MANUFACTURER QUALITY MANAUAL NAME: ADDRESS:

Quality Control System Manual for Shop and Field Fabrication of Items in accordance with ASME B31.1, ASME Section I and ASME Section VIII, Div. 1 and Repairs and Alterations in Accordance with the National Board Inspection Code and Jurisdictional Requirements at Shop and Field Locations.

Edition: 1

Date: XXXXX

Approval:

A.I. Acceptance:

Manual Control:

Assigned To:

Table of Contents

1. STATEMENT OF AUTHORITY 2. ORGANIZATIONAL CHART 3. GLOSSARY OF TERMS 4. QUALITY CONTROL DEPARTMENT 5. AUTHORIZED INSPECTOR 6. DRAWINGS, DESIGN CALCULATIONS AND SPECIFICATIONS 7. MATERIAL CONTROL 8. EXAMINATION AND INSPECTION PROGRAM

Page 1 Page 2 Page 3 Page 7 Page 8 Page 9 Page 11 Page 14 Page 16 Page 18 Page 20

9. CORRECTION OF NON-CONFORMITIES
10. WELDING CONTROL 11. NON-DESTRUCTIVE EXAMINATION (NDE) 12. HEAT TREATING 13. CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT 14. RECORDS RETENTION

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Page 23 Page 24 Page 25 Page 26 Page 32

15. REGISTRATION WITH NATIONAL BOARD

16. REPAIRS & ALTERATIONS 17. EXHIBITS

1. STATEMENT OF AUTHORITY

The Quality Control System of MANUFACTURERS NAME. shall comply with ASME B31.1, ASME Section I, and ASME Section VIII Div. 1 for fabrication in both shop and field locations and Repairs and Alterations (Shop and Field) in accordance With The National Board Inspection Code. Manufacturers Name gives the Quality Control Manager the authority, the responsibility, and the organizational freedom to identify quality control problems and to initiate, recommend, and provide solutions. The Quality Control Manager is responsible for the editing of the Quality Control Manual and the compliance of it. The Quality Control Manager has the full support of the management of Manufacturers Name, Inc. to carry out his responsibilities and to fulfill his purpose. The Quality Control Managers authority and responsibility include both shop and field sites. Any disagreement between the Quality Control Manager and other Departments shall be settled by myself. Resolutions, when made, shall not compromise the Code.
Signed, Manufacturers Name

Name: PRESIDENT

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2. ORGANIZATIONAL CHART

President Vice-President

Quality Control Manager

Purchasing

Engineering

Sales

Forman Q.C. Inspectors Shop & Field

Material Receiving Shop & Field

Shop Fabrication & Field Activities

Legend
Line of Authority Technical Coordination

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3. GLOSSARY OF TERMS ALTERATION :

3.0.1 Any change in the item described on the original Manufacturers Data Report which affects the pressure containing capability of the pressure retaining item. Non-physical changes such as an increase in the maximum allowable working pressure (internal or external) or design temperature of a pressure retaining item shall be considered an alteration. A reduction of the MDMT such that additional mechanical tests are required shall also be considered an alteration.

ASME:
3.0.2 The American Society of Mechanical Engineers.

AUTHORIZED INSPECTOR (AI):

3.0.3 The Authorized Inspector shall be an Inspector regularly employed by an ASME Accredited Authorized Inspection Agency, i.e., the inspection organization of a state or municipality of the United States, a Canadian province, an insurance company authorized to write boiler and pressure vessel insurance. The inspector shall not be in the employ of the Manufacturer. All Inspectors shall have been qualified by a written examination under the rules of any state of the United States or province of Canada which has adopted the Code.

AUTHORIZED INSPECTION AGENCY (AIA):

3.0.4 An AIA shall be either a Jurisdiction or an Insurance Company which meets the requirements as defined in the National Board Inspection Code.

CODE:
3.0.5 The ASME Boiler and Pressure Vessel Code, Section I, Section VIII, Div. 1, and ASME B31.1 including addenda and code cases approved by the council of the ASME and latest Addenda.

COMPANY:
3.0.6 Manufacturers Name.

DEPARTMENT:
3.0.7 Where department is referred to in this manual, it shall be the responsibility is the person in charge of that department.

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EXAMINATIONS:
3.0.8 Are those performed by Manufacturers Name. Quality Control personnel.

FOREMAN:
3.0.9 Shop and field fabrication

INSPECTIONS:
3.0.10 Are those performed by the AI in all Code work for compliance to Code Rules.

MTR:
3.0.11 Mill Test Reports, or Material Test Reports.

NDE:
3.0.12 Non-destructive examination.

