51212999 sample qc manual

A Brief Introduction

The sample text in this document should be used as a guide in preparing a QC Manualthat will comply with the ASME Boiler & Pressure Vessel Codes Section I, Section VIIIDiv. 1, Section VIII Div. 2 and Section VIII Div. 3, for Shop and Field Activities and alsofor Repairs and Alterations according to the National Board Inspection Code.

It is important to understand that this is only a guide and should be modifiedaccordingly to reflect the QC System currently in use and for the Scope ofCertificates of Authorization, which are being sought.

For ease of reading, certain references have been made to various sample forms thatmany manufacturers use in meeting the various Code requirements. When preparingyour system, the forms, and title of forms used by your organization should bereferenced in place of these samples. For identification of the sample forms referencedin this Manual they have been identified in blue text.

Individuals responsible for performing various duties within this Manual in meeting Coderequirements have been indicated as TITLE OF RESPONSIBLE in red.

The Company Legal Name, and Address are shown in purple.

Throughout this sample the various paragraphs identified with ASME are Coderequirements, placing your mouse over ASME will open a pop-up window whichidentifies the referencing Code paragraph or Check List item.

This document is provided as a GUIDE ONLY and is not to be used VERBATIUM

The text shown in this sample QC Manual should act as a guide in developing a QC program which meets the requirements of theASME Boiler and Pressure Vessel Code Section I, ASME B31.1, Section VIII Div. 1, Div. 2, and Div. 3 it should not be usedverbatim, without review of the system and modification to reflect the system which is actually in use.

QUALITY CONTROL

MANUAL

of

Company Legal NameAND

ACTUAL ADDRESS

for the

SHOP FABRICATION, FIELD ASSEMBLY, AND REPAIR

of

BOILERS, HEAVY WALL, REACTORS, COLUMNS AND STORAGE VESSELS & PARTS FOR THE PETRO-CHEMICAL INDUSTRY AND GENERAL PRESSURE VESSELS

ACCORDING TO SECTION I, SECTION VIII Division 1, 2 & 3 and ASME B31.1 OF THE ASME BOILER AND PRESSURE VESSEL CODE

and for

REPAIRS AND ALTERATIONS TO BOILERS & PRESSURE VESSELS IN ACCORDANCE

WITH THE NATIONAL BOARD INSPECTION CODE

CONTROLLED COPY: YES NO

MANUAL NUMBER: E

Edition: 1 - 22 November 2009


QUALITY CONTROLMANUAL

Section: PrefacePage: 1 of 1Revision: 0Date: 22 November 2009

TABLE OF CONTENTS

Section Description Revision Date

- Cover Page 0 22 November 2009

Preface Table of Contents 0 22 November 2009

0 Statement of Policy and Authority 0 22 November 2009

1 Glossary 0 22 November 2009

2 Manual Control 0 22 November 2009

3 Organization 0 22 November 2009

4 Drawings, Design Calculations & Specifications 0 22 November 2009

5 Material Control 0 22 November 2009

6 Examination and Inspection 0 22 November 2009

7 Nonconformities 0 22 November 2009

8 Welding 0 22 November 2009

9 Nondestructive Examination 0 22 November 2009

10 Heat Treatment 0 22 November 2009

11 Calibration 0 22 November 2009

12 Records, MDR, Code Stamping And National Board 0 22 November 2009

13 Authorized Inspector 0 22 November 2009

14 Field Sites 0 22 November 2009

15 Repairs & Alterations 0 22 November 2009

16 Exhibit Index 0 22 November 2009

Nov. 22, 09 Nov. 22, 09

Approved

TITLE OF RESPONSIBLE

Accepted

Authorized Inspector



Section: 0Page: 1 of 1Revision: 0Date: 22 November 2009

STATEMENT OF POLICY AND AUTHORITY

0.1 This Manual describes the Quality Control System to be followed at Company Legal Name for theShop Fabrication at Address and Field Assembly of ASME Code Stamped Boilers, PressurePiping, Pressure Vessels and Parts controlled from this location in accordance with Section I,Section VIII Division 1, Div.2, and Div.3. This Manual also covers the requirements for theRepair & Alteration of Boilers and Pressure Vessels according to the NBIC.

0.2 The Management of Company Legal Name is totally committed to meet all of the requirements ofthe ASME Boiler and Pressure Vessel Code, NBIC, and the Quality Control System describedin this Manual.

0.3 The TITLE OF RESPONSIBLE is responsible for the preparation, revision and issuance of thisQuality Control Manual, and for the administration and implementation of the Quality ControlSystem at this location, and at field sites controlled from this location.

0.4 The TITLE OF RESPONSIBLE has the authority, responsibility and organizational freedom toidentify Quality Control problems, provide their solutions, and verify the resolution of suchproblems, and to stop work if further processing would result in a nonconformance of the Codeor this Manual.

0.5 When there are differences of interpretation of the Code or this Manual that cannot be resolvedthrough the organizational structure described in this Manual, such problems shall be broughtdirectly to me for resolution in accordance with the ASME Code, this Manual and goodengineering practice.

0.6 This Manual has been prepared in the English language and translated into "Native Language"for use by non-English speaking personnel.

0.7 In case of any conflict in understanding the requirements of this Manual, the English version shallgovern.

CEO 22 November 2009




GLOSSARY

1.0 GENERAL

1.0.1 The following Section covers the terms and abbreviations used through this Manual, along with abrief description of their meaning.

Company Legal Name - The Company who’s Quality Control System is documented in thisManual.

ACCEPTANCE - The act of accepting, by signing-off and dating on a document for anoperation after, verification that the applicable requirements were met.

AI - Authorized Inspector regularly employed by an Authorized InspectionAgency as defined in the Code and holds an A Endorsement on theirvalid National Board commissioning card.

AIA - Authorized Inspection Agency: one designated as such by theappropriate legal Authority of a State or Municipality of the USA orProvince of Canada and Accredited by the ASME.

AIS - Authorized Inspector Supervisor.

APPROVAL - The act of approving, by signing-off on a document after verification thatall the requirements have been met.

ASME - The American Society of Mechanical Engineers

CERTIFY - The act of verifying and attesting in writing that documents, processes,products, or personnel qualifications comply with specified requirements.

CMTR - A Certified Material Test Report, indicating that the material supplied hasbeen manufactured, tested and inspected in accordance with therequired material specification and the requirements of AM-101

CODE - The ASME Boiler & Pressure Vessel Code of Construction Edition and/orAddenda’s and reference Sections.

MATERIAL - Material manufactured to an SA, SB or SFA specification or any otherspecification permitted by the applicable Construction Code

MDR - Manufacturer’s Data Report as defined in the ASME Code.

MAWP - Maximum Allowable Working Pressure an item is permitted to operate at.

MDMT - Minimum Design Metal Temperature, the lowest expected temperaturethe vessel is expected to operated at when in service.

MTR - Material Test Report

NAT´L BD. - The National Board of Boiler and Pressure Vessel Inspectors.

NBIC - National Board Inspection Code

NCR - Nonconformance Report.




GLOSSARY

NDE - Nondestructive Examination.

PQR - Welding Procedure Qualification Record.

PREPARE - To issue a document, with signature and date.

PROCEDURE - A document with step-by-step instructions describing how actions shallbe performed in order to produce results in accordance with the specifiedrequirements.

WPS - Welding Procedure Specification.

WPQ - Welders and Welding Operators Performance Qualification Record.

Etc...... - Enter any abbreviations or acronyms, which are used within this QualityControl Manual.




MANUAL CONTROL

2.0 GENERAL

2.0.1 The TITLE OF RESPONSIBLE is responsible for the administration and distribution of this

Manual and all revisions thereto. Only Controlled copies of this Manual shall be used within theworks and at field sites.

2.1.0 CONTROLLED MANUAL DISTRIBUTION

2.1.1 The TITLE OF RESPONSIBLE will issue copies of the Manual in accordance with the "List of

Manual Holders" (Exhibit 2-1) maintained by the TITLE OF RESPONSIBLE using the ManualTransmittal Sheet (Exhibit 2-2). Each Manual will bear the same control number on its titlepage as is shown on the list: For Manuals in the English language they shall be identified withthe letter "E" after their control number.

2.1.2 Manual holders within the works shall acknowledge receipt of a new Manual by signing and

dating the Manual Transmittal Sheet and returning this to the TITLE OF RESPONSIBLE.

2.1.3 For internal Manual holders who do not acknowledge receipt within 10 days, the TITLE OF

RESPONSIBLE shall personally contact the recipient, verify that the Manual is current andobtain a signed copy of the Manual Transmittal Sheet.

2.1.4 Controlled Manuals issued outside the works shall be sent by Post, requiring the recipient to

acknowledge receipt of the Manual by dating the transmittal letter and returning this to theTITLE OF RESPONSIBLE.

2.1.5 Code Editions and Addenda are reviewed by the TITLE OF RESPONSIBLE to determine the

need for revisions to the Quality Control System and procedures. The TITLE OFRESPONSIBLE signing and dating the Summary of Change page of each Code Section shalldocument this review.

2.1.6 When revisions are required, they shall be made and distributed within six months of theAddenda issue date, or for Editions prior to the Edition becoming mandatory.

2.1.7 Revisions to this Manual will be approved by the TITLE OF RESPONSIBLE and submitted to the

Authorized Inspector for their review and acceptance prior to issue. The approval of the TITLEOF RESPONSIBLE and acceptance of the Authorized Inspector is documented on the Tableof Contents page by signature and date in the space provided.

2.1.8 Revisions are indicated on the affected page in italic type showing the changed portion of text.

2.1.9 Revisions will be made by Section, except for Exhibits; revised exhibit pages are issued

individually with a revised "Exhibit Index" page and Table of Contents page.

2.1.10 Revised Sections of the Manual are distributed by the TITLE OF RESPONSIBLE using the

Manual Transmittal Sheet and will include a revised Table of Contents page showing the latestRevision Number and date of each Section of the Manual, and the signature and date of theTITLE OF RESPONSIBLE and the Authorized Inspector.

2.1.11 Manual holders within the works shall acknowledge receipt of revisions and the destruction of

superseded Manual Sections by signature and date on the Manual Transmittal Sheet andreturning this to the TITLE OF RESPONSIBLE.




MANUAL CONTROL

2.1.12 For internal Manual holders who do not acknowledge receipt within 10 days, the TITLE OF

RESPONSIBLE shall personally contact the recipient, verify that the Manual is current andobtain a copy of the signed Manual Transmittal Sheet.

2.1.13 Revisions issued outside the works shall be sent by Post, requiring the recipient to acknowledge

receipt of the Revisions and that the obsolete pages have been destroyed by the recipientsigning and dating the transmittal letter and returning this to the TITLE OF RESPONSIBLE.

2.1.14 If acknowledgment of receipt is not received in thirty (30) days the TITLE OF RESPONSIBLE will

advise external Manual holders that their Manual will be decontrolled if acknowledgment ofreceipt is not received within an additional 30 days.

2.1.15 Manuals distributed to personnel of Company Legal Name or Manuals sent to the Authorized

Inspection Agency cannot be decontrolled.

2.1.16 The TITLE OF RESPONSIBLE shall retain one copy of each revision of the Manual and the

original of the current Manual, for a period of at least 3 years.

2.1.17 A current copy of the Quality Control Manual is available for use by the Authorized Inspector atthe shop and at the field sites.

2.2.0 UNCONTROLLED MANUALS

2.2.1 Uncontrolled Manuals are Manuals, current at the date of issue but which are not kept up-to-date

and may only be issued to outside organizations, for information only.

2.2.2 Such uncontrolled Manuals shall be clearly marked on the cover page, and not recorded on the

List of Manual Holders.

2.3.0 ELECTRONIC DISTRIBUTION

2.3.1 The TITLE OF RESPONSIBLE shall be responsible for maintaining the original and at least one

hard copy of this Manual with the dated signatures of the TITLE OF RESPONSIBLE, and theAuthorized Inspector, for use by the Authorized Inspector.

