Pressure Vessel Quality Manual 2

Printed copies of this manual are Uncontrolled

Hardy Machine & Design, Inc.

5737 Windfern

Houston, Texas 77041

QUALITY CONTROL MANUAL

ASME U STAMP

FOR

PRESSURE VESSELS

MASTER COPY

February 23, 2004

Hardy Machine & Design, Inc. February 23, 2004

Quality Assurance Manual Page 1 of 47

Printed copies of this manual are Uncontrolled Rev. 1


REVISION SHEET

REV DATE DESCRIPTION BY CHECKED

Q.A.M Approved By: ____________________ Date: ____________________

A.I. Accepted By: ____________________ Date: ____________________





Table of Contents

1. GLOSSARY .................................................................................................................................. 3

2. STATEMENT OF POLICY AND AUTHORITY ..................................................................... 7

3. MANUAL CONTROL ................................................................................................................. 8

4. DRAWING, DESIGN CALCULATIONS AND SPECIFICATION ........................................ 9

5. MATERIALS CONTROL ........................................................................................................ 12

6. EXAMINATION AND INSPECTION PROGRAM ............................................................... 14

7. CORRECTION OF NONCONFORMITIES .......................................................................... 18

8. WELDING CONTROL ............................................................................................................. 20

9. NON DESTRUCTIVE EXAMINATION - NDE ..................................................................... 25

10. POSTWELD HEAT TREATMENT ........................................................................................ 27 28

11. CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT .................................... 29

12. RECORDS RETENTION ......................................................................................................... 30

13. AUTHORIZED INSPECTOR .................................................................................................. 31

14. ANNUAL AUDIT ....................................................................................................................... 33

15. CONTROL OF CODE STAMP ................................................................................................ 34

16. ORGANIZATIONAL CHART ................................................................................................. 35

17. NATIONAL BOARD OF REGISTRATION ........................................................................... 36

18. EXHIBITS .................................................................................................................................. 37

Q.A.M Approved By: ____________________ Date: ____________________

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A.I. Accepted By: ____________________ Date: ____________________

1. GLOSSARY

As used in the quality Control Manual, the following terms and abbreviations are defined:

AI

Authorized Inspector from the ASME accredited Authorized Inspection Agency for Code

items.

Approve

Signature/initials including date of acceptance as being in compliance with Code and

Client Requirements.

ASME

American Society of Mechanical Engineers

ASNT

American Society for Nondestructive Testing

Code

The Applicable Codes and Standards to which work is being performed. This may be the

ASME Boiler and Pressure Vessel Code, Sections I, V, VIII DIV. 1 and IX and associated

ANSI Standards or Local Jurisdictional codes also National Board requirements.

Client

The contract requirements supplied by the Client to which Hardy Machine & Design is

responsible for compliance. Client Requirements may include design specifications or

drawings or applicable data from specifications as necessary for Hardy Machine & Design

to perform fabrication and installation in compliance with the Code(s).





Customer/Client

The organization that has instructed, by Contract, that Hardy Machine & Design furnishes

fabrication services. Also applies to designees or representatives of the customer.

Data Report

Appropriate Code Form completed by the fabricator certifying Code compliance and

certified by Authorized inspector.

Department

When department is specified, it shall be interpreted as being the manager of that

department's responsibility or his designated representative.

Design

The basic owner document including specifications, drawings and calculations, which are

required.

Document

A drawing, calculation, specification, procedure, instruction or other controlled printed

information.

Documentation

Any form, record, or drawing that contributes to traceability or verification.

Example Forms

Attachments to this manual for "as-is" use or modification to project forms.

Items

Material, parts, sub-assemblies, components or services.

Manual

This Quality Control Manual.

MT

Magnetic Particle Examination (a form of NDE)





NBIC

National Board Inspection Code

NDE

Nondestructive Examination - A method of indicating flaws in material or parts without

altering effective use of the material or parts. Examples are: RT, UT, MT, PT, VT.

PT

Liquid Penetrant Examination (a form of NDE)

Project Document

A document prepared for a specific project either totally or by modification of a generic

document.

Q.A.M.

Quality Assurance Manager

Q.C.

Quality Control

QCSM

Quality Control System Manual

Repair

Process of restoring a nonconforming characteristic to a condition so that the capability of

an item to function reliably and safely is unimpaired, even though that item still may not

conform to the original requirement. However, in all cases, it must conform to the Code as

required.

Rework

Process by which a nonconforming item is made to conform to a prior specified

requirements by completion, re-machining, reassembling, or other corrective means.





RT

Radiographic Examination (a form of NDE)

SNT-TC-1A

ASNT Recommended Practice SNT-TC-1A Code Accepted Condition

UT

Ultrasonic Examination (a form of NDE)

Vendor

A material manufacturer, material supplier, or subcontractor providing services.

WPS

Welding Procedure Specification





2. STATEMENT OF POLICY AND AUTHORITY

2.1. This Quality Manual documents the quality system for manufacturing, fabricating and

assembling of pressure vessels by Hardy Machine & Design which will meet all the

requirements of the AMERICAN SOCIETY OF MECHANICAL ENGINEERS Boiler &

Pressure Vessel Code Section VIII, Division 1.

2.2. Hardy Machine & Design management is totally committed to the execution of the

procedures established in this Quality Assurance System and in complete compliance with

A.S.M.E. Boiler & Pressure Vessel Code Section VIII, Division 1.

