QUALITY CONTROL MANUAL
B and M Industrial Services
6314 Wade Road
Baytown, Texas 77521
QUALITY CONTROL MANUAL FOR THE SHOP FABRICATION AND FIELD ASSEMBLY OF PRESSURE VESSELS IN ACCORDANCE WITH ASME SECTION VIII, DIVISION 1, AND SHOP AND FIELD REPAIRS AND ALTERATIONS IN ACCORDANCE WITH THE NATIONAL BOARD INSPECTION CODE AND JURISDICTIONAL REQUIREMENTS.
Edition: 1
Approval: _____________________________________________________
Quality Control Manager Date
Acceptance: ___________________________________________________
Authorized Inspector Date
Manual control number ______ Assigned to: ______________________
Section: A
Page 1 of 1
Revision: 0
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Table of Contents
Sections:
Cover Page………………………………………..…Rev. 0 Date: 29NOV08
A. Table of Contents………………………………..…..Rev. 0 Date: 29NOV08
1. Statement of Authority………………...………..…..Rev. 0 Date: 29NOV08
2. Organizational Chart……………………………..….Rev. 0 Date: 29NOV08
3. Glossary of Terms…………………………………...Rev. 0 Date: 29NOV08
4. Quality Control Department.....……………...…..….Rev. 0 Date: 29NOV08
5. Authorized Inspector……………………..………....Rev. 0 Date: 29NOV08
6. Drawings, Design Calculations and Specifications....Rev. 0 Date: 29NOV08
7. Material Control……………………………………..Rev. 0 Date: 29NOV08
8. Examination and Inspection Program……………….Rev. 0 Date: 29NOV08
9. Correction of Non-conformities…………………….Rev. 0 Date: 29NOV08
10. Welding Control…………………………………….Rev. 0 Date: 29NOV08
11. Non-Destructive Examination (NDE)……………….Rev. 0 Date: 29NOV08
12. Heat Treating…………………………………………Rev. 0 Date: 29NOV08
13. Calibration of Measurement and Test Equipment……Rev. 0 Date: 29NOV08
14. Records Retention…………………………………….Rev. 0 Date: 29NOV08
15. Registration with the National Board……………… Rev. 0 Date: 29NOV08
16. Repairs & Alterations………………………………...Rev. 0 Date: 29NOV08
17. Exhibits……………………………………………….Rev. 0 Date: 29NOV08
Section: 1
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1. STATEMENT OF AUTHORITY
The Quality Control System of B and M Industrial Services (B&M) shall comply with ASME Section VIII Div. 1 for Code shop fabrication and field assembly, and Repairs and Alterations (Shop and Field) in accordance with the National Board Inspection Code and the Jurisdictional Authority.( B&M) gives the Quality Control Manager the authority, responsibility, and the organizational freedom to identify quality control problems, and to initiate, recommend, and provide solutions. The Quality Control Manager is responsible for the editing of the Quality Control Manual and its compliance.
The Quality Control Manager has the full support of the management of (B&M) to carry out his responsibilities and fulfill his purpose. The Quality Control Manager’s authority and responsibility include both shop and field sites. I shall settle any disagreement between the Quality Control Manager and other departments. Resolutions, when made, shall not compromise the Code or this QC Manual.
________________________________ Date: ____________
President
Section: 3
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3. GLOSSARY OF TERMS
ASME
3.1 The American Society of Mechanical Engineers
ASME CODE
3.1 The Boiler & Pressure Vessel Code published by the ASME, including addenda and Code Classes approved by the council of that society.
ASME STAMP
3.2 The symbol issued by the ASME for stamping pressure vessels and Code parts.
AUTHORIZED INSPECTOR (INSPECTOR)
3.3 The Authorized Inspector shall be an Inspector regularly employed by an ASME accredited Authorized Inspection Agency, i.e. the inspection organization of a state or municipality of the United States, a Canadian province, or an insurance company authorized to write boiler and pressure vessel insurance. The Inspector shall not be in the employ of the Manufacturer. All Inspectors shall have been qualified by a written examination under the rules of any state of the United States or province of Canada, which has adopted the ASME Code and with whom B&M has a contract.
AUTHORIZED INSPECTION AGENCY (AIA)
3.4 An insurance company which has been licensed or registered by the Authority of a State of the United States or Province of Canada to write Boiler or Pressure Vessel Insurance in such a state or province, and accredited by the ASME and with whom has a contract (B&M).
BILL OF MATERIALS (BOM)
3.5 Drawing field that lists material, material specifications and standards to be used.
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CODE
3.6 The ASME Boiler and Pressure Vessel Code, including addenda and Code cases approved by the council of the ASME.
COMPANY
3.7 B and M Industrial Services (B&M )
DEPARTMENT
3.8 Where Department is used in this manual, the responsibility is assigned to the person in charge of that Department and its activity.