2.3.2 The TITLE OF RESPONSIBLE shall be responsible to present to the Authorized Inspector all

proposed revisions to the Manual in hard copy form for review and acceptance prior to beingplaced on the company’s’ server for public access.

2.3.3 Access to the file to make modifications stored on the company's computers shall be limited to

the TITLE OF RESPONSIBLE, by the server administrator and/or passwords.

2.3.4 Revisions to the Electronic version of this Manual are only made after approval by the TITLE OF

RESPONSIBLE and acceptance of the Authorized Inspector by signature and date on the hardcopy version.

2.3.5 Revisions made to the electronic version are indicated in red showing the changed portion of text.

2.3.6 The signature of the Authorized Inspector shall never be scanned or in any other way storedelectronically. In the event of discrepancies between the electronic version and the hard copyversion of this Manual the hard copy version shall govern.




MANUAL CONTROL

2.3.7 Electronic versions of this Manual will not have an identification number.

2.3.8 Hard copies of this Manual may be printed for reference only, and are not controlled, whenprinted they shall show a date stamp and are only valid for 24 hours.

2.3.9 Server Access

2.3.9.1 The TITLE OF RESPONSIBLE through email shall notify individuals having access to theManual. The recipient returning the email to the TITLE OF RESPONSIBLE, which they shallprint and maintain on file, shall document acknowledgment of this notification and inunderstanding their individual responsibility under this program.

2.3.9.2 Notification of approved and accepted changes to this Manual are sent to all those assignedresponsibilities with in the program by the TITLE OF RESPONSIBLE through the use of emailas described in paragraph 2.3.11.1.

2.3.10 File Distribution

2.3.10.1 When the electronic version of the Manual is distributed as a file, to be placed on individualcomputers, distribution shall be controlled in the same manner as the hard copy versiondescribed in paragraph 2.1.0.

2.3.11 Hard Copy for Joint Reviews

2.3.11.1 The TITLE OF RESPONSIBLE will provide the Review Team current necessary number ofhard copies versions of the Manual for review and use during the Joint Review.




ORGANIZATION

3.0 GENERAL

3.0.1 The interrelation of all personnel who manage, perform and verify work affecting the quality are

shown in this Section. The organization chart of Company Legal Name establishing the lines ofAuthority and communications for the proper implementation of this Manual are given in Figure1 of this Section.

3.1.0 DELEGATION OF DUTIES

3.1.1 Each person in a supervisory position may delegate the performance of their duties to competent

and when required qualified certified personnel under their supervision. However, they may notdelegate their responsibility.

3.1.2 Each person in a supervisory position may carry out the duties of personnel under theirsupervision, provided they are qualified and when required certified to perform this work.

Example Only – Names of individuals are not required or recommended




DRAWINGS, DESIGN CALCULATIONS & SPECIFICATIONS

4.0 GENERAL

4.0.1 All inquires are received in Company Legal Name by the TITLE OF RESPONSIBLE.

4.0.2 On receipt of an inquiry for a Code item, to be designed by Company Legal Name, the TITLE OF

RESPONSIBLE reviews the Customer’s design specification with consultation from the TITLEOF RESPONSIBLE for adequacy, and for compliance to applicable Code requirements by theTITLE OF RESPONSIBLE. Any deficiencies are reconciled with the customer. This review isnot documented.

4.0.3 When the inquiry becomes an order the TITLE OF RESPONSIBLE assigns the item a

Manufacture's Serial number taken from a register, and this number is used to identify alldocuments related to this order.

4.0.4 For ASME Section I, Section VIII Div.1, Div.2 or Div.3 vessels or parts, the mandatory CodeEdition & Addenda requirements for the order shall be the basis of the design calculations. Theclient's drawings and specifications shall never override the Code.

4.1.0 PREPARATION OF DRAWINGS, CALCULATIONS AND SPECIFICATIONS

4.1.1 The TITLE OF RESPONSIBLE selects a Design Engineer to prepare the drawings, calculations,

and Material Purchase Specification (Exhibit 4-1). The Design Engineer shall be responsiblefor specifying materials to be used in Code work and they shall be limited to either SA or SB asper the applicable section of the Code and for which allowable stresses are listed in Section IIPart D of the Code or as permitted in other areas of the Code.

4.1.2 Such drawings shall include as a minimum details of Code Edition and Addenda, welded and

bolted joints, NDE, PWHT, material specifications including type and grade, dimensions,tolerances, MAWP, (for Div.2 & 3 Design Pressure) and temperature, minimum design metaltemperature at MAWP, hydrostatic or pneumatic test pressure, requirement or exemption fromimpact testing and when requested by the client or if the item is to be installed in the UnitedStates or Canada that the vessel is to be National Board registered.

4.1.3 Completed drawings and design calculations along with the Material Purchase Specifications are

submitted to the TITLE OF RESPONSIBLE for review and approval for Code compliance,including verification that maximum and minimum design metal temperatures, Charpy impacttest requirements, loadings, and when cold forming is performed that fiber elongation has beenconsidered.

4.1.4 The calculation sheets shall be numbered consecutively with the revision status on each pageand Code Paragraphs and Formula shall be noted on the calculation sheets.

4.1.5 Any disapproved documents are returned to the Design Engineer for correction and resubmitted.

The dated signature of the TITLE OF RESPONSIBLE shows approval.

4.1.6 Revisions to the above design documents are prepared and approved in the same way as theoriginals.

4.1.7 If due to difficulties in procurement, the material may be substituted with approval of the TITLE

OF RESPONSIBLE and the acceptance of the AI. Substitution of material shall require revisionof drawings, parts list and calculations.




4.1.7.1 For Section VIII Div.2 & Div.3 items reconciliation by the Registered Professional Engineer withthe Users Design Specification and the Manufacturers Design Report is also required.





4.2.0 COMPUTER AIDED DESIGNS

4.2.1 When computer aided design calculations are used for Company designed Code items, theDesign Engineer is responsible for the input of correct design data and for the verification thatthe correct output has been obtained, and the TITLE OF RESPONSIBLE shall be responsiblefor the approval.

4.2.2 Computer aided design calculations shall show the program name and version number on theoutput and the pages shall be numbered.

4.2.3 If commercially available or in-house developed computer aided design software is used theTITLE OF RESPONSIBLE, shall verify the accuracy of computer programs for each elementused, prior to use by performing manual calculations or by an alternate method and comparingthe results against those of the program, these results shall be maintained and made availableto the Authorized Inspector. Any revisions to the program will require re-verification.

4.2.4 The TITLE OF RESPONSIBLE will review the Code Addenda to determine if computer programsare affected. Required revisions will be made within six months of the Addenda date.

4.2.5 The review of programs and all revisions are documented on a dated record signed by the TITLEOF RESPONSIBLE, showing the program name and version number and Code Edition and/orAddenda.

4.2.6 Computer aided calculations output are available for review and acceptance by the AuthorizedInspector. The TITLE OF RESPONSIBLE shall provide the Authorized Inspector with anymanual calculations requested to verify the computer output.

4.3.0 STANDARD CALCULATIONS & DRAWINGS

4.3.1 When standard design calculations or drawings are used for Company designed Code items, theTITLE OF RESPONSIBLE is responsible for the verification that the drawings and/orcalculations comply with the applicable Code Edition and/or Addenda.

4.3.2 Verification by the TITLE OF RESPONSIBLE to assure compliance of standard drawings andcalculations is documented on a dated record indicating the drawing and/or calculationsnumber, the revision level of the documents verified and the applicable Code Edition and/orAddenda they are valid for.

4.3.3 The TITLE OF RESPONSIBLE shall provide this record and all drawings and calculations to theAuthorized Inspector for review.

4.4.0 DESIGN BY OTHERS

4.4.1 When drawings or calculations are provided to Company Legal Name by others, the TITLE OFRESPONSIBLE reviews these documents for compliance to the Code. Any discrepancies arebrought to the attention of the design concern for correction to meet Code requirements.

4.4.2 When design documents meet Code requirements, including maximum and minimum designmetal temperatures and Charpy impact test requirements, they are approved by the TITLE OFRESPONSIBLE, who signs and dates each document.

4.4.3 The TITLE OF RESPONSIBLE shall be responsible to obtain the necessary documentation of theverification of computer programs used for calculations when these calculations are providedby an outside organization.





4.5.0 DISTRIBUTION OF DRAWINGS AND CALCULATIONS

4.5.1 All design calculations and Material Purchase Specifications are filed in the Design Engineers jobfile.

4.5.2 The TITLE OF RESPONSIBLE shall be responsible for submittal of the drawings and calculationsto the Authorized Inspector for review prior to start of fabrication. The Authorized Inspectorshall not be held responsible for the accuracy of the calculations.

4.5.3 The job is released to the shop after approval by the TITLE OF RESPONSIBLE, and review ofthe drawings and calculations by the Authorized Inspector.

4.5.4 The Design Engineer prepares a Document Transmittal Sheet (Exhibit 4-2) indicating thedocument number and revision level.

4.5.5 Each person receiving the document is required to sign and date the sheet for acknowledgingreceipt. In case of revisions to documents, the obsolete copy shall be returned to the TITLE OFRESPONSIBLE.

4.5.6 Superseded documents existing in the company shall be withdrawn and substituted with the newrevision and cancelled copies shall be destroyed or marked "CANCELLED".

4.5.7 Superseded documents are retrieved and destroyed, except for one copy kept on file in theEngineering Department for record purposes. These documents shall be marked in red"CANCELLED".

4.5.8 One set of the above documents is provided to the TITLE OF RESPONSIBLE for use by theTITLE OF RESPONSIBLE.

4.6.0 ADDITIONAL REQUIREMENTS FOR SECTION VIII, DIVISION 2 & DIVISION 3 VESSELS

4.6.1 User's Design Specification:

4.6.1.1 A User's Design Specification, which sets forth, expected operating conditions and requiredvessel supports shall also specify whether or not a fatigue (cyclic) analysis is required.

4.6.1.2 If required, sufficient details shall be provided to the vessel manufacturer as a basis for a fatigueanalysis in accordance with Appendix 5 of Division 2.

4.6.1.3 The design specification shall also specify amount of corrosion or erosion allowance, if required,and whether lethal fluid or gas is to be contained.

4.6.1.4 The User's Design Specification for Section VIII, Division 3 items shall include all requirements asspecified in the Code, and fatigue analysis shall be mandatory.

4.6.1.5 A Professional Engineer registered in one or more states of the United States of America orprovinces of Canada who is experienced in pressure vessel design shall certify the User’sDesign Specification for both Section VIII Div.2 and Div.3 items. He must certify to compliancewith the above requirements.





4.6.2 Manufacturer's Design Report:

4.6.2.1 The TITLE OF RESPONSIBLE or if necessary a design agent is responsible for producing aManufacturer's Design Report consisting of calculations and drawings establishing that thedesign, as shown on the drawings, complies with the requirements of Section VIII, Division 2 orDivision 3, for the conditions set forth in the User's Design Specification.

4.6.2.2 When required by the rules of sub-paragraph AD-160 and based upon the listed expectedoperating conditions, a fatigue (cyclic) analysis is mandatory and shall become part of theManufacturer's Design Report. This Manufacturer's Design Report must be certified by aprofessional engineer registered in one or more states of the United States of America orprovinces of Canada who is experienced in pressure vessel design, as complying with allapplicable requirements of Section VIII, Division 2 (AG-302).

4.6.2.3 For Div.3 items the design shall be by analysis and the Manufacturer’s Design Report shallinclude a Design Analysis, As Built Drawings, Fatigue Analysis, consideration of effects ofheating, Statement of openings without closures and Limiting thermal gradients acrosssections.

4.6.2.4 Changes made to information provided in the User's Design Specification and/or Manufacturer'sDesign Report shall be reconciled with the registered professional engineer who certified theoriginal documents.

4.6.2.5 Any revisions, which might reflect on the stress analysis, shall be reconciled in the finalManufacturer's Design Report.

4.6.2.6 The TITLE OF RESPONSIBLE shall take into consideration the following points: restrictedrequirements on allowable materials, as reflected by the fatigue curves of Appendix 5, must beconsidered where a fatigue (cyclic) analysis is required by AD-160 (Div.2 items).

