Qc Sample Manual Generic

7/31/2019 Qc Sample Manual Generic

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Quality Control System Manual for Shop and Field Fabrication of Items in accordance with

ASME B31.1, ASME Section I and ASME Section VIII, Div. 1 and Repairs and Alterations inAccordance with the National Board Inspection Code and Jurisdictional Requirements at

Shop and Field Locations.

Edition: 1 Date: XXXXX

Approval:

A.I. Acceptance:

Manual Control: Assigned To:

MANUFACTURER QUALITY MANAUAL

NAME:

ADDRESS:


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Table of Contents

1. STATEMENT OF AUTHORITY Page 1

2. ORGANIZATIONAL CHART Page 2

3. GLOSSARY OF TERMS Page 3

4. QUALITY CONTROL DEPARTMENT Page 7

5. AUTHORIZED INSPECTOR Page 8

6. DRAWINGS, DESIGN CALCULATIONS AND SPECIFICATIONS Page 9

7. MATERIAL CONTROL Page 11

8. EXAMINATION AND INSPECTION PROGRAM Page 14

9. CORRECTION OF NON-CONFORMITIES Page 16

10. WELDING CONTROL Page 18

11. NON-DESTRUCTIVE EXAMINATION (NDE) Page 20

12. HEAT TREATING Page 22

13. CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT Page 23

14. RECORDS RETENTION Page 24

15. REGISTRATION WITH NATIONAL BOARD Page 25

16. REPAIRS & ALTERATIONS Page 26

17.

EXHIBITSPage 32


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1. STATEMENT OF AUTHORITY

The Quality Control System of MANUFACTURERS NAME. shall comply with ASME B31.1,

ASME Section I, and ASME Section VIII Div. 1 for fabrication in both shop and field locations

and Repairs and Alterations (Shop and Field) in accordance With The National Board Inspection

Code. Manufacturers Name gives the Quality Control Manager the authority, the responsibility,

and the organizational freedom to identify quality control problems and to initiate, recommend,

and provide solutions. The Quality Control Manager is responsible for the editing of the Quality

Control Manual and the compliance of it.

The Quality Control Manager has the full support of the management ofManufacturers Name,

Inc. to carry out his responsibilities and to fulfill his purpose. The Quality Control Managers

authority and responsibility include both shop and field sites. Any disagreement between the

Quality Control Manager and other Departments shall be settled by myself. Resolutions, when

made, shall not compromise the Code.

Signed,

Manufacturers Name

Name: PRESIDENT

Page 1


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2. ORGANIZATIONAL CHART

Page 2

President

Shop Fabrication &

Field Activities

Quality Control

ManagerPurchasing Engineering Sales

Q.C. Inspectors

Shop & Field

Material Receiving

Legend

Line of Authority

Technical Coordination

Shop & Field

Vice-President

Forman


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3. GLOSSARY OF TERMS

Page 3

ALTERATION :

ASME:

AUTHORIZED INSPECTOR (AI):

AUTHORIZED INSPECTION AGENCY (AIA):

CODE:

COMPANY:

DEPARTMENT:

3.0.1 Any change in the item described on the original Manufacturers Data

Report which affects the pressure containing capability of the pressure retaining

item. Non-physical changes such as an increase in the maximum allowableworking pressure (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 tests are required shall also be considered an alteration.

3.0.2 The American Society of Mechanical Engineers.

3.0.3 The Authorized Inspector shall be an Inspector regularly employed by an ASME

Accredited Authorized Inspection Agency, i.e., the inspection organization of a state ormunicipality of the United States, a Canadian province, an insurance company

authorized to write boiler and pressure vessel insurance. The inspector shall not

be in the employ of the Manufacturer. All Inspectors shall have been qualified by

a written examination under the rules of any state of the United States or province

of Canada which has adopted the Code.

3.0.4 An AIA shall be either a Jurisdiction or an Insurance Company which

meets the requirements as defined in the National Board Inspection Code.

3.0.5 The ASME Boiler and Pressure Vessel Code, Section I, Section VIII,

Div. 1, and ASME B31.1 including addenda and code cases approved by the council of

the ASME and latest Addenda.

3.0.6 Manufacturers Name.

3.0.7 Where department is referred to in this manual, it shall be the responsibility is

the person in charge of that department.


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Page 4

EXAMINATIONS:

FOREMAN:

INSPECTIONS:

MTR:

NDE:

NON-CONFORMITY:

PQR:

PRINT:

QCM:

QC:

REPAIR

3.0.8 Are those performed by Manufacturers Name. Quality Control

personnel.

3.0.9 Shop and field fabrication

3.0.10 Are those performed by the AI in all Code work for compliance to Code

Rules.