MAWP
3.9 Maximum Allowable Working Pressure.
MDMT
3.10 Minimum Design Metal Temperature
MTR
3.11 Mill Test Reports, or Material Test Reports
NATIONAL BOARD
3.12 The National Board of Boiler & Pressure Vessel Inspectors
NDE
3.13 Nondestructive Examination.
NON-CONFORMITY
3.14 Any condition existing in raw material, work in progress, or finished product that does not comply with drawings, specifications, Code, (B&M) standards, Jurisdictional requirements and procedures and this Quality Control Manual.
PQR
3.15 Procedure Qualification Record
Section: 3
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PWHT
3.16 Post Weld Heat Treatment
QCM or QC MANAGER
3.17 Quality Control Manager
QC INSPECTOR
3.18 Quality Control Department Shop/Field Inspector
S/N
3.19 Serial Number
SNT-TC-1A (Latest Code Accepted Edition and Addenda)
3.20 American Society of Non-Destructive Testing. A set of guidelines to assist the manufacturer in developing uniform procedures for the qualification and certification of the NDE personnel.
CODE ITEM
3.21 Any pressure vessel or part that is manufactured to the ASME Code.
WPS
3.22 Welding Procedure Specifications.
Section: 4
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4. QUALITY CONTROL DEPARTMENT
4.1 The Quality Control Manger is responsible for preparation, revision, approval, distribution, control, and implementation of the Quality Control System Manual.
4.2 All in-house examinations conducted by B&M Personnel, are conducted in accordance with this manual and approved inspection procedures when required.
4.3 All Code editions and addenda will be reviewed, within six months of their issue, for impact on QC Manual requirements. Initials and date by QCM on the edition or addenda cover sheets will document this review. Revisions will be made by section, except exhibits, which will be revised by page. Any revision to the manual will be presented to the Authorized Inspector for his acceptance prior to implementation. Quality Control Manager approval & Inspector acceptance of each revision will be documented on the cover page.
4.4 The Inspector will have access to a controlled copy of the Quality Control Manual in the shop or field location.
4.5 The QCM has custody of the Code Symbol Stamps and controls their use. The Code Symbol Stamp may be applied only with the concurrence of the Inspector.
4.6 The QCM heads the Quality Control Department and is responsible for performance of required examinations and tests. He, or his designee, will prepare and review the Traveler (Exhibits 2) or Repair Plan (Exhibit 3) and prepare and sign the Manufacturer’s Data Report or National Board “R” Form.
4.7 Controlled Quality Control System manuals and revisions are issued by the QCM. Authorized personnel will be issued controlled manuals, documentation of issued manuals will be noted on the QC Manual Issue Log (Exhibit 1). Uncontrolled manuals, stamped uncontrolled, will be issued to clients, or anyone else who requests one, and no updates will be provided.
Section: 5
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5. AUTHORIZED INSPECTOR
5.1 The QCM is the Company Liaison with the Authorized Inspector.
5.2 The Inspector and his Supervisor shall have free access to the premises of (B&M) for the surveillance of records, specifications, design drawings, calculations, procedures and other documents relating to Code fabrication and inspection of materials, parts and appurtenances, and to field sites where ASME Code work is in progress. The Inspector has the right of visiting any vendor or supplier of materials, parts and service that he deems necessary to satisfy inspection requirements of such materials, parts and service.
5.3 A controlled copy of the Quality Control Manual is provided for use by the Inspector at all shop and field locations.
5.4 Any non-conformity requiring Inspector acceptance is referred to him for his concurrence of proposed resolution.
5.5 The Quality Control Manager will contact the Inspector sufficiently in advance of upcoming hold points.
Section: 6
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6. DRAWINGS, DESIGN CALCULATIONS AND SPECIFICATIONS
6.1 Engineering Manager will perform the review of customer’s calculations, specifications and drawings to assure Code compliance can be attained.
6.2 Each Code item is given a S/N. S/N’s are listed in a Serial Number and National Board Number Log to avoid duplication (Exhibit 4).
6.3 Design Calculations may be prepared in-house, subcontracted, or supplied by the customer. Engineering Manager will check all design calculations for Code compliance. Calculations are based on allowable stress listed in ASME Section II, Part D, for use by the applicable construction Code.
6.4 Drawings may be prepared in-house, subcontracted, or supplied by the customer. Specifications on drawings shall include NDE requirements, post weld heat treat requirement, maximum allowable working pressure, design pressure, design temperature, MDMT at corresponding pressure, test pressure, material specifications (BOM), serial number, welding procedures, and name plate information, Code edition and addenda with construction tolerances.
6.5 The Engineering Manager specifies materials to be used in Code fabrication. Materials are specified as SA, SB, SFA, or AWS. The Engineering Manager shall note the need for MTR’S or any other special ordering requirements on the BOM.