4.6.2.7 Provision of adequate overpressure protection or nozzles of adequate cross sectional area formounting of overpressure protection devices shall be considered. Loadings to be consideredare shown in AD-110.

4.6.2.8 Company Legal Name may subcontract the certification of the Design Report to a registeredProfessional Engineer. However the TITLE OF RESPONSIBLE shall be responsible for itsadequacy.

4.6.2.9 For Div.3 Items the registered professional engineer shall be other than the individual whocertified the User’s Design Specification for the item.

4.6.2.10 The Design Engineer shall indicate the supplementary purchase, examination and testrequirements in the Material Purchase Specification.





4.7.0 ADDITIONAL REQUIREMENTS FOR SECTION I

4.7.1 When the pressure parts of a forced-flow steam generator according to Section I, with no fixedsteam and waterline are designed for different pressure levels, the owner shall provide orcause to be provided a boiler pressure system design diagram, certified by a ProfessionalEngineer experienced in the mechanical design of power plants, which supplies the followinginformation.

a) The relative location of the various pressure parts, with respect to the path of water-steam

flow;

b) A line showing the expected maximum sustained pressure, indicating the expected

variation in pressure along the path of water-steam flow;

c) The maximum allowable working pressure of the various pressure parts;

d) The location and set pressure of the overpressure protection devices;

e) Copy of this diagram shall be attached to the Master Data Report

4.7.2 For an isolable or separately fired superheater which discharges steam directly to a process

stream, the required stop valve and safety valves may be omitted when, flow and pressurecalculations demonstrating that the superheater will not be overpressurized under any steamflow.

4.7.2.1 The TITLE OF RESPONSIBLE shall assure that the pressure system design diagram or thecalculations are certified by a Professional Engineer experienced in the mechanical design ofpower plants and made available to the Authorized Inspector.




MATERIAL CONTROL

5.0 GENERAL

5.0.1 This Section describes the system, which is used to assure that only material, which has beenproperly ordered, received and inspected, is used in ASME Code construction.

5.1.0 MATERIAL REQUISITIONS

5.1.1 The TITLE OF RESPONSIBLE is responsible to prepare, in accordance with the applicable

documents and the Code requirements, the Material Purchase Specifications that are thenapproved by the TITLE OF RESPONSIBLE.

5.1.2 The Material Purchase Specification shall include as a minimum, marking and material test report

required; any additional requirements of the Code Section, such as UG-79, UHA when hotforming, special testing, and Charpy impact tests at minimum design metal temperature.

5.1.3 The Material Purchase Specification shall provide all Code requirements; this includes material

specification, type or grade, permitted by the applicable design Code Section I, Section VIIIDivision 1, 2 or 3 and all other purchase requirements of the applicable construction Code andof that specification given in Section II.

5.1.4 The approved Material Purchase Specifications is then sent to the TITLE OF RESPONSIBLE.

5.2.0 PURCHASE ORDERS

5.2.1 Before purchasing, the TITLE OF RESPONSIBLE checks with the TITLE OF RESPONSIBLE, to

find out, which materials are on stock.

5.2.2 For all Code material, which must be ordered the TITLE OF RESPONSIBLE, prepares the

Purchase Order (Exhibit 5-1) and attaches a copy of the approved Material PurchaseSpecification.

5.2.3 The requirements for Code stamping and Partial Data Reports shall be included either in the

Purchase Order or reference the attached Material Purchase Specification when purchasingASME Code Parts.

5.2.4 The TITLE OF RESPONSIBLE then transmits the Purchase Order along with the approved

Material Purchase Specification, to the appropriate vendor, and a copy to TITLE OFRESPONSIBLE for use during receiving inspection.

5.2.5 Changes to the Purchase Order will be only be made from revised Material Purchase

Specifications which have been approved in the same manner as the originals and withconcurrence of the Authorized inspector.

5.3.0 RECEIVING INSPECTION

5.3.1 Incoming materials shall not be released (except as described in 5.3.9 & 5.3.10) before thereceiving inspection has take place as described in 5.3.3 – 5.3.8.

5.3.2 Materials are received in the works by the TITLE OF RESPONSIBLE. The TITLE OF

RESPONSIBLE is responsible to assure that the arrived material is placed in an appropriatearea awaiting inspection and prepares the Receiving Inspection Report (Exhibit 5-2) also toperform the control indicated below:




• Verify the quantity of the material against the Bill of Laden, visual examination forshipping damage and for stainless steel rust traces.




MATERIAL CONTROL

5.3.3 The TITLE OF RESPONSIBLE transmits the Receiving Inspection Report to the TITLE OF

RESPONSIBLE to show that material is awaiting inspection.

5.3.4 Upon receipt of the Receiving Inspection Report, the TITLE OF RESPONSIBLE shall verify that

the material is correctly marked in accordance with the material specification of the Code asgiven on their copy of the Material Purchase Specification, Record the full material markings,actual dimensions and minimum thickness found, use templates to control forming and radiusof shell and heads and to record this information on the Receiving Inspection Report.

5.3.5 The TITLE OF RESPONSIBLE then verifies the Receiving Inspection Report and the MTR,

CMTR or C of C to the material specification in the Code and any additional requirementsgiven in the Material Purchase Specification.

5.3.6 At this time if any additional material testing is required, the TITLE OF RESPONSIBLE shall

establish which tests must be performed in order to assure Code compliance.

5.3.7 When acceptable the TITLE OF RESPONSIBLE, signs and dates the Receiving Inspection

Report in the release block, and sends a copy to the TITLE OF RESPONSIBLE thus allowingthe material to be released for fabrication.

5.3.8 The TITLE OF RESPONSIBLE may release material for fabrication prior to final acceptance.

Material, which is released in this manner, shall be positively identified. The TITLE OFRESPONSIBLE will authorize release by returning the Receiving Inspection Report to theTITLE OF RESPONSIBLE marked with "Released Except for Welding". Only when the finalReceiving Inspection Report has been completed may welding begin. The TITLE OFRESPONSIBLE shall also note on the TRAVELER at the final operation prior to welding thatwork may not proceed beyond this point until signed by the TITLE OF RESPONSIBLE.

5.3.9 When materials released in accordance with paragraph 5.3.8 show a nonconformity, whichcannot be resolved through the provisions of this Manual and the Code they shall be replacedwith conforming material.

5.4.0 MATERIAL TRACEABILITY

5.4.1 Before cutting Code material into two or more pieces where the original markings would be lost or

destroyed, a coded marking or the entire material marking is transferred by the TITLE OFRESPONSIBLE, and verified by the TITLE OF RESPONSIBLE. The coded marking, traceableto the MTR or CMTR and the required material marking shall be acceptable to the AuthorizedInspector.

5.4.2 Permanent attachments welded to pressure parts shall be identified as in 5.4.1 thoseattachments too small for the marking, to be stamped and visible after welding shall be stored,prior to fixing, in a box marked with the required material marking or codification.

5.4.3 Temporary attachments welded to pressure parts shall be identified with at least the P-Number of

the material. For material, which has no assigned P-Number, a WPS shall be established asdescribed in Section 8 of this Manual to prove weldability.

5.4.4 Temporary and permanent attachments to pressure parts shall be welded using a qualified WPS.




MATERIAL CONTROL

5.5.0 CUSTOMER SUPPLIED MATERIAL

5.5.1 All Code material supplied by the customer or his designee is received and inspected asdescribed in 5.3.3 - 5.3.8 & 5.3.9.

5.5.2 Nonconforming material is handled as described in Section 7 of this Manual.

5.6.0 STOCK MATERIAL

5.6.1 If the Receiving Inspection Report exists, which meet the requirement of this program, utilization

of stock material shall be accomplished by the TITLE OF RESPONSIBLE reviewing theexisting Receiving Inspection Report and certificates against the applicable Code Editionand/or Addenda of the applicable construction Code and Section II for the materialspecification. When no Receiving Inspection Report exists the inspections described in 5.3.3 -5.3.8 shall be performed.

5.6.2 When found to be acceptable approval for usage shall be given by signature and date of the

TITLE OF RESPONSIBLE on the Receiving Inspection Report and recording the applicableCode Edition and/or Addenda on the MTR or CMTR.

5.7.0 RECEIVING INSPECTION OF CODE STAMPED PARTS

5.7.1 Any item received with a Partial Data Report shall be inspected by the TITLE OF RESPONSIBLE

for possible damage and identification with the Partial Data Report.

5.7.2 The TITLE OF RESPONSIBLE shall review the Partial Data Report for completeness and then

submit it to the Authorized inspector prior to it being used in fabrication.

5.8.0 WELDING MATERIALS

5.8.1 All welding consumables shall be purchased in accordance with Welding Material Purchase

Specification (Exhibit 5-3) prepared by the TITLE OF RESPONSIBLE for common weldingmaterials used in production this is a standard form.

5.8.2 Based on predetermined stock levels the TITLE OF RESPONSIBLE, for common welding

materials informs the TITLE OF RESPONSIBLE the need to order welding material the TITLEOF RESPONSIBLE then prepares a Purchase Order and attaches a copy of the WeldingMaterial Purchase Specification and sends to the appropriate vendor.

5.8.3 For non-standard material, a Welding Material Purchase Specification is prepared by the TITLE

OF RESPONSIBLE copies are then sent to the TITLE OF RESPONSIBLE for use in receivinginspection.

5.8.4 Welding consumables are received in the works by the Storekeeper, the receiving inspection is

as follows:

• Verify the marking on the consumables identification label against the Welding Material

Purchase Specification.

5.8.5 Accepted welding consumables are then stored in the welding material storeroom.




MATERIAL CONTROL

5.9.0 SUBSTITUTION OF MATERIAL

5.9.1 Is permitted only as described in paragraph 4.1.7, 5.2.5, and 4.1.8 for Division 2 & 3

5.10.0 NONCONFORMING MATERIAL

5.10.1 Material, which does not meet all Purchase Order, purchase specifications, and Code

requirements, is identified as nonconforming and handled as described in Section 7 of thisManual.




EXAMINATION & INSPECTION

6.0 GENERAL

6.0.1 This Section describes the documents used and their use for complying with the Coderequirements for examination, inspection and tests within our works.

6.1.0 SHOP FABRICATION

6.1.1 The fabrication of Code items is controlled through the use of the TRAVELER (Exhibit 6-1),

prepared by TITLE OF RESPONSIBLE from drawings, fabrication operations and proceduresand lists the control operations sequences they occur for each item.

6.1.2 The completed TRAVELER covers the requirements for inspection, examination and tests and

the procedures used for these operations. When completed, the TITLE OF RESPONSIBLEreviews the TRAVELER and drawings with the Authorized Inspector for designation ofAuthorized Inspector inspection points.

6.1.3 The TRAVELER provides space in columns for both the TITLE OF RESPONSIBLE and the

Authorized Inspector to sign and date on the applicable line for those operations they haveaccepted.

6.1.4 Authorized Inspector inspection points are designated on the TRAVELER as follows:

• H No work may proceed beyond this operation until the Authorized Inspector has

accepted it;

• W No work may proceed beyond this operation until the Authorized Inspector has

accepted it or has given his written permission to waive this inspection point allowingwork to proceed;

• R Is a review point, which would cover the review of documents and would not require

acceptance of the Authorized Inspector before proceeding with the next operation, butmust be seen prior to the Stamping of the item.

6.1.5 All operations shown on the TRAVELER are manufacturers hold points.

6.1.6 The TITLE OF RESPONSIBLE and the Authorized Inspector initial and date the TRAVELER in

the space provided to document their review and to release the TRAVELER to start Codefabrication.

6.1.7 Over and above those Authorized Inspector inspection points the AI is free to make any and allsuch inspections they consider necessary.

6.1.8 During fabrication the TITLE OF RESPONSIBLE shall be responsible for the safe keeping of the

TRAVELER and to notify the TITLE OF RESPONSIBLE of approaching inspections orexaminations.

6.1.9 The TITLE OF RESPONSIBLE is responsible for notifying the Authorized Inspector well in

advance of the approaching inspection points.