3.0.11 Mill Test Reports, or Material Test Reports.

3.0.12 Non-destructive examination.

3.0.13 Any condition existing in raw material, or work in process, or finished

product that does not comply with drawings, specifications, Code, or Company Name

3.0.14 Procedure Qualification Record

3.0.15 Drawing

3.0.16 Quality Control Manager

3.0.17 Quality Control Department

3.0.18 The work necessary to restore a pressure retaining item to a safe and satisfactory

operating condition.

standards and procedures and this Quality Control Manual.


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Page 5

SN:

SNT-TC-1A

VESSEL:

WPS:

JURISDICTION OR JURISDICTIONAL AUTHORITY:

INSPECTOR:

ORIGINAL CODE OF CONSTRUCTION:

RE-RATING:

3.0.19 Serial number

3.0.20 Recommended Practices, America Society of Non-destructive Testing -a set of guidelines to assist the manufacturer in developing uniform procedures for

the qualification and certification of NDE personnel to the latest Code accepted

Edition & Addenda will be used.

3.0.21 Visual Examination

3.0.22 Any Code Item manufactured to B31.1 Section I, or Section VIII Division 1.

3.0.23 Welding Procedure Specification

3.0.24 A governmental entity which administers and enforces one or more

sections of the ASME Code, all references to jurisdiction in this section are

applicable only when involvement is required by jurisdictional policy.

3..0.25 An individual who holds a valid and current National Board Commission,

3.0.26 Documents promulgated by recognized National Standards Writing

Bodies that contain technical requirements for construction of pressure retainingitems or equivalent to which the pressure retaining items were certified by the

original manufacturer.

3.0.27 SeeAlteration

Addenda

VT:


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Page 6

NON-CODE ITEM:

ROUTINE REPAIRS:

NBIC:

3.0.28 A pressure retaining item which was not designed or constructed to any

code of construction or an item which was designed in accordance with the

ASME Code but not inspected, certified, and stamped with the Code Symbol.

3.0.29 Those repairs listed and defined in the NBIC as Acceptable Routine

Repairs.

3.0.30 Nation Board Inspection Code

RT:

UT:

MT:

3.0.31 Radiographic Examination

3.0.32 Ultrasonic Examination

3.0.33 Magnetic Particle Examination

PT:3.0.34 Liquid Penetrant Examination

WPQ:

3.0.35 Welder Performance Qualification. WPQ: Welding Operator

Performance Qualification.

PRI: Pressure Retaining Item:Any boiler, pressure vessel, piping or material used for the containment of

Pressure, either internal or external.


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4. QUALITY CONTROL DEPARTMENT

Page 7

4.1 The Quality Control Manager is responsible for preparation, revision,

distribution, control, and implementation of the Quality Control System Manual.

4.2 Any revision of the manual, however, results in a new edition and is presented

to the Authorized Inspector for his acceptance prior to implementation.

4.3 The ASME accredited Authorized Inspection Agency (AIA) will be presented

with a controlled copy of the Quality Control System Manual.

4.4 The QCM has custody of the Code Symbol Stamps and controls them.

A Code Symbol Stamp may be applied only with the concurrence of the AI.

4.5 The QCM heads the Quality Control Department and is responsible for

performance of required examinations and tests. He will prepare and sign the

Traveler and Manufacturers Data Report. In case of his absence, his designee

will prepare and sign the Traveler (Exhibit 3a, 3b, & 3c) and ManufacturersData Report.

4.6 Controlled Quality Control Systems Manuals are issued by the QCM. Revision

to manuals are treated as new editions and previous edition filed. Records of issuance

of each edition are kept by the QCM. (See Exhibit #8).


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5. AUTHORIZED INSPECTOR

Page 8

5.1 The QCM is the company Liaison with the Authorized Inspector.

5.2 The AI shall have free access to the premises ofManufacturers Name. for

the surveillance of records, specifications, design drawings, calculations, procedures

and other documents relating to Code fabrication and inspection of materials, partsand appurtenances, and to field sites where ASME Code work is in progress. The AI

has the privilege of visiting any vendor or supplier of materials, parts, and service to

Manufacturers Name. that he deems necessary to satisfy inspection requirements

of such materials, parts and service. All access afforded the authorized inspector shall

be extended to his supervisor to perform any required audits or reviews.

5.3 A controlled copy of the Quality Control System Manual is provided for use by

the AI

5.4 Any non-conformity requiring AI acceptance is referred to him for his

concurrence of proposed resolution.

5.5 The Authorized Inspector, as defined by 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 has adopted the Code. He will

be employed by an AIA with which Manufacturers Name has a current

agreement for services.


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6. DRAWINGS, DESIGN CALCULATIONS AND

Page 9

SPECIFICATIONS

6.1 The QCM along with Engineering will perform the review of customers

specifications, and drawings to assure Code compliance can be attained.

