Asmeqcmanual 11-02-05 PDF

QUALITY CONTROL MANUAL

AAF INTERNATIONALLOUISVILLE INDUSTRIAL PARK

7625 NATIONAL TURNPIKEUNIT 130

LOUISVILLE, KY 40214

FOR THE FABRICATION OF BOILERS, POWER PIPING AND PRESSURE VESSELS TOTHE REQUIREMENTS OF ASME SECTION I, B31.1, VIII Div. 1, Div. 2, Div. 3

ANDFOR REPAIRS AND ALTERATIONS TO THE NATIONAL BOARD INSPECTION CODEAND JURISDICTIONAL REQUIREMENTS ON ABOVE LISTED ITEMS AND SECTION

IV BOILERS

ALL THE ABOVE TO BE PERFORMED IN THE SHOP AND AT FIELD LOCATIONSCONTROLLED BY THE ABOVE LOCATION

11/02/05REVISION 1

Control Number .Uncontrolled .

i

Table of Contents Section iiPage 1 of 1Revision 1

Section Title Rev. Date

i Facing Page 1 11-02-05

ii Table of Contents 1 11-02-05

1 Statement of Authority 0 12/11/02

2 Manual Control 0 12/11/02

3 Organizational Chart 0 12/11/02

4 Drawings, Design and Specification Control 0 12/11/02

5 Material Control 0 12/11/02

6 Examination and Inspection 1 11-02-05

7 Correction of Nonconformities 0 12/11/02

8 Welding Control 0 12/11/02

9 Nondestructive Examination 0 12/11/02

10 Heat Treatment 0 12/11/02

11 Calibration of Measuring and Test Equipment 0 12/11/02

12 Records Retention 0 12/11/02

13 Authorized Inspector 0 12/11/02

14 Repairs and Alterations 1 11-02-05

15 Exhibits 0 12/11/02

Quality Control Manager Date .

Authorized Inspector Date .

1.0 Statement of Policy and Authority Section 1Revision 0Page 1 of 112/11/02

The Management of AAF INTERNATIONAL is committed to meeting the requirements ofthe ASME Code, the National Board Inspection Code (NBIC), the Jurisdiction, and the QualityControl System outlined in this manual for the fabrication and assembly of Power Boilers toASME Section I, of Power Piping to ASME B31.1, of Pressure vessels to ASME Section VIIIDiv. 1, Div. 2, Div. 3 and Repairs and Alterations to the above items as well as Section IVBoilers using the NBIC and jurisdictional requirements.

The Quality Control Manager (QCM) is responsible for the preparation, revision, approval, andissuance of the Quality Control Manual and the administration and implementation of theQuality Control System in the shop and field. He has the organizational freedom to identify andcorrect Quality Control problems. The QCM shall be the liaison with the Authorized Inspector.

Department Head responsibilities are as outlined in the text of this manual.

Should a disagreement arise between Department Heads and/or Quality Control, the problemshall be brought to me for resolution in accordance with the requirements of the Code and thisQuality Control Manual.

Date .Vice President and General ManagerEnvironmental Products Division

2.0 Manual Control Section 2Revision 0Page 1 of 112/11/02

2.1 Revisions to this Quality Control Manual shall be prepared and approved by the QCMand submitted to the Authorized Inspector (AI) for his review and acceptance prior toissue. QCM approval and AI acceptance are shown by signature on the Table of ContentsPage.

2.2 Revisions to this manual with the exception of the Exhibits will be by section with therevision level and date of the section displayed on the Table of Contents and in the upperright hand corner of each page of the section. Exhibits will be revised individually withthe revision level of each exhibit displayed on the exhibit itself and on the Exhibit indexpage. The exhibit page will also list the date of the revision to each exhibit. The revisionlevel and date of the Exhibit index page will also be displayed on the Table of Contents.

2.3 The QCM will issue controlled copies of the manual to the individuals listed on thecontrolled manual holder list, which the QCM maintains. Controlled Manuals will bear acontrolled copy number on the Facing Page that corresponds to an individual on thecontrolled manual holder list. Only controlled copies of the Quality Control Manual willbe issued to AAF INTERNATIONAL personnel. The QCM will recall obsolete copiesof controlled manuals and redistribute revised copies after revisions have been installed.

