ABC Qc Manual

Cumulative of 45 123 ANY LANE • P.O. BOX 123 • ANYTOWN, ANYPLACE USA 12345-6789

PHONE: (555) 555-5555 • FAX: (555) 555-5555 • EMAIL: [email protected]

ABC COMPANY Quality Control Program

For

Shop and Field Construction of:

Boiler External Piping ("PP" Stamp) And

Shop and Field Repair and Alterations ("R" Stamp) of:

Power Boilers, Boiler External Piping Heating Boilers and Unfired Pressure Vessels

This Manual Applies to Code Activities at

123 Main St

Any town, Anyplace USA 12345

And

Various Field Sites

1st EDITION, 01/01/01

Controlled Copy No:

Uncontrolled Copy: Assigned to:

REVISION, 01/01/01

QUALITY CONTROL MANUAL



TABLE OF CONTENTS SECTION DESCRIPTION REV.

DATE

Title Page 0 01/01/01

Preface i Table Of Contents 0 01/01/01

Preface ii Statement of Authority and Responsibility 0 01/01/01

1.0 Manual Control 0 01/01/01

2.0 Organization, Delegation of Authority, Scope 0 01/01/01

3.0 Drawings and Design Control 0 01/01/01

4.0 Materials and Replacement Parts Control 0 01/01/01

5.0 Control of Manufacturing Processes 0 01/01/01

6.0 Welding and Heat Treatment 0 01/01/01

7.0 Nondestructive Testing 0 01/01/01

8.0 Measuring and Test Equipment Control 0 01/01/01

9.0 Pressure Tests 0 01/01/01

10.0 Nonconformities 0 01/01/01

11.0 Reports, Records and Code Stamping 0 01/01/01

12.0 Repair and Alteration Controls 0 01/01/01

13.0 Authorized Inspector 0 01/01/01

14.0 Exhibit Index 0 01/01/01

President: Date: ABC Company.

Accepted by: Date: Authorized Inspection Agency

Preface i REVISION, 01/01/01




STATEMENT OF AUTHORITY AND RESPONSIBILITY

This Quality Control Program has been established to assure manufacturing and field assembly of Boiler External Piping (PP Stamped items) are conducted as required by the Rules of ASME Code Section I, ASME B31.1, the Jurisdiction, and this manual. These activities, as defined within the Scope of Work (section 2), may be performed at ABC COMPANY, Any town, USA and various field sites. The purpose of this program is to assure that all activities performed by the company are completed in a manner that ensures the safety and reliability of boiler external piping manufactured by the company.

In addition this Quality Control Program shall ensure repairs and alterations to pressure retaining boundaries conform to the requirements of the Jurisdiction, the Rules of the NBIC and applicable ASME Code sections.

ABC COMPANY personnel involved in these activities will be responsible for the quality of workmanship and adherence to this program. The President has the overall responsibility for the maintenance and administration of this program, including authority to revise this program to keep it current. It is the President's responsibility to assure full compliance with this program. The President has the authority to identify quality problems and to initiate solutions to those problems. The President shall have authority to take actions necessary to stop work and prevent further processing when nonconforming conditions exist. In all cases, the Code and this manual shall not be violated. The Code shall be defined as the applicable rules, laws and statute of the Jurisdiction, National Board Inspection Code, and ASME Code Sections.

The Authorized Inspection Agency's representatives shall be provided freedom of access to all locations where Code work is occurring or has been completed. Upon request, arrangements shall be made to allow the Authorized Inspector free access to such parts of all plants as are concerned with the supply or manufacture of materials for Code work. Drawings, calculations, specifications, procedures, material documentation, and any other documents required to ascertain Code compliance shall be made available to the Authorized Inspector by the President.

President

ABC COMPANY

Date

Preface ii REVISION, 01/01/01




1.0 MANUAL CONTROL

1.1 General

1.1.1 The President is responsible for the maintenance, approval, and distribution of this Manual. The Authorized Inspector's acceptance is required prior to the implementation of this manual.

1.1.2 The use of the words "will" or "shall" are used to convey requirements. The words "should" or "may" convey recommended good practice and failure to implement the suggested action does not constitute a Manual violation.

1.2 Revisions

1.2.1 The President will review new Code Editions and addenda annually, prior to the mandatory effective date, for changes that may affect this program. Revisions to this Manual may be necessary to keep it current and address changes in the ASME Code or changes to policies within the Company. Code Edition reviews will be documented by letter to the AI indicating manual changes to be made, if any. When revisions are necessary, they shall be prepared, approved and distributed by the President.

1.2.2 Each section of the Manual shall be identified by its latest revision date. Revised text within the Manual shall be identified with bold text.

1.2.3 The Table Of Contents shall be used to identify the revision status of the Manual and its sections. Each time the Manual is revised, the Table Of Contents shall be updated to reflect the affected sections and document approval and acceptance. The President will review the revisions with the Authorized Inspector before implementing revisions.

1.3 Manual Distribution

1.3.1 The President shall maintain a Controlled Manual Holders List (Exhibit 1). The President shall distribute and familiarize controlled manual holders with the requirements of the Manual and revisions.

1.3.2 Manuals shall be issued such that personnel with implementation responsibilities have access to a Controlled Manual. Informational copies (Uncontrolled) of the Manual will be available upon request from the President. Uncontrolled copies of the Manual will be identified on the title page and will not be maintained current. Uncontrolled Manuals are not to be used for Code activities.

Section 1 REVISION, 01/01/01




2.0 ORGANIZATION

3.0 Delegation of Authority

3.1.1 Throughout this manual, described actions and functions are assigned to individuals whose titles appear on the organization chart. These individuals may delegate the authority for these actions and functions to other individuals within the Company, provided: .1 Individuals are competent and qualified where necessary. .2 Individuals are under the direct line of supervision while implementing the

assigned actions or functions. .3 Responsibilities and accountability for the delegated actions and functions

remains that of the designated individual. .4 Authority, responsibility, and delegation there of apply to activities both

within the shop and at field sites.

3.2 Scope of Work

3.2.1 The work performed under this program applies to both shop and field fabrication of Boiler External Piping as defined within ASME Section I ("PP" stamped items).

3.2.2 Repairs and Alterations to pressure retaining items, and their parts (excluding safety relief valves), located either in the shop or field, shall be made in accordance with this program. All repair and alteration work shall conform to applicable requirements of the Jurisdiction Rules and the NBIC. When applicable, an "R" stamping or nameplate shall be affixed to the repaired or altered item.


PRESIDENT Overall Responsibility

Shop Craft Foreman Supervision of Work

Field Purchasing Procurement of Materials

Field Craft ForemanSupervision of Work

Shop QC Inspector

QC DELEGATES QC Administration and

Inspection

Shop Purchasing Procurement of Materials

Shop Welders / Craft Personnel

Field QC Inspector

Field Welders / Craft Personnel




3.0 DRAWINGS AND DESIGN CONTROL

3.1 General

3.1.1 Upon receipt of an order, a Job Work Order (Exhibit 2) shall be initiated to define the applicable Code, item(s) descriptions, and required nature of the work. The Job Work Order shall appear on all project documents.