6.2 Each vessel is given a SN. SNs are listed in a log to avoid duplication.

(Exhibit #9).

6.3 Engineering prepares and checks all design calculations. Customers

calculations are not used. Calculations are based on allowable stress listed

in ASME Section II, Part D, for use by the applicable construction Code and

not from information on MTRs.

6.4 Drafting prepares in-house drawings. Drafting specifies on drawings:

Construction Code Section; Edition and Addenda; NDE Requirements; Post

Weld Heat Treatment requirements; Design Parameters such as temperature and

pressure; Hydrostatic Test Pressure; Material Specifications; Job Number;Welding Procedures; and stamping information. Welding procedures to be used

are determined by the Q.C. Manager.

6.5 Engineering specifies materials to be used in Code fabrication. Materials are

specified as SA, SB, SFA, AWS or identical ASTM specifications (see Section II,

Part A & B)

6.6 Drawings, Specifications and Design Calculations must be approved by the

QCM. (By initialing and dating)

6.7 Distribution of prints is the responsibility of QC. Upon receipt of prints fromDrafting, an appropriate number of sets are distributed to the applicable departments.

Prints are issued to Foremen by QC.

6.8 QC hand carries one set of revised prints to the Foreman (or Foremen) over the

job. Old prints are destroyed before new prints are substituted. Other prints are

distributed appropriately to QC and Fabrication. Any drawings affected by a revision

will be exchanged. Unissued sets of prints are also destroyed.

6.9 QC reviews drawings and calculations, prior to the start of fabrication, with the

A.I. so that he may designate on the Traveller his required inspection points.

6.10 Any revisions or change will be handled as the originals.

6.11 Engineering for field jobs shall be handled in the same manner as shop jobs,

and by the same personnel.


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Page 1Page 10

6.12 Access to computer programs for mechanical design calculations or stress and

fatigue analysis shall be only through engineering. Before computer programmed

results are used, the engineering shall have the accuracy of the original programs

and their revisions checked by running manually calculated test problems. The

accuracy shall be demonstrated to the satisfaction of the A.I. Engineering shall review

each Code Edition or addenda for impact upon design programs and assure the design

program is accurate for Edition/ addenda in use.

The design programs shall conform to any and all changes in the Code, a record of this

review shall be kept on file


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7. MATERIAL CONTROL

Page 11

MATERIAL REQUISITION:

7.1 The Engineering Department shall prepare and check all Bills of Material

(Exhibit #1), except for welding materials which are requisitioned (Exhibit #10)

by the Foreman.

7.2 The Bill of Material shall include the following:

A. Material Specifications using the appropriate SA, SB, SFA, AWS, or

identical ASTM designation.

B. Material Size.

C. Number of pieces.

D. Job Number.

E. Mill Test Reports when required by Code.F. Forming requirements as required by the construction code

G. Any other special requirements when applicable.

7.3 All Bills of Material will be sent to the QCM, who will check them for ASME

Code and customer requirements and if acceptable, forward them to Purchasing.

MATERIAL PURCHASING:

7.4 The Purchasing Department shall order and purchase material required as

shown of the Bill of Materials (Exhibit #1). When material is purchased for morethan one (1) job, the QC Department shall mark all materials with Job Numbers, or

SN. Small parts shall be in marked container, or in a marked bundle. Any material

change or substitution must have prior approval by the Engineering Department.

7.5 A copy of the Bill of Material (Exhibit #1) will be sent to receiving, QC and

placed in job file.

7.6 When purchasing parts of a vessel that have been fabricated by welding with

filler metal added, a Manufacturers Partial Data Report will be required and partial

stamping as required by the applicable Code Section.

7.7 When ordering cold formed materials, Code requirements shall be requested.

7.8 Welding material for field work will be procured through Purchasing by QC, and

prepared by Foremen in the same way as for shop work.


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CUSTOMER FURNISHED MATERIAL:

Page 12

7.9 Customer furnished material will be handled in the same manner as material

purchased by the Company, upon receipt and throughout fabrication.

RECEIVING INSPECTIONS:

7.10 Upon receipt of material the Quality Control Inspector will notify the QCM.

7.11 Upon notification of receipt of material, the Quality Control Inspector shall

perform the following physical inspections:

7.11.1 A. Check surfaces and edges for visible defects.

7.11.2 B. Check for physicals and forming specs.

7.11.3 C. Check Heat Numbers and document on Receiving Inspection Report.

7.11.4 D. Check materials to Bill of Materials for requested special marking

requirements and/or documentation.

7.11.5 E. Materials ordered for a specific vessel shall be marked with the Serial

Number when received. (Small items shall be placed in a container marked with

the Job Number or Serial Number.)

7.12 The QC Inspector shall record the results of the above inspection on Receiving

Inspection Reports (Exhibit #2) and send to QCM for filing.