2.3. The Quality Assurance Manager of Hardy Machine & Design is delegated with authority

and responsibility to establish, maintain, administer and audit this Quality Assurance

System. It is his responsibility to formally report the findings, advise regarding corrective

action and monitor that the proposed corrective action has been effectively implemented.

2.4. If during the implementation, conflicts arise regarding Code compliance between the

Quality Assurance Manager and other departments, it will be resolved by the Manager and

will not negate the Code rules.

2.5. The Quality Assurance Manager at Hardy Machine & Design is responsible for

implementing this Quality Assurance System.

2.6. This Quality Manual will be printed and distributed only in the English language.

_____________________________

Ravi Goel

President, Hardy Machine & Design

Date: ________________________





3. MANUAL CONTROL

3.1. This Quality Manual has been prepared by Hardy Machine & Design. The Quality

Assurance Manager is responsible for the Manual's compliance with the current A.S.M.E.

Code. The Quality Assurance Manager is responsible for the initial issue of this Manual

and any subsequent revisions.

3.2. Revisions are approved by the Quality Assurance Manager and submitted to the Authorized

Inspector for review and acceptance, prior to inclusion into the Manual and subsequent

implementation. The Quality Assurance Manager and the Authorized Inspector will

document their approval and acceptance on the Table of Contents. This Manual shall not

be revised to meet client requirements. Client specifications shall be addressed via an

addendum outside the scope of this Manual. Whenever revisions are made, the part of the

manual that is being revised will be identified by the symbol < > adjacent to the paragraph

revised at the left-hand margin.

3.3. A controlled copy of the Quality Manual is available for the Authorized Inspector at the

Shop.

3.4. The Quality Assurance Manager will issue controlled and uncontrolled copies of the

Manual in accordance with the list of Manual holders maintained by him as per exhibit

number 1 (QCSM DISTRIBUTION LOG). Each Manual will bear the same control

number on its title page as is shown on the list. Only controlled copies shall be issued

within the Hardy Machine & Design organization.

3.5. No part of this Manual may be reproduced or transmitted in any form or by any means

including photocopying and recording without the written permission of Hardy Machine &

Design.





3.6. The Quality Assurance Manager will review Code addenda to determine if this Quality

Manual is affected. Required revision will be made and implemented within six months of

the addenda issue date and maintained in the QCSM Revision Log as per exhibit number 2.

4. DRAWING, DESIGN CALCULATIONS AND SPECIFICATION

4.1. Document Distribution (Pre-fabrication)

4.1.1. Upon being awarded the project, the Project Manager obtains a unique project job

number. The Project manager will then notify the Design Engineer, and all others in

operations the identity of the job number.

4.1.2. The Design Engineer is responsible for the distribution of all documents relative to the

project as per exhibit number 3 (DRAWING TRANSMITTAL FORM).

4.1.2.1. Client data sheet(s), drawing(s), and specification(s) shall be distributed to the Design

Engineer, QA/QC Department and Shop to begin job preparation.

4.1.2.2. The Design Engineer is responsible for issuing the latest revision(s), addendum (a) or

change(s) of the specifications and drawings to all defined document holders.

4.2. Drawing & Design Calculation Approval

4.2.1. The Design Engineer is responsible for the approval process of all drawings and

calculations as specified herein.

4.2.1.1. The Design Engineer upon receipt of the client documents, begins preparation of the

Design Calculations and drawings material list.

The drawings shall include all data, informations and details required by the ASME

Code as follows:

1) The applicable Code edition and addenda.

2) Identification Number

3) Bill of Materials as per exhibit number 4 with ASME material specification including

nominal size, grade/type, classification number and special material requirements, if





any, NDE or impact test requirements.

4) Dimensions and Tolerances

5) Weld joint configurations and/or symbols.

6) Hydrostatic/Pneumatic Test Pressure.

7) Reference to applicable approved procedure (WPS).

8) Minimum Design Metal Temperature.

4.2.1.2. One (1) set of documents are transmitted by the Design Engineer to the Client and

Authorized Inspector for review and comments.

4.2.1.2.1. The Design Engineer shall be responsible for pursuing a timely response to the

documents from all parties. Any comments shall be evaluated prior to being

incorporated into the design documents or drawings.

4.2.1.2.2. Upon incorporation of comments all documents shall be returned back to all parties

with final revision.

4.2.2. The "original" documents are returned to the Design Engineer and shall be stamped or

marked "Approved for Construction" on each drawing. A reproducible copy will be

transmitted to the Project Manager for Official distribution and retention.

4.3. Distribution & Revision of Drawings & Design Calculations

4.3.1. The Design Engineer is responsible for the distribution of drawing and/or revisions.

4.3.1.1. If during fabrication, changes to the drawing(s) are required, the proposed revision shall

be reviewed by the Design Engineer, who will submit for review to the client for

approval.

4.3.1.1.1. After the client approval of the revised drawings, the drawing(s) shall reflect the

changes and revision(s) and shall be noted in the revision blocks provided on drawing.





4.3.1.1.2. Design calculations to support the revision (change or alteration of Design) may be

required. The Design Engineer shall provide the calculations required.

4.3.2. Standard and Computer Aided Designs:

4.3.2.1. When standard or computer-aided design calculations and drawings are used, the Design

Engineer is responsible for the input of correct design data and the verification that the

correct output has been obtained.

4.3.2.2. The Design Engineer will review Code addenda to determine if standard designs or

programs are affected. Required revisions will be made and implemented within six

months of the addenda issue date.