3.1.2 The President shall be responsible for preparation and/or approval of design calculations, drawings, engineering specifications and any other technical documents. Each of these documents shall be identified with a revision level. The President shall maintain a record of changes along with the reason for the change in the applicable project file(s). The Project Revision Form (Exhibit 4) shall be use for this record.

3.1.3 Prior to the start of work, the President will provide the AI with drawings, calculations, specifications or other project documents requested in order to determine that Code requirements are being fulfilled. Copies of calculations, specifications and drawings shall be available for review at applicable work locations. Changes made to these documents shall be presented to the AI.

3.1.4 Specification requirements relative to manufacture or construction shall be included, to the degree practical, in applicable drawings and procedures. When it is not practical to include all specification data, separate engineering specifications may be issued for dissemination to the Company's work force.

3.2 Design Calculations, Engineering Specifications and/or Drawings

3.2.1 Design calculations, specifications and drawings may be furnished by the client, an outside source, or may be prepared in their entirety by the ABC COMPANY personnel. In any case, responsibility for assuring that design calculations, engineering specifications and/or drawings conform to the Code shall be that of the President.

3.2.2 If calculations are required to justify repair and alteration parameters, or are required by the AI, they shall be accomplished by the technically competent ABC COMPANY personnel, the original manufacturer, or a competent outside organization selected by the President. Calculations performed by an outside source shall be reviewed and approved by the President.





3.3 Drawings

3.3.1 Drawings shall be provided for manufacture and installation by the President. Client furnished drawings may be used provided the information, details or instructions required by this Manual are added.

3.3.2 Drawings used for production shall include the information, details and instruction necessary to assure that manufacture and/or installation conforms to Code and engineering specification requirements. Based on the nature of work, the following shall be prescribed or referenced, as applicable:

.1 Job Work Order Number, drawing and revision number.

.2 Code of construction, Edition and addenda.

.3 Design configuration, dimensions and tolerances.

.4 Unique weld identification, weld joint details, the applicable welding procedure specification(s) to be used, and if applicable, postweld heat treatment requirements.

.5 A bill of materials which specifies sizes, specifications, grades, part or subassembly numbers, etc., as applicable.

.6 Code stamping locations should be prescribed on the appropriate assembly drawings along with the pertinent design information (e.g., max. allowable working pressure and temperature, serial number, National Board Number, etc., as applicable).

.7 NDE requirements with reference to acceptance criteria.

.8 Inspection and test requirements with reference to acceptance criteria.

.9 Any other notes, specification requirements or production details necessary to achieve compliance with the Code and/or engineering specifications.

3.3.3 Drawings shall be reviewed and approved for use by the President. Approval shall be indicated by initial and date on the drawings.

3.3.4 The President shall be responsible for the issue and recall of drawings to ensure use of the proper drawing revisions. The President may allow recipients to retain superseded documents provided they are clearly marked "void", "superseded" or "for reference only". For distribution to the field, the President shall compile a package of pertinent design drawings and specifications. These shall be transmitted by a Letter of Transmittal (Exhibit 12) with acknowledgment returned to the President for retention.





4.0 MATERIALS AND REPLACEMENT PARTS CONTROL

4.1 General 4.1.1 Materials used for manufacture or construction shall conform to the applicable

Code section(s). The Company shall maintain a system of material control to assure that drawings and Purchase Orders (Exhibit 5) list Code material per SA, SB, and SFA specifications for which allowable stress values are given in the applicable Code section.

4.1.2 It is the intent of the company to procure materials to the applicable ASME specifications given in Section II of the Code, applicable Edition and addenda. However, materials produced under corresponding ASTM specifications may be used provided the requirements of the ASTM specification are identical (excluding editorial differences) to the respective ASME specification (refer to the foreword of the applicable Code section). It shall be the responsibility of the President to determine acceptability of such materials when received on a case by case basis.

4.2 Procurement 4.2.1 The President shall be responsible for the preparation of Purchase Orders from the

bill of material on approved drawing(s) or as required to implement a Traveler (Exhibit 3). Purchase Orders shall be completed with all information required by the material specification(s) and the applicable Code section.

4.2.2 Purchase Orders shall not be changed, other than for quantity, without the approval of the President. Material substitutions will require revision of all applicable purchase documents and shall be approved by the President to assure Code compliance.

4.3 Material Receipt and Inspection (Shop)

4.3.4 Code materials received at the shop shall be placed into a segregated hold area pending the completion of receipt inspection. Materials which are impractical to segregate shall be physically identified "Hold" to prevent inadvertent use (e.g., paint stick, marker, and tags).

4.3.3 Documents received with the shipment shall be forwarded to President who is responsible for performing a receipt inspection. The receipt inspection shall be documented on a Material Receiving Inspection Report (Exhibit 6). The following shall be verified, as applicable:





4.3.2 Continued .1 Products received agree with the description on the Purchase Order, are properly

marked, and are free of damage. For plate, pipe and bar, the verified markings shall be recorded on the Material Receiving Inspection Report.

.2 Receipt of the required documentation (Material test reports (MTR) or certificates of compliance (C of C)1, Manufacturers Data Reports, as applicable). The marking and identification on the products shall agree with the identification described on the documentation.

.3 MTR's shall be reviewed to determine that the characteristics required to be reported by the material specifications, Code Section, and the Purchase Order have been reported and the results are acceptable. MTR's shall be compared to the latest Edition and addenda of Section II of the Code. Acceptability shall be documented by initials and date on the Material Receiving Inspection Report.

.4 Materials shall be physically inspected to determine the absence of manufacturing defects. Receiving inspections shall be made to determine the acceptability of thickness, diameter, or other critical dimension(s).

.5 Formed shell sections and heads shall be checked for required radii by use of templates, in addition to the circumferential dimensions.

4.3.3 Unacceptable materials shall remain in a segregated area pending disposition by the President. Dispositions shall be handled per section 10 of this manual.

4.3.4 Upon completion of receipt inspection, materials will be marked with the Purchase Order and Heat/Lot number (slab where applicable). Alternatively, a coded marking shall be applied (See paragraph 4.6.4) The President will release the materials for storage or use by initialing the respective line item entries in the release column of the Material Receiving Inspection Report. Original documentation shall be maintained in file by the President. If the products are to be inventoried for use on various projects, they shall be maintained in an identified segregated storage area. Documentation shall be retained until the products have been consumed (See paragraph 4.5).

Section 4

REVISION, 01/01/01

1 Mill or producer identification marking in accordance with the material specification may be

accepted as evidence of material acceptability in lieu of a Certificate of Compliance. Material purchased solely for non-load attachments need not be supplied with documentation provided the material is suitably identified with a material specification for which a P-number has been assigned.