NON-CONFORMITY:
3.0.13 Any condition existing in raw material, or work in process, or finished product that does not comply with drawings, specifications, Code, or Company Name standards and procedures and this Quality Control Manual.

PQR:
3.0.14 Procedure Qualification Record

PRINT:
3.0.15 Drawing

QCM:
3.0.16 Quality Control Manager

QC:
3.0.17 Quality Control Department

REPAIR
3.0.18 The work necessary to restore a pressure retaining item to a safe and satisfactory operating condition.
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SN:
3.0.19 Serial number

SNT-TC-1A Addenda
3.0.20 Recommended Practices, America Society of Non-destructive Testing a set of guidelines to assist the manufacturer in developing uniform procedures for the qualification and certification of NDE personnel to the latest Code accepted Edition & Addenda will be used.

VT:
3.0.21 Visual Examination

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

WPS:
3.0.23 Welding Procedure Specification

JURISDICTION OR JURISDICTIONAL AUTHORITY:

3.0.24 A governmental entity which administers and enforces one or more sections of the ASME Code, all references to jurisdiction in this section are applicable only when involvement is required by jurisdictional policy.

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

ORIGINAL CODE OF CONSTRUCTION:

3.0.26 Documents promulgated by recognized National Standards Writing Bodies that contain technical requirements for construction of pressure retaining items or equivalent to which the pressure retaining items were certified by the original manufacturer.

RE-RATING:
3.0.27 SeeAlteration
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NON-CODE ITEM:
3.0.28 A pressure retaining item which was not designed or constructed to any code of construction or an item which was designed in accordance with the ASME Code but not inspected, certified, and stamped with the Code Symbol.

ROUTINE REPAIRS:
3.0.29 Those repairs listed and defined in the NBIC as Acceptable Routine Repairs.

NBIC:
3.0.30 Nation Board Inspection Code

RT:
3.0.31 Radiographic Examination

UT:
3.0.32 Ultrasonic Examination

MT:
3.0.33 Magnetic Particle Examination

PT:
3.0.34 Liquid Penetrant Examination

WPQ:
3.0.35 Welder Performance Qualification. WPQ: Welding Operator Performance Qualification.

PRI: Pressure Retaining Item:

Any boiler, pressure vessel, piping or material used for the containment of Pressure, either internal or external.
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4. QUALITY CONTROL DEPARTMENT

4.1 The Quality Control Manager is responsible for preparation, revision, distribution, control, and implementation of the Quality Control System Manual. 4.2 Any revision of the manual, however, results in a new edition and is presented to the Authorized Inspector for his acceptance prior to implementation. 4.3 The ASME accredited Authorized Inspection Agency (AIA) will be presented with a controlled copy of the Quality Control System Manual. 4.4 The QCM has custody of the Code Symbol Stamps and controls them. A Code Symbol Stamp may be applied only with the concurrence of the AI. 4.5 The QCM heads the Quality Control Department and is responsible for performance of required examinations and tests. He will prepare and sign the Traveler and Manufacturers Data Report. In case of his absence, his designee will prepare and sign the Traveler (Exhibit 3a, 3b, & 3c) and Manufacturers Data Report. 4.6 Controlled Quality Control Systems Manuals are issued by the QCM. Revision to manuals are treated as new editions and previous edition filed. Records of issuance of each edition are kept by the QCM. (See Exhibit #8).

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5. AUTHORIZED INSPECTOR
5.1 The QCM is the company Liaison with the Authorized Inspector.

5.2 The AI shall have free access to the premises of Manufacturers Name. for the surveillance of records, specifications, design drawings, calculations, procedures and other documents relating to Code fabrication and inspection of materials, parts and appurtenances, and to field sites where ASME Code work is in progress. The AI has the privilege of visiting any vendor or supplier of materials, parts, and service to Manufacturers Name. that he deems necessary to satisfy inspection requirements of such materials, parts and service. All access afforded the authorized inspector shall be extended to his supervisor to perform any required audits or reviews.

5.3 A controlled copy of the Quality Control System Manual is provided for use by the AI
5.4 Any non-conformity requiring AI acceptance is referred to him for his concurrence of proposed resolution. 5.5 The Authorized Inspector, as defined by the ASME Code, shall have been qualified by a written examination under the rules of any State of the United States or Province of Canada which has adopted the Code. He will be employed by an AIA with which Manufacturers Name has a current agreement for services.