6.6 Drawings, Specifications and Design Calculations , whether in-house, subcontracted, or supplied by the customer, must be reviewed and approved by the Engineering Manager. His initial and date will be noted on the first page of the drawings and calculations.
6.7 The Engineering Manager is responsible for maintaining a log of drawings and changes to those drawings. The Engineering Manager shall maintain a copy of all drawings and drawing changes.
6.8 The QCM reviews all drawings and calculations with the Inspector, Prior to the start of fabrication, so that the inspector may designate on the Traveler his required inspection points.
Section 6
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6.9 The QCM keeps two sets of prints and hand carries one set of prints to the Shop/Field Supervisor for shop work. Old Prints are collected and destroyed after exchanging them for new prints.
6.10 Distribution of prints is the responsibility of the QCM. Upon receipt of prints from Engineering, an appropriate number of sets are distributed to the applicable departments.
6.11 Any revision or change to the drawings will be handled as the originals.
6.12 Engineering for field jobs shall be handled in the same manner as shop jobs, and by the same personnel.
6.13 Access to computer programs (if used) for mechanical design calculations or stress and fatigue analysis shall be only through the Engineer Manager. Before computer programmed results are used. The Engineer Manager shall have the accuracy of the original programs and their revisions checked by manually calculated test problems. The accuracy shall be demonstrated to the satisfaction of the Inspector. The Engineer Manager shall review each Code edition and addenda for impact upon design programs and assure the design program is accurate for edition and addenda in use. The design programs shall conform to any and all changes in the Code.
6.14 All documentation used for Code work in the field shall be forwarded using a Transmittal Form (Exhibit 5).
Section: 7
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7. MATERIAL CONTROL
MATERIAL REQUISITION
7.1 The Engineering Manager shall prepare and check all Bills of Material, except for welding materials which are requisitioned by the Shop/Field Supervisor.
7.2 The Bill of Material shall be located on the drawing and shall include the following:
7.2.1 Material Specifications using the appropriate “SA” or “SB”, SFA or AWS specifications.
7.2.2 Material Type.
7.2.3 Number of pieces.
7.2.4 Notes listed by number for special requirements of the Construction Code.
MATERIAL PURCHASING
7.3 The Purchasing Manager shall prepare a Purchase Order (Exhibit 6) with information, including all notes as shown on the Bill of Material. Any material change must have prior approval by the Engineering Manager, QCM and acceptance of the Inspector.
7.4 A copy of the Purchase Order will be sent to QC for Code compliance, and placed in the job file.
7.5 When purchasing parts that have been fabricated by welding, a Manufacturer’s Partial Data Report with partial stamping will be supplied as required by Code.
7.6 When ordering cold formed carbon and low alloy materials, certification to the requirements of paragraph UCS-79 and UHA-44 Section VIII, Division 1 shall be requested, as applicable.
7.7 Material for field work will be procured in the same manner as for shop work.
CUSTOMER FURNISHED MATERIAL
7.8 Customer furnished material will be handled in the same manner as material purchased by the company, upon receipt and throughout fabrication.
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RECEIVING INSPECTIONS
7.9 Upon receipt of material Quality Control will be notified.
7.10 Upon notification of receipt of material, the Quality Control Inspector shall perform the following physical inspection.
7.10.1 Check surfaces and edges for visible defects.
7.10.2 Check for dimensions and forming tolerances.
7.10.3 Check Heat Numbers and document on Receiving Inspection Report (Exhibit 7).
7.10.4 Check materials to the Purchase Order for requested special requirements and/or Documentation.
7.10.5 Materials ordered for a specific repair or Code item shall be marked with the Job Number or Serial Number when received. Small items shall be placed in a container marked with the Job Number or Serial Number.
7.11 The Quality Control Inspector shall record the results of the above inspection on the Receiving Inspection Report (Exhibit 7), and file in the job file.
7.12 The QC Inspector indicates on the Receiving Inspection Report at this time if material is acceptable. Receiving Inspection Report is forwarded to QCM for review and sign off indicating release for fabrication.
DOCUMENTATION VERIFICATION
7.13 The QC Inspector shall verify the MTR as follows:
7.13.1 Check Material Heat Number against heat Numbers on MTR.
7.13.2 Check Chemical and Physical properties against specifications in Section II of ASME Code
7.13.3 After checking MTR to ASME Section II, QC shall sign and date.
7.14 The QC Inspector shall record job and or the serial number on MTR for traceability to vessel.
7.15 The QCM shall file the MTR in the job file.
Section: 7
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MATERIAL IDENTIFICATION
7.16 Prior to cutting materials, the required material markings will be transferred to the part to be cut or a documented coded marking system, acceptable to the Inspector, may be used.