4.4 Material Receipt and Inspection (Field Site) 4.4.1 Code materials shipped directly to a field site by the supplier shall be placed into a

segregated hold area by the Craft Forman pending the completion of Material Receiving Inspection Report. Materials which are impractical to segregate shall be physically identified "Hold" to prevent inadvertent use. Consumables and materials from the Company inventory shall be handled as specified in paragraph 4.5. Documents received with the shipment shall be forwarded to the President for performing the receipt inspection in accordance with paragraph 4.3. Upon completion of receipt inspection, the President will release the materials for use by initialing the respective line item entries in the Release column of the Material Receiving Inspection Report. The President shall maintain original documents on file and supply a copy to the field site. The Craft Forman shall use the Material Receiving Inspection Reports to verify acceptable materials. Only materials "Released" shall be removed from the hold area.

4.5 Distribution of Consumables and Inventory Materials 4.5.1 Welding materials may be shipped directly to the field by the supplier and handled

in accordance with paragraph 4.4. 4.5.2 When materials are issued to a field site from the company inventory, the President

shall be responsible for supplying a copy of the Material Receiving Inspection Report and material documentation to the field site. The Craft Forman shall retain the documents until the completion of the project.

4.5.3 Welding materials shall remain in unopened containers and stored in a controlled area until issued for use. They shall be kept dry and free of contamination. Open containers of low hydrogen electrodes shall be stored in holding ovens maintained at a temperature recommended by the weld material manufacturer and shall not be issued in quantities greater than that required for a four hour supply, unless issued in portable ovens. Unused electrodes shall be discarded. The welder will record the type of welding material used on the Traveler.

Section 4

REVISION, 01/01/01




4.6 Identification During Fabrication or Construction

4.6.1 Plate, pipe and bar shall remain marked with the Purchase Order number and Heat/Lot number (slab where applicable). Alternatively, a coded marking (see paragraph 4.6.4) may be applied.

4.6.2 When material is cut into two or more pieces, identification markings shall be transferred prior to cutting. Alternatively, markings may be transferred after cutting provided only one Heat/Lot is cut at a time and marking is performed prior to moving pieces. Miscellaneous pressure parts shall be marked with the name or trademark of the manufacturer and such other markings as required by the Code, including ANSI Std. designation and pressure class. Miscellaneous small pressure parts issued from stock such as couplings, fittings and bolting materials may be identified by a tag with the material specification number, service rating, P.O. number and heat number if applicable. The tag shall be securely attached to the container. Material used for non-pressure parts welded to pressure parts shall be of weldable quality and marked with the SA or SB material specification number.

4.6.3 The welder(s) shall be responsible for transferring identification markings to all pieces. The method of marking shall be acceptable to the AI.

4.6.4 The use of a coded marking system as an alternative to full identification marking transfer is allowed provided traceability is maintained to the complete identification markings as required by the Code. Upon completion of acceptable receiving inspection, the President will assign a unique coded marking to the MTR, Material Receiving Inspection Report, and then shall physically mark the material with the same unique coded marking. (bins or drums or containers used to store small parts may be marked with the unique code number). Multiple items of the same Heat/Lot (Slab when applicable), but of a different size or shape will be given a numeric-alpha code with a consecutively numbered suffix identifying each individual item. These multiple items shall be clearly indicated on the Material Receiving Inspection Report

4.6.5 The President will keep and maintain a Coded Marking Log (Exhibit 14) listing the item description, identifying number(s), date received and Purchase Order number. The President will be responsible for marking the material with the numeric-alpha code numbers





4.6.6 The numeric alpha code; (example: 99ABC) is comprised as follows:

The first two numerical digits (99) to indicate the year the material was received. Subsequent alpha digits (ABC) are assigned in sequential order starting with A-Z, AA-AZ, BA-BZ, etc... The annual numeric alpha sequence shall be restarted on January 1 of each New Year by advancing the year digits and restarting the alpha digits with A-Z, etc...

4.7 Customer Supplied Material 4.7.1 Customer supplied materials may be used provided a material receipt inspection is

performed in accordance with paragraph 4.3 or 4.4, as applicable. Approved manufacturer’s drawings, material and engineering specifications, as applicable, and the client's Purchase Order shall be used as the basis for the inspection. As a minimum the attributes defined in paragraph 4.3 or 4.4 shall be verified to have been met.

4.8 Identification of Accepted Materials

4.8.1 Acceptable materials shall be stored in a separate storage area. The Craft Forman shall be responsible for control and maintenance of materials in the storage area.

4.8.2 Positive identification shall be maintained to prevent the inadvertent use of incorrect materials. Marking, when required, shall be of a method, and applied in a location and manner that will not interfere with the function of the product. The Craft Forman shall be responsible for assuring identification markings are transferred to all pieces and identification is maintained until fit for final welding, at which time identification shall be transcribed to Traveler(s).

Section 4

REVISION, 01/01/01




5.0 CONTROL OF MANUFACTURING PROCESSES

5.1 Establishment of Project(s)

5.1.1 The President is responsible for the preparation of the Traveler and designation of Inspection Hold Points before release for work.

5.1.2 Prior to the start of work, the President shall contact the AI and advise the AI of the nature of the item(s) to be manufactured and the proposed schedule. The President shall review the Traveler (and drawings) with the AI. The AI may then designate the Hold Points desired. If time is of the essence and the AI grants authorization to proceed by telephone, the President shall document the phone conversation on the Traveler (date, time and name of the inspector), along with any Hold Points the AI requires. Travelers shall not be implemented without prior acceptance by the AI.

5.2 Control of Work

5.2.1 Once Travelers have been approved, they will be provided to the Craft Forman who will direct crews to perform the work.

5.2.2 Travelers shall remain at the general work area while work is in progress. The Craft Forman shall notify the President of upcoming HOLD points reasonably in advance. The President shall be responsible for notifying the AI of upcoming hold points established by the AI. Work shall not proceed beyond assigned inspection (Hold) points without consent from the AI.

5.2.3 The Craft Forman shall be responsible for coordination and scheduling of subcontracted activities. The President shall be responsible for assuring subcontractor's procedures and personnel records, when appropriate, have been reviewed and approved in accordance with Sections 6.0 and 7.0, and are available for the AI's review.

5.2.4 If work cannot be performed in accordance with the approved Traveler, the Craft Forman shall notify the President and indicate the need for the revision. All revisions to the Traveler shall be reviewed and approved by the President and made available to the Authorized Inspector prior to issuing the revised Traveler. The President shall maintain a record of the changes to the Traveler along with the reason for the change in the applicable project file(s). The Project Revision Form (Exhibit 4) shall be used for this record.

Section 5

REVISION, 01/01/01




6.0 WELDING AND HEAT TREATMENT

6.1 General

6.1.1 Welding, including tack welding, shall be performed by qualified welders using Welding Procedure Specifications (WPS's) qualified in accordance with Section IX of the ASME Code and appropriate construction Codes. Heat treatment shall be accomplished when required by the applicable ASME Code Section.