4.3.2.3. All revisions are documented, signed by the Design Engineer and recorded on each

affected document or in computer program documentation.

4.3.2.4. Standard and computer-aided drawings and calculations output is available for review

and acceptance by the AI. The Design Engineer provides the AI with any manual

calculations he requests to verify computer output.

4.3.3. Design Calculations shall be prepared and issued by the Design Engineer.

4.3.3.1. The design calculation shall be completed by the Design Engineer.

4.3.3.2. He shall also be responsible for the calculations and drawings, control of the changes

and dated record of the changes.

4.3.3.3. Design calculations that require revisions shall be performed and/or verified by the

Design Engineer.

4.3.4. The Design Engineer prepares a Bill Of Materials as per exhibit number 4 for the entire

job based on the approved drawings.

4.3.4.1. The Bill Of Materials is distributed along with contract drawings and design

calculations.





4.3.4.2. As contract drawings are revised, so shall the Bill Of Materials to reflect such changes.

4.3.4.3. The Bill Of Materials shall specify Code materials in accordance with ASME Section

VIII Division 1 and ASME Section II specifications to the required edition and

addendum or identical ASTM specifications per Appendix A in Section II.

5. MATERIALS CONTROL

5.1. The Project Manager is responsible for obtaining Code materials as specified on the Bill Of

Materials as per exhibit number 4 and for all materials. Welding materials may be ordered

verbal or by use of a Purchase Order Exhibit 5

5.2. The Project Manager will first source from stock inventory meeting ASME Code

Specifications.

5.2.1. Code materials available in stock inventory shall be identified and their mill certificates

retrieved.

5.2.2. Code materials determined acceptable and in conformance to Code requirements shall be

identified with green mark. Materials not in conformance to Code requirements shall be

identified with red mark.

5.3. Preparations of material Purchase Order as per exhibit number 5 based on the material lists

are the responsibility of the Project Manager.

5.3.1. Completed Purchase Order is reviewed for Code compliance by and updated with any

required corrections. It is then signed and dated.

5.3.2. The Project Manager will approve the Purchase Order.

5.4. The Project Manager is responsible for purchasing all materials, consumables and supplies

in accordance with specifications. Any special ordering information must be noted on the

Purchase order such as UCS-79(d), UG-80 on request for mill test reports.





5.4.1. A copy of the Purchase Order with suppliers documentation shall be sent to the QC

Department for review.

5.5. Free issue material or customer supplied material must meet all Code requirements of

ASME Section II and Section VIII, Division 1. Received material shall be documented on

the Material Examination Report as per exhibit number 6.

5.6. The QC Inspector is responsible for the inspection and verification of all materials

including consumables received and/or issued to be in accordance with Code compliance.

5.6.1. All materials are inspected visually, dimensionally and readily traceable to the mill

certificates. The QC Inspector shall inspect and verify for conformance to the

requirements. Material received and inspected shall be transferred to shop with all

original receiving and inspection reports. All original records of vessel material shall be

kept by shop. Mill test report review and acceptance will be documented by initial and

date of the QC Inspector on the mill test report.

5.6.2. A copy of all documentation is retained in a job file for reference fabrication.

5.6.3. Substitution of material shall only be made with the review and approval of the Client,

Design Engineer and Authorized Inspector.

5.7. Material traceability shall be verified and recorded by the QC Inspector.

5.7.1. Prior to cutting Code material, the material traceability number shall be transferred to

each pre-determined piece to maintain traceability to cutting.

5.7.2. All drop-off materials shall be positively identified.





6. EXAMINATION AND INSPECTION PROGRAM

6.1. Vessel Fabrication Stage Inspection

6.1.1. The Examination and Inspection of ASME Code Pressure Vessels is the responsibility of

the QC department.

6.1.2. Stage Inspection of pressure vessels is controlled by means of a Inspection Traveler

Sheets as per exhibit number 7 prepared from the shop drawings by the QC Inspector who

shall assign his QC Inspection points, Hold (H), Witness (W), Review (R) or Monitor

(M) points and sign and date the quality plan. The QC Inspector shall submit the

Inspection Traveler Sheet to the AI prior to fabrication for his designation of inspection

points. AI inspection points shall be noted by *.

6.1.3. The Shop Foreman shall review the sequence of the activities provided on the Traveler

Sheet. The sequence includes examination and inspection activities.

6.1.4. When fabrication is complete, the QC Inspector shall perform his final inspection. If

acceptable, he shall signify his approval by initialing and dating the Inspection Traveler

Sheet when he has ascertained that all Code requirements have been met and shall submit

to the Authorized Inspector and Client for approval.

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

inspect internal surfaces, an inspection point for the QC Inspector, client and AI will be

shown to permit internal inspection before starting final closure weld or bolted joint.

6.2. Pressure Testing

6.2.1. Pneumatic tests as prescribed in this paragraph may be used in lieu of hydrostatic testing

or when specified, except when the Code requires hydrostatic testing.





6.2.1.1. The QC Inspector and Authorized inspector/Client shall witness the test. They shall

affix their initials and date onto the test chart.

6.2.1.2. The test pressure for pneumatic testing shall be 1.25 times the Maximum Allowable

Working Pressure (MAWP).

6.2.1.3. The pressure shall be gradually increased to not more than half of the test pressure (1.25

X MAWP). Thereafter, the pressure shall be increased in step one-tenth up to the test

pressure.