NON-CONFORMITY
7.17 Non-conformities found in material receiving will be controlled as outlined in this Quality Control Manual.
FURTHER MATERIAL TESTING
7.18 If further material testing is required to be performed at receiving inspection or during manufacturing operations, the QCM will subcontract the required testing, and must review and approve test results prior to final certification of the Code item. QCM approval will be by initials and date on the test report.
Section: 8
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8. EXAMINATION AND INSPECTION PROGRAM
DUTIES OF QUALITY CONTROL MANAGER
8.1 The QCM shall be responsible for in process examination and acceptance or rejection of fabrication.
DUTIES OF ENGINEER
8.2 Engineering Manager shall inform the QC Manager and Shop/Field Supervisor of any Engineering change.
DUTIES OF SUPERVISOR
8.3 The Shop/Field Supervisor is responsible for the overall quality of the fabricated item and for job progress notification to the QCM for inspection and examination purposes.
EXAMINATIONS
8.4 The QC Inspector shall be responsible for but not limited to the following examinations and verifications for conformance to Code requirements:
8.4.1 Weld Procedure Specifications, Procedure Qualification Record, and Welder performance Qualifications.
8.4.2 Fit-up Examination to include edge preparation, fitting of edges on longitudinal seams, girth seams, heads, nozzles, and pipe. NOTE: Fit-up examinations are performed after components have been tacked in place, and prior to root pass.
8.4.3 Root Pass Examination to include weld penetration.
8.4.4 Finished Weld Examination to include the weld size, weld appearance and welder’s symbols
8.4.5 Perform any other required examination for completed quality product.
8.5 The QC Inspector shall record the above examinations on the Traveler.
FINAL CHECKS
8.6 The Inspector will witness the pressure testing of all ASME items
in the presence of the QC Inspector.
8.6.1 The Code Symbol stamp shall be applied only on concurrence of the Inspector.
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8.6.2 The Manufacturer’s Data Reports shall be prepared, checked and signed by the QCM or his designee prior to presenting to the Inspector for his review, acceptance and signature.
8.6.3 The QCM shall check the nameplate or stamping information for correctness prior to the application of Code Stamps.
8.6.4 Responsibilities for field work and examination are identical to shop work and examination.
8.6.5 All material for field site work will be received and processed at the shop location prior to transfer to field.
8.6.6 When received at field site all materials will be examined for damage due to transit.
8.6.7 Any damages will be handled as a non-conformity.
Section: 9
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9. CORRECTION OF NON-CONFORMITIES
NON-CONFORMING (MATERIAL)
9.1 The QCM shall notify the Shop/Field Supervisor in the event non-conforming material is received. Identification of Non-Conforming Material and generation and processing of Non-conformance Reports, (Exhibit 10) shall be as described in 9.5.
9.2 The QCM shall Chair a Material Review Board consisting of the following members:
9.2.1 Purchasing Department Representative
9.2.2 Engineering Department Representative
9.2.3 Shop/Field Supervisor
9.3 Based on the findings of the Material Review Board, the non-conforming material will be repaired or replaced by the Company, or returned to the Vendor or used as-is.
9.4 Material to be used as-is shall have the concurrence of the Inspector. Material to be repaired by welding shall have the concurrence of the Inspector.
NON-CONFORMITY (FABRICATION)
9.5 Any time a non-conformity deviation is noted, a Hold Tag (Exhibit 9) will be filled out and placed on the non-conforming component, and a Non-Conformance Report (Exhibit 10) will be initiated by the QC Inspector. The Non-Conformance Report will then be forwarded to the QCM who is responsible for determining an acceptable course of action.
9.6 Where repair by welding is required to correct a deviation in design or fabrication, the QCM will determine the welding procedure to be used, and AI concurrence must be obtained for the method and extent of repair.
9.7 When a repair procedure has been devised by the Engineering Manager and reviewed by the QCM, then it will be presented to the Inspector for his acceptance prior to commencing work.
9.8 The QCM is primarily responsible for resolution and disposition of all problems that may arise.
9.9 The Inspector is included in the proposed resolution and final disposition of all Non-Conformities.
Section: 9
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9.10 Records concerning non-conformities shall be kept in the job file of each Code item.
9.11 Discrepant parts and/or materials are tagged with a Hold Tag.
9.12 After repairs have been completed and accepted by the Inspector, the QCM will remove the Hold Tag.
9.13 Non-conformities shall be handled in the same manner for both shop and field.
Section: 10
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10. WELDING CONTROL
WELDING PROCEDURES
10.1 All Welding Procedures Specifications are written and non-essential variables revised, when required, by the QC Manager. A Welder is assigned by the Shop/Field Supervisor to weld a test specimen using the variables of the specification as a guide. This coupon is tested by a qualified testing laboratory in accordance with ASME Section IX with additional requirements of the applicable Code section to which work is performed and a Procedure Qualification Record filled out and certified by the QCM.