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6. DRAWINGS, DESIGN CALCULATIONS AND SPECIFICATIONS

6.1 The QCM along with Engineering will perform the review of customers specifications, and drawings to assure Code compliance can be attained. 6.2 Each vessel is given a SN. SNs are listed in a log to avoid duplication. (Exhibit #9). 6.3 Engineering prepares and checks all design calculations. Customers calculations are not used. Calculations are based on allowable stress listed in ASME Section II, Part D, for use by the applicable construction Code and not from information on MTRs. 6.4 Drafting prepares in-house drawings. Drafting specifies on drawings: Construction Code Section; Edition and Addenda; NDE Requirements; Post Weld Heat Treatment requirements; Design Parameters such as temperature and pressure; Hydrostatic Test Pressure; Material Specifications; Job Number; Welding Procedures; and stamping information. Welding procedures to be used are determined by the Q.C. Manager. 6.5 Engineering specifies materials to be used in Code fabrication. Materials are specified as SA, SB, SFA, AWS or identical ASTM specifications (see Section II, Part A & B)

6.6 Drawings, Specifications and Design Calculations must be approved by the QCM. (By initialing and dating)
6.7 Distribution of prints is the responsibility of QC. Upon receipt of prints from Drafting, an appropriate number of sets are distributed to the applicable departments. Prints are issued to Foremen by QC. 6.8 QC hand carries one set of revised prints to the Foreman (or Foremen) over the job. Old prints are destroyed before new prints are substituted. Other prints are distributed appropriately to QC and Fabrication. Any drawings affected by a revision will be exchanged. Unissued sets of prints are also destroyed. 6.9 QC reviews drawings and calculations, prior to the start of fabrication, with the A.I. so that he may designate on the Traveller his required inspection points. 6.10 Any revisions or change will be handled as the originals. 6.11 Engineering for field jobs shall be handled in the same manner as shop jobs, and by the same personnel.

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6.12 Access to computer programs for mechanical design calculations or stress and fatigue analysis shall be only through engineering. Before computer programmed results are used, the engineering shall have the accuracy of the original programs and their revisions checked by running manually calculated test problems. The accuracy shall be demonstrated to the satisfaction of the A.I. Engineering shall review each Code Edition or addenda for impact upon design programs and assure the design program is accurate for Edition/ addenda in use. The design programs shall conform to any and all changes in the Code, a record of this review shall be kept on file

Page 1 10

7. MATERIAL CONTROL MATERIAL REQUISITION:

7.1 The Engineering Department shall prepare and check all Bills of Material (Exhibit #1), except for welding materials which are requisitioned (Exhibit #10) by the Foreman. 7.2 The Bill of Material shall include the following: A. Material Specifications using the appropriate SA, SB, SFA, AWS, or identical ASTM designation. B. Material Size. C. Number of pieces. D. Job Number. E. Mill Test Reports when required by Code. F. Forming requirements as required by the construction code G. Any other special requirements when applicable. 7.3 All Bills of Material will be sent to the QCM, who will check them for ASME Code and customer requirements and if acceptable, forward them to Purchasing.

MATERIAL PURCHASING:
7.4 The Purchasing Department shall order and purchase material required as shown of the Bill of Materials (Exhibit #1). When material is purchased for more than one (1) job, the QC Department shall mark all materials with Job Numbers, or SN. Small parts shall be in marked container, or in a marked bundle. Any material change or substitution must have prior approval by the Engineering Department. 7.5 A copy of the Bill of Material (Exhibit #1) will be sent to receiving, QC and placed in job file. 7.6 When purchasing parts of a vessel that have been fabricated by welding with filler metal added, a Manufacturers Partial Data Report will be required and partial stamping as required by the applicable Code Section.

7.7

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

7.8 Welding material for field work will be procured through Purchasing by QC, and prepared by Foremen in the same way as for shop work.

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CUSTOMER FURNISHED MATERIAL:

7.9 Customer furnished material will be handled in the same manner as material purchased by the Company, upon receipt and throughout fabrication.

RECEIVING INSPECTIONS:
7.10 Upon receipt of material the Quality Control Inspector will notify the QCM. 7.11 Upon notification of receipt of material, the Quality Control Inspector shall perform the following physical inspections: 7.11.1 A. Check surfaces and edges for visible defects. 7.11.2 B. Check for physicals and forming specs. 7.11.3 C. Check Heat Numbers and document on Receiving Inspection Report. 7.11.4 D. Check materials to Bill of Materials for requested special marking requirements and/or documentation. 7.11.5 E. Materials ordered for a specific vessel shall be marked with the Serial Number when received. (Small items shall be placed in a container marked with the Job Number or Serial Number.) 7.12 The QC Inspector shall record the results of the above inspection on Receiving Inspection Reports (Exhibit #2) and send to QCM for filing. 7.13 The QC Inspector indicates on the Receiving Inspection Report at this time if material is acceptable. Receiving Inspection Report is forwarded to QCM for review and sign off indicating release for fabrication.