6.1.2 Welding Procedure Specifications shall be readily available to the welders.

6.2 Welding Procedure Specifications

6.2.1 The President shall be responsible for the preparation of Welding Procedure Specifications. Procedure qualification testing shall be accomplished by a skilled welder under the direction of the Craft Forman and documented on a Procedure Qualification Record (PQR). The actual variables, including ranges, used in the welding of the test coupon shall be recorded.

6.2.2 Test results shall be recorded on the PQR and reviewed for acceptability by the President. The PQR shall be assigned a unique identifying number and certified as accurate by the President’s signature and date. Each WPS shall reference the PQR(s) that support it.

6.2.3 The WPS shall be revised when changes to non-essential variables are made. A new PQR will be qualified for changes to essential variables and supplemental essential variables, when required.

6.3 Welder Qualification

6.3.1 The Craft Forman is responsible for qualification of welders. Welders shall be qualified in accordance with an approved WPS under the direction of the Craft Forman.

6.3.2 Welder performance qualification shall be documented on a Welder Performance Qualification (WPQ) record by recording the actual variables used and the resultant ranges of qualification. Test results shall be recorded on the WPQ which shall then be signed and dated by the Craft Forman.

Section 6

REVISION, 01/01/01




6.3.3 Welder Performance Qualification records shall be maintained by the President. Using the data given on the WPQ, the Craft Forman shall be responsible for assuring that welders are assigned welds within the ranges of their qualifications.

6.3.4 Each welder shall be assigned a unique number or symbol to identify his work. Welder identifications shall be recorded on the applicable Traveler by the welder for work in process.

6.3.5 Continued maintenance of welder qualifications shall be documented on a Welder Performance Continuity Record (Exhibit 7) and reviewed by the President at a minimum every 90 days (3 Months). Renewal of a welder’s qualification is required for any process for which the welder has not used for a period of six (6) months or more.

6.3.6 WPS’s, PQR’s and WPQ’s shall be available for the AI’s review. The AI may request requalification of welding personnel or a WPS when there is reason to question the ability to produce sound welds.

6.4 Heat Treatment

6.4.1 Current designs do not require Post Weld Heat Treatment (PWHT). Heat treatment, when required, shall be subcontracted. The President shall approve procedures prior to heat treatment. Heat treatment times and temperatures shall conform to heat treatment requirements of the qualified WPS and applicable ASME Code Section(s).

6.4.2 Records of specific heat treatments shall include time and temperature summaries or temperature recorder charts which establish the following:

.1 Piece or weld identification.

.2 Heating and cooling rates.

.3 Holding time and temperature (in conformance to applicable WPS).

.4 Thermocouple locations

.5 Calibration record for recorder(s)

.6 Signature of operator and date.

6.4.3 Heat treat charts or summaries shall be submitted to the Craft Forman who will review them to assure acceptability and completeness. The Craft Forman shall forwarded results and charts to the President. The President shall approve acceptability of results and charts by initial and date on the documents. These documents shall become part of the completed Job File and shall be made available to the AI.

Section 6

REVISION, 01/01/01




7.0 NONDESTRUCTIVE TESTING

7.1 General

7.1.1 Nondestructive examination (NDE) will be subcontracted to a qualified testing agency or performed In-house in accordance with approved procedures.

7.1.2 Current products do not require radiography, however if the opportunity arises, the following NDE requirements shall be met.

7.1.3 Personnel performing visual weld examination shall meet the qualification requirements of ASME B31.1 (paragraph. 136.1), or SNT-TC-1A, CP-189, or AWS QC1.

7.1.4 In house liquid dye penetrant and/or visual examination personnel shall be certified in accordance to company’s written procedures by the President.

7.2 NDE Personnel

7.2.1 Subcontracted NDE personnel shall be qualified and certified in accordance with a written practice using SNT-TC-1A (current Code accepted edition) of the American Society of Nondestructive Testing.

7.2.2 When NDE is required, the President shall either request services from an NDE test agency or perform the NDE in-house. In-house NDE will be limited to visual examination and liquid dye penetrant examinations. The external services request for an NDE test agency shall require the vendor to submit their current written practice and NDE Level III qualifications for review and acceptance. The President shall be responsible for appointing the NDE test agency’s Level III as the Company’s Level III.

7.2.3 The President shall maintain on file a copy of the external testing agency’s written practice and current certification of their NDE Level III authorized to act on behalf of the Company.

7.3 Application and Procedures

7.3.1 NDE procedures shall conform to Section V of the ASME Code. Technique, applications and acceptance criteria shall conform to the applicable ASME Code Sections governing new construction.

7.3.2 NDE procedures shall be demonstrated to the satisfaction of the AI.

Section 7

REVISION, 01/01/01




7.3.3 In-house visual examiners shall use the Visual Examination Procedure developed by ABC Company. The examiner may either be an employee of ABC Company or be an examiner employed by an NDE organization, approved by the President. If the Visual Examiner is an employee of ABC Company. the following is required In-house visual examiners shall have annual eye exams and shall have vision to

enable them to read a Jaeger Type 2 standard eye chart and be capable of distinguishing and differentiating contrast between the colors used.

If the examiner has not performed any visual examination within one year, the examiner shall be requalified and certified. In no case shall an examiner be used that exceeds this time limit unless requalified and recertified.

The President shall certify all in-house visual examiners.

7.3.4 The AI may call for the requalification of NDE examiners and/or procedures if the AI doubts the effectiveness of results obtained. (for cause)

7.4 NDE Records

7.4.1 NDE results shall be evaluated by a certified Level II or III examiner. NDE reports shall be submitted to the Craft Forman for incorporation with the Traveler. Prior to the sign-off of NDE Hold Points, the President shall review NDE reports to assure the completion and acceptability of the examinations.

7.4.2 In addition to NDE reports, the President shall maintain a copy of personnel certifications and annual visual acuity results for personnel performing NDE.

7.4.3 NDE procedures, personnel qualification/certification records, and NDE reports shall be available for the AI's review.

7.5 Extent of Examination

7.5.1 All final welds will be visually inspected.

7.5.2 The method and extent of NDE shall conform to the Code of construction as determined by the President.

Section 7

REVISION, 01/01/01




8.0 MEASURING AND TEST EQUIPMENT CONTROL 8.1 General

8.1.1 Measuring and test equipment used to meet Code requirements shall be checked at established intervals to assure accuracy.

8.1.2 It is not the intent for this section to include normal commercial devices, such as rulers, tape measures, fillet weld gauges, etc. which provide the desired level of accuracy throughout their useful life.

8.2 Selection and Control

8.2.1 The President is responsible for assuring that measuring and testing equipment are of the proper type, range and accuracy. The President shall be responsible for identifying the equipment required to be calibrated.

8.2.2 Each piece of equipment will be identified with a calibration sticker indicating date calibrated and calibration due date. Damaged or doubtful equipment will not be issued for use until recalibrated. .1 All calibrated equipment will be identified with a serial number. .2 Test pressure gauges shall be calibrated within the twelve (12) month

period prior to use.