6.2.0 FINAL INSPECTION

6.2.1 The Authorized Inspector will make the final inspection following the hydrostatic or pneumatic testrequired by the Code.

6.2.1.1 For parts not tested, the inspection is made after fabrication of the part is completed, prior tobeing Code Stamped.

6.2.1.2 For items not tested until field assembly is completed, the inspection is made after fabrication ofthe item is completed, prior to being shipped to the field.

6.2.2 When a pressure vessel is not provided with an opening or other means of access to inspect

internal surfaces, an inspection point for the TITLE OF RESPONSIBLE and the AuthorizedInspector will be indicated on the TRAVELER to permit internal inspection before starting thefinal closure weld.

6.3.0 HYDROSTATIC TESTS

6.3.1 Code required hydrostatic tests are witnessed by the TITLE OF RESPONSIBLE and the

Authorized Inspector, following a preliminary test to determine and stop any leakage fromflanges and fittings.

6.3.2 The TITLE OF RESPONSIBLE will assure that the Authorized Inspector has been notified

sufficiently in advance of each test so that he may witness them and complete his inspections.

6.3.3 The hydrostatic test shall be performed by the TITLE OF RESPNSIBLE, as specified in the

procedure shown on the TRAVELER.

6.3.4 Upon completion of test and final inspection, the TRAVELER and supporting documents are

returned to the TITLE OF RESPONSIBLE for review and filing as described in Section 10 ofthis Manual.

6.4.0 PNEUMATIC TESTS

6.4.1 Pneumatic tests are conducted by the Shop Foreman using a written procedure prepared by the

TITLE OF RESPONSIBLE to include minimum metal test temperature, test pressure andholding time, pressure increase increments, dial range of gauges and other specialrequirements applicable to the type of test.

6.5.0 TEST GAUGES

6.5.1 At least one directly connected calibrated pressure gauge, visible to the operator controlling the

pressure, and having a dial graduated over a range of about double the intended maximumtest pressure but in not less than 1.5 times nor more than 4 times that pressure shall be usedfor all types of tests.

6.5.2 The TITLE OF RESPONSIBLE shall record the pressure gauge used on the TRAVELER.





6.6.0 RECORDS

6.6.1 All records are returned to the TITLE OF RESPONSIBLE for retention as described in Section 12

of this Manual.

6.7.0 NONCONFORMITIES

6.7.1 All nonconformities found during fabrication are recorded on the TRAVELER next to the operation

where it occurred and are controlled and corrected as described in Section 7 of this Manual.




NONCONFORMITIES

7.0 GENERAL

7.0.1 A nonconformity is any condition, which does not comply with the applicable rules of the Code,

this Quality Control System or other specified requirements. It is the duty of all employees toreport suspected nonconformities to their supervisor, who will immediately notify the TITLE OFRESPONSIBLE. Nonconformities must be corrected before the completed component can beconsidered to comply with the Code.

7.1.0 NONCONFORMITIES DURING RECEIVING INSPECTION

7.1.1 The TITLE OF RESPONSIBLE notifies the TITLE OF RESPONSIBLE who places a

Nonconformity Label (Exhibit 7-1) or marks with “red” on the item and enters the reason for thenonconformity on the Receiving Inspection Report. If there is not adequate space to describethe nonconformity on the Receiving Inspection Report a Nonconformity Report (Exhibit 7-2) willbe issued.

7.1.2 The Receiving Inspection Report along with the NCR when applicable is sent to the TITLE OF

RESPONSIBLE for resolution.

7.2.0 NONCONFORMITIES DURING FABRICATION

7.2.1 As soon as a nonconforming condition is reported, the TITLE OF RESPONSIBLE inspects the

item, and if verified as nonconforming, identifies it by recording on the TRAVELER next to thespecific operation, the number of the Nonconformity Report taken from a register. The TITLEOF RESPONSIBLE then places a Nonconformity Label or marks the item in “red” with theNonconformity Report number. If practical the nonconforming item is moved to a segregatedarea pending disposition.

7.2.2 The Nonconformity Report is then sent to the TITLE OF RESPONSIBLE for resolution.

7.3.0 CORRECTION OF NONCONFORMITIES

7.3.1 USE-AS-IS : When the disposition is use-as-is, the TITLE OF RESPONSIBLE consults with, and

obtains the approval of the TITLE OF RESPONSIBLE, who may consult with the applicableDesign Engineer. Any required revisions to drawings, calculations or procurementdocumentation are made as described in this Manual, including submittal to the AuthorizedInspector for his review and acceptance.

7.3.1.1 For Section VIII Div. 2 & 3 items reconciliation with the User’s Design Specification and theManufacturers Design Report by the registered Professional Engineer is required.

7.3.2 REPAIR/REWORK : All dispositions requiring repair or rework may be carried out using written

procedures, approved by the TITLE OF RESPONSIBLE and accepted by the AuthorizedInspector.

7.3.2.1 For repairs to base metal, the proposed disposition is submitted to the Authorized Inspector foracceptance of the method and extent of repair, and for designation of required inspectionpoints, on the Nonconformity Report or TRAVELER.

7.3.3 SCRAP/RETURN TO VENDOR : This disposition requires the TITLE OF RESPONSIBLE to verify

and document on the Nonconformity Report that the item has been removed from the workarea and tagged or clearly marked in red with "NATIVE LANGUAGE" (Scrap) to prevent itsinadvertent use before disposal.




NONCONFORMITIES

7.4.0 VERIFICATION OF CORRECTIONS

7.4.1 The TITLE OF RESPONSIBLE re-inspects items after completion of dispositions described in

7.3.2. When satisfied that the item meets Code requirements, including acceptance ofoperations, which the Authorized Inspector designated as inspection points, the TITLE OFRESPONSIBLE and the AI sign the Nonconformity Report, and allow fabrication to continue.

7.5.0 RECORDS

7.5.1 All records of nonconformities are made available to the Authorized Inspector for review andacceptance.

7.5.2 Completed Nonconformity Reports are returned to the TITLE OF RESPONSIBLE for filing

according to Section 12 of this Manual.




WELDING

8.0 GENERAL

8.0.1 All welding on Code work is performed using procedures, welders and welding operators qualifiedin accordance with Section IX, as required by Section I, Section VIII Div.1, 2 and 3.

8.1.0 WELDING PROCEDURE SPECIFICATION

8.1.1 Welding Procedure Specifications (WPS) are written by the TITLE OF RESPONSIBLE to include

all essential, nonessential and when required supplementary essential variables required forthe process by ASME Code Section IX and the intended range of production welding. TheTITLE OF RESPONSIBLE witnesses the test coupon welding, recording the actual variablesused in making the qualification test welds.

8.1.2 Preparation and testing of the required test specimens is performed to meet Section IX and

Section I, Section VIII Div.1, 2 & 3 requirements either in-house or by an external testinglaboratory, the report of test results are reviewed by the TITLE OF RESPONSIBLE. Ifacceptable, they prepare and certify, by signature and date, the Procedure QualificationRecord (PQR).

8.1.3 Copies of the qualified WPS's are provided to the Shop for use by production welders. The TITLE

OF RESPONSIBLE maintains the WPS and PQR file and is responsible for their distribution.

8.1.4 The WPS's along with the supporting PQR´s are submitted to the Authorized Inspector for reviewand acceptance, and are available for review at any time.

8.1.5 WPS's are revised whenever there is a change in a nonessential variable. A new WPS isprepared and qualified if an essential variable or when required a supplementary essentialvariable is changed.

8.1.6 The Authorized Inspector may request re-qualification of a WPS at any time when their is reasonto doubt the soundness of the weld being made using the specified WPS.

8.2.0 QUALIFICATION OF WELDERS AND WELDING OPERATORS

8.2.1 All welders and welding operators to be used for Code welding are qualified in accordance with

Section IX, Section I and Section VIII Div.1, 2, & 3 under the supervision of the TITLE OFRESPONSIBLE.

8.2.2 Preparation and testing of the required specimens are performed in house or by an external

testing laboratory. The TITLE OF RESPONSIBLE reviews the test report and if acceptable,they prepare and certify the Welders or Welding Operators Performance Qualification Record(WPQ), which documents the essential variables, actually used for the test weld, and theranges qualified for production welding by these variables.

8.2.3 Based on the WPQ the TITLE OF RESPONSIBLE prepares the ASME Qualified Welders List

(Exhibit 8-1), which is distributed, to the TITLE OF RESPONSIBLE and only those welders oroperators shall be assigned to Code work, within the qualified limits given. This list is reissuedevery six months or when revised.

8.2.4 WPQ's and the ASME Qualified Welders List are available for review by the Authorized Inspector

at any time.




WELDING

8.2.5 The Authorized Inspector may request re-qualification of a Welder or Welding Operator at anytime they question their ability to deposit a sound weld or to follow the variables established inthe WPS.

8.3.0 REQUALIFICATION OF WELDERS AND WELDING OPERATORS

8.3.1 Welders and Welding Operators are re-qualified per paragraph 8.2 when:

• A performance essential variable changes;

• When he has not welded with a process during a period of 6 months or more, hisqualifications for that process shall expire; unless, within the six month period, prior to hisexpiration of qualification;

• a welder has welded using a manual or semiautomatic welding process, which willmaintain his qualification for manual and semiautomatic welding with that process;

• a welding operator has welded with a machine or automatic welding process, which willmaintain his qualification for machine and automatic welding with that process;

• The Authorized Inspector has reason to question a welder or welding operator’s ability todeposit a sound weld that meets the specification or to follow the variables established inthe WPS.

8.4.0 RETENTION OF WELDER AND WELDING OPERATOR QUALIFICATIONS

8.4.1 Each qualified welder is listed on the Welders and Operators Retention Record (Exhibit 8-2)

maintained by the TITLE OF RESPONSIBLE from monthly data provided by the TITLE OFRESPONSIBLE. The record indicates the job order number and the last date each welder oroperator has welded in each process for which they are qualified.

8.4.2 The TITLE OF RESPONSIBLE determines from the list when a welder or welding operator’s

qualification will expire, so as to ensure they perform production welding or are re-qualified.

8.5.0 PRODUCTION WELDING

8.5.1 Each qualified welder or welding operator is issued an identification stamp by the TITLE OF

RESPONSIBLE with which to identify each weld they make adjacent to the weld at least every0.9-meter. Should a welder or welding operator leave the employ of Company Legal Name theassigned identification stamp shall not be re-issued for a period of at least six months?

8.5.2 Should more than one welder be involved in performing a weld seam, both welders shall mark the

weld seam with their identification stamp. When conditions prevent stamping of welds, thewelder or operator enters their identification on the TRAVELER next to the relevant operation.

8.5.3 The TITLE OF RESPONSIBLE verify that all production welders and welding operators are

qualified for the production essential variables to be used, base on the ASME QualifiedWelders List and is responsible for instructing the welder in the correct use of the specifiedWPS.

8.5.4 In the case of tube-to-tube sheet welds it is the responsibility of the TITLE OF RESPONSIBLE to

maintain a record clearly indicating the area welded by each welder or welding operator.




WELDING

8.6.0 TACK WELDS

8.6.1 Tack welds, shall be made in accordance with a qualified WPS, whether left in place orcompletely removed. Tack welds left in place shall be made only by qualified welders.

8.6.2 When left in place, tack welds shall be made by qualified welders, and the ends of each tack weld

ground to ensure complete fusion into the final weld, and the welder’s identification recordedon the TRAVELER or marked adjacent to the weld.

8.6.3 After preparation, the TITLE OF RESPONSIBLE visually examines each tack weld, and if

cracked or otherwise defective, it is completely removed and replaced.

8.7.0 CONTROL OF WELDING CONSUMABLES

8.7.1 Welding Consumables are ordered, received and stored as per paragraph 5.8.

8.7.2 Prior to being used, the welding consumables (fluxes, covered electrodes) are stored in dryheated storage space in the storeroom.

8.7.3 Moisture sensitive welding consumables are received in sealed containers. When opened, they

are place in a heated oven maintained at the temperature recommended by theirmanufacturer.