7.13 The QC Inspector indicates on the Receiving Inspection Report at this time if

material is acceptable. Receiving Inspection Report is forwarded to QCM for review

and sign off indicating release for fabrication.

DOCUMENTATION VERIFICATION:

7.14 The QC Inspector shall verify the MTR as follows:

7.14.1 A. Check Material Heat Number against heat Numbers on MTR.

7.14.2 B. Check Chemical and Physical properties against specifications in

Section II of ASME Code.

7.14.3 C. After checking MTR to Section II ASME, QC shall sign and date.

7.15 The QC Inspector shall record vessel SN on MTRS for traceability to vessel.

7.16 The QCM shall file the MTR in the job folder.


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MATERIAL IDENTIFICATION:

Page 13

7.17 Prior to cutting material, identification will be transferred to the part to be cut,

by the person doing the cutting. For Section I construction, all original markings

shall be transferred for plate.

RECEIVING INSPECTIONS:

7.18 Non-conformities found in material receiving will be controlled as outlined in

Manual on page 16.

7.19 When further material testing is performed by other than the material

manufacturer, documents shall be obtained to determine that they meet the

requirements of the material specification or construction Code. The Quality

Control Manager is responsible for review of documentation for compliance with

procedure and Code.


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8. EXAMINATION AND INSPECTION PROGRAM

Page 14

DUTIES OF QUALITY CONTROL MANAGER:

8.1 The QCM shall be responsible for in process examination and acceptance or

rejection of fabrication.

INSPECTIONS:

DUTIES OF CHIEF ENGINEER:

8.3 Engineering Department shall inform the QC Manager and Foreman of any

Engineering change.

DUTIES OF FOREMEN:

8.4 The Foreman is responsible for the overall quality of the

fabrication item and for job progress notification to the QCM for inspection andexamination purposes.

8.5 The QC Inspector shall be responsible for but not limited to the following

typical examination and verification for conformance to Code requirements:

A. Weld Procedure Specification and Procedure Qualification Record, and

Welder / Welding Operator Performance Qualifications.

B. Fit-up Inspection to include edge preparation, fitting of edges on longitudinal

seams, girth seams, heads, nozzles and pipe. NOTE: Fit-up inspection or

examination is performed after components have been tacked in place, and

prior to root pass.

C. Finished Weld Inspection or Examination to include the weld size and weld

appearance and welders symbols.

D. Perform any other required examination for completed quality product.

8.6 The QC Inspector shall record the above examinations on the Traveler andnotify the AI reasonably in advance of his up-coming inspection point.

FINAL CHECKS:

8.2 The QCM shall prepare the Traveler and present it to the AI prior to the startof fabrication.

8.7 The AI will witness the hydrostatic testing of all ASME items.


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Page 15

8.9 The Manufacturers Data Reports shall be prepared, checked and signed by the

QCM or his designee prior to presenting to the AI for his review, acceptance and

signature. Safety valve info shall be recorded on a P-7 or P-3 per PG 112.2.8.

8.10 The QCM shall check the nameplate stamping information for correctness priorto applying the Code stamp symbol. Boilers shall be Code stamped as required by Section I.

8.11 Responsibilities for field work and examination are identical to shop work and

examination.

8.12 All material for field site work will be received and processed the same as shop

material prior to transfer to field.

8.13 When received at field site all materials will be examined for damage due to

transit.

8.14 Any damages will be handled as a non-conformity. (See pg. 16)

PNEUMATIC TESTING:

8.15 Boilers shall not be pneumatically tested. Pressure Vessels may be

pneumatically tested in accordance with the applicable Code Section and paragraph.

8.8 The Code Symbol stamp shall be applied only on concurrence of the AI.


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9. CORRECTION OF NON-CONFORMITIES

Page 16

NON-CONFORMING MATERIAL:

9.1 The QCM shall notify the Foreman in the event non-conforming material is

received.

NON-CONFORMITY (FABRICATION):

9.9 The AI is included in the proposed resolution and the final disposition of all

non-conformities except return to vendor.

9.10 Records concerning non-conformities shall be kept in the job file of each Code

Vessel.

9.2 The QCM shall Chair a Material Review Board consisting of the following

members:

9.2.1 A. Purchasing Department Representative

9.2.2 B. Engineering Department Representative

9.2.3 C. Foreman

9.3 Based on the findings of the Material Review Board, the non-conforming

material will be repaired by the Company or returned to the Vendor or use as is.

9.4 Material to be repaired by welding shall have the concurrence or the Authorized

Inspector for the method and NDE to be used for repairs on the NCR Form prepared

by the QCM.