10.2 Written Welding Procedure Specifications and Procedure Qualification Records for each process to be performed are maintained by the QCM of D&R and filed at the shop location. Field sites are issued the applicable WPS to use.
WELDER QUALIFICATIONS
10.3 Prior to any welding on a Code item, the welder or welding operator shall pass a welder qualification test in accordance with the Process to be used, and Section IX of the ASME Code. If he passes his test a Welder Performance Qualification Record Form is filled out and certified by the QCM.
10.4 Written Welder Qualification Forms are kept on file and maintained by the QC Manager.
10.5 A Welder Continuity Log (Exhibit 11) will be initiated and maintained by the QCM. This log will be updated by the QCM, at least every three months to assure the welder’s continuity. Welders or Welding Operators who have not welded with a specific process for 6 months shall be required to re-qualify for that process.
10.6 The Inspector may require re-qualification of procedures, welders or welding operators.
Section: 10
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PROCEDURE ASSURANCE
10.7 The Welding Procedure(s) to be used on a job are indicated on the approved design drawing.
10.8 The QCM and Shop/Field Supervisor will monitor the welding to assure the correct procedure is being used during fabrication utilizing only qualified welders / welding operators.
WELDER IDENTIFICATION
10.9 The QC Manager is responsible for issuing the Welders and Welding Operator’s unique symbol(s).
10.10 The QCM shall record the symbol of the welder on the Traveler and the Welder shall apply his stamp to each three (3) feet or less of weld, when required, or a Weld Map will be used.
10.11 Welder symbols for terminated employees shall not be re-issued for a period of one year after termination date.
WELDING MATERIAL CONTROL
10.12 The Shop/Field Supervisor may order verbally or with a written Purchase Order. The QCM will check welding material upon receipt by reviewing the receiving tickets.
10.13 The Shop/Field Supervisor shall supervise the distribution and storage of all welding materials.
10.14 All open cans of low Hydrogen Electrodes shall be maintained in a heated oven. No more than four, (4) hour supply will be issued at one time. All unused, low Hydrogen Electrodes will be turned in to the Shop/Field Supervisor at the end of the shift or four (4) hours, whichever is less. Electrodes shall be stored in a temperature controlled area as recommended by the Manufacturer or ASME Section II, Part C.
10.15 Welding material storage and use for field work is the responsibility of the Shop/Field Supervisor. Storage and use is monitored by QCM the same as in the shop.
Section: 10
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TACK WELDS
10.16 All D&R tack welds shall be applied by a Welder Qualified to a Qualified Welding Procedure in accordance with Section IX of the ASME code. Tack welds made by a vendor shall be removed. Vendor must supply copy of WPS used for tacks to B&M and this WPS must be qualified in accordance with ASME Section IX, or a qualified WPS may be provided to the vendor by B&M
10.17 All tack welds shall be inspected and feather-ground prior to enclosure and final welding all welds. If tack weld is found defective, it will be removed. All vendor tack welds will be removed.
WPS QUALIFICATIONS FOR TEST
10.18 The QCM shall be responsible for preparing the Welding Procedures Specification and Procedure Qualification Record in accordance with ASME Code Section IX.
TRAINING AND SUPERVISING
10.19 The Shop/Field Supervisor shall be responsible for training and supervision of all welders and welding operators.
Section: 11
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11. NON-DESTRUCTIVE EXAMINATION (NDE)
RESPONSIBILITY
11.1 All NDE requirements shall be determined by the Engineering Manager and recorded on the drawing. They shall be in accordance with the Applicable ASME Code section with respect to design conditions.
11.2 All NDE examinations shall be subcontracted to NDE Subcontractors.
11.3 The NDE subcontractor’s Level III shall be appointed by letter to act as B&M ’s Level III for RT, UT, MT, PT, VT by the QCM.
11.4 NDE examinations shall be performed by Level II or Level III personnel. All subcontracted NDE personnel shall be qualified and certified in accordance with the latest Code accepted edition and addenda of SNT-TC-1A.
NDE PROCEDURES
11.5 All subcontracted NDE procedures will be written by a Level III and shall comply with the applicable Code section, They shall be reviewed and approved by the QCM.
11.6 All NDE procedures must be demonstrated as being capable of producing meaningful results to the satisfaction of the Inspector.
ACCEPTANCE
11.7 Acceptance criteria for NDE examinations shall be in accordance with the applicable section of the ASME Code.
NDE TEST REPORTS
11.8 All subcontracted NDE reports must bear the signature of the Level II or Level III interpreter and the date.
11.9 All NDE reports, including radiographic film, shall be reviewed and accepted by the QCM and then presented to the Inspector for his review.
11.10 Viewing equipment and a calibrated film density strip shall be made available to the Inspector.
Section: 11
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QUALITY CONTROL MANAGER
11.11 The QCM shall make copies of all NDE written practices, procedures, and personnel qualifications available to the Inspector.