8.7.4 Welders will obtain from the TITLE OF RESPONSIBLE weld material, which is specified on the

WPS they are working to. For coated electrodes only a quantity sufficient to complete the weldor for a period of eight hours which ever is less will be issued.

8.7.5 Unconsumed electrodes returned for storage are examined by the TITLE OF RESPONSIBLE for

condition, cleanliness and identification before return to a segregated oven for reconditioning ifthey have not been maintained in a portable oven. Damaged or unidentified electrodes arescraped.

8.8.0 PRODUCTION TEST PLATES

8.8.1 Welded test plates for ASME Code required production vessel tests, impact, welds and heat

affected zones, are prepared in accordance with a procedure prepared by the TITLE OFRESPONSIBLE and shown on the TRAVELER.

8.8.2 The TITLE OF RESPONSIBLE supervises the welding of test plates, which are prepared and

tested by a testing laboratory whose test report is reviewed by the TITLE OF RESPONSIBLEfor acceptable results or the need for retest.

8.8.3 Test results are submitted for review and acceptance to the Authorized Inspector, who maywitness the tests if desired.

8.9.0 WELDING RECORDS

8.9.1 All records mentioned in this Section are available for review by the Authorized Inspector and areretained in as described in Section 12 of this Manual.




NONDESTRUCTIVE EXAMINATION

9.0 GENERAL

9.0.1 All NDE required by the Code is specified on the TRAVELER, and is performed by qualified, and

certified personnel, using written procedures and calibrated equipment.

9.1.0 NDE PROCEDURES

9.1.1 All Code NDE is performed using written procedures that are verified by the TITLE OF

RESPONSIBLE and approved by the Level III Examiner who is qualified in the method andappointed by letter from the TITLE OF RESPONSIBLE, of Company Legal Name as our LevelIII in accordance by our Written Practice which meets the requirements of the latest Codeaccepted edition of SNT-TC-1A.

9.1.2 All NDE procedures are reviewed and approved by the Level III with his signature and date.

9.1.3 All NDE procedures are submitted to the Authorized Inspector for his review and acceptance.

Written procedures for radiographic (RT), ultrasonic (UT), liquid penetrant (PT) and magneticparticle (MT) examination of ASME Code items are demonstrated to the satisfaction of theAuthorized Inspector, certified in accordance with Section V, paragraph T-150, and distributedaccording to a list maintained by the TITLE OF RESPONSIBLE.

9.2.0 NDE PERSONNEL

9.2.1 The Level III certifies, the personnel used for Code NDE as having the training, experience andqualifications for the method, in accordance with our Written Practice, which conforms to therequirements of the latest accepted edition of SNT-TC-1A, when examiners are performing PTon Section VIII Div.3 items or on steel castings according to Section I. For Section VIII Div.1,MT and PT examiners they may be certified in accordance with Appendix 6 and 8 respectively,or Appendix 9 for Section VIII Div.2. Section I Power Piping VT examiners are certified inaccordance with our VT Written Practice, which meets the requirements of ASME B-31.1.

9.2.2 NDE Personnel Records are available for review by the Authorized Inspector, who may requestre-qualification if there is reason to question an examiners ability to perform the examination.

9.2.3 Copies of NDE personnel qualification records for all examiners performing Code NDE are kept

on file by the TITLE OF RESPONSIBLE and made available to the Authorized Inspector.

9.3.0 NDE REPORTS

9.3.1 All required NDE Reports including RT film, are reviewed and accepted by the Level II or III priorto submittal to the Authorized Inspector for his review.

9.3.2 NDE Reports, including RT film for Code required RT, are filed by the TITLE OF RESPONSIBLE

for record retention as described in Section 12 of this Manual.




NONDESTRUCTIVE EXAMINATION

9.4.0 ADDITIONAL NDE REQUIREMENTS

9.4.1 Before performance of pneumatic tests as permitted by ASME Code Section VIII Division 1 & 2,the full length of the following welds are examined by MT or PT, whichever is applicable, forthe purpose of detecting possible cracks as follows.

• All welds around openings;

• All attachment welds, including welds attaching non-pressure parts, having a throatthickness greater than 1/4" or 6mm.

9.4.2 For Section VIII Div.3, all surfaces of pressure boundary components including internal andexternal surfaces and weld metal shall be examined by wet magnetic particle method (ifferromagnetic) or by liquid penetrant method (if nonmagnetic) over the entire surface of thevessel or component following all applicable heat treatment and autofrettage hydro test, unlessaccessibility prevents meaningful interpretation and characterization of defects.

9.5.0 SUBCONTRACTED NDE SERVICES

9.5.1 All Code NDE is performed using written procedures that are reviewed by TITLE OF

RESPONSIBLE and approved by the Level III Examiner who is a subcontractor, qualified inthe method and certified by letter from the TITLE OF RESPONSIBLE of Company Legal Nameas our Level III in accordance with the subcontractors Written Practice which meets therequirements of the latest Code accepted edition of SNT-TC-1A.

9.5.2 All NDE procedures are reviewed and approved by the Level III with his signature and date.

9.5.3 All NDE procedures are submitted to the Authorized Inspector for their review and acceptance.Written procedures for radiographic (RT), ultrasonic (UT), liquid penetrant (PT) and magneticparticle (MT) examination of ASME Code items are certified in accordance with T-150 of theASME Code Section V, as demonstrated to the satisfaction of the Authorized Inspector.

9.5.4 The Level III certifies the subcontracted personnel used for Code NDE as having the training,experience and qualifications for the method, in accordance with their employer's WrittenPractice, which conforms to the requirement of the latest Code, accepted edition of SNT-TC-1A.

9.5.5 NDE Personnel Records are available for review by the Authorized Inspector, who may requestre-qualification if there is reason to question an examiners ability to perform the examination.

9.5.6 Copies of NDE personnel qualification records for all examiners performing Code NDE are kept

on file by the TITLE OF RESPONSIBLE and made available to the Authorized Inspector andthe ASME Designee.

9.5.7 All required NDE Reports by the subcontractor including RT film, are reviewed and accepted bythe Level II or III prior to submittal to the Authorized Inspector for their review.

9.5.8 NDE Reports, including film for full, partial and spot Code required RT, are filed by the TITLE OF

RESPONSIBLE for record retention as described in Section 12 of this Manual.




HEAT TREATMENT

10.0 GENERAL

10.0.1 Heat treatment required by the Code, which is limited to post weld heat treatment (PWHT) for

stress relieving welds, maybe performed in-house or by a qualified subcontractor inaccordance with Company Legal Name procedures, using calibrated equipment.

10.1.0 POST WELD HEAT TREATMENT

10.1.1 All heat treatment shall be performed in accordance with written procedures prepared, by the

Design Engineer and approved by the TITLE OF RESPONSIBLE.

10.1.2 Heat Treatment procedures shall describe the placement and method of attachment forthermocouples, temperature gradients for heating and cooling, support locations, time attemperature and required records as a minimum and are submitted to the Authorized Inspectorfor review.

10.1.3 In-house heat treatment shall be done under the responsibility of the TITLE OF RESPONSIBLE

and monitored by the TITLE OF RESPONSIBLE.

10.1.4 The time-temperature recording charts shall indicate as a minimum the:

• Procedure & revision;

• The order number;

• Date of heat treatment;

• Vessel or part number;

• Identification of thermocouples;

•Signature and date of the TITLE OF RESPONSIBLE.

10.1.5 The TITLE OF RESPONSIBLE signs and dates the Time Temperature Charts and sends them to

the TITLE OF RESPONSIBLE for presentation to the Authorized Inspector and for recordretention as described in Section 12 of this Manual.

10.2.0 SUBCONTRACTED POST WELD HEAT TREATMENT

10.2.1 The TITLE OF RESPONSIBLE shall review and approve the subcontractor’s controls, equipment

and calibration records prior to placement of a Purchase Order for Heat Treatment and obtainsa copy of the calibration records for time-temperature recorder and thermocouples.

10.2.2 All Heat Treatment records submitted by the subcontractor shall be the actual furnace charts

which record the procedure and revision, identification of thermocouples, date of heattreatment and items treated, and signed and dated by the furnace operator.

10.2.3 The Company Legal Name Purchase Order assures free access for the Company Legal Name

representatives and the Authorized Inspector.

10.2.4 Identification of materials or parts sent to the subcontractor's facilities for heat treatment, usingnumbers, tags or hard stamping shall be described in the heat treatment procedures. Careshall be taken when test coupons are involved.

10.2.5 Upon return the TITLE OF RESPONSIBLE examines each one for damage or loss of

identification, the TITLE OF RESPONSIBLE shall review all records supplied by thesubcontractor to assure that they comply with the requirements of the Purchase Order and theheat treatment procedures.




HEAT TREATMENT

10.3.0 HEAT TREATMENT RECORDS

10.3.1 Heat Treatment records are submitted to the Authorized Inspector for review and acceptance,after acceptance they are filed in the job file.

10.4.0 NONCONFORMITIES

10.4.1 Any deviation from these requirements shall result in an NCR. NCR's shall be handled perSection 7.




CALIBRATION

11.0 GENERAL

11.0.1 All measurement, examination and test equipment used for acceptance of a Code item iscalibrated in accordance with this Section.

11.1.0 CALIBRATION PROCEDURES

11.1.1 All measurement, examination and test equipment is identified by marking the item or itscontainer with a unique serial number.

11.1.2 Each item is recorded on a List of Calibrated Equipment (Exhibit 11-1), which shows as a

minimum, equipment description, serial number, frequency of calibration, and date of nextcalibration.

11.1.3 The TITLE OF RESPONSIBLE is responsible for maintaining all equipment in calibration, unless

out of service and clearly marked "NOT CALIBRATED".

11.1.4 Calibration may be performed by a qualified testing laboratory, which provides certified records ofcalibration, and has suitable standards whose accuracy is traceable to the National Standardsor similar.

11.1.5 The frequency of calibration is as determined from the manufacturer's recommendations, or fromexperience with the instrument.

11.1.6 Pressure gauges used for hydrostatic, pneumatic or proof testing are calibrated against a dead-weight tester or calibrated master gauge once annually, and whenever there is reason toquestion their accuracy.

11.1.7 The Level II using a calibrated step wedge film, which is traceable to national standards and

calibrated annually, performs the calibration of the radiographic densitometer every 90 days.The densitometer or density step wedge comparison film is verified by the RT Level IIExaminer, at the start of each 8-hour shift, or at each change of operator.

11.2.0 CALIBRATION RECORDS

11.2.1 All equipment is identified with a Calibration Sticker (Exhibit 11-3) which records the item, date of

last calibration, and due date for the next calibration.

11.2.2 Calibration records, including those of subcontractors who perform NDE, PWHT and mechanicaltesting, are available for review by the Authorized Inspector.

11.3.0 DISCREPANT EQUIPMENT

11.3.1 When instruments are found out of calibration or damaged, the TITLE OF RESPONSIBLE

removes it from the work area and arranges for calibration or replacement.

11.3.2 All Code items checked with such discrepant instruments are nonconforming until the TITLE OF

RESPONSIBLE has verified that they meet all Code requirements, or they are retested withaccurate instruments.

11.3.3 Traceability is provided from location of equipment, or by recording the identification number of

instrument used for an examination or inspection on the TRAVELER other inspectiondocumentation.




11.3.4 After removal of a calibrated instrument or pressure gauge from a field site, it is immediatelycalibrated, so as to verify that the item was in calibration when last used at the field site.




RECORDS, MDR, CODE STAMPING and NATIONAL BOARD

12.0 GENERAL

12.0.1 The TITLE OF RESPONSIBLE shall be responsible for the safe keeping of all records related to

Code work performed at Company Legal Name and at Field Sites.

12.1.0 RECORDS

12.1.1 As a minimum, the TITLE OF RESPONSIBLE retains the following documents at Company Legal

Name:

a. Final drawings;b. Calculations and applicable specifications;c. Material test certificates (MTR's & CMTR's);d. NDE Reports, RT films, and interpretation reports;e. Nonconformity Reports;f. Hydrostatic test reports;g. Dimensional Records;h. Manufacturer's Data Reports;i. Partial Data Reports;j. Photocopy or rubbing of nameplate or stamping.