8.3 Calibration and Accuracy Checks

8.3.1 The President will maintain a Calibration Log (Exhibit 9) for each piece of controlled equipment which establishes the intervals between calibration checks - based on equipment stability characteristics, intended use, and where applicable, Code requirements.

8.3.2 Each piece of measuring and testing equipment shall be checked for accuracy on or prior to its due date, or taken out of service until checked. Calibration checks shall be performed using measurement standards which have a known relationship to national standards, where such standards exist. .1 Calibration checks performed by the company shall be documented on the

Calibration Control Record at the specified intervals. .2 Calibration agencies, when used, shall furnish a certificate of calibration or

other suitable certification attesting to the use of nationally recognized standards.





9.0 PRESSURE TESTS 9.1 General

9.1.1 The pressure retaining boundary of Code items shall be subject to a hydrostatic pressure test(s) performed to the requirements of the applicable ASME Code section. If installed equipment is included in the pressure test boundary, the Craft Forman or President shall coordinate pressure tests with the client / owner.

9.1.2 Pressure tests shall be documented on a Traveler (Exhibit 3) and witnessed by the President and the Authorized Inspector.

9.2 Test Pressure, Temperature and Water Quality

9.2.1 For boiler components (including boiler external piping), the water temperature used when filling the boiler shall not be less than 70° F nor the metal temperature greater than 120° F. The test should not be performed until all pressure parts being tested have metal temperatures of at least 70° F. but not more than 120° F. The test pressure for manufactured boiler parts shall not be exceeded by 6% nor at any time shall the boiler be subjected to a general primary membrane stress greater than 90% of its yield strength (0.2%) at the test temperature or as specified by the President.

9.3 Test Gauges and Static Head

9.3.1 Dial indicating pressure test gauges should have a range of approximately double the test pressure but not less than 1.5 times. Digital pressure gauges having a wider range of pressure readings may be used provided the readings give the same or greater degree of accuracy as obtained with dial gauges. Dual test gauges shall be used for pressure tests. Installed gauges may be used for pressure tests provided they meet ABC Company calibration, range and accuracy requirements. Pressure gauge calibrations and accuracy checks shall be in accordance with approved procedures and records shall be traceable to recognized national standards.

9.3.2 The test gauge must be directly connected and located where it will be visible to the person controlling the application of the test pressure during the test. The actual pressure occurring at the top of the item or system being tested shall be considered the valid pressure. Therefore, the location of the gauge shall take into account the effects of water leg or static pressure on the test gauge.

Section 9

REVISION, 01/01/01




10.0 NONCONFORMITIES

10.1 General

10.1.1 A nonconformity is any condition which does not comply with the applicable rules of the Jurisdiction, the requirements of this Quality Control Manual, or the specific rules of the applicable ASME Code Section. Some examples of nonconformities may be: .1 Use of materials which do not meet ASME Code requirements. .2 Use of a test gauge which is out of calibration. .3 Welding or NDE examination performed by personnel who are not properly

qualified. .4 Failure to adhere to procedure requirements. .5 Bypass of a HOLD point.

10.1.2 Nonconformities must be corrected or eliminated before a Code item is complete and acceptable.

10.1.3 Material receipts which are not accepted by the President and result in prompt disposal or return to the supplier are not considered nonconformities.

10.2 Identification

10.2.1 All Company personnel are responsible for reporting potential nonconforming conditions to the President who shall:

.1 Investigate the condition and determine if a nonconformity exists.

.2 Identify the affected item(s) as on “Hold" with appropriate marking or tags to prevent further processing or use. Whenever possible, nonconforming items shall be physically segregated from acceptable items.

.3 The President shall document the nonconformity on a Nonconformity Report (Exhibit 8) and initiate actions to prevent further work on the item(s) until the nonconforming condition has been resolved.

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10.3 Disposition

10.3.1 The President shall be responsible for assuring that nonconforming conditions are either resolved or eliminated using the following dispositions:

.1 Rework (including repair by welding): If disposition actions require repair or rework to return the affected item(s) to a conforming condition, they shall be planned and controlled in accordance with the requirements of this Manual.

.2 Accept as is: If the disposition involves no physical rework or repair activities, the President will ensure that the disposition instructions include the appropriate design reconciliation, drawing revision, or technical justification for these actions.

.3 Reject: This disposition shall include instructions for the removal, replacement and disposal of the nonconforming material or item.

10.3.2 The President shall obtain the AI's acceptance of the disposition prior to implementing any corrections. Instructions prepared for weld repair of base materials or base material defects shall be presented to the AI for review and concurrence prior to making the repair. If required, Hold points may be established.

10.4 Processing and Closure

10.4.1 The President shall verify that the disposition actions are complete and acceptable, including the removal of rejected items from the work area, and that the nonconforming condition has been eliminated. Upon completion of correction, the President shall verify acceptance and obtain concurrence from the AI.

10.4.2 The President shall be the only individual to remove an item from "Hold".

10.4.3 The President shall be responsible for maintaining a file of nonconforming conditions. Nonconformity Report(s) will be available for the AI's review. Copies of Nonconformity Report(s) shall be included in applicable Job File(s).

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11.0 REPORTS, RECORDS AND CODE STAMPING

11.1 General

11.1.1 Code symbol stamps shall be maintained and controlled by the President. The Code symbol shall be applied only with the concurrence of and in the presence of the AI.

11.2 Reports and Records

11.2.1 Upon completion of manufacture, the President will assemble completed records and review Travelers to assure all manufacturing activities, including inspections, examinations and tests, have been completed and accepted.

11.2.2 The President shall prepare required "Manufacturer's Data Report" (MDR) form2. When applicable, Manufacturers' Partial Data Report forms for parts and components furnished by others shall be attached to these forms. The President will sign MDR's for company certification.

11.2.3 The President will review the MDR's and completed Job records, including Traveler(s), with the AI. When the AI is satisfied that the work conforms to the ASME Code, the AI may sign the MDR's, and Traveler.

11.2.4 The President shall file the MDR’s with the Authorized Inspection Agency, Jurisdiction, client and, the National Board, as applicable. One copy shall be retained in the Job File for five (5) years, unless National Board registered.

11.2.5 For ASME Code Section I and B31.1, radiographs and reader sheets shall be maintained on file for five (5) years.

11.3 Code Stamping and Identification

11.3.1 Completed items shall be identified with stamping / nameplate (Exhibit 10) or (Exhibit 11) containing the data and official Code symbol stamp required by the applicable Code section


2 Sample copies of the "Manufacturers' Data Report" forms are found in the appendices to the applicable Code section.




12.0 REPAIR AND ALTERATION CONTROLS

12.1 General

12.1.1 This section establishes the requirements for making welded repairs and/or alterations to pressure retaining items of ASME Section I Power Boilers, ASME Section IV Heating Boilers (except Cast Iron), ASME Section VIII Div. 1 Unfired Pressure Vessels and ASME B31.1 Power Piping.