DOCUMENTATION VERIFICATION:
7.14 The QC Inspector shall verify the MTR as follows: 7.14.1 A. Check Material Heat Number against heat Numbers on MTR. 7.14.2 B. Check Chemical and Physical properties against specifications in Section II of ASME Code. 7.14.3 C. After checking MTR to Section II ASME, QC shall sign and date.

7.15 The QC Inspector shall record vessel SN on MTRS for traceability to vessel.
7.16 The QCM shall file the MTR in the job folder.

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MATERIAL IDENTIFICATION:
7.17 Prior to cutting material, identification will be transferred to the part to be cut, by the person doing the cutting. For Section I construction, all original markings shall be transferred for plate.

RECEIVING INSPECTIONS:
7.18 Non-conformities found in material receiving will be controlled as outlined in Manual on page 16.

7.19 When further material testing is performed by other than the material manufacturer, documents shall be obtained to determine that they meet the requirements of the material specification or construction Code. The Quality Control Manager is responsible for review of documentation for compliance with procedure and Code.

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8. EXAMINATION AND INSPECTION PROGRAM DUTIES OF QUALITY CONTROL MANAGER:

8.1 The QCM shall be responsible for in process examination and acceptance or rejection of fabrication. 8.2 The QCM shall prepare the Traveler and present it to the AI prior to the start of fabrication.

DUTIES OF CHIEF ENGINEER:

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

DUTIES OF FOREMEN:
8.4 The Foreman is responsible for the overall quality of the fabrication item and for job progress notification to the QCM for inspection and examination purposes.

INSPECTIONS:
8.5 The QC Inspector shall be responsible for but not limited to the following typical examination and verification for conformance to Code requirements: A. Weld Procedure Specification and Procedure Qualification Record, and Welder / Welding Operator Performance Qualifications. B. Fit-up Inspection to include edge preparation, fitting of edges on longitudinal seams, girth seams, heads, nozzles and pipe. NOTE: Fit-up inspection or examination is performed after components have been tacked in place, and prior to root pass. C. Finished Weld Inspection or Examination to include the weld size and weld appearance and welders symbols. D. Perform any other required examination for completed quality product. 8.6 The QC Inspector shall record the above examinations on the Traveler and notify the AI reasonably in advance of his up-coming inspection point.

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

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8.8

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

8.9 The Manufacturers Data Reports shall be prepared, checked and signed by the QCM or his designee prior to presenting to the AI for his review, acceptance and signature. Safety valve info shall be recorded on a P-7 or P-3 per PG 112.2.8. 8.10 The QCM shall check the nameplate stamping information for correctness prior to applying the Code stamp symbol. Boilers shall be Code stamped as required by Section I. 8.11 Responsibilities for field work and examination are identical to shop work and examination. 8.12 All material for field site work will be received and processed the same as shop material prior to transfer to field. 8.13 When received at field site all materials will be examined for damage due to transit. 8.14 Any damages will be handled as a non-conformity. (See pg. 16)

PNEUMATIC TESTING:
8.15 Boilers shall not be pneumatically tested. Pressure Vessels may be pneumatically tested in accordance with the applicable Code Section and paragraph.

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9. CORRECTION OF NON-CONFORMITIES NON-CONFORMING MATERIAL:

9.1 The QCM shall notify the Foreman in the event non-conforming material is received. 9.2 The QCM shall Chair a Material Review Board consisting of the following members: 9.2.1 9.2.2 9.2.3 A. Purchasing Department Representative B. Engineering Department Representative C. Foreman

9.3 Based on the findings of the Material Review Board, the non-conforming material will be repaired by the Company or returned to the Vendor or use as is. 9.4 Material to be repaired by welding shall have the concurrence or the Authorized Inspector for the method and NDE to be used for repairs on the NCR Form prepared by the QCM.

NON-CONFORMITY (FABRICATION):
9.5 Non-conformity is defined as any deviation from accepted standards for a given finished product. At time when a deviation is noted, a Hold Tag (Exhibit #4) will be filled out and placed on the product (all work stops on it until resolved) and a Non-conformance Report (Exhibit #5) will be initiated by the QC Department. The Non-conformance Report will then be forwarded to the QCM who is responsible for determining an acceptable course of action. As an alternative to the hold tag, hold may be written on the nonconforming item with a paint stick. 9.6 Fabrication Errors. These errors could be in design or fabrication after welding has started, and requires repair by welding to correct. Engineering Department will determine the welding procedure to be used. 9.7 When a repair procedure has been devised by the Engineering Department and reviewed by the QCM, then it will be presented to the AI prior to commencing work for his acceptance. 9.8 The QCM is primarily responsible for resolution and disposition of all problems that may arise. 9.9 The AI is included in the proposed resolution and the final disposition of all non-conformities except return to vendor. 9.10 Records concerning non-conformities shall be kept in the job file of each Code Vessel.
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9.11 After repairs have been completed and accepted by the AI, the QCM will remove the Hold Tag or hold written on the item. 9.12 Non-conformities shall be handled in the same manner for both shop and field.