12.1.2 All the above records shall be retained for a minimum period of 5 years and shall be available forreview by the AI.

12.1.3 ADDITIONAL REQUIREMENTS SECTION VIII DIV.2

12.1.3.1 For Section VIII, Div.2 vessels, all documents mentioned in paragraphs 12.1.1 shall bemaintained in a safe repository by Company Legal Name for the life of the vessel or (10) tenyears, whichever is longer.

12.1.3.2 In addition to the records shown in paragraph 12.1.1, Company Legal Name shall maintain:

a. All data on repaired material, items and assemblies; b. The User's Design Specification, certified by a Registered Professional Engineer;c. The Manufacturer's Design Report, certified by a Registered Professional Engineer;d. All material certificates, Partial Data Reports, examination procedures, test procedures, heat

treat procedures and records, manufacturing procedures, specifications and drawing used.

12.1.3.3 After the ten years period TITLE OF RESPONSIBLE may offer the records to the vessel useror their designated agent and if receiving rejection, they may be destroyed.

12.1.3.4 Records as mentioned above shall be filed and maintained in a manner which will allow accessby the AI to specific information contained therein within a period not in excess of 24 hours atany time during the period of vessel manufacture.





12.1.4 ADDITIONAL REQUIREMENTS SECTION VIII DIV.3

12.1.4.1 For Section VIII, Div. 3 vessels, all documents mentioned in paragraphs 12.1.1 shall bemaintained in a safe repository by Company Legal Name for the life of the vessel or ten years,whichever is longer.

12.1.4.2 The Manufacturer shall furnish to the User the records listed below:

a. User’s Design Specification complete with all reference documentsb. Manufacturer’s Data Reportc. Manufacturer’s Design Reportd. Manufacturer’s Construction Records:

d.1.1 As-built drawings;d.1.2 Materials certifications, all Material Test Reports, record of repairs;d.1.3 Welding Procedures;d.1.4 Weld repair reports;d.1.5 NDE Examination Procedures, Records of Procedure Qualification, and Records of

Personnel Qualifications;d.1.6 Record of all heat treatments (these records may be either the actual heat

treatment charts or a certified summary description of heat treatment time andtemperature);

d.1.7 Pre-stressing procedures and verification data;d.1.8 NDE reports and as-built sketches showing all relevant NDE indications;d.1.9 Record of nonconformance’s and disposition.

12.1.5 Company Legal Name shall take the necessary steps as maybe require to provide suitable

protection of all records from deterioration or damage.

12.2.0 MANUFACTURERS DATA REPORT

12.2.1 Upon completion of a Code item the TITLE OF RESPONSIBLE prepares the Manufacture's Data

Report from design documents and final records. The TITLE OF RESPONSIBLE or theirdesignee certifies it in ink when correct.

12.2.2 The Manufacturer's Data Report shall contain no erasures, white outs or cross-outs. Each spaceshall be completed on the Manufacturer's Data Report, for those spaces with no information;NA (meaning Not Applicable) shall be used in these spaces.

12.2.3 The completed Manufactures Data Report, together with the final records is then presented to the

Authorized Inspector for review. When satisfied that all Code requirements have been met, theAuthorized Inspector will authorize and verify the application of the Code Symbol Stamp to theNameplate or directly on the correct boiler, pressure vessel or part, and sign and date theManufacturers Data Report.

12.2.4 If required by client or if the final location is U.S.A. or Canada the Manufacturer's Data Reportshall be registered with the National Board of Boiler and Pressure Vessel Inspectors.





12.2.5 DISTRIBUTION OF MANUFACTUERS DATA REPORTS (MDR)

12.2.5.1 For Section I items a copy of the Manufacturer’s Data Report shall be furnished to:

a. Userb. Inspection Agencyc. Jurisdictional authorities;

d. Keep a copy of the Manufacturer’s Data Report on file in a safe repository for atleast 5 years or for the intended life of the vessel, whichever is greater.

e. In lieu of (d) above, the vessel may be registered and the Data Reports filed with theNational Board of Boilers and Pressure Vessel Inspectors

12.2.5.2 For Section VIII Div.1 items the Manufacture shall furnish a copy of the Manufacturers DataReport:

a. User or their designated Agent;b. Upon request, to the Inspector;c. Keep a copy of the Manufacturer’s Data Report on file in a safe repository for atleast 5 years or for the intended life of the vessel, whichever is greater.d. In lieu of (c) above, the vessel may be registered and the Data Reports filed withthe National Board of Boilers and Pressure Vessel Inspectors


a. User;b. Upon request, to the Inspector;c. Jurisdiction in which the vessel is to be installed where required by law;d. Keep a copy of the Manufacturer’s Data Report on file in a safe repository for atleast 10 years or for the intended life of the vessel, whichever is greater.e. In lieu of (c) and (d) above, the vessel may be registered and the Data Reportsfiled with the National Board of Boilers and Pressure Vessel Inspectors


a. User;b. The Inspector;c. Jurisdiction in which the vessel is to be installed;d. Keep a copy of the Manufacturer’s Data Report on file in a safe repository for atleast 10 years or for the intended life of the vessel, whichever is greater.e. In lieu of (c) and (d) above, the vessel may be registered and the Data Reportsfiled with the National Board of Boilers and Pressure Vessel Inspectors

12.3.0 CODE STAMPING

12.3.1 The TITLE OF RESPONSIBLE has custody and control of the ASME Code Symbol Stamps. The

required Stamp will be issued for use only when all fabrication, examinations and inspectionsare completed, and the AI has authorized Code Stamping to the TITLE OF RESPONSIBLE.

12.3.2 For Code items completed in the field the TITLE OF RESPONSIBLE shall either be hand carry or

send by courier the applicable Code Stamp to the TITLE OF RESPONSIBLE, and isresponsible for the safe keeping and control of its use, After its use it shall be immediatelyreturn to the TITLE OF RESPONSIBLE in the same manner





12.3.3 For Section VIII Div.1, Div.2, and Div.3 vessels the Code Stamping is applied on a Nameplate

(Exhibit 12-1, 12-2, and 12-3), which is permanently attached to the vessel. For Section I andASME B31.1 items the marking as shown in (Exhibit 12-4 or 12-5) shall be directly stamped onthe item. The TITLE OF RESPONSIBLE shall prepare the information provided on theNameplate.

12.3.4 When Stamping the Code Symbol on the Nameplate after attachment to the vessel is not

possible, it may be applied, with the prior concurrence of the Authorized Inspector, aftercompletion of all fabrication and examination, and immediately before the hydrostatic orpneumatic test, and the Nameplate attached to the vessel in the presence of the AuthorizedInspector. Any nonconformance found which cannot be corrected shall require immediateremoval of the Nameplate and Code Symbol.

12.4.0 NATIONAL BOARD

12.4.1 The National Board serial numbers shall be controlled and issued consecutively by the TITLE OF

RESPONSIBLE.

12.4.2 The National Board serial numbers shall be issued in a progressive numerical order from 1

without jumps or gaps and without prefix or suffix. The TITLE OF RESPONSIBLE shallmaintain a register of National Board serial numbers issued, showing date of issue, CompanyLegal Name manufacturer’s serial number, description of vessels or part, National Board serialnumber, and the date of dispatch of Manufacturer's Data Report to the National Board forregistration.

12.4.3 When items are registered with the National Board, the TITLE OF RESPONSIBLE shall send the

Manufactures Data report to the National Board within 3 weeks after certification.




AUTHORIZED INSPECTOR

13.0 GENERAL

13.0.1 This Section describes who an Authorized Inspector is and the relationship within ourorganization.

13.1.0 AUTHORIZED INSPECTOR

13.1.1 The Authorized Inspector is the independent third-party Inspector required by the Code,

employed by the Authorized Inspection Agency with whom Company Legal Name has acontract to perform the inspection services required by the Code.

13.1.2 The Authorized Inspector is regularly employed by an Authorized Inspection Agency as defined inthe Code and holds an “A” Endorsement on their valid National Board commission card.

13.1.3 For those field sites where use of a different AIA than used for shop fabrication is required, theirservices for Code inspection may be provided only after signing a separate contact for suchwork.

13.1.4 The TITLE OF RESPONSIBLE arranges for the Authorized Inspector to have free access to the

shop and field site whenever Code work is being done; and to such parts of all plants that areconcerned with the manufacturer and supply of parts or materials for the vessel whenrequested.

13.1.5 When requested by the Authorized Inspector, inspection points will be inserted on the

TRAVELER for those operations they may wish to witness or verify before work proceeds.

13.1.6 The TITLE OF RESPONSIBLE at the shop or the TITLE OF RESPONSIBLE at a field site, are

the Company's liaison with the Authorized Inspector, and are responsible for informing them ofthe progress of Code work so that they may perform the designated inspections.

13.1.7 The Authorized Inspector has access to and is provided with all drawings, calculations,specifications, procedures, process sheets, repair records, test and examination results,inspection records and any other documents required to perform their duties.

13.1.8 All Nonconformity Reports for Code work are submitted to the Authorized Inspector for their

review and acceptance.

13.1.9 The TITLE OF RESPONSIBLE or TITLE OF RESPONSIBLE will notify the Authorized Inspector

sufficiently in advance of hydrostatic, pneumatic, proof tests or any other designated inspectionpoints on the TRAVELER so that they may be present to witness them.

13.1.10 The final records, together with the completed Manufacturer's Data Report signed by the

TITLE OF RESPONSIBLE, are submitted to the Authorized Inspector for their authorization toapply the Code Symbol stamp and signature, when they have satisfied themselves that allCode requirements have been met.

13.1.11 A current copy of the Quality Control Manual is available for use by the Authorized Inspector atthe shop and field site.

13.1.12 The Authorized Inspector will review and accept all changes to the Quality Control Manual, beforethey are issued to Manual holders.

13.1.13 The TITLE OF RESPONSIBLE will assist the Authorized Inspector Supervisor during their

required audits, and the Authorized Inspector while monitoring the Quality Control System.




FIELD SITES

14.0 GENERAL

14.0.1 This Section describes how Company Legal Name will control those operations for Code items

are controlled when final assembly is conducted at field sites controlled from this location.

14.1.0 AUTHORITY AND RESPONSIBILITY

14.1.1 Reporting directly to the TITLE OF RESPONSIBLE the TITLE OF RESPONSIBLE has the overall

responsibility for all field fabrication activities.

14.1.2 The TITLE OF RESPONSIBLE reports directly to the TITLE OF RESPONSIBLE at the Home

Office. They are responsible for implementation of this Quality Control Manual at the field siteand for the coordination of Quality Control field activities.

14.2.0 FIELD SITE ORGANIZATION

14.2.1 The organization at field site locations is as shown on the Organization Chart in figure 1 ofSection 3 of this Manual.

14.3.0 DRAWINGS, DESIGN CALCULATIONS AND SPECIFICATIONS

14.3.1 The necessary drawings and specifications are prepared, reviewed and approved as perparagraph 4.1.1 through 4.1.7 of this Manual.

14.3.2 The distribution of drawings and specifications is as described in paragraph 4.4.1 through 4.4.5with the exception, that drawings and specifications may also be distributed to field sitelocations through the use of normal post or express carriers.

14.3.3 The TITLE OF RESPONSIBLE is responsible for providing the Authorized Inspector with all

drawings and necessary documents for review prior to the start of work.

14.3.4 Revisions to the above documents are handled in the same way as the originals.

14.4.0 MATERIAL CONTROL

14.4.1 Additional Code material requested by the TITLE OF RESPONSIBLE or the TITLE OF

RESPONSIBLE is requisitioned by the TITLE OF RESPONSIBLE, as described in paragraph5.1.1 of this Manual.

14.4.2 Code material cut to shape in the Shop shall be clearly marked with:

a. Job identity number; b. Item number; c. The full material markings as required by the material specification or an acceptable coded

marking; d. Part number.

14.4.3 All material from the Shop to the field site shall be sent with a copy of the Receiving Inspection

Report, which has been verified by the TITLE OF RESPONSIBLE and the MTR or CMTR tothe site that the TITLE OF RESPONSIBLE will use in verifying the material marking prior to thematerial being released.