9.5 Non-conformity is defined as any deviation from accepted standards for a given

finished product. At time when a deviation is noted, a Hold Tag (Exhibit #4) will be

filled out and placed on the product (all work stops on it until resolved) and a

Non-conformance Report (Exhibit #5) will be initiated by the QC Department. The

Non-conformance Report will then be forwarded to the QCM who is responsible for

determining an acceptable course of action. As an alternative to the hold tag, holdmay be written on the nonconforming item with a paint stick.

9.6 Fabrication Errors. These errors could be in design or fabrication after welding

has started, and requires repair by welding to correct. Engineering Department will

determine the welding procedure to be used.

9.7 When a repair procedure has been devised by the Engineering Department and

reviewed by the QCM, then it will be presented to the AI prior to commencing work

for his acceptance.

9.8 The QCM is primarily responsible for resolution and disposition of all problemsthat may arise.


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Page 17

9.11 After repairs have been completed and accepted by the AI, the QCM will

remove the Hold Tag or hold written on the item.

9.12 Non-conformities shall be handled in the same manner for both shop and field.


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10. WELDING CONTROL

Page 18

WELDING PROCEDURES:

10.1 All Welding Procedures Specifications are written and non-essential variables

revised, when required, by the Engineering Department. A Welder is assigned by the

Foreman to weld a test specimen using the variables of the specification as a guide.

This coupon is tested by a testing laboratory, in accordance with Section IXof the ASME Code. All welding procedures shall be qualified in accordance with

Section IX with additional requirements of the applicable Code section to which work

is performed and a Procedure Qualification Record filled out and certified by the QCM.

PROCEDURE ASSURANCE:

10.2 Written Welding Procedures Specifications for each process to be performed

are filed in Manufacturers Name. files.

WELDING QUALIFICATIONS:

10.3 Prior to any welding on a Code Vessel, the welder or welding operator shall

pass a welding qualification test in accordance with the procedure to be used and

Section IX of the ASME Code. A Welder Performance Qualification or record form

is filled out and certified by the QCM (QW-484) for a competent welder or Welder

Operator Performance Qualification for welding operators.

10.6 The Welding Procedure(s) to be used on a job are indicated on the Approved

Design Drawing.

10.7 The QCM and Foreman will both monitor the welding to assure the correct

procedure is being used during fabrication.

WELDER IDENTIFICATION:

10.8 The QC Manager is responsible for issuing the Welders and WeldingOperators unique symbol.

10.9 The QCM shall record the symbol of the welder on the Traveler and the Welder

shall apply his stamp to each three (3) feet or less of weld, when required, or a Weld

Map will be used.

10.4 Written welder qualification forms are kept on file and maintained by the QC

Manager.10.5 A Welder Continuity Log (Exhibit #6) will be initiated by and maintained

as a record by the QCM. This log will be initialed by QCM, at least every three months,

to assure welders continuity.


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WELDING MATERIAL CONTROL:

Page 19

10.10 The Foreman will submit a purchase requisition (Exhibit 10) for welding material

to the QCM for review per Code compliance. If acceptable, it will be forwarded to the

Purchasing Department with a copy for receiving inspection. Receiving inspection

shall be by the QC Department.

10.11 The Foreman shall supervise the distribution and storage of the welding

materials.

10.12 All open cans of low Hydrogen Electrodes shall be maintained in a heated oven.

No more than a four (4) hour supply will be issued at one time. All unused low

Hydrogen Electrodes will be turned in to the Foreman at the end of the shift or four (4)

hours, whichever is less. Electrodes shall be stored in a temperature controlled area as

recommended by the Manufacturer or 50 degrees F.above ambient temperature.

10.13 Welding material storage and use for field work is the responsibility of the

Foreman. Storage and use is monitored by QC the same as in the shop.

TACK WELDS:

10.15 All tack welds shall be applied by a Welder Qualified to a Qualified Procedure

in accordance with Section IX to the ASME Code. Tack welds made by a vendor

shall be removed. Vendor must supply copy of WPS used for tacks welds.

10.16 All tack welds shall be feather-ground prior to filling and capping all welds. If

tack weld is found defective, it will be removed.

WPS QUALIFICATIONS FOR TEST:

10.17 The Engineering Department shall be responsible for preparing the Welding

Procedures Specification and Procedure Qualification Record in accordance with

ASME Code Section IX.

10.18 The WPS will be made available to all welders and welding operators.

TRAINING AND SUPERVISING:

10.19 The Foreman shall be responsible for training and supervision of all welders and

welding operators.

10.20 Joint preparation and alignment will be checked by the QC Department and/or

the Foreman.

10.21 The AI shall have the right at anytime to call for and witness

tests of the welding procedure or the ability of any welder or welding operator.