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10. WELDING CONTROL WELDING PROCEDURES:

10.1 All Welding Procedures Specifications are written and non-essential variables revised, when required, by the Engineering Department. A Welder is assigned by the Foreman to weld a test specimen using the variables of the specification as a guide. This coupon is tested by a testing laboratory, in accordance with Section IX of the ASME Code. All welding procedures shall be qualified in accordance with Section IX with additional requirements of the applicable Code section to which work is performed and a Procedure Qualification Record filled out and certified by the QCM. 10.2 Written Welding Procedures Specifications for each process to be performed are filed in Manufacturers Name. files.

WELDING QUALIFICATIONS:
10.3 Prior to any welding on a Code Vessel, the welder or welding operator shall pass a welding qualification test in accordance with the procedure to be used and Section IX of the ASME Code. A Welder Performance Qualification or record form is filled out and certified by the QCM (QW-484) for a competent welder or Welder Operator Performance Qualification for welding operators. 10.4 Written welder qualification forms are kept on file and maintained by the QC Manager. 10.5 A Welder Continuity Log (Exhibit #6) will be initiated by and maintained as a record by the QCM. This log will be initialed by QCM, at least every three months, to assure welders continuity.

PROCEDURE ASSURANCE:
10.6 The Welding Procedure(s) to be used on a job are indicated on the Approved Design Drawing. 10.7 The QCM and Foreman will both monitor the welding to assure the correct procedure is being used during fabrication.

WELDER IDENTIFICATION:
10.8 The QC Manager is responsible for issuing the Welders and Welding Operators unique symbol. 10.9 The QCM shall record the symbol of the welder on the Traveler and the Welder shall apply his stamp to each three (3) feet or less of weld, when required, or a Weld Map will be used.

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WELDING MATERIAL CONTROL:

10.10 The Foreman will submit a purchase requisition (Exhibit 10) for welding material to the QCM for review per Code compliance. If acceptable, it will be forwarded to the Purchasing Department with a copy for receiving inspection. Receiving inspection shall be by the QC Department.
10.11 The Foreman shall supervise the distribution and storage of the welding materials. 10.12 All open cans of low Hydrogen Electrodes shall be maintained in a heated oven. No more than a four (4) hour supply will be issued at one time. All unused low Hydrogen Electrodes will be turned in to the Foreman at the end of the shift or four (4) hours, whichever is less. Electrodes shall be stored in a temperature controlled area as recommended by the Manufacturer or 50 degrees F.above ambient temperature. 10.13 Welding material storage and use for field work is the responsibility of the Foreman. Storage and use is monitored by QC the same as in the shop.

TACK WELDS:
10.15 All tack welds shall be applied by a Welder Qualified to a Qualified Procedure in accordance with Section IX to the ASME Code. Tack welds made by a vendor shall be removed. Vendor must supply copy of WPS used for tacks welds. 10.16 All tack welds shall be feather-ground prior to filling and capping all welds. If tack weld is found defective, it will be removed.

WPS QUALIFICATIONS FOR TEST:

10.17 The Engineering Department shall be responsible for preparing the Welding Procedures Specification and Procedure Qualification Record in accordance with ASME Code Section IX. 10.18 The WPS will be made available to all welders and welding operators.

TRAINING AND SUPERVISING:

10.19 The Foreman shall be responsible for training and supervision of all welders and welding operators. 10.20 Joint preparation and alignment will be checked by the QC Department and/or the Foreman. 10.21 The AI shall have the right at anytime to call for and witness tests of the welding procedure or the ability of any welder or welding operator.
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11. NON-DESTRUCTIVE EXAMINATION (NDE) RESPONSIBILITY:

11.1 NDE PROCEDURE MUST BE APPROVED BY LEVEL III 11.2 For Section VIII, Div. 1 construction. RT, UT, and MT shall be subcontracted to a qualified testing firm. The subcontractors Level III shall be appointed by Manufacturers Name. PT, and VT may be performed by company personnel in accordance with written procedures that meet Code requirements and are acceptable to the A.I. For Section I construction, all NDE methods, except V.T., shall be subcontracted. 11.3 All RT, UT and MT testing shall be performed by Level II or III personnel qualified in accordance with the applicable acceptable edition and addenda of SNT-TC-1A. Level I may perform the above function if under the direct supervision of a Level II or III. NDE Subcontractors written practice shall be held on file by the QC and approved by the AI.