6.2.1.4. Then the pressure shall be reduced to four-fifths of the test pressure and held for

sufficient time to permit inspection.

6.2.1.5. When accepted, the QC Inspector/Client and Authorized Inspector shall sign and date

the Pneumatic Test Record.

6.2.2. Hydrostatic tests will be conducted as per ASME Code Requirements. The gauge should

be rated over a range twice the intended test pressure but in no case less than 1-1/2 the

test pressure or more than 4 times the test pressure.

6.2.2.1. The temperature of the water shall be maintained as per Code requirements.

6.2.2.1.1. For Section VIII, Division 1 vessels, they shall be subjected to a hydrostatic test

pressure which at every point in the vessel is at least equal to 1-1/2 times the

maximum allowable working pressure to be marked on the vessel multiplied by the

lowest ratio (for the materials of which the vessel is constructed) of the stress value S

for the test temperature on the vessel to the stress value S for the design temperature.

All loading that may exist during this test shall be given consideration.

6.2.2.1.2. It is recommended that the test pressure shall not be applied until the vessel and its

contents are at about the same temperature. If the test temperature exceeds 120

degrees F, it is recommended that inspection of the vessel be delayed until the

temperature is reduced to 120 degrees F or less.





6.2.2.2. The QC Inspector/Client shall affix his initials and date onto the test chart.

6.2.2.3. The test pressure for hydrostatic testing shall be at least equal to 1.5 times the Maximum

Allowable Working Pressure (MAWP).

6.2.2.4. After successful application of the test pressure, it is reduced to two-thirds for a close

examination of all welds.

6.2.2.5. When accepted, the QC Inspector and Authorized Inspector/Client shall sign and date

the Inspection Traveler Sheet.

6.3. Data Reports

6.3.1. Upon completion of a vessel the applicable Manufacturer's Data Report shall be prepared

as completed from the final records by the QA Manager.

6.3.2. The completed Manufacturer's Data Report, together with the final records, shall be

presented to the Authorized Inspector for his review. When he is satisfied that all Code

requirements have been met as per the Code, he will sign and date the Manufacturer's

Data Report.

6.3.3. The Authorized Inspector shall verify the application of the Code Symbol U-Stamp to the

nameplate.

6.3.4. The National Board serial numbers shall be controlled and issued by the Q.A.M.

6.3.4.1. A record of issuance shall be kept showing date issued, type of vessel to be used upon,

and manufacturer's serial number and date sent to the National Board.

6.3.4.2. All pressure vessels meeting all Code requirements of the Code shall be stamped with

the ASME Code Stamp.

6.3.4.3. The Project Manager shall submit to the National Board the original and one legible

copy of all Manufacturer's Data Reports required for the stamped vessel (See Section

18).





6.3.5. All documentation shall be retained on file.





7. CORRECTION OF NONCONFORMITIES

This section describes the methods used to control and resolve nonconforming conditions

found in material, fabrication, documentation or construction.

7.1. Definition

Nonconformance - is a deficiency in characteristic, documentation or procedure which

renders the quality of an item unacceptable or indeterminate and not in compliance with the

ASME Code and this Manual.

7.2. Responsibility

All personnel have the responsibility to report any non-conforming conditions, which

they have knowledge of.

7.2.1. It is the QC Inspector's responsibility to initiate and issue the Non-Conformance Report

as per exhibit 8.

7.2.2. The QC Inspector shall prescribe a recommended corrective action.

7.3. Procedures

Deviations will be handled by the QC Inspector.

7.3.1. When nonconformity is found, if it cannot be immediately resolved by the QC Inspector,

it shall be identified.

7.3.2. A Non-Conformance Report shall be prepared for non conforming items by the QC

Inspector

7.3.3. Copies of the Non-Conformance Report are issued to the Addressee, Authorized

Inspector, Project Manager Client and Shop Foreman. The original shall be retained in

the Job File. In case of repair to the base material, the Authorized Inspector/Client will

be notified for his concurrence and designation of his 'hold' points. All use as is

dispositions shall be notified to the AI prior to implementation.





7.3.4. The Project Manager shall be responsible for the final rectification of the

nonconformance. When corrective action has been completed/accepted by the QC

Inspector and AI, the QC Inspector and AI shall sign and date.

7.3.5. The QC inspector shall verify that the corrective action taken has satisfactorily restored

the condition to within compliance of the Code.

7.3.5.1. Satisfactory results shall be documented by the Project Manager. Copies shall be

distributed and the original retained in the file.

7.3.5.2. Unsatisfactory results that have been ineffective in correcting the non-conformance shall

be re-addressed by issuing a revised Non-Conformance Report.





8. WELDING CONTROL

8.1. General

8.1.1. All welding on Code vessels shall comply with a written Welding Procedure

Specification (WPS) in accordance with ASME Section IX.

All welding on Code vessels shall be performed by qualified welders and/or operators in

accordance with ASME Section IX.

8.1.2. Welder(s) and Welding Operator(s) are qualified and certified to the essential variables by

the Project Manager.

8.2. Project Planning (Pre-Fabrication)

8.2.1. When documents are received from the Design Engineer, the Project Manager reviews

the drawings and specifications from which he prescribes appropriate Welding Procedure

Specification (WPS) and Welder Qualifications for the Project.