RE-QUALIFICATION
11.12 The Inspector may require re-qualification of NDE personnel or procedures.
NDE AT FIELD SITE
11.13 NDE at field site is the responsibility of the QCM and will be conducted in accordance with this manual. Records shall be maintained at the shop location.
Section: 12
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12. HEAT TREATING
HEAT TREATING REQUIREMENTS
12.1 All Heat Treatments, required by ASME Code or Customer Specification shall be indicated on the drawings. Heat treatment will be performed in accordance with written procedures. The written procedures shall be prepared and approved by the Engineering Manager and written in accordance with the applicable ASME Code with respect to design conditions. The heat treatment procedure will be issued a number which will be noted on the drawings. All heat treatment will be Subcontracted.
HEAT TREAT PROCEDURE
12.2 The heat treatment procedure shall require that the subcontractor furnish records that show the following:
12.2.1 Strip chart containing heating, holding and cooling times and temperatures.
12.2.2 Identification of items heat treated.
12.2.3 Name of the heat treatment firm.
12.2.4 Date of the heat treatment.
12.2.5 Signature of responsible official of heat treating firm on chart.
12.2.6 Copy of heat treat recording instruments calibration certification.
12.2.7 Map of thermocouple locations.
RECORDS
12.3 The QCM will review all heat treatment records.
12.4 The heat treatment records shall be made available to the Inspector. Thermocouples shall be used to assure that metal temperature rather than furnace temperature is recorded.
Section: 12
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HEAT TREATING, FIELD SITE
12.5 Heat treatment required for field sites will be the responsibility of the Engineering Manager. The QCM in conjunction with the Shop/Field Supervisor will be responsible to see that the heat treatment is performed in accordance with approved procedures.
12.6 QC Manager has the responsibility of monitoring heat treatment facilities to assure that thermocouples are placed at intervals provided by the Code, and that proper equipment is used.
12.7 Prior to heat treatment, Quality Control will stamp the item’s serial number in the area of the name plate or Code stamping. Upon return from heat treatment, the item will be inspected for damage and identification by the QCM.
Section: 13
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13. CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT
RESPONSIBILITY
13.1 The QCM shall be responsible for the calibration and storage of measuring and test equipment and for maintenance of the Calibration Record (Exhibit 12)
13.2 Calibration of subcontracted equipment is the responsibility of the subcontractor. Documentation shall be reviewed and approved by the QCM prior to use.
CALIBRATION
13.3 All calibrations are to the appropriate National Standards where such standards are in existence.
13.4 All test gauges shall be calibrated at any time there is a reason to believe they are in error
13.4.1 All hydraulic test gauges shall be serialized
13.4.2 Indicating Pressure Gauges used in testing shall have dials graduated over a range of about double the intended maximum test pressure, but in no case shall the range be less than 1 ½ times or greater than 4 times that pressure.
13.5 Other equipment, if used for Code acceptance, shall be calibrated annually or according to manufacturer’s test requirements.
13.6 The Inspector may require recalibration of equipment if he has reason to doubt its accuracy.
STORAGE
13.7 All test equipment shall be stored by the QCM or his designee.
Section: 14
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14. RECORDS RETENTION
RESPONSIBILITY
14.1 It is the responsibility of the QCM to initiate a job file at the start of a job and collect the following data and maintain through-out fabrication. This data shall be available to the Inspector; including but not limited to:
14.1.1 Calculations, drawings Bill of Materials and Purchase Orders.
14.1.2 Receiving Inspection Reports.
14.1.3 Material Test Reports, Manufacturer’s Partial Data reports, and/or Certificate of Compliance when required.
14.1.4 Non-Conformance Report (if applicable).
14.1.5 Heat treatment charts (if applicable).
14.1.6 Hardness test results (if applicable).
14.1.7 RT Film, Reader Sheets, NDE Reports (and NDE location map when applicable)
14.1.8 Charpy V-Notch test results (if applicable).
14.1.9 Traveler/Repair Plan.
14.2 It is the responsibility of QCM to prepare, review, certify and distribute the Manufacturer’s Data Report and NBIC Form R 1 thru 4 according to the applicable Code and Jurisdiction requirements.
PERMANENT RECORDS
14.3 The Manufacturer’s Data Report, if not registered with the National Board, will be filed for a minimum of 5 years. UT Reports, RT Film Reader Sheets, and location maps shall be retained for the retention periods required by the Code.
14.4 R-forms not registered with National Board will be maintained on file for a minimum of 5 years.
Section: 15
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15. REGISTRATION WITH THE NATIONAL BOARD
15.1 National Board serial numbers shall be controlled and issued by the QCM. He shall maintain a Serial Number and National Board Number Log (Exhibit 4) showing date issued, description of the Code item, and manufacturer’s serial number. The QCM shall submit to the National Board an original copy of all Manufacturer’s Data Reports required for the Code stamped items within a period of 60 days after the Inspector’s signature. National Board numbers shall begin with the number 1 and shall continue without skips, gaps, or omissions.