FIELD SITES

14.4.4 For all Code material received directly at the field site(s), the TITLE OF RESPONSIBLE sends

the Site TITLE OF RESPONSIBLE a copy of the Purchase Order and the approved MaterialPurchase Specification for use in receiving inspection as described in paragraph 5.3.1 through5.3.4 of this Manual.

14.4.5 The Receiving Inspection Report is then returned to the TITLE OF RESPONSIBLE for further

processing as described in paragraph 5.3.6 through 5.3.9 with a verified copy of the ReceivingInspection Report sent to the TITLE OF RESPONSIBLE showing that the material can bereleased for fabrication.

14.4.6 All Code material, items or Code Parts are unloaded in the assigned lay-down area, and

examined by the TITLE OF RESPONSIBLE for:

a. Physical damage, which may have occurred during transport; b. Proper tagging and identification of each item, which provides traceability to assembly

drawings; c. In case of items supplied with Manufacturers Partial Data Reports, the stamping shall be

verified against the Data Report; d. The required material marking as described in paragraph 14.4.2.

14.4.7 Both the TITLE OF RESPONSIBLE and the Authorized Inspector at the Shop location shall

certify all items shipped to the field site(s), which have not been Code Stamped as Parts, forcompliance with Code requirements on the TRAVELER in the shop.

14.4.8 For these items the TITLE OF RESPONSIBLE and the Authorized Inspector shall verify the

extent of work completed as indicated on the shop TRAVELER and that no damage hasoccurred in transit. When satisfied the item described on the shop TRAVELER is the same asthe item received and no damage has occurred the TITLE OF RESPONSIBLE and theAuthorized Inspector shall then sign and date the copy of shop TRAVELER in the spaceprovided. The TITLE OF RESPONSIBLE shall return the signed copy to the TITLE OFRESPONSIBLE for filing.

14.4.9 Upon satisfactory completion of the above activities the TITLE OF RESPONSIBLE shall record

the Manufacturers Serial Number, piece-marking numbers of each item received in a log.

14.4.10 In the case of plate or pipe, the TITLE OF RESPONSIBLE maintains a log of sequential

numbers assigned, which contains the material heat and lot number from the material testreports, thus providing the relation between the sequential number and material test reports.

14.4.11 All welding consumables requested by the TITLE OF RESPONSIBLE or TITLE OF

RESPONSIBLE shall be ordered as described in paragraphs 5.8.1 and 5.8.3 of this Manual.

14.4.12 Receiving of all welding consumables shall be performed at the Shop location as described inparagraphs 5.8.4.

14.4.13 Accepted welding consumables shall be shipped to the field site with a copy of the signed copy

of the Weld Material Purchase Specification. For use by the TITLE OF RESPONSIBLE duringthe material verification.

14.4.14 Accepted welding consumables shall be stored in a locked storage area in their original

package away from the elements, in accordance with the manufacturer’s recommendations.




14.4.15 Parts, items and material that do not meet all requirements are considered nonconforming and

the TITLE OF RESPONSIBLE in accordance with Chapter 7 of this Manual shall prepare aNonconformity Report.




FIELD SITES

14.5.0 FIELD EXAMINATION AND INSPECTION PROGRAM

14.5.1 The field assembly of Code pressure vessels is controlled by assembly drawings and the

TRAVELER, which is prepared and reviewed as per, paragraph 6.1.1 through 6.1.8 of thisManual.

14.5.2 The approved TRAVELER is sent to the TITLE OF RESPONSIBLE by the TITLE OF

RESPONSIBLE.

14.5.3 Prior to start of work the TITLE OF RESPONSIBLE, shall make the TRAVELER and all related or

required documents available to the Authorized Inspector at the site location, for review andselection of inspection points as described in paragraph 6.1.2 of this Manual.

14.5.4 Code required hydrostatic or pneumatic tests shall be performed by the TITLE OF

RESPONSIBLE as specified by the procedure on the TRAVELER, and under the supervisionof the TITLE OF RESPONSIBLE and always in the presence of the Authorized Inspector.

14.5.5 For all Code vessels, the procedure shall specify the required test pressure and a maximum testpressure. Under no circumstances shall the maximum test pressure be exceeded. Theprocedure shall also specify the minimum metal temperature the test shall be performed at.

14.5.6 Two calibrated pressure gauges shall be used, to reduce the risk of using gauges, which havebeen damaged in transit.

14.5.7 Upon completion of the field assembly of a Code item, the TITLE OF RESPONSIBLE shall verify

and certify the Certificate of Field Assembly portion of the Manufacturers Data Report.

14.5.8 The completed Data Report, together with the final records are then presented to the AuthorizedInspector for review. When satisfied that all Code requirements have been met, the AuthorizedInspector will authorize and verify the application of the Code Symbol Stamp to the Nameplateor item as applicable and sign the Field Assembly portion of the Data Report.

14.5.9 All records are returned to the TITLE OF RESPONSIBLE at the Home Office for retention as

described in Chapter 12 of this Manual.

14.6.0 CORRECTION OF NONCONFORMITIES

14.6.1 Nonconformities found during field assembly are recorded on the TRAVELER next to the

operation where they occurred and are controlled as described in Section 7 of this Manual.

14.6.2 All requirements of Section 7 of this Manual shall apply.

14.6.3 However for Nonconformities where the disposition is "Reject", the TITLE OF RESPONSIBLE on

site is authorized to make such dispositions.

14.6.4 All Nonconformities may be transmitted by fax or by telex. The written disposition of the TITLE

OF RESPONSIBLE shall in all cases be obtained, with the exception of 14.6.1 above prior toany action taken.

14.6.5 The TITLE OF RESPONSIBLE shall inform the TITLE OF RESPONSIBLE of all dispositions and

all corrective actions to be taken.

14.6.6 All Nonconformity Reports shall be sent to the TITLE OF RESPONSIBLE at the Home Office for

retention as described in Section 12 of this Manual.




FIELD SITES

14.7.0 WELDING

14.7.1 All welding shall be done in accordance with Section 8 of this Manual, and in addition the TITLE

OF RESPONSIBLE, together with the TITLE OF RESPONSIBLE shall establish the actionnecessary to protect the welding activities from adverse weather conditions such as wind, rain,temperature and humidity.

14.7.2 All concerned WPS´s and supporting PQR´s shall be sent to the TITLE OF RESPONSIBLE by

the TITLE OF RESPONSIBLE, they shall then be distributed to the TITLE OF RESPONSIBLE.WPS´s shall be made available to the welders for their use. All WPS´s and PQR´s shall bemade available to the Authorized Inspector at the field site for review.

14.7.3 Welders shall be qualified as described paragraph 8.2.3.

14.7.4 The List of Qualified Welders shall be prepared as described in paragraph 8.2.3 and sent by the

TITLE OF RESPONSIBLE to the TITLE OF RESPONSIBLE for use in assigning welders totheir work. This list along with the welder’s qualifications shall be made available to theAuthorized Inspector for review.

14.7.5 The TITLE OF RESPONSIBLE is responsible for the issuance of welding consumables in

accordance with paragraphs 8.7.4 and 8.7.5 of this Manual. The TITLE OF RESPONSIBLE isresponsible for transmitting the manufacturer’s recommendations for handling and storage ofthe welding consumables to the field location.

14.8.0 NONDESTRUCTIVE EXAMINATION

14.8.1 All NDE shall be carried out in accordance with Section 9 of this Manual. Dossiers of all NDE

personnel shall be maintained by the TITLE OF RESPONSIBLE and be made available to theAuthorized Inspector.

14.8.2 All radiographs and test reports shall be made available to the Authorized Inspector for review.

Following the Authorized Inspectors acceptance, all radiographs and test reports shall beforwarded to the TITLE OF RESPONSIBLE at the Home Office.

14.9.0 HEAT TREATMENT

14.9.1 Post weld Heat Treatment, when required shall be carried out in accordance with Section 10 ofthis Manual.

14.9.2 The TITLE OF RESPONSIBLE shall be responsible for forwarding the procedure after approval

as per paragraph 10.1.1 to the TITLE OF RESPONSIBLE for distribution to the TITLE OFRESPONSIBLE.

14.9.3 After acceptance by the Authorized Inspector, the time/temperature charts shall be forwarded to

the TITLE OF RESPONSIBLE for retention as described in Section 12 of this Manual.

14.10.0 CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT

14.10.1 All required measuring and test equipment to be used for acceptance shall be calibrated

directly prior to shipment to the field site and shall bear Calibration Sticker showing the date ofcalibration and the period of validity.

14.10.2 Traceability is provided from the TRAVELER, which records the equipment identification

number of those instruments used for examination and inspection.




FIELD SITES

14.10.3 A copy of the relevant calibration report shall accompany all measuring and test equipment.

14.11.0 AUTHORIZED INSPECTOR

14.11.1 The TITLE OF RESPONSIBLE shall be responsible for the coordination with the Authorized

Inspector at the field location.

14.11.2 A current hard copy of this Quality Control Manual shall be available for use by the AuthorizedInspector at the field location.

14.12.0 RECORDS, MANUFACTURER'S DATA REPORTS, NAMEPLATE AND STAMPING

14.12.1 Records, Manufacturer's Data Reports, Code Stamping & National Board numbers shall behandled in accordance with Section 12 of this Manual.




REPAIRS & ALTERATIONS

15.0 GENERAL

15.0.1 Shop or field repairs and alterations to boilers and pressure vessels, when required by the owner,user, jurisdiction or AIA responsible for in-service inspection of the unit, are made inaccordance with the applicable requirements of the National Board Inspection Code (NBIC);ASME Code and this Quality Control Manual.

15.0.2 Repair - is defined as the work to restore a boiler or pressure vessel to a safe and satisfactoryoperating condition, provided there is no deviation from the original construction.

15.0.3 Alteration - is defined as a change in any item described in the original ASME Manufacturer'sData Report, which affects the pressure containing capability of a boiler or pressure vessel.

15.0.4 Re-rating - a boiler or pressure vessel by increasing the maximum allowable working pressure ortemperature is considered an alteration, provided there is no physical change to the object. Areduction in minimum temperature for a pressure vessel, requiring additional mechanical tests,is also an alteration.

15.1.0 AUTHORITY AND RESPONSIBILITY

15.1.1 The TITLE OF RESPONSIBLE is responsible for compliance with this Quality Control Manual for

shop and field repairs to Code items.

15.2.0 PROCEDURES

15.2.1 All repairs and alterations to Code boilers and pressure vessels are subject to the acceptance ofthe Authorized Inspector, who may require that evidence of acceptance of the method andextent of repair or alteration by the jurisdiction or insurance carrier responsible for the in-service inspection be provided before starting work.

15.2.2 The TITLE OF RESPONSIBLE, prior to the start of work, provides the Authorized Inspector with

drawings, calculations, procedures, TRAVELER, copy of the original ASME Manufacturer'sData Report for the item and any other documents necessary for the Authorized Inspector toaccept the method of repair or alteration and to designate their required inspection points.

15.2.3 For alterations to boilers and pressure vessels, the TITLE OF RESPONSIBLE will provide the

Authorized Inspector with:

a. The Form R-1 Report of Welded Repair or Alteration prepared by the original manufactureror another holder of a valid "S", "U" or "U2" Certificate of Authorization as applicable,certifying that the design changes meet the NBIC and have been verified by theirAuthorized Inspector.

b. Revised calculations.c. For physical changes, Partial Data Reports for welded parts.

15.2.4 For alterations consisting only of re-rating, when revised calculations cannot be obtained from theoriginal manufacturer, they may be prepared by a registered professional engineer, and sentfor review to the jurisdiction at the location of installation, before being presented to theAuthorized inspector.





15.2.5 For Section VIII Div.2 vessels, the TITLE OF RESPONSIBLE verifies that the User or his agent

has prepared a detailed repair plan, which has been reviewed and certified by a registeredprofessional engineer as compatible with the original User's Design Specification andManufacturers Design Report. The repair plan is then submitted to the Authorized Inspectorresponsible for in-service inspection for their review and acceptance, and, when required, tothe jurisdictional authority for approval before start of work.