12.1.2 In the absence of specific State Rules and Statutes governing repairs and alterations, the rules of the NBIC or ASME Code for construction shall apply. Acceptance of the repair method(s) shall be obtained from the Inspector prior to execution of the repairs. Pre-acceptance of Routine Repairs may be obtained from the Inspector in accordance with 12.3.4 of this manual, provided these are allowed by the Jurisdiction Rules.

12.1.3 Alterations shall be controlled in the same manner as manufacture of new pressure retaining items as delineated previously in this manual. These controls include, as applicable, design calculations, engineering drawings, purchase of materials, welding, post weld heat treatment, nondestructive examinations, and pressure testing.

12.1.4 Examples of repairs within the scope of this program include, but not limited to: .1 Welded repairs or replacements of pressure parts or attachments that have

failed in a weld or in the base material. .2 The addition of welded attachments to pressure parts such as, but not

limited to: a. Studs for insulation or refractory lining. b. Hex steel or expanded metal for refractory lining. c. Ladder clips. d. Brackets. e. Tray support rings. f. Corrosion-resistant strip lining. g. Corrosion-resistant weld overlay. h. Weld build-up of wasted areas.

.3 Replacement of pressure retaining parts identical to those existing on the boiler or pressure vessel and described on the original manufacturer's data report such as, but not limited to:

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Paragraph 12.1.4.3(Continued) a. Replacement of furnace floor tubes, sidewall tubes, or both, in a

boiler. b. Replacement of a shell or head in accordance with the original

design. c. Rewelding or repair welding of circumferential or longitudinal seams

in a shell or head. d. Replacement of nozzles of a size where reinforcement is not a

consideration. .4 Replacement of boiler tubes where welding is involved..5 The installation

of a flush patch to a boiler. .6 Welding of gauge holes. .7 Welding of wasted or distorted flange faces. .8 Replacement of slip-on flanges with weld neck flanges.

12.1.5 Routine Repairs are repairs that restore the original design configuration and material of the boiler and its pressure parts. The President shall determine that the routine repair method is acceptable to the Jurisdiction where the repair is to be performed.

Examples of routine repairs: .1 Weld repair or replacement of a section of tubes or pipes five (5) NPS in

diameter and under, and their attachments. .2 The addition or repair of non-load bearing attachments to pressure retaining

items where postweld heat treatment is not required, such as lugs or pins for refractory lining or insulation.

.3 Weld build-up of wasted areas in shells and heads not exceeding 100 sq. in. or 25% of the nominal wall thickness or 1/2 inch, whichever is less.

.4 Corrosion resistant weld-metal overlay not exceeding 100 sq. in.

12.1.6 A Job Work Order (Exhibit 2) shall be initiated defining the required nature of the work and shall appear on all related documents.

12.2 Materials

12.2.1 All new materials and parts shall be purchased, received, and controlled in the same manner as described in section 4 of this manual.

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12.2.2 Materials used to make repairs and alterations shall conform to the requirements of the original Code of Construction. Materials shall have at least the minimum physical properties of the material to be repaired and shall be compatible with the original material.

12.2.3 Prior to initiating any work, the President shall identify base materials in order to ascertain the welding process(es) to be used, preheat and postweld heat treatment, filler metals, etc. Base material types of the item to be repaired shall be determined using manufacturer's data reports, drawings, or equipment records, as applicable. When necessary, other means acceptable to the Inspector shall be used to determine base metal compositions.

12.3 Establishment of Repair Methods

12.3.1 Processes used for repair/alteration may consist of any combination of mechanical or thermal means appropriate for the circumstances, as permitted by Jurisdictional Rules or the NBIC, followed by required inspections, examinations and tests. When there is a conflict between the NBIC and Jurisdictional rules, the Jurisdictional Rules will take precedence.

12.3.2 Repairs/alterations shall be carefully reviewed by the President to determine if the described work requires the preparation of a Traveler (Exhibit 3). The Traveler shall be prepared, reviewed and approved in accordance with paragraph 5.2.3 of this manual.

12.3.3 For repairs and alterations, the President shall contact the Inspector and advise the Inspector of the nature and extent of the repair or alteration, and the proposed method(s). Traveler shall not be implemented without prior acceptance by the Inspector.

.1 If the Inspector chooses to witness operations or assign inspection Hold Points, the President shall review the Traveler (and drawings or sketches) with the Inspector. The Inspector may then designate the Hold Points desired. If the Inspector grants authorization to proceed by telephone, the President shall document the phone conversation on the Traveler (date, time and name of the Inspector), along with any Hold Points the Inspector requires.

.2 The Inspector shall be promptly notified of any revisions to the Traveler due to unforeseen circumstances or unanticipated damage.

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12.3.4 The Inspector shall provide prior acceptance of Routine Repair procedures (Reference 12.1.2). For such repairs, the President shall note “Routine Repair” in the “AI” Review prior to fabrication space on the Traveler and also indicate the date of AI acceptance in the space provided. The completed Job package shall be forwarded to the Inspector for review and signature of National Board Form, R-1.

12.3.5 Repair Traveler(s) shall be implemented in the same manner as described in section 5 of this manual.

12.4 Welding, NDE, and PWHT

12.4.1 The requirements of section 6 of this manual shall apply to welded repairs and alterations.

12.4.2 Heat treatment of repair welds shall be accomplished when required by the original ASME Code section for new construction, unless the use of alternate methods (such as elevated preheat or half bead techniques) are acceptable to the Inspector.

12.4.3 Repair welds shall be subject to the same NDE requirements as the original welds, unless alternate methods are accepted by the Inspector and the Jurisdiction where the pressure retaining item is installed.

12.5 Inspection and Testing

12.5.1 All repairs and alterations shall be subject to a hydrostatic pressure test(s) performed to the requirements of the NBIC, Jurisdiction Rules, or when, in the opinion of the Inspector, hydrostatic tests are considered necessary. When required for installed equipment, the Craft Forman shall coordinate pressure tests with the client / owner.

12.5.2 Repairs shall be pressure tested to the minimum pressure required to verify the leak tightness of the repair but not greater than 1.5 times the MAWP stamped on the pressure retaining item. Water or other liquid medium shall be used for hydrostatic pressure tests. Replacement parts used in repairs shall be pressure tested at least to the maximum allowable working pressure stamped on the pressure retaining item being repaired.

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12.5.3 Water and metal temperature requirements specified in section 9 of this manual shall apply to pressure tests of repair welds and alterations.

12.5.4 The pressure test shall not be conducted until the metal temperature is at least 60° F. but not greater than 120° F., unless the owner provides information on the fracture toughness of the materials indicating a lower temperature may be used. Prior to performing hydrostatic tests on vessels located outdoors, the minimum design metal temperature must be determined. Hydrostatic test pressure shall not be applied until the vessel and its contents are at about the same temperature. The hydrostatic test pressure shall be as specified on the Manufacturer's Data Report form or as determined by the President. Hold time for the pressure test shall be a minimum of 10 minutes.