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11. NON-DESTRUCTIVE EXAMINATION (NDE)

Page 20

RESPONSIBILITY:

11.1 NDE PROCEDURE MUST BE APPROVED BY LEVEL III

11.2 For Section VIII, Div. 1 construction. RT, UT, and MT shall be subcontracted

to a qualified testing firm. The subcontractors Level III shall be appointed by

Manufacturers Name. PT, and VT may be performed by company personnel in

accordance with written procedures that meet Code requirements and are acceptable to

the A.I. For Section I construction, all NDE methods, except V.T., shall be

subcontracted.

11.3 All RT, UT and MT testing shall be performed by Level II or III personnel qualified

in accordance with the applicable acceptable edition and addenda of SNT-TC-1A.

Level I may perform the above function if under the direct supervision of a Level II or III.

NDE Subcontractors written practice shall be held on file by the QC and approved by the

AI.

ACCEPTANCE:

11.4 Acceptance criteria for NDE testing shall be in accordance with the applicable

section of the ASME Code. Interpretation of the results of subcontracted NDE shall

be by Level II or Level III examiner.

11.5 After the RT films have been accepted by the QCM, they shall be presented to

the AI for his review.

11.6 Viewing equipment and calibrated density strip shall be available to the AI.

QUALITY CONTROL MANAGER:

11.7 The QCM shall maintain a copy of all NDE procedures and personnel

qualifications. These records shall be available to the AI for his review.

11.8 All NDE requirements shall be prepared by the Engineering Department,

recorded on drawing and shall be in accordance with the ASME Code with respect to

design conditions.

RE-QUALIFICATION:

11.9 The Authorized Inspector may request requalification of NDE procedures or

examiners whenever he has reason to question their code compliance.

NDE AT FIELD SITE:

11.10 NDE at field site is the responsibility of QC Department in conjunction with the

foreman and will be conducted in accordance with this manual.


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NDE PROCEDURES:

Page 21

11.11 Subcontract NDE procedures will be written by Level III and demonstrated as

being capable of obtaining meaningful results to the satisfaction of the AI. The AIs

acceptance may be noted by initialing the NDE procedure. The procedures, practices,

and qualifications must be acceptable to the AI. The VT procedure shall be prepared

and approved by Manufacturers Name QC M and must be accepted by the

AI. The VT Examiner shall be certified to perform visual examination by the company.

NDE TEST REPORTS:11.12 All NDE reports including RT film shall be reviewed and accepted by QCM

and then presented to the AI.


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12. HEAT TREATING

Page 22

HEAT TREATING REQUIREMENTS:

12.1 All heat treatments, required by ASME Code or Customer Specification shall

be indicated on the production drawings. All heat treatment will be performed in

accordance with written procedures. The written procedures shall be prepared by the

Engineering Department in accordance with the ASME Code with respect to designconditions. The procedure number will be noted on the production drawings. The

heat treatment will be subcontracted.

Quality control will inspect all returned items for conditions and shipping damage.

Unacceptable items will be handled per Section 9.0; acceptance of items will be recorded

on the Traveler.

When conditions for post weld heat treating in accordance with the original code of

Construction are inadvisable or impractical, alternative methods as allowed in RD-1000

may be used.

Thermocouple attachment by capacitor discharge welding for Section VIII, Div. 1

Vessels will be performed using a welding procedure specification meeting the

Requirements of UW-37 (h).

HEAT TREAT PROCEDURE:12.2 The Heat Treat Procedure shall require that the subcontractor furnish records

that show the following:A. Strip chart containing heating, holding and cooling times and temperatures.

B. Identification of item heat treated.

C. Name of the heat treat firm.

D. Date of heat

treatment.E. Signature of responsible official of heat treating firm.

F. Copy of heat treat recording instruments calibration certification.

RECORDS:12.3 The QCM will review all heat treat records.

12.4 The heat treat records shall be made available to the AI.

HEAT TREATING, FIELD SITE:12.5 Heat treating as required at field site will be the responsibility of QC

Department in conjunction with the foreman and will be performed in accordance

with this manual.

12.6 QC Manager has the responsibility of monitoring heat treat facilities to assure

thermo-couples placement at intervals provided by the applicable Code and proper

equipment used.


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13. CALIBRATION OF MEASUREMENT AND TEST

EQUIPMENT

Page 23

RESPONSIBILITY:

13.1 The QCM shall be responsible for the calibration and storage of measuring and

test equipment and for maintenance of the calibration records.

13.2 NDE Calibration shall be maintained by the Subcontractors when such NDE is

not performed by the Company. Calibrations shall be in accordance with National

Standards where such standards exist.

CALIBRATION:

13.4 All test gauges shall be calibrated by a subcontractor at any time there is

a reason to believe they are in error.A. All test gauges shall be numbered.

B. All calibration shall be recorded on a test gauge calibration form showing

gauge number, date and calibrators initials. Calibration records are available

to the AI upon request.