8.2.2. Welding Procedure Specification(s) (WPS) shall be sourced from the Design Engineer

files to meet project requirements. Should project requirements fall outside the limits of

the variables expressed in the Welding Procedure Specification, a new Procedure will be

required to meet these requirements. However, if only nonessential variables are

changed, then the WPS can be revised to reflect that change.

8.2.3. Only qualified welders will be used for welding of Code items.

8.2.4. Copies of the applicable Welding Procedure Specification(s) (WPS), and Welder's

certificate shall be submitted to client through Project Management. These documents

will be available for review to the Authorized Inspector at all times.

8.3. Qualification of Welding Procedures





8.3.1. The Project Manager is responsible for conducting the qualification of procedures and

certifying the procedure qualification record.

8.3.2. Materials and Consumables required are sourced as per engineering requirement.

8.3.3. Qualification and documentation of the welding procedure shall be in accordance with

ASME IX.

8.3.4. WPS shall be submitted to the A.I. upon request. The AI may require re-qualification of

welders or procedures for just cause.

8.4. Welder and Welding Operator Renewal

8.4.1. The Project Manager will have ultimate responsibility for the maintenance of welders and

welding operator's qualification. Qualified welders and operators continuity is

documented on the Welders Performance Record Exhibit #9.

8.4.2. The performance qualification of a welder or welding operator shall be affected when one

of the following condition occur:

8.4.2.1. When he has not welded during a period of 6 months or more using a specific process.

8.4.2.2. When there is a specific reason to question his ability to make welds that meet the

specification, the qualifications which support the welding he is doing shall be revoked.

All other qualifications not questioned remain in effect.

8.4.3. Adequate proof of documentation that supports the effective use of a welding process by

the welder shall renew that welders qualification for another period.

8.4.3.1. Welders that have inadequate proof of documentation or have exceeded the limits shall

require requalification.

8.5. Qualification of Welders and Welding Operators

8.5.1. The Qualification of welders shall be the responsibility of the Project Manager.





8.5.2. Welders and welding operators are qualified by any of the two methods listed below:

test coupon

or Production test (If not GMAW Short circuiting)

8.5.3. Qualification of Welders and Welding Operators shall be in accordance with ASME IX.

8.6. Production Welding

8.6.1. The QA Manager is responsible for verifying that all production welders are qualified,

and the Shop Foreman is responsible for instructing each welder in the appropriate WPS

he shall use.

8.6.2. Each welder and welding operator shall stamp or stencil the identifying number, letter, or

symbol, assigned by the QA Manager, adjacent to and at intervals of not more than 3 ft.

along the welds which he makes in steel plates 1/4 in. and over in thickness and in

nonferrous plates 1/2 in. and over in thickness; or a record shall be kept by the QA

Manager of welders and welding operators employed on each joint which shall be

available to the Inspector. For identifying welds on vessels in which the wall thickness is

less than 1/4 in. (6mm) for steel material and less than 1/2 in. (13mm) for nonferrous

material, suitable stencil or other surface markings shall be used; or a record shall be kept

of the welders and welding operators employed on each joint by the QA Manager which

shall be available to the Authorized Inspector/Client.

8.6.3. The appropriate Welding Procedure Specification (WPS) use shall be determined by the

QA Manager after consultation with the Shop Foreman. The procedures will be noted on

the "Approved for Construction" drawings (AFC).





8.6.4. Tack welds shall be made in accordance with qualified procedures and welders; all tack

welds, which are not, removed, shall be feather ground and visually inspected for defects

by the Shop Foreman. Tack welds made by subcontractors shall be removed. However,

they shall be made in accordance with a qualified procedure approved by the Q.A.M.

8.6.5. Welder and Welding Operators I.D. numbers are recorded onto the Welders Performance

Record. This record is retained on file.

8.6.6. The QC Inspector shall audit the welding in compliance to the WPS.

8.7. Welding Material

8.7.1. All welding filler metals and fluxes are purchased as per requirements either verbally or

by use of a Purchase Order.

8.7.2. All welding materials are received as per requirements.

8.7.3. Welding materials are to be stored in accordance with the Code and Filler Metal

Manufacturing Recommendations.

8.7.4. It is the Shop Foremans responsibility to ensure correct Welding Consumables are used in

accordance with the applicable Welding Procedure Specification (WPS). Sufficient

quantity is issued to the welders to complete the welding job by the Shop Foreman who

then instructs the welders of the correct WPS to be used. WPS are made available to all

welders/welding operators.

8.8. Equipment Maintenance

8.8.1. All welding leads, cutting torches and other apparatus shall be kept clean and free of

unnecessary dirt, grease, moisture or any other foreign matter.

8.8.2. Welding machines shall be blown free of dust.

8.8.3. Electrode Holding and Storage Ovens shall utilize thermostats to ensure proper

temperature control.





8.9. Authorized Inspector

8.9.1. The WPS and the Welder/Welding Operator shall be requalified when required by the AI.





9. NON DESTRUCTIVE EXAMINATION - NDE

9.1. General

9.1.1. All NDE shall be performed by a qualified examiner or outside company, under the

direction of a written procedure, using calibrated equipment in accordance with ASME

Section V and VIII, Division 1.


9.2.1. When documents are received from the Design Engineer, the Project Manager reviews

the drawings and specifications from which he prescribes the appropriate NDE

Procedures.

9.3. The NDE requirements of pressure vessels are noted on the fabrication drawings by the

Engineering Manager.