12.5.5 When contamination of the contents of pressure retaining item by liquid is possible or when pressure testing is not practical, other methods shall be used to evaluate the structural integrity of the item. As an alternate to the pressure test, NDE methods that verify the integrity of the repair may be used subject to the concurrence of the Inspector, and where required the Jurisdiction, prior to performing the examination.

12.5.6 When pressure tests are conducted above operating pressure, safety valves must be gagged or have hydrostatic test plugs installed. Test plugs are recommended on any test being conducted above design pressure. Gags, when used, shall be hand tightened to prevent stem damage.

12.6 Stamping, Reports and Records

12.6.1 After the repair or alteration is complete, the President shall review job records, including Traveler(s), to assure all planned work is complete and acceptable. The President shall then prepare the applicable "Report of Repair" or "Report of Alteration"3. Each form shall be assign a number and recorded on the “Assigned ‘R’ Report Number Log (Exhibit 13). The President shall sign the form as company certification.

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3 Sample "Report of Repair” (R-1 form), "Report of Alteration" (R-2 form), and other forms are found in Appendix 5 of the NBIC.




12.6.2 The President shall present the "Report of Repair" or "Report of Alteration" form and applicable records to the Inspector. When the Inspector is satisfied all Jurisdiction and NBIC requirements have been met, the Inspector may sign and date the form. The President will then file the Form R-1 with the Jurisdiction when required, Owner, and Authorized Inspection Agency responsible for inservice inspection, and the Inspector when requested. Form(s) R-1 shall be registered with the National Board when required by the Jurisdiction. For alterations, the President shall distribute Form R-2 as specified above, as well as with the National Board, including additional support documentation providing that the item is registered.

12.6.3 Pressure retaining items repaired or altered in accordance with this manual may have a nameplate attached or be stamped with the "R" symbol (Exhibit 11). The "R" symbol stamps shall be maintained and controlled by the President and will only be applied with the concurrence of the Inspector. When stamping at a field location, appropriate safeguards for the "R" stamp shall be employed. For Routine Repairs the nameplate requirements may be waived, if allowed by the Jurisdiction.

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13.0 AUTHORIZED INSPECTOR

13.1 General

13.1.1 This section describes the relationship between the Company and the Authorized Inspector relative to access and coordination necessary to perform the duties described in this Manual.

13.1.2 The President shall be responsible to ensure a service contract is maintained between the Company and a qualified Authorized Inspection Agency.

13.2 Duties and Responsibilities

13.2.1 The Authorized Inspector shall be regularly employed by an ASME accredited Authorized Inspection Agency and qualified by written examination under rules of any state of the United States or province of Canada which adopted the ASME Code. The Authorized Inspector shall posses an "A" endorsement. In the Repair Section, reference to AI may be a commissioned inspector.

13.2.2 The President shall be the primary liaison with the Authorized Inspector. The President will coordinate schedules to ensure the Authorized Inspector has sufficient notice for witness and verification of activities requested in advance and of established "Hold Points".

13.2.3 The President has responsibility to ensure the Authorized Inspector has access to or is provided with documents deemed necessary. The President shall make a current controlled copy of this Manual available to the Authorized Inspector. The Authorized Inspector shall be granted free access to all parts of the shop or field sites involving Code work, and to supplier's facilities involving manufacturers of or suppliers of Code materials or subcontracted services. The same access shall be provided to the Authorized Inspector Supervisor at anytime requested.

13.2.4 The Authorized Inspector will be required to adhere to all Company safety rules and facility access procedures. The Authorized Inspector shall also adhere to safety and access requirement of the Company's customer at field locations. The President shall be responsible for making the Authorized Inspector aware of applicable policies and rules.

13.2.5 The Company will furnish the Authorized Inspector a suitable work area and an area for filing of documents.

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14.0 EXHIBIT INDEX

EXHIBIT NO. DESCRIPTION Revision

1 Controlled Manual Holders List 01/01/01

2 Job Work Order 01/01/01

3 Traveler (2 Pages) 01/01/01

4 Project Revision Form 01/01/01

5 Purchase Order 01/01/01

6 Material Receiving Inspection Report 01/01/01

7 Welder Performance Continuity Record 01/01/01

8 Nonconformity Report 01/01/01

9 Calibration Log 01/01/01

10 Nameplate Facsimile ("PP") 01/01/01

11 Repair and Alteration Nameplate Facsimile(s) 01/01/01

12 Letter of Transmittal 01/01/01

13 Assigned ‘R’ Report Number Log 01/01/01

14 Coded Marking Log 01/01/01

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EXHIBIT 1

Controlled Manual Holders List

Revision No. Revision No. Revision No. Copy No. Issued to (Name and Title) Date

ReceivedDate

ReturnedDate

ReceivedDate

Returned Date

ReceivedDate

Returned

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EXHIBIT 2

Job Work Order

Job Work Order Number Date of Order Description Of Work

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EXHIBIT 3

Master Traveler Customer Job Work Order Number Address: Serial Number Shop or Field Ship to: “PP” “Repair” “Alteration” Nat’l Board Number(s) Drawing Number(s) Drawing (Rev level and date) Customer PO# Drawing (Rev level and date) Starting Date Equipment Description Delivery Date Authorized Inspectors Review prior to Fab. Date

QUALITY CONTROL AUTHORIZED INSPECTOR

HOLD POINT

Initial Date HOLD POINT

Initial Date

CALCULATION REVIEW CONSTRUCTION DRAWING REVIEW WELDING PROCEDURE REVIEW WELDERS QUALIFICATION REVIEW MATERIAL CODE IDENTIFICATION FINAL INTERNAL INSPECTION DYE PENETRANT EXAM (when reqd) RADIGRAPHIC EXAM (when reqd) PWHT COMPLETE (when reqd) NCR’S COMPLETE (when reqd) TYPE OF PRESS. TEST HYDROSTATIC PNEUMATIC OTHER (Describe in Remarks) PRE-PRESS. TEST PSIG FINAL PRESS. TEST PSIG TEST GAUGE SN’S & DATA PLATE / STAMPING VERIFIED DATA PLATE / STAMPING COMPLETE DATA REPORTS SIGNED

REMARKS: Describe important information such as impact testing, special service, and nameplate

NUMBER OF DRAWINGS IN SHOP A/I Hold Points Summary

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EXHIBIT 3

Sub-Traveler

Job Work Order No. QUALITY CONTROL AUTHORIZED INSPECTOR

Serial No. Weld Procedure / Joint ID /

Materials / Location

WELDER ID

HOLD POINT Initial Date HOLD

POINT Initial Date

Joint ID Material Coded Marking FIT-UP ROOT

WPS No. Material Coded Marking FINAL NDE















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EXHIBIT 4

Project Revision Form

Job Work Order Number

Change Number Date Changed By Drawings or

Documents Affected Description of

Change/Revision

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EXHIBIT 5

PURCHASE ORDER

ABC Company More than just the alphabet….

