board shall be maintained for 5 Years.

The NBIC Report Forms shall not be used to record a repair or alteration unless the work

has been performed in accordance with the NBIC.

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12.14 When the Form R Report is to be registered with the National Board, the Quality Control

Manager shall be responsible for assigning a Form R Number to each repair or alteration in

sequential order at or prior to the time of final acceptance. He shall keep a Form R Number Log

(exhibit 14.4) of all numbers used so there will be no missing or repeated numbers. The log shallshow the Job Number, whether it is a repair or alteration, date issued, and the Form RNumber

assigned. He will send the original Form R Report to the National Board for each item so

registered within 60 days of final certification.

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13.0 FIELD SITES

13.1 ASME Code assembly AND/OR NBIC REPAIRS AND ALTERATIONS at field sites will be

controlled by the requirements of the Quality Control Manual from the shop facility as referencedon the organizational chart with the following modifications.

13.2 The field QCI and/or field Superintendent shall maintain a controlled copy of this Quality ControlManual and Job File on Site.

The Job File shall contain the following (as applicable): The QCM prepared and A.I. accepted Traveler (Exhibit 14.9) or the QCM approved and

Inspector accepted Repair Plan along with all applicable Calculations, Drawings, and

B.O.M. All applicable WPSs, PQRs, WPQs, and Welders Qualifications Records. Material Test Reports and/or Certificates of Compliance.

Radiographic film with interpretation and technique sheets. Ultrasonic, Magnetic Particle, Liquid Penetrant, and Visual Examination Reports. PWHT documentation

Non-conformance Reports

13.3 Material for the field may be purchased and received at the shop location in accordance withSection 3 of this Manual and shipped to the field site along with any required documentation. At

the field site the Field QCI will verify the correct materials and their quantities have been received

and inspect them for any shipping damage.

13.4 Purchasing of materials in the field will be performed by the Field Superintendent in lieu of

purchasing per the requirements of Sections 3.1 and 3.2. Material receiving inspection formaterials purchased in the field will be performed per Sections 3.3 and 3.4

13.5 Welding consumables will be stored, issued and controlled by the Field Superintendent in

accordance with Section 6 of this Manual. Also, during inclement weather a protective blind orshield shall be used while welding is in progress. Low hydrogen rods will be issued in portableheated rod containers or 10 pound sealed containers.

13.6 All field documentation will be controlled by the Field Quality Control inspector and returned to

the shop facility for review and retention by the Quality Control Manager in the Job File.

13.7 If a particular field assembly should require any modification to the Manual, the changes will be

documented by the Field Quality Control Inspector, approved by the President of the Company,and presented to the Authorized Inspector for acceptance. When accepted, On-Site Addenda shall

be initiated and are to be included in all Manuals on the site as well as the Quality Control

Manager's copy. Upon completion of the job at that site, a copy of any On-Site Addenda shall beretained in the Job File until the Manufacturer's Data Report/R Form has been certified by the

Quality Control Manager and Authorized Inspector/Inspector.

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14.0 EXHIBITS

14.1 Quality Control Manual Issue Form

14.2 Non-Conformance Report

14.3 Code Stamping

14.4 Form R Number Log

14.5 Calibration Log

14.6 Transmittal Form

14.7 Bill of Material

14.8 Repair Plan

14.9 Quality Assurance Traveler

14.10 Welders Qualification Record

14.11 National Board Number Log

14.12 Hold Tag

14.13 On-Site Addenda

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EXHIBIT 14.1

QUALITY CONTROL MANUAL ISSUE FORM

MANUAL

NUMBER

DATE

ISSUED

ISSUED TO

(TITLE)

SIGNATURE EDITION

NO.1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

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EXHIBIT 14.2

NON-CONFORMANCE REPORT

NCR No.: _________________________________ Date: _____________________________________

Workmanship: Materials: Calibration: Other:

Conditions Discovered By: ____________________________________________________________

Non-Conformance Description:

__________________________________________________________________________________________________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

Proposed Disposition Description:

__________________________________________________________________________________________________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

QCM Approved: ____________________________A.I. Accepted_______________________________

Corrective Action Taken: (Indicate A.I. Hold Points If Any)

__________________________________________________________________________________________________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

Verified And Closed:

Approved QCM: _____________________________________________ Date: ______________________

Accepted A.I.:_______________________________________________ Date: _____________________

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EXHIBIT 14.4

FORM R NUMBER LOG

JOB NO. REP ALT DATE ISSUED FORM R

NO.