ACCEPTANCE:
11.4 Acceptance criteria for NDE testing shall be in accordance with the applicable section of the ASME Code. Interpretation of the results of subcontracted NDE shall be by Level II or Level III examiner. 11.5 After the RT films have been accepted by the QCM, they shall be presented to the AI for his review. 11.6 Viewing equipment and calibrated density strip shall be available to the AI.

QUALITY CONTROL MANAGER:

11.7 The QCM shall maintain a copy of all NDE procedures and personnel qualifications. These records shall be available to the AI for his review. 11.8 All NDE requirements shall be prepared by the Engineering Department, recorded on drawing and shall be in accordance with the ASME Code with respect to design conditions.

RE-QUALIFICATION:
11.9 The Authorized Inspector may request requalification of NDE procedures or examiners whenever he has reason to question their code compliance.

NDE AT FIELD SITE:

11.10 NDE at field site is the responsibility of QC Department in conjunction with the foreman and will be conducted in accordance with this manual.
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NDE PROCEDURES:
11.11 Subcontract NDE procedures will be written by Level III and demonstrated as being capable of obtaining meaningful results to the satisfaction of the AI. The AIs acceptance may be noted by initialing the NDE procedure. The procedures, practices, and qualifications must be acceptable to the AI. The VT procedure shall be prepared and approved by Manufacturers Name QC M and must be accepted by the AI. The VT Examiner shall be certified to perform visual examination by the company.

NDE TEST REPORTS:

11.12 All NDE reports including RT film shall be reviewed and accepted by QCM and then presented to the AI.

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12. HEAT TREATING HEAT TREATING REQUIREMENTS:

12.1 All heat treatments, required by ASME Code or Customer Specification shall be indicated on the production drawings. All heat treatment will be performed in accordance with written procedures. The written procedures shall be prepared by the Engineering Department in accordance with the ASME Code with respect to design conditions. The procedure number will be noted on the production drawings. The heat treatment will be subcontracted. Quality control will inspect all returned items for conditions and shipping damage. Unacceptable items will be handled per Section 9.0; acceptance of items will be recorded on the Traveler. When conditions for post weld heat treating in accordance with the original code of Construction are inadvisable or impractical, alternative methods as allowed in RD-1000 may be used. Thermocouple attachment by capacitor discharge welding for Section VIII, Div. 1 Vessels will be performed using a welding procedure specification meeting the Requirements of UW-37 (h).

HEAT TREAT PROCEDURE:

12.2 The Heat Treat Procedure shall require that the subcontractor furnish records that show the following: A. Strip chart containing heating, holding and cooling times and temperatures. B. Identification of item heat treated. C. Name of the heat treat firm. D. Date of heat treatment. of responsible official of heat treating firm. E. Signature F. Copy of heat treat recording instruments calibration certification.

RECORDS:
12.3 The QCM will review all heat treat records. 12.4 The heat treat records shall be made available to the AI.

HEAT TREATING, FIELD SITE:

12.5 Heat treating as required at field site will be the responsibility of QC Department in conjunction with the foreman and will be performed in accordance with this manual. 12.6 QC Manager has the responsibility of monitoring heat treat facilities to assure thermo-couples placement at intervals provided by the applicable Code and proper equipment used.

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13. CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT RESPONSIBILITY:

13.1 The QCM shall be responsible for the calibration and storage of measuring and test equipment and for maintenance of the calibration records. 13.2 NDE Calibration shall be maintained by the Subcontractors when such NDE is not performed by the Company. Calibrations shall be in accordance with National Standards where such standards exist.

CALIBRATION:
13.3 Micrometers and calipers will be checked against a known calibrated thickness before each use, in lieu of calibration. 13.4 All test gauges shall be calibrated by a subcontractor at any time there is a reason to believe they are in error. A. All test gauges shall be numbered. B. All calibration shall be recorded on a test gauge calibration form showing gauge number, date and calibrators initials. Calibration records are available to the AI upon request. C. Indicating Pressure Gauges used in testing shall preferably have dials graduated over a range of about double the intended maximum test pressure, but in no case shall the range be less then 1 1/2 times nor more than 4 times that pressure. Specific ranges shall be per applicable Code Section. .

STORAGE:
13.5 All test equipment shall be stored by the QCM.