.

13.3 Micrometers and calipers will be checked against a known calibrated thickness

before each use, in lieu of calibration.

13.5 All test equipment shall be stored by the QCM.

STORAGE:

C. Indicating Pressure Gauges used in testing shall preferably have dials

graduated over a range of about double the intended maximum test pressure,

but in no case shall the range be less then 1 1/2 times nor more than 4 times

that pressure. Specific ranges shall be per applicable Code Section.


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14. RECORDS RETENTION

Page 24

RESPONSIBILITY:

14.1 It is the responsibility of the QCM to initiate a job file on a start of a job and

collect the following data and maintain through-out fabrication. This data shall be

available to the AI; including but not limited to:

A. Calculations, prints and Bill of Materials.

B. Receiving Inspection Reports

C. Material Test Reports and/or Partial Data Reports, when required.

D. Non-conformance Report (if applicable)

E. Heat Treat Charts (if applicable)

F. Hardness Test Results (if applicable)

H. Charpy V-Notch Test Results (if applicable)

PERMANENT RECORDS:

14.2 The Manufacturers Data Reports, UT Reports, RT Film, RT Reports, and

location maps shall be retained for retention period required by the applicable Code.

G. RT Film, Reader Sheets and NDE Reports (film location map when

applicable)

I. Traveller


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15. REGISTRATION WITH NATIONAL BOARD

Page 25

15.1 National Board and serial numbers shall be controlled and issued by the QCM. He

shall maintain a record showing date issued, type of vessel, and manufacturers serial

number. The QCM shall submit to the National Board an original of all ASME

Manufacturers Data Reports requiring registration within 60 days. Registration with the

National Board will be made when required by Jurisdiction and/or Customers. NationalBoard numbers shall begin with the number 1 and shall continue without skips, gaps, or

omissions. (See Exhibit #9)


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16. REPAIRS & ALTERATIONS

Page 26

SCOPE:

16.1 This section defines the requirements established for repairs and alterations as

defined by the current Edition and Addenda of the National Board Inspection Code

(NBIC) for pressure retaining items.

REPAIRS AND ALTERATIONS TO ASME CODE ITEMS:

16.1.1 Shall be carried out in accordance with the requirements of the NBIC,

this Quality Control Manual, and Jurisdiction requirements (when applicable)and shall conform to the Edition and Addenda of the applicable ASME Code

Section.

REPAIRS AND ALTERATIONS TO NON-CODE ITEMS:

16.1.2 Repairs and Alterations shall be carried out in accordance with the

requirements of the NBIC, this Manual, Jurisdictional Requirements when

applicable shall conform insofar as possible, to the Edition and Addends of the

ASME Code Section most applicable to the work, provided Manufacturers

Name has the concurrence of the Jurisdiction and the Inspector.


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Page 27

ROUTINE REPAIRS:

16.1.3 Routine Repairs to ASME Code items shall be carried out in the

accordance with the requirements of NBIC, this Quality Control Manual, and

Jurisdictional requirements (when applicable) and shall conform to the Edition

and Addenda of the applicable ASME Code; however, the requirement for

in-process involvement of the Inspector and stamping may be waived provided

all of the following conditions are met:

1. Manufacturers Name shall verify, to the satisfaction of the Inspector,

that routine repairs are acceptable to the jurisdiction.

2. Prior approval for routine repairs shall be obtained from the Inspector.

3. Routine repairs shall be documented on a Form R-1 with a statement on

line 10, Remarks: Routine Repair.

RESPONSIBLE PARTY:

16.1.4 Manufacturers Name shall assume overall responsibility for the

performance of repairs and alterations and for originating the construction

procedures necessary to direct the course of the work.

METHOD OF REPAIR OR ALTERATION:16.1.5 Shall be made available to the Authorized Inspection Agency (AIA)

responsible for the in-service inspection of the item or the AIA of record.

a. The Quality Control Manager shall make available to theInspector a proposed Repair Plan (Exhibit 11) for the method and

extent of repairs or alterations. If applicable, drawings and

calculations shall be made available.

b. 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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RERATING OF A PRESSURE RETAINING ITEM:

Page 28

16.1.6 Shall only be performed only after the following requirements have been

met to the satisfaction of the jurisdiction at the location of the installation.

a. Revised calculations verifying the new service conditions shall be

prepared in accordance with this Quality Control Manual.

b. All re-ratings shall be established in accordance with the Edition and

Addenda of the applicable ASME Code Section.

c. Current inspection records verify that the pressure retaining item is

satisfactory for the proposed service conditions.

d. The pressure retaining item has been pressure tested, as required, for

the new service conditions.

DESIGN ENGINEERING:

16.1.7 Shall conform to the requirements of this Quality Control Manual, the

NBIC, and insofar as possible, the ASME Code section most applicable to the

work involved.