9.4. Non Destructive Examination (NDE) performed on the Code Vessels shall be conducted in

accordance with a written procedure certified by the Level III personnel, who shall be

qualified in accordance with written practice. SNT-TC-1A

9.4.1. All NDE reports including radiographic film shall be reviewed for Code compliance by

the QA Manager.

9.4.2. Should the examiner have any doubt, he shall consult with the QC Inspector.

9.5. Documentation & Reporting

9.5.1. The NDE As-built drawings of the Code vessels shall be maintained by the QC Inspector

for documentation purposes.

9.5.2. Any or all NDE Documentation shall be made available for review to the Authorized

Inspector/Client.





9.5.3. All NDE Documentation shall be retained on file.

9.6. Subcontracting

9.6.1. The subcontractor is to perform all NDE testing. The QA Manager shall appoint by letter

a Level III to act on behalf of Kamgage for all NDE. The Level III shall accept this

appointment by letter.

9.6.2. The subcontractor shall submit the calibration of his equipment and procedures for QA

Manager's approval. All NDE personal shall be qualified in accordance with SNT-TC-1A

Code accepted edition.

9.6.3. Materials sent to the subcontractor's facility shall be properly identified/marked and

inspected upon return from the vendor for proper identification and damage.

9.6.4. As a minimum, a calibrated density strip and a film viewer will be available.

9.6.5. The A.I. may call for requalification of procedures or personnel for just cause.





10. POSTWELD HEAT TREATMENT

10.1. General

10.1.1. Postweld heat treatment shall be performed in accordance with a procedure approved by

the QC Inspector. The requirements of the applicable sections of ASME Section VIII

Division 1 shall be met.


10.2.1. Before preparing the vessel for stress relieve the final visual and dimensional checks

should be carried out. When it is found to be satisfactory, the QC Inspector shall sign the

final inspection reports and the release for stress relieve.

10.2.2. The QA Manager shall review the Postweld Heat Treatment Procedure and the Approved

for Construction (AFC) drawings to establish the vessel thermocouple assignment.

10.2.3. The QA Inspector and Shop Foreman shall review the thermocouple arrangement

drawings and mark the location on the vessel.

10.2.4. After the clamps have been welded in place in accordance with a qualified welding

procedure, the QC Inspector shall inspect the location of the clamps prior to furnace start

up to assure correct thermocouple location. Clamps shall be welded by Kamgage and

shall be of appropriate material.

10.3. Subcontracting

10.3.1. The subcontractor is to perform a postweld heat treatment operation. The QC Inspector or

the Project Manager will review the procedure with the subcontracting company

representative.

10.3.2. The subcontractor shall submit the calibration certificate of the recorder to the QA

Manager for the approval.





10.3.3. Materials sent to the subcontractor's facilities shall be properly identified/marked and

inspected upon return from the vendor for proper identification and damage.

10.4. Documentation & Records

10.4.1. All postweld heat treatment documentation shall be signed and dated by the

subcontractor.

10.4.2. Visual inspection of the internals after PWHT shall be carried out by the QC Inspector.

10.4.3. The documentation shall be presented to the Authorized Inspector/Client for his review.

10.4.4. All documentation shall be retained on file.





11. CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT

11.1. All test equipment, including subcontractors used for verifying Code items shall be

calibrated in accordance with this section and Gauge Calibration Log maintained as per

exhibit 10.

11.2. Each item of measurement, test and examination equipment which requires calibration

shall be identified by marking with a serial number and calibration date.

11.3. The QC Inspector is responsible for ensuring that all equipment is maintained in current

calibrated condition.

11.4. Calibration may be performed by a qualified testing laboratory, having adequate standards

traceable to the National Standards or similar, and able to provide certificates of

calibration.

11.5. Mechanical Test Equipment (Laboratory) shall be calibrated in accordance with ASME SA

370.

11.6. Each calibrated item shall have a Calibration Record maintained by the QA Manager or his

designee in the calibration file.

11.7. Calibration record shall be available for review.

11.8. When instruments are found out of calibration, the QC Inspector or his designee will

remove it from the work area and arrange for its calibration or replacement.

11.9. Calibration of all measurements and test instruments are controlled. There will be

calibrations on an annual basis.

11.10. Micrometers and/or calipers shall be checked for accuracy before and after each use to a

test block of a known thickness. These verifications will not be recorded.





12. RECORDS RETENTION

12.1. All documentation described in this manual is collated at the completion of the job, and

reviewed for completeness, prior to preparation of the Manufacturer's Data Report.

12.2. Manufacturer's Data Reports, upon certification by the QAM and AI, shall be furnished to

the user or his agent, and to the Authorized Inspector if required.

12.3. All documentation for the job shall be assembled into a Job Data Book. The original data

book will be retained by the company and copies of which will be distributed to the client.

12.4. Manufacturer Data Reports shall be retained for a minimum of five (5) years if not

registered with the National Board.

12.5. The National Board serial numbers shall be controlled and issued by the Project Manager.

All pressure vessels will be stamped with the A.S.M.E. Code Symbol Stamp upon

satisfactory completion.





13. AUTHORIZED INSPECTOR

13.1. The Authorized Inspector is the Inspector required by Code, who is employed by an

ASME, accredited Authorized Inspection Agency.

13.2. When requested by the Authorized inspector, hold witness and review points shall be

identified on the checklist for those activities he wishes to witness and verify.

13.3. The QC Inspector is the liaison with the Authorized Inspector, and is responsible for

keeping him advised of the progress of the work.