P.O. # [100] DATE: JUNE 6, 2007

VENDOR

[Name] [Company Name] [Street Address] [City, ST ZIP Code] [Phone] Customer ID [ABC12345]

SHIP TO

[Name] [Company Name] [Street Address] [City, ST ZIP Code] [Phone] Customer ID [ABC12345]

SHIPPING METHOD SHIPPING TERMS DELIVERY DATE

QTY ITEM # DESCRIPTION JOB UNIT PRICE LINE TOTAL

SUBTOTAL

SALES TAX TOTAL

1. Please send two copies of your invoice.

2. Enter this order in accordance with the prices, terms, delivery method, and specifications listed above.

3. Please notify us immediately if you are unable to ship as specified.

4. Send all correspondence to: [Name] [Street Address] [City, ST ZIP Code] Phone [000.000.0000] Fax [000.000.0000]

Authorized by Date

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EXHIBIT 6

Material Receiving Inspection ReportStock/Part No Rev: Qty: Job Work Order No: Date:

Vendor: P.O. No: P.O. Item: Complete

Incomplete Material Spec No: Issue / Addenda Date: Grade: Type: Class:

Description: Release Column Initial/Date

1. Check identification markings of parts or material to applicable material specification or purchase order marking requirements. Spec/Doc: _________________________

2. Check Certificate of Compliance for completeness, signature and traceability to parts or material

3. Check Material Test Report for:

a. ABC Company verification signature and date (MTR). b. Traceability of MTR to parts or materials. c. All tests reported as required by P.O.

4. Check and record the following dimensions:

a. Length: ________ b. Width: ___________ c. Thickness: ___________ d. OD/ID: ________ e. Roundness: __________ f. Other_________________

5. Check finish (dents, burns, seams, laps, cracks, flaws) Spec/Doc: _________________________

6.. Record vendor material markings: ______________________________________ ______________________________________________________________________

7 ABC Company coded marking assigned: __________________________________

Comments: All inspections above complete and ready to release for Code Work

________________________________________________________________________________

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EXHIBIT 7

Welder Performance Continuity Record WELDERS NAME &

ID NUMBER

PROCESS

JAN

FEB

MAR

APR

MAY

JUN

JUL

AUG

SEP

OCT

NOV

DEC

When updating this record, the job number and date are entered in the box for the month welding was performed. The welder’s qualifications shall expire if no welding is performed for six (6) months.





EXHIBIT 8

Nonconformity Report DISTRIBUTION: NCR Number: ___________________________________ Original: NCR Master Log Job Number/Serial Number: ________________________ Copy: Job file Location of Item in Shop: ___________________________

DESCRIPTION OF NONCONFORMITY: Reported By: ________________________________ Date: __________

PROPOSED DISPOSITION: Engineering: ________________________________ Date: __________ Quality Control:___ ___________________________ Date: __________ Authorized Inspector: _________________________ Date: __________

CORRECTIVE ACTION / REINSPECTION: Quality Control: ______________________________ Date: __________ Authorized Inspector: _________________________ Date: __________

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EXHIBIT 9

Calibration Log INSTRUMENT: ____________________________________________________ S/N: _______________________________________________

INSTRUMENT RANGE: _________________ *WORKING RANGE: ____________________ TOLERANCE: ____________________________

CALIBRATION FREQUENCY: ____________________________________________________________________________________________

TO BE CALIBRATED BY: OUTSIDE SOURCE ABC Company STANDARD: _________________________________________________

OUT OF SERVICE AND CALIBRATION DUE

DATE DATE CALIBRATED AND

PLACED BACK IN SERVICE% DEVIATION FOUND

(INDICATE %+/-) INSTRUMENT ADJUSTED (YES/NO)

LABEL PLACED ON INSTRUMENT(YES/NO)

CALIBRATED OR

ACCEPTED Initial / Date

Instrument is not to be released for use past due date until it has been checked for accuracy and re-calibrated

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EXHIBIT 10

Nameplate Facsimile ("PP") I. For piping operating at 800○ F or below.

1. Stamp “ABC Company” and Job Number (obtain from President) at the weld point farthest from boiler.

2. Use 5/16” steel stamp numbers and letters. 3. Apply “PP” stamp at same location.

II. For piping operating above 800○ F. 1. Fabricate a nameplate out of light gauge black or galvanized mild steel sheet

to facilitate easy stamping. All letters should be made with minimum 5/16” steel stamps.

2. Tack the plate in each corner to a suitably sized channel iron or steel plate stand-off. This channel iron or steel plate stand-off should be securely welded to the assembly in question next to the last weld at the farthest limit of Code jurisdiction (such as next to the weld on the flange bolted to the second valve on a steam supply pipe off a boiler.

3. This plate should be so mounted as to be readily visible after the piping is installed and after the insulation is installed on the assembly.

4. This identification plate will normally be made up in the Shop under the direction of the President for installation per above by the Craft Foreman.

PPPPPP ABC COMPANY, INC.

SERIAL NO.________ Note: Stamping or mounting of nameplate may be done only after final approval of

the Authorized Inspector.

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EXHIBIT 11

Repair and Alteration Nameplate Facsimile

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REPAIRED ABC Company

Certificate Holder

R

______________ _______________________National Board R Date RepairedCertificate Number

ALTERED ABC Company

Certificate Holder

R M.A.W.P. P.S.I.

AT ºF


RE-RATED ABC Company .. Certificate Holder

R M.A.W.P. P.S.I.

AT ºF





EXHIBIT 12

Letter of Transmittal TO: ________________________________________________ FROM: _________________________________________________

CUSTOMER: ________________________________________ JOB NO.: _______________________________________________

SERIAL NO.(s): ______________________________________ MODEL: ________________________________________________ SEND REC ITEM REMARKS # ORIGINALS # COPIES Q.A. MANUAL / MANUAL REVISIONS FABRICATION PRINTS BILL OF MATERIALS DESIGN CALCULATIONS PWHT DESCRIPTION NON CONFORMITY REPORT MATERIAL RECEIVING INSPECTION MILL CERT’S / C OF C NDE RECORDS PWHT RECORDS

NAMEPLATE FACSIMILE COMMENTS:______________________________________________________________________________________________________________

SENT RECEIVED ACKNOWLEDGEMENT RECEIPT INIT. __________________ DATE ___________ INIT. _________________ DATE ___________ INIT. ___________________ DATE ____________

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EXHIBIT 13

Assigned “R” Report Number Log REPAIR /

ALTERATION SERIAL NUMBER

NATIONAL BOARD

NUMBER

NATIONAL BOARD

FORM TYPE DESCRIPTION

OF ITEM CUSTOMER DATE ISSUED

DATE MAILED TO NAT’L BD.

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EXHIBIT 14 Coded Marking Log Released

Unique Coded Marking

Number

Purchase Order

Number Material Description and

Dimensions Material

Specification Grade Type Class

*Material Heat Number

Received Date Initial Date

* When the material specification requires slab number traceability, the heat and slab numbers shall be recorded

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ABC Qc Manual

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