Section: 16
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16. REPAIRS & ALTERATIONS
DEFINITIONS OF SOME TERMS USED IN THIS SECTION:
ALTERATION
16.1 Any changes in the item described on the original Manufacturer’s Data Report which affects the pressure containing capability of the pressure retaining item. Non-physical changes such as an increase in the MAWP (internal or external), or design temperature of a pressure retaining item shall be considered an alteration. A reduction of the MDMT shall be considered an alteration.
AUTHORIZED INSPECTION AGENCY (AIA)
16.2 An AIA shall be either a jurisdiction or an insurance company, which meets the requirements as defined in the National Board Inspection Code.
JURISDICATION OR JURISDICTIONAL AUTHORITY
16.3 A Governmental Entity, which administers and enforces one or more sections of the ASME Code, one of which shall be Section I (Power Boilers).
INSPECTOR
16.4 An individual who holds a valid and current National Board Commission.
ORIGINAL CODE OF CONSTRUCTION
16.5 Documents promulgated by recognized National Standards writing bodies that contain technical requirements for construction of pressure retaining items or equivalent to which the pressure retaining item was certified by the original manufacturer.
REPAIR
16.6 The work necessary to restore pressure retaining items to a safe and satisfactory operating condition.
RE-RATING
16.7 See Alteration.
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NON-CODE ITEMS
16.8 A pressure retaining item which was not designed or constructed to any code of construction or an item which was designed in accordance with the ASME Code but not inspected, certified, and stamped with the Code symbol.
ROUTINE REPAIRS
16.9 Those repairs listed and defined in the NBIC as “Acceptable routine repairs”.
NBIC
16.10 National Board Inspection Code.
16.10.1This section defines the requirements established for repairs and alterations as
defined by the National Board Inspection Code (NBIC).
16.10.2Repairs and alterations to ASME Code items, shall be carried out in
accordance with NBIC requirements (when applicable) and shall conform to
applicable sections of the ASME Code.
16.10.3 Repairs and alterations to Non-Code items, shall be carried out in accordance
with NBIC requirements (when applicable) and shall conform, insofar as
possible, to the most applicable code of construction.
16.10.4Routine Repairs shall be carried out on ASME Code items only. Routine Repairs to ASME Code items, shall be carried out in accordance with the requirements of
the NBIC, conform to the applicable ASME Code section; however, the
requirement for in-process conditions are met:
16.10.4.1B and M Industrial Services shall verify, to the satisfaction of the
Inspector, that routine repairs are acceptable to the jurisdiction.
16.10.4.2Prior approval for routine repairs shall be obtained from the Inspector.
16.10.4.3Routine repairs shall be documented on a Form “R-1” with a statement on Line 10, remarks “Routine Repair”.
16.11 The Quality Control Manager shall assume overall responsibility for the performance of repairs and alterations and for originating the construction procedures necessary to direct the course of the work.
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16.12 The method of repair or alteration shall be made available to the Authorized Inspection Agency (AIA) responsible for the in-service inspection of the item or the AIA of record.
16.12.1 The Quality Control Manager will present to the Inspector a proposed Repair Plan (Exhibit 3) for the method and extent of repairs or alterations for acceptance. If applicable, drawings and calculations shall also be made available.
16.12.2 Under no circumstances shall work be started without authorization of the Inspector. The Inspector making the acceptance inspection should be the same Inspector who authorized the repairs or alteration, but in all cases, shall be an employee of the same organization as that of the Inspector that authorized the repair or alteration.
16.13 Re-rating of a pressure retaining item shall only be preformed on ASME Code stamped items and only after the following requirements have been met to the satisfaction of the jurisdiction at the location of the installation.
16.13.1 Revised calculations verifying the new service conditions shall be prepared in accordance with this Quality Control Manual.
16.13.2 All re-ratings shall be established in accordance with the ASME Code Section for the original construction.
16.13.3 Verify that the condition of the pressure retaining item is satisfactory for the proposed service.
16.13.4 The pressure retaining item has been pressure tested, as required for the new service conditions.
16.14 Design engineering shall conform to the requirements of this Quality Control Manual and NBIC.
16.15 Materials used in making repairs and alterations shall conform to the applicable section of the ASME Code, or for non-code items the construction standard most applicable to the work.
16.15.1 If B&M provides the materials, the procurement, inspection, and handling of materials shall be in accordance with the applicable section of this manual.
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16.15.2 If the materials are provided by others, sufficient documentation and material identification shall be provided for acceptance of the material by D&R and the Inspector. Receiving Inspection and handling of these materials shall be in accordance with the applicable sections of this manual.