13.4. The Authorized Inspector shall have access to and be furnished with all drawings,

calculations, specifications, procedures, repair procedures, records, test results and any

other documents as required performing his duties.

13.5. All non-conformance and corrective actions shall be submitted to the Authorized Inspector

for his review.

13.6. The QA Manager shall notify the Authorized Inspector sufficiently in advance of pressure

tests so that he may be present to witness them.

13.7. The final records, together with the completed Manufacturer's Data Report shall be

submitted to the Authorized Inspector for his review and signature. The Authorized

Inspector shall sign the Manufacturer's Data Report when he has satisfied himself that all

Code requirements have been met.

13.8. The QC Inspector shall provide a controlled copy of the Quality Manual for the Authorized

Inspector at all times.

13.9. The Authorized Inspector will review and accept all changes to the Quality manual prior to

distribution to manual holders.





13.10. The Authorized Inspector and/or the AI's Supervisor shall have free access to all parts of

the Shops, suppliers or material manufacturers where work is being performed.

13.11. The Authorized Inspector shall be responsible for his inspection requirements as ASME

Section VIII Specifies.

13.12. The QC Inspector will provide necessary assistance to the Authorized Inspector during

the Annual Audit required by the National Board rules and regulations and ASME QAI-1.





14. ANNUAL AUDIT

14.1. An Annual Audit of the Quality Control System may be made by an independent person

within Hardy Machine & Design, Inc., if deemed necessary by the QAM.

14.2. The Audit shall verify implementation of the entire Quality Control System and report

findings.

14.3. Audit Reports are submitted to the Quality Assurance Manager for review and copies shall

be forwarded to the affected department.





15. CONTROL OF CODE STAMP

15.1. The Hardy Machine & Design policy is to maintain control over the Code Symbol Stamp

and to assure its proper use.

15.2. Procedures

15.2.1. The Code Symbol Stamp is controlled by the Quality Assurance Manager. All requests

for the use of the Code symbol stamp shall be made directly to the Quality Assurance

Manager.

15.2.2. The Project Manager, prior to start of work, shall obtain from the client, and prepare from

drawings and/or specifications, a list of the items or systems that will be required to be

stamped and stamping to be witnessed by the Authorized Inspector.





16. ORGANIZATIONAL CHART

Kamgage Fabrication

Company Secretary

Design Engineers

& CAD Drafting

Estimating

Technical/Sales

QC Inspector

QA Manager

Procurement

Project Managers

NDE X-Rays

Postweld Heat-treating

Subcontractors Manager

Shop Welders

Shop Foreman

Operating Officer

President





17. NATIONAL BOARD OF REGISTRATION

Items that require National Board numbers shall be issued in numerical order without skips

or gaps by the QA Manager. The QA Manager shall maintain a record, which includes date

of issue, type of item and manufacturers serial number, and date sent to National Board,

which will be transmitted within 90 days of issuance.

The QA Manager shall submit to the National Board the original and one legible copy of all

Manufacturers Data Reports required for Code items. The arrangement of nameplate

marking is indicated on Exhibit #11.





18. EXHIBITS

EXHIBIT NO. 1: Q.C.S.M DISTRIBUTION LOG

EXHIBIT NO. 2: Q.C.S.M. REVISION LOG

EXHIBIT NO. 3: DRAWING TRANSMITTAL FORM

EXHIBIT NO. 4: BILL OF MATERIAL

EXHIBIT NO. 5: PURCHASE ORDER

EXHIBIT NO. 6: MATERIAL EXAMINATION REPORT

EXHIBIT NO. 7: INSPECTION TRAVELER SHEET

EXHIBIT NO. 8: NON-CONFORMANCE REPORT

EXHIBIT NO. 9: WELDERS PERFORMANCE RECORD

EXHIBIT NO. 10: GAUGE CALIBRATION LOG

EXHIBIT NO. 11: STAMPING ARRANGEMENT


EXHIBIT NO. 1

Q.C.S.M DISTRIBUTION LOG

NUMBER ISSUED TO SIGNATURE TITLE DATE


EXHIBIT NO. 2

Q.C.S.M. REVISION LOG

REVISON SUMMARY Q.C.M

SIGNATURE & DATE

A.I.

SIGNATURE & DATE


EXHIBIT NO. 3

DRAWING TRANSMITTAL

TO: _________________________________ WORK ORDER NO: ____________________

ATTACHED ARE THE FOLLOWING:

THESE ARE TRANSMITTED FOR:

BY: _______________________________________________ DATE: __________________


EXHIBIT NO. 4

BILL OF MATERIALS

DATE

BILL OF MATERIALS NO.

TO:

QTY. DESCRIPTION UNIT

WEIGHT

TOTAL

WEIGHT

UNIT

PRICE

TOTAL

PRICE

Hardy Machine & Design

5737 Windfern St.

Houston, TX 77041


EXHIBIT NO. 5

PURCHASE ORDER

ISSUE DATE PURCHASE ORDER NO.