15.2.6 The TITLE OF RESPONSIBLE, when requested by the Authorized Inspector, arranges for their

access to make all inspections of the vessel they deems necessary in order to accept themethod of repair or alteration.

15.2.7 The TITLE OF RESPONSIBLE, or TITLE OF RESPONSIBLE, keeps the Authorized Inspector

informed of the progress and completion of the work so they may perform their designatedinspections, and accept the repair or alteration after final inspection of the completed work.

15.2.8 All examinations and tests required by the Code for the original construction of the boiler orpressure vessel are required for the repair or alteration, except that if impossible or impractical,alternate methods acceptable to the Authorized Inspector may be used.

15.3.0 RECORDS

15.3.1 The repair or alteration, including a description of the relocation of Code stamping or nameplatewhen performed shall be documented on the current National Board Form R-1, Report ofWelded Repair or Alteration.

15.3.2 When the work is completed, the Form R-1 is prepared and certified in ink by the TITLE OF

RESPONSIBLE.

15.3.3 The final records, together with the completed Form R1 and any Manufacturer's Data Reports,

and for alterations the original Manufacturer's Data Report, are presented to the AuthorizedInspector for their review. When satisfied that all NBIC, Code and Manual requirements havebeen met, they will authorize application of the "R" Symbol to the appropriate NBIC stamping(Exhibit 15) and sign the Form R-1.

15.3.4 All records referenced in this Section are available for review by the Authorized Inspector. TheForm R-1 is distributed as listed in 15.4 below.

15.3.5 If, during the repair or alteration of a boiler or pressure vessel, it is necessary to remove theoriginal Manufacturer's ASME Code stamping or nameplate, the Authorized Inspector will,subject to the approval of the jurisdiction:

a. Witness the marking of a facsimile or rubbing of the old and new stamping.b. Witness obliteration or removal of the old stamping, and transfer of the stamping to the

new part or location on the item, less the original Code Symbol. The Code Symbol is NOTre-stamped.

15.3.6 When the stamping is on a nameplate, the Authorized Inspector witnesses the transfer of thenameplate to its new location.

15.3.7 When a new part is fabricated for inclusion in the repair or alteration, the requirements of Section12 of this Manual apply only to the Code stamping located on the new Part, as required by theCode.





15.3.8 When authorized and witnessed by the Authorized Inspector, the stamping of, or attachment of anameplate to, the repaired or altered vessel adjacent to the original Manufacturer's stampingor nameplate, shall comply with the NBIC and Exhibit 15-1.of this Manual.

15.3.9 The TITLE OF RESPONSIBLE retains custody and control of the "R" stamp as described in

12.3.1 of this Manual. This Symbol is the property of the National Board.

15.4.0 DISTRIBUTION OF FORM R-1

15.4.1 One copy of Form R-1, Report of Welded Repair, with applicable ASME Manufacturer's DataReport attached, is filed with the Authorized Inspection Agency responsible for the in-serviceinspection, when requested a copy is sent to the jurisdiction, one copy sent to the user and acopy retained in the job file.

15.4.2 One copy of Form R-1, Report of Welded Alteration, with the original Manufacturer's Data Reportand applicable Partial Data Report(s) attached, provided to the Authorized Inspector,Authorized Inspection Agency responsible for in-service inspection, the owner/user,jurisdiction, and to the National Board if so requested. A copy is retained in the job file.




EXHIBIT INDEX

Exhibit N° Name Revision Date

2-1 List of Manual Holders 0 Nov. 22, 09

2-2 Manual Transmittal Sheet 0 Nov. 22, 09

4-1 Material Purchase Specification 0 Nov. 22, 09

4-2 Document Transmittal Sheet 0 Nov. 22, 09

5-1 Purchase Order 0 Nov. 22, 09

5-2 Receiving Inspection Report 0 Nov. 22, 09

5-3 Welding Material Purchase Specification 0 Nov. 22, 09

6-1 TRAVELER (Name of Document to control examinations) 0 Nov. 22, 09

7-1 Nonconformity Label 0 Nov. 22, 09

7-2 Nonconformity Report 0 Nov. 22, 09

8-1 ASME Qualified Welders List 0 Nov. 22, 09

8-2 Welders & Operators Retention Record 0 Nov. 22, 09

10-1 List of Calibrated Equipment 0 Nov. 22, 09

10-2 Calibration Sticker 0 Nov. 22, 09

12-1 Nameplate “U” 0 Nov. 22, 09

12-2 Nameplate “U2” 0 Nov. 22, 09

12-3 Nameplate “U3“ 0 Nov. 22, 09

12-4 Nameplate “S” 0 Nov. 22, 09

12-5 Nameplate “PP” 0 Nov. 22, 09



Exhibit: 2-1Page: 1 of 1Revision: 0Date: 22 November 2009

LIST OF MANUAL HOLDERS

TITLE

Edition: Revision: Edition: Revision:MANUALNUMBER

DATESENT

DATERETURNED

DATESENT

DATERETURNED




Manual Transmittal Sheet

TO: DATE: 22-Nov-09

FROM:

Enclosed / Attached is a copy of the new:

Edition N°

Revision N°

PLEASE ACKNOWLEDGE RECEIPT OF THIS MANUAL OR REVISIONS BY COMPLETING THELOWER SECTION OF THIS TRANSMITTAL SHEET AND RETURNING IT TO MY ATTENTIONWITHIN TEN (10) DAYS FOR DOCUMENT CONTROL. YOUR SIGNATURE IS A VERIFICATION OFRECEIPT OF THE NEW DOCUMENT(S) SHOWN ABOVE. THIS FORM MUST BE RETURNEDALONG WITH ANY OBSOLETE QUALITY CONTROL MANUALS, MANUAL SECTIONS OREXHIBITS.

TITLE OF RESPONSIBLE

ACKNOWLEGMENT OF RECEIPT

MANUAL NUMBER:

MANUAL HOLDER (Please print):

MANUAL HOLDER (Signature): DATE:




Material Purchase Specification




Document Transmittal Sheet




Purchase Order




Welding Material Purchase Specification




TRAVELER EXAMPLE (Document used to control examinations)

COMPANY LEGAL NAME

PROJECT:

CLIENT:

JOB N°:

DOCUMENT TITLE: TRAVELER Page 1 of 2

ITEM:

REQUIREMENTS: ASME SECTION VIII DIV. 1, ED. 2001 ADDENDA 2002

SPECIFICATION (CLIENT):

CLIENT

USE

ONLY

CLIENT APPROVAL STATUS1(A) 2(B) 3(C) 4(D)

Signature

Date

1(A) APPROVED (Without comments) � PLEASE PROCEED WITH FABRICATION

1(B) APPROVED (With comments) � PLEASE PROCEED WITH FABRICATION AFTERINCORPORATION OF COMMENTS & RE-ISSUE

3(C) NOT APPROVED � FABRICATION MAY NOT START UNTIL RE-ISSUED & APPROVED

4(D) INDORMATION ONLY � NO FURTHER COMMENTS

APPROVAL REQUIRED YES NO ONLY FOR INFORMATION

Revision Date Revision Description Approved AI Review

JOB N° TRAVELER Page 1 of 2




H = Hold Point

W = Witness Point

R = Document Review

N° DESCRIPTIONAPPLICABLEDOCUMENTS

INSPECTED BY

QC Client AI

A GENERAL

1.0 Review of TRAVELER H H

1.1 Review of Drawings and Calculations H R

1.2 Review of WPS’s, and PQR’s H R

1.3 Review of WPQ’s H R

1.4 Review of NDE Procedures H R

1.5 Review of NDE Operator’s Qualification H R

1.6 Material Identification H R

B NOZZLE PREFABRICATION

2.0 Verification of Material Marking Transfer H R

2.1 Check Fit-up & Tackweld Flange to Pipe N1WPS ?

H W

2.2 Check Fit-up & Tackweld Flange to Pipe N2WPS ?

H

Etc…..

C SHELL FABRICATION

3.0 Review of MTR’s H R

3.1 Verification of Material Marking Transfer H

3.2 Examination of Weld Bevels H

3.3 Check Fit-up & Tackwelding Longitudinal (L1)WPS ?

H

3.4 Visual examination of weld H

3.5 RT of Longitudinal Seam (L1) H R

3.6 Etc…




Nonconformity Label(s)


STOPNo Further Processing

NCR N°: Date:



N o n c o n f o r m i t y R e p o r t Page: 1 of

1. NCR No.

Ident i fy Nonconformance

Descr ipt ion2. Originator: Date:

Org:

3. Item Name: Qty:

4. Drawing / Part / Lot / Serial No:

5. Found During:

7. Actual Condition:

Disposi t ion Nonconformance

Di sposi t ion8. Disposition: Rework To Original Spec.

Scrap

Return to Supplier

Repair

Re-grade

9. Cause Classification: Design

Manufacturing

Supplier

Training

Other (explain) _____________________________________

10. Disposition Rational:

11. Responsible Manager: Signature: Date:

12. Request Waiver Yes Waiver No:

No

13. Disposition Details:

15. Corrective Action Required Yes No 16. CAR No:

Rationale (if yes):

16. Disposition Approved: Signature: Date:

17. Accepted AI (When Required):Signature: Date:

18. Client (When Required): Signature: Date:

Nonconformance D isposi t ion Ver i f ied

Veri f ica t ion 19. NCR Closed: Signature: Date:

20. NCR Closed (AI): Signature: Date:

20. NCR Closed (Other): Signature: Date:




N o n c o n f o r m i t y R e p o r t Page: 2 of

NCR No.

Continuat ion Page




ASME QUALIFIED WELDERS LIST




WELDERS AND OPERATORS RETENTION RECORDL

ast

Nam

e

Fir

st

Nam

e

Pro

ce

ss

Weld

ers

Id

en

tifi

cati

on

Date

Qu

alifi

ed

Qu

alifi

cati

on

Valid

Till

Last

Veri

fic

ati

on

Veri

fied

on

Jo

b N

um

ber

Co

mm

en

ts


This Document is maintained asan Excel Spread sheet and it ispass word protected.



List of Calibrated Equipment

Description Serial N° Frequency ToleranceDate

CalibratedNext

CalibrationRemarks


This Document is maintained asan Excel Spread sheet and it ispass word protected.



Calibration Sticker


Identification N°:Calibration Date:Valid Till:



“U” Nameplate

* When Direct Stamping on item minimum letter size is 8mm


Certified By:Company Legal Name as on CertificateMAWPpsiat°FMDMT°FatpsiManufacturers Serial N°:Year

Built:

National Board Serial Number

*Only When National Board Registered

The required markings on a nameplate shall be in characters not lessthan 5 / 32 in. (4 mm) high, Characters shall be either indented orraised at least 0.004 in. (0.10 mm) and shall be legible and readable.



“U2” Nameplate

* When Direct Stamping on item minimum letter size is 8mm


Certified By:Company Legal Name as on CertificateDesign Pressurepsiat°FMDMT°FManufacturers Serial N°:Year Built:


The required markings on a nameplate shall be in characters not lessthan 5 / 32 in. (4 mm) high, Characters shall be either indented orraised at least 0.004 in. (0.10 mm) and shall be legible and readable.




“U3” Nameplate


Certified By:Company Legal Name as on CertificateDesign Pressurepsiat°FCDMT°FMDMT°FManufacturers Serial N°:Year Built:



The Nameplate shall be corrosion resistant and at least 0.15 inch thick. Thestamping shall be stamped with letters and figures at least 5/8th in. (8 mm) high.



“S” Stamping


Certified By:Company Legal Name as on CertificateMAWPpsiHeating Surface ft²Steaming Capacity:lb/hrYear Built:


The stamping shall be stamped with letters and figures at least 5/8th in. (8 mm)high, directly on the item.




“PP” Stamping


Certified By:Company Legal Name as on CertificateMAWPpsiYear Built:


The stamping shall be stamped with letters and figures at least 5/8th in. (8 mm) high, directly on the item.


51212999 sample qc manual

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