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14. RECORDS RETENTION RESPONSIBILITY:

14.1 It is the responsibility of the QCM to initiate a job file on a start of a job and collect the following data and maintain through-out fabrication. This data shall be available to the AI; including but not limited to: A. B. C. D. E. Calculations, prints and Bill of Materials. Receiving Inspection Reports Material Test Reports and/or Partial Data Reports, when required. Non-conformance Report (if applicable) Heat Treat Charts (if applicable)

F. Hardness Test Results (if applicable) G. RT Film, Reader Sheets and NDE Reports (film location map when applicable) H. Charpy V-Notch Test Results (if applicable) I. Traveller

PERMANENT RECORDS:
14.2 The Manufacturers Data Reports, UT Reports, RT Film, RT Reports, and location maps shall be retained for retention period required by the applicable Code.

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15. REGISTRATION WITH NATIONAL BOARD

15.1 National Board and serial numbers shall be controlled and issued by the QCM. He shall maintain a record showing date issued, type of vessel, and manufacturers serial number. The QCM shall submit to the National Board an original of all ASME Manufacturers Data Reports requiring registration within 60 days. Registration with the National Board will be made when required by Jurisdiction and/or Customers. National Board numbers shall begin with the number 1 and shall continue without skips, gaps, or omissions. (See Exhibit #9)

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16. REPAIRS & ALTERATIONS SCOPE:

16.1 This section defines the requirements established for repairs and alterations as defined by the current Edition and Addenda of the National Board Inspection Code (NBIC) for pressure retaining items.

REPAIRS AND ALTERATIONS TO ASME CODE ITEMS:

16.1.1 Shall be carried out in accordance with the requirements of the NBIC, this Quality Control Manual, and Jurisdiction requirements (when applicable) and shall conform to the Edition and Addenda of the applicable ASME Code Section.

REPAIRS AND ALTERATIONS TO NON-CODE ITEMS:

16.1.2 Repairs and Alterations shall be carried out in accordance with the requirements of the NBIC, this Manual, Jurisdictional Requirements when applicable shall conform insofar as possible, to the Edition and Addends of the ASME Code Section most applicable to the work, provided Manufacturers Name has the concurrence of the Jurisdiction and the Inspector.

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ROUTINE REPAIRS:
16.1.3 Routine Repairs to ASME Code items shall be carried out in the accordance with the requirements of NBIC, this Quality Control Manual, and Jurisdictional requirements (when applicable) and shall conform to the Edition and Addenda of the applicable ASME Code; however, the requirement for in-process involvement of the Inspector and stamping may be waived provided all of the following conditions are met: 1. Manufacturers Name shall verify, to the satisfaction of the Inspector, that routine repairs are acceptable to the jurisdiction. 2. Prior approval for routine repairs shall be obtained from the Inspector. 3. Routine repairs shall be documented on a Form R-1 with a statement on line 10, Remarks: Routine Repair.

RESPONSIBLE PARTY:
16.1.4 Manufacturers Name shall assume overall responsibility for the performance of repairs and alterations and for originating the construction procedures necessary to direct the course of the work.

METHOD OF REPAIR OR ALTERATION:

16.1.5 Shall be made available to the Authorized Inspection Agency (AIA) responsible for the in-service inspection of the item or the AIA of record.
a. The Quality Control Manager shall make available to the Inspector a proposed Repair Plan (Exhibit 11) for the method and extent of repairs or alterations. If applicable, drawings and calculations shall be made available. b. Under no circumstances shall work be started without authorization of the Inspector. The Inspector making the acceptance inspection should be the same Inspector who authorized the repair or alteration, but, in all cases, shall be an employee of the same organization as that of the Inspector that authorized the repair or alteration.

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RERATING OF A PRESSURE RETAINING ITEM:

16.1.6 Shall only be performed only after the following requirements have been met to the satisfaction of the jurisdiction at the location of the installation. a. Revised calculations verifying the new service conditions shall be prepared in accordance with this Quality Control Manual. b. All re-ratings shall be established in accordance with the Edition and Addenda of the applicable ASME Code Section. c. Current inspection records verify that the pressure retaining item is satisfactory for the proposed service conditions.

d. The pressure retaining item has been pressure tested, as required, for the new service conditions.

DESIGN ENGINEERING:
16.1.7 Shall conform to the requirements of this Quality Control Manual, the NBIC, and insofar as possible, the ASME Code section most applicable to the work involved.

MATERIALS:
16.1.8 Used in making repairs and alterations shall conform to the applicable section of the ASME Code. a. If Manufacturers Name provides the materials, the procurement, inspection, and handling of materials shall be in accordance with the applicable sections of this manual. b. If the materials are provided by others, sufficient documentation and material identification shall be provided for acceptance of the material by Manufacturers Name and the Inspector. Receiving Inspection and handling of these materials shall be in accordance with the applicable sections of this manual. c. When existing materials cannot be identified, the Quality Control Manager shall be responsible for any testing required to establish the material specification. The method used and the results shall be available to the Inspector.