MATERIALS:

16.1.8 Used in making repairs and alterations shall conform to the applicable

section of the ASME Code.

a. IfManufacturers Name provides the materials, the procurement,

inspection, and handling of materials shall be in accordance with theapplicable sections of this manual.

b. If the materials are provided by others, sufficient documentation and

material identification shall be provided for acceptance of the material

by Manufacturers Name and the Inspector. Receiving Inspection

and handling of these materials shall be in accordance with the

applicable sections of this manual.

c. When existing materials cannot be identified, the Quality Control

Manager shall be responsible for any testing required to establish the

material specification. The method used and the results shall be

available to the Inspector.


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Page 29

PRESSURE PARTS:

16.1.9 Pressure parts for which ASME Manufacturers Partial Data Reports are

required shall be fabricated and inspected to the applicable Code, stamped with the

appropriate Code symbol and the word Part, and reported on the applicable

Manufacturers Partial Data Report. When such parts are a part of the repair or

alteration the Manufacturers Partial Data Report shall be reported on the FormsR-1 or R-2, as applicable, and attached thereto.

WELDING, NDE, & HEAT TREATMENT:

16.1.10 All welding, non-destructive examination (NDE), and heat treatment

(HT), as required, shall be in accordance with the NBIC, the ASME Code, and

the applicable sections of this Quality Control Manual.

PRESSURE TESTS:

16.1.11 Shall conform to the requirements of the NBIC and will be witnessed by

the Inspector. Manufacturers Name is responsible for all activities relating to

pressure testing.

16.1.11a When this is not possible or practical, other methods as

described

in the NBIC may be used provided the required concurrences have

first been obtained. As an alternative to the pressure test, an

examination or NDE method that will verify the integrity of therepair or alteration, subject to the concurrence of the Inspector,

jurisdiction and customer (when required) may be used.


32/34

Page 30

RE-MOVING ORIGINAL CODE STAMPING:

16.1.12 When a repair or alteration requires the removal of that part of the item

bearing the original Code stamping, 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 to the new

item. The ASME Code symbol is not to be restamped. When the stamping is on

a nameplate, the Inspector shall witness the transfer of the nameplate to the newlocation.

Any relocation is to be reported on the applicable NBIC Report Form

CUSTODY OF R STAMP:

16.1.13 The Quality Control Manager shall be responsible for the

custody and use of the National Board R Symbol stamp.

REPAIR, ALTERATION, or RE-RATING, stamping or nameplate

information, size, location, and attachment (nameplates) shall conform to therequirements of the NBIC and will only be applied with the concurrence of the

Inspector.

ORIGINAL MANUFACTURERS DATA REPORT:

16.1.14 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 the jurisdiction when

applicable.


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Page 31

NBIC REPORT FORM:

16.1.15 The Quality Control Manager or his/her designee shall initiate the

applicable NBIC Report Form and sign the applicable 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

Manufacturers Nameand shall be performed by the Quality Control Manager

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 inspection of the item, and the Jurisdiction (if

required). The Form R-1, may be registered with the National Board in

accordance with the NBIC or they have to be retained for 5 years.

ALTERATIONS AND RE-RATING - Legible copies of the Form R-2,

together with all required attachments, shall be distributed to the Inspector, the

AIA 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, one original copy

shall be submitted to the National Board.

If the item is not registered with the National Board, the Form R-2 may be

registered with the National Board.

The NBIC Report Forms shall not be used to record a repair or alterationunless the work has been performed in accordance with the NBIC.

Parts fabricated by welding for non Code items shall be stamped R Part and

documented on an R 3.

When R forms are registered with the National Board, the Q.C. Manager will

establish and maintain an R Number Log Exhibit 7. These numbers shall be

assigned in sequential order. 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. R forms not registered with the National Board will be retained for

5 years.

16.1.16 Revisions to this Quality Control Manual shall have the acceptance of

the AIA prior to issuance of the manual and implementation.

REVISIONS:


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Page 32

17.0 Exhibits:

1. BILL OF MATERIAL Page 33

2. RECEIVING INSPECTION REPORT Page 34

3A. TRAVELLER (PRESSURE VESSEL)

3B. TRAVELLER (POWER BOILER)

Page 35

Page 36

3C. TRAVELLER - PIPING Page 38

4. HOLD TAG Page 39

5. NON-CONFORMANCE Page 40

6. WELDER CONTINUITY LOG Page 41

Page 43

Page 44

Page 45

Page 46

7. R NUMBER LOGPage 42

8. MANUAL ISSUE LOG

9. SERIAL NO./NATL. BD. N. LOG

10. PURCHASE REQUISITION

11. REPAIR PLAN

Date post:	05-Apr-2018
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