SUPPLIER: SHIP TO:

Contact Phone : Contact

Phone :

Fax : Fax :

REQD DELIVERY DATE SHIPPING METHOD TAXABLE PAYMENT TERMS SIGNATURE & DATE

YES NO

ITEM NO. DESCRIPTION QTY UNIT

WEIGHT

UNIT

PRICE

TOTAL

PRICE

TAX

TOTAL

5733 Windfern Rd.

Houston, TX 77041


EXHIBIT NO. 6

MATERIAL EXAMINATION REPORT

P.O.________________________________ SHOP ORDER____________________________

ITEM NO.___________________________ DESCRIPTION___________________________

CHECK LIST

1. APPEARANCE: ______________________________________________________

2. THICKNESS: ______________________________________________________

3. DEFECTS: ______________________________________________________

4. TRACEABILITY: ______________________________________________________

5. HEAT NUMBERS: ______________________________________________________

6. MATERIAL ID: ______________________________________________________

7. DIMENSIONS: ______________________________________________________

8. MISCELLANEOUS:_____________________________________________________

MATERIAL RECEIVED BY: ________________________________ DATE: ___________


EXHIBIT NO. 7-1

Job Number:__________

SECTION:

INSPECTION TRAVELERS SHEET

O.D. ________________ I.D. _______________

VESSEL ____________ PIPE ______________ CUSTOMER/INSPECTO

R Q.C. A.I.

REMARKS

*A.I. HOLD

POINTS

CALCULATIONS

SERIAL NUMBER

DRAWING NUMBER

NATIONAL BOARD NUMBER

DATA REPORT

MILL TEST REPORTS

SHELL THICKNESS

HEAD THICKNESS

FORMED SECTIONS

HEAT NUMBER, SHELL

HEAT NUMBER, HEAD

GRADE OF MATERIAL, SHELL

GRADE OF MATERIAL, HEAD

CUT EDGES

PIPE SURFACE

PLATE SURFACE

INSPECTION FITTINGS

ALIGNMENT

WELDING PROCEDURE

WELDER QUALIFICATION

WELDER SYMBOLS

PREHEAT

WELDING APPEARANCE

POST WELD HEAT TREATMENT

X-RAY, R-1, R-2, R-3, R-4

MAGNA FLUX-DYE PENETRANT

HYDRO TEST

NAME PLATE, STAMPED OR ATTACHED

TEST GAUGE NUMBER

INTERIOR OR EXTERIOR COATING

CUSTOMER ______________________________________ P.O. # __________ ITEM # _______

SHIP TO: ______________________________________________________________________________


EXHIBIT NO. 7-2

JOB # CUSTOMER: DESCRIPTION:

MATERIAL IDENTIFICATION

ITEM HEAT NO. MNFR SLAB MIKE

H-

H-

RG-1

RG-2

RG-3

RG-4

RG-5

FLANGES AND COUPLINGS

MK MFG MK MATL. MK MFG MK MATL.

SPECIAL NOTES:


EXHIBIT NO. 7-3

JOB # CUSTOMER: DESCRIPTION:

PART FUNCTIONS IN PROCESS FABRICATION & INSP.

& L.O. PREP FORM FIT WELD X-RAY NDE

ITEM QC AI QC AI QC AI QC AI QC AI QC AI QC AI

SPECIAL NOTES:


EXHIBIT NO. 8

NONCONFORMANCE REPORTS

WORK ORDER NO: REPORT NO.

CUSTOMER:

DESCRIPTION OF NONCONFORMITY:

SIGNED: ___________________ QC INSPECTOR

RECOMMENDED DISPOSITION

USE-AS-IS REPAIR/REWORK SCRAP/RETURN TO VENDOR

SIGNATURE & TITLE:

DATE:

DISPOSITION APPROVAL:

DESIGN ENGINEER: DATE:

Q.C. MANAGER: DATE:

AUTHORIZED INSPECTOR: DATE:

DISPOSITION VERIFIED:

INSPECTED BY: DATE:

AUTHORIZED INSPECTOR REVIEW:

ACCEPTED

REJECTED

SIGNED: DATE:


EXHIBIT NO. 9

WELDERS PERFORMANCE RECORD

DATE: ______________

NAME: _______________________ STAMP NO.: ________________ YEAR: ___________

CHECK THE MONTHS DURING WHICH THE WELDER WELDED UNDER THE

FOLLOWING PROCEDURE:

WPS _____________________________________

PROCESS ________________________________

JANUARY ______________ FEBRUAURY ___________ MARCH ____________

APRIL ______________ MAY ___________ JUNE ____________

JULY ______________ AUGUST ____________ SEPTEMBER ____________

OCTOBER ______________ NOVEMBER ___________ DECEMBER ___________

_____________________________

PRODUCTION MANAGER


EXHIBIT NO. 10

GAUGE CALIBRATION LOG

NAME OF EQUIPMENT______ MODEL NO. _______________ SERIAL NO. ________

SIZE AND TYPE ____________ MANUFACTURER __________ ACCURACY ________

DATE ACQUIRED __________ CALIBRATION FREQUENCY ______________________

STATUS

CALIBRATED RESULTS DATE CHECKED BY DATE DUE DATE

MAINTENANCE HISTORY


EXHIBIT NO. 11

Stamping Requirements

Facsimile of Required Stamping for National Board Registration

Acceptable forms of National Board marking:

NATL BD. NATL BD

NATIONAL BD

NATIONAL BOARD

The size of the National Board stamping shall not be less than that required by the applicable

code of construction for the item being stamped.

National Board markings shall appear only on pressure retaining items registered with the

National Board.

* NATL BD. (National Board Serial Number)

Stamping in this area shall comply with the requirements of the applicable

construction code

Pressure Vessel Quality Manual 2

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Transcript of Pressure Vessel Quality Manual 2