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PRESSURE PARTS:
16.1.9 Pressure parts for which ASME Manufacturers Partial Data Reports are required shall be fabricated and inspected to the applicable Code, stamped with the appropriate Code symbol and the word Part, and reported on the applicable Manufacturers Partial Data Report. When such parts are a part of the repair or alteration the Manufacturers Partial Data Report shall be reported on the Forms R-1 or R-2, as applicable, and attached thereto.

WELDING, NDE, & HEAT TREATMENT:

16.1.10 All welding, non-destructive examination (NDE), and heat treatment (HT), as required, shall be in accordance with the NBIC, the ASME Code, and the applicable sections of this Quality Control Manual.

PRESSURE TESTS:
16.1.11 Shall conform to the requirements of the NBIC and will be witnessed by the Inspector. Manufacturers Name is responsible for all activities relating to pressure testing. 16.1.11a When this is not possible or practical, other methods as described in the NBIC may be used provided the required concurrences have first been obtained. As an alternative to the pressure test, an examination or NDE method that will verify the integrity of the repair or alteration, subject to the concurrence of the Inspector, jurisdiction and customer (when required) may be used.

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RE-MOVING ORIGINAL CODE STAMPING:

16.1.12 When a repair or alteration requires the removal of that part of the item bearing the original Code stamping, the Inspector shall witness, subject to the approval of the Jurisdiction, the making of a facsimile of the stamping, the obliteration of the old stamping, and the transfer of such stamping to the new item. The ASME Code symbol is not to be restamped. When the stamping is on a nameplate, the Inspector shall witness the transfer of the nameplate to the new location. Any relocation is to be reported on the applicable NBIC Report Form

CUSTODY OF R STAMP:
16.1.13 The Quality Control Manager shall be responsible for the custody and use of the National Board R Symbol stamp.

REPAIR, ALTERATION, or RE-RATING, stamping or nameplate information, size, location, and attachment (nameplates) shall conform to the requirements of the NBIC and will only be applied with the concurrence of the Inspector.

ORIGINAL MANUFACTURERS DATA REPORT:

16.1.14 A copy of the original Manufacturers Data Report for the item being altered or re-rated shall be required and attached to the completed Form R-2. When this is not possible, agreements on the method of establishing design basis for the alteration shall be obtained from the Inspector and the jurisdiction when applicable.

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NBIC REPORT FORM:

16.1.15 The Quality Control Manager or his/her designee shall initiate the applicable NBIC Report Form and sign the applicable Certification before presenting it, together with all supporting documentation, to the Inspector for review and signature. Distribution of the applicable NBIC Report Forms is the responsibility of Manufacturers Name and shall be performed by the Quality Control Manager as follows: REPAIRS - Legible copies of the Form R-1, together with all required attachments, shall be distributed to the owner or user, the Inspector, the AIA responsible for the in service inspection of the item, and the Jurisdiction (if required). The Form R-1, may be registered with the National Board in accordance with the NBIC or they have to be retained for 5 years. ALTERATIONS AND RE-RATING - Legible copies of the Form R-2, together with all required attachments, shall be distributed to the Inspector, the AIA responsible for the in-service inspection of the pressure retaining item, the owner or user, and the Jurisdiction (if required). If the item is registered with the National Board, one original copy shall be submitted to the National Board.

If the item is not registered with the National Board, the Form R-2 may be registered with the National Board.
The NBIC Report Forms shall not be used to record a repair or alteration unless the work has been performed in accordance with the NBIC. Parts fabricated by welding for non Code items shall be stamped R Part and documented on an R 3. When R forms are registered with the National Board, the Q.C. Manager will establish and maintain an R Number Log Exhibit 7. These numbers shall be assigned in sequential order. The NBIC Report Forms shall not be used to record a repair or alteration unless the work has been performed in accordance with the NBIC. R forms not registered with the National Board will be retained for 5 years.

REVISIONS:
16.1.16 Revisions to this Quality Control Manual shall have the acceptance of the AIA prior to issuance of the manual and implementation.
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17.0 Exhibits: 1. 2. BILL OF MATERIAL RECEIVING INSPECTION REPORT Page 33 Page 34 Page 35 Page 36 Page 38 Page 39 Page 40 Page 41 Page 42 Page 43 Page 44 Page 45 Page 46

3A. TRAVELLER (PRESSURE VESSEL) 3B. TRAVELLER (POWER BOILER) 3C. TRAVELLER - PIPING 4. 5. 6. 7. 8. 9. 10. HOLD TAG NON-CONFORMANCE WELDER CONTINUITY LOG R NUMBER LOG MANUAL ISSUE LOG SERIAL NO./NATL. BD. N. LOG PURCHASE REQUISITION

11. REPAIR PLAN

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