Pressure Parts for which ASME Manufacturer’s Partial Data Reports are required shall be fabricated and inspected to the applicable Code, stamped with the appropriate Code symbol & the word “PART”, and reported on the applicable Manufacturer’s Partial Data Report. When such parts are a part of the repair or alteration, the Manufacturer’s Partial Data Report shall be reported on the forms “R-1” or “R-2”, as applicable, and attached thereto.
When the original code of construction is other than ASME, replacement parts subject to internal or external pressure, fabricated by welding, shall be manufactured by an organization certified as required by the original code of construction. Certification to the original code of construction as required by the original code of construction or equivalent shall be supplied with the item. When this is not possible or practicable, the organization fabricating the part may have a National Board Certificate of Authorization. Replacement parts shall be documented on Form R-3 and the “R” symbol stamp applied as described in Appendix 2.
16.16 All welding, nondestructive examination (NDE), and heat treatment (HT), as required, shall be in accordance with the NBIC, the ASME Code, and the applicable sections of this Quality Control Manual.
16.17 Pressure Tests shall conform to the requirements of the NBIC and will be witnessed by the Inspector. B&M is responsible for all activities relating to the pressure testing.
16.17.1 Repairs shall be pressure tested as required by the NBIC.
16.17.2 Alterations (Re-rating) shall be pressure tested as required by the NBIC.
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16.18 When a repair or alteration requires the removal of that part of the item bearing the original Code stamping, the Inspector shall subject to the approval of the Jurisdiction witness the making of a facsimile of the stamping, the obliteration of the old stamping, and the transfer of such stamping to the new item. The ASME Code symbol is not to be re-stamped. When the stamping is on a nameplate, the Inspector shall witness the transfer of the nameplate to the new location.
Any relocation is to be reported on the applicable NBIC Report Form
16.19 The Quality Control Manager shall be responsible for the custody and use of the National Board “R” Repair Symbol stamp.
REPAIR, ALTERATION, or RE-RATING stamping or nameplate information, size location, and attachment (nameplate) shall conform to the requirements of the NBIC and will only be applied with the concurrence of the Inspector. See Stamping and Nameplate Information (Exhibit 8).
16.20 A copy of the original Manufacturer’s Data Report for the item being altered or re-rated shall be required and attached to the completed form “R-2”. When this is not possible, agreements on the method of establishing design basis for the alteration shall be obtained from the Inspector and the jurisdiction.
16.21 The Quality Control Manager or his designee shall initiate the applicable NBIC Report Form and sign the applicable Certification before presenting it, together with all supporting documentation, to the Inspector for review and signature.
Distribution of the applicable NBIC Report Forms is the responsibility of B&M and shall be performed by the Quality Control Manager as follows:
Repairs- Legible copies of the form “R-1”, together with all required attachments, shall be distributed to the owner or user, the Inspector, the AIA responsible for the in-service inspection of the item, and the Jurisdiction (if required). The Form “R-1” may be registered with the National Board in accordance with the NBIC.
Alterations and Re-Ratings- Legible copies of the form “R-2”, together with all required attachments, shall be distributed to the Inspector, the AIA responsible for the in-service inspection of the pressure retaining item, the owner or user, and the Jurisdiction (if required).
If the item is registered with the National Board, the Form “R-2” shall be registered with the National Board in accordance with the NBIC. If the item is not registered with the National Board, the Form “R-2” may be registered with the National Board in accordance with the NBIC.
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16.22 When the “form R” Report is to be registered with the National Board, the Quality Control Manager shall be responsible for assigning “Form R” Number to each repair or alteration in sequential order at or prior to the time of final Acceptance. He shall keep a FORM R NUMBER LOG (Exhibit 13) of all numbers issued, there will be no missing or repeating numbers. The log shall show the Job Number, indicate whether it is a repair or an alteration, the date issued, and the “Form R” Number assigned. He will send the original “Form R” Report to the National Board for each item so registered within 60 days of final certification.
16.23 Revisions to the Quality Control Manual shall have the acceptance of the Inspector prior to issuance of the manual and implementation.
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17. EXHIBITS REV DATE
1. QC Manual Issue Log 0 29NOV08
2. Traveler 0 29NOV08
3. Repair Pl 0 29NOV08
4. Serial Number and National Board Number Log 0 29NOV08
5. Transmittal Form 0 29NOV08
6. Purchase Order 0 29NOV08
7. Receiving Inspection Report 0 29NOV08
8. Stamping and Name Plate Information 0 29NOV08
9. Hold Tag 0 29NOV08
10. Non-Conformance Report 0 29NOV08
11. Welder Continuity Log 0 29NOV08
12. Calibration Record 0 29NOV08
13. Form “R” Number Log 0 29NOV08