NOTES:

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EXHIBIT 14.6

TRANSMITTAL FORM

THE FOLLOWING LISTED DOCUMENTATION IS BEING SENT TO YOU FOR USE AS INDICATEDABOVE. REPLACE OLD DOCUMENTS (IF APPLICABLE) WITH THESE NEW DOCUMENTS AND

RETURN THE OLD DOCUMENTS TO THE QUALITY CONTROL MANAGER OR DESTROY THE OLD

DOCUMENTS AS APPLICABLE.

SIGN AND DATE BELOW TO INDICATE RECEIPT AND RETURN THIS FORM TO THE QCM.

NOTE: SENDER SHOULD INDICATE A COMPLETE DESCRIPTION OF DOCUMENTS SENTINCLUDING DOCUMENT IDENTIFYING NUMBERS AND REVISION LEVELS.

DOCUMENTATION RECEIVED BY:________________________________________________DATE:______________________

25

FROM: DATE:

TO: DATE:

JOB SITE:

JOB No.: SERIALNo.

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EXHIBIT 14.7

BILL OF MATERIAL

Prepared By: Sheet: of

Approved By: ASME Code: Yes No

Description:

Item Qty. Mark Description Matl Spec Notes (*) Matl Accepted

NOTES (*):

MILL TEST REPORT REQUIRED

B. CERTIFICATE OF COMPLIANCE REQUIRED

C. SA-53 & 106 IF CUT TO LENGTH SHALL BE MARKED WITH THE PROCESSORS (SUPPLIERS) NAME

D. ASME B16.5 or B16.47 as applicable (FLANGES)

E. ASME B16.9 (WROUGHT BUTT WELD FITTINGS

F. ASME B16.11 (FORGED FITTINGS, SOCKET-WELDING AND THREADED)

G. CERTIFICATION IAW ASME I, PG-80(ROLLED SHELLS) OR PG-81(FORMED HEADS) H. CERTIFICATION IAW ASME VIII-1, UG-80(ROLLED SHELLS) OR UG-81(FORMED HEADS)

I. CERTIFICATION IAW ASME I, PG-19 or VIII-1, UCS-79 AND/OR UCS-85 AS APPLICABLE

J. OTHER:_____________________________________________________________________________

26

Dwg. No. Date: By:

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EXHIBIT 14.8

REPAIR PLAN

A.

REPAIR ALTERATION NO. ____________ DATE: ____________ NBIC _____ EDITION ____________________

Original Mfr. ________________________________ Serial No. __________ Natl Bd No.___________ Yr Built _______

Job No._________________

Description of Repair Alteration:

Jurisdictional Approval Reqd? YES NO Verified by: __________________ Date: ____________ see back

Acceptance of Repair/Alteration Plan:

QCM: ___________________________ Date: ____________ Insp. ________________________ Date: __________

IN-PROCESS & FINAL * QC Date Inspection Date

A. Repair/Alteration Plan

B. WPS No.(s):

1) Welders Identification:

2) Welders Qualifications

C. Engineering

1)

Original Data Report reviewed

2)

Stamping checked to verify applicable Code

3)

Drawings & Calculations accepted

D. New Material Issuance (see back)

E. Fabrication: fit-up, prep, etc.

1) Shell:

2)

Head(s):

3)

Nozzles:

4)

Patch:5)

Tubes:

6)

Other:

F. NDE: RT1 RT2 RT3 RT4 PT MT UT Other

G. Heat Treatment:

H. Final InspectionInternal:

I. Final InspectionExternal:

J. Pressure Test

K. Name plate stamping and installation:

L. R-1 R-2 R-3 R-4 Report reviewed and signed

Asterisk (*) indicates Inspectors Hold Points - NOTES:

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EXHIBIT 14.10

WELDERS QUALIFICATION RECORD

Name: Stencil No.:

Date QC Inspector WPS Filler Metal Joint Design Position Examination

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Inspector: Date:

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EXHIBIT 14.11

NATIONAL BOARD NUMBER LOG

Job No. Client Date Issued Number Notes:

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EXHIBIT 14.12

HOLD TAG

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EXHIBIT 14.13

On-Site Addenda

Section: Date:

Reason for addition/change:

Description of change:

QCM Approved: Date:

President Approved: Date:

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