2.4 A controlled copy of the manual shall be made available to the AI.

2.5 Uncontrolled manuals may be distributed to outside personnel with the understandingthat they will not be recalled for revision. These manuals shall be marked Uncontrolledon the Facing Page.

2.6 The Engineering Manager shall review all Code Editions and Addenda. If revisions to themanual are needed they shall be presented to the QCM for his review and approval.These revisions shall be incorporated into the system within 6 months of the Edition orAddenda date. The Engineering Managers review shall be documented either by initialand dating the cover page of the new Edition or Addenda, or by memo.

3.0 Organizational Chart Section 3Revision 0Page 1 of 112/11/02

Designer(Section VIII, Div. 3)

Engineering Manager

Quality Control Inspector(Shop & Field)

Quality Control Manager Purchasing Manager

Welders

Shop/Field Foreman

Project Manager

General Manager

NOTE: Duties may be delegated but responsibility remains with the above titled individual.

4.0 Drawings, Design, and Specification Control Section 4Revision 0Page 1 of 412/11/02

4.1 When an order for Code work is received, it is issued a Job Number by the ProjectManager. This Job Number is used to identify all documents related to the Code itemthrough construction and assembly.

4.2 DESIGN

4.2.1 Upon receipt of an order for Code work, the Engineering Manager shall review thecustomer specifications and verify that they are adequate for Code compliance.Deficiencies must be reconciled prior to the start of design work.

4.2.2 When the customers specification is approved, the Engineering Manager preparesdrawings, detail sheets, design calculations and a Bill of Material (BOM Exhibit 1)which lists all the material specifications for the material to be used in the item. Inlieu of Exhibit 1, the BOM may be listed on the production drawing.

4.2.3 Drawings Shall list the following items as a minimum:

- Drawing number and revision- Code issue and addenda used for construction- Design pressure and temperature (also MDMT for Section VIII items)- Dimensions in English and SI- Identification of welded joints including AWS welding symbols- Welding procedure specifications and revision level- Non-destructive examination requirements- Post-weld heat treatment requirements- Pressure test requirements- Other testing requirements (e.g. charpy impact, ferrite, etc.)- Amplifying instructions as necessary (Notes)- Material types- Pipe schedules- Pressure classes of valves and flanges

4.2.4 When drawings and calculations are provided by an outside concern, they arereviewed by the Engineering Manager for compliance to Code. Discrepancies arebrought to the attention of the design concern for correction to the requirements ofthe Code.

4.0 Drawings, Design, and Specification Control Section 4Revision 0Page 2 of 412/11/02

4.2.5 When the Engineering Manager has satisfied himself that the design documentsmeet code, he indicates his approval by initialing and dating each document.

4.2.6 After the QCM approves the design documents, he submits them to the AI foracceptance which is indicated by the AIs initials in the appropriate block on the Traveler(Exhibit 2 & 2a). After the AI accepts the design documents, the QCM keeps one copyfor the QC file and gives a copy to the Project Manager to place in the job file forproduction.

4.3 REVISION CONTROL

4.3.1 Revisions to design documents shall be handled as per paragraph 4.2. Upon finalapproval and AI acceptance of the revision, the QCM shall hand carry the reviseddocuments to the Project Manager and collect the obsolete documents. Theobsolete documents shall be destroyed except that one copy may be maintained forreference. If an obsolete copy of a design document is maintained for reference, itshall be marked in a manner acceptable to the AI (e.g. VOID - FORREFERENCE ONLY) so that it will not inadvertently be used for production.

4.3.2 The Project Manager maintains master copies of calculations, BOMS and detaildrawings.

4.3.3 All changes made to controlled documents are noted in bold type or by othersuitable means.

4.3.4 Drawing changes shall be noted by (X) with X representing the revision changeletter.

4.4 COMPUTER CALCULATIONS 4.4.1 Calculations performed to computer programs shall be verified by the EngineeringManager for accuracy prior to use on Code work. They shall also be checked for accuracywhenever there is a Code change, which affects them.

4.0 Drawings, Design, and Specification Control Section 4

Revision 0Page 3 of 412/11/02

4.5 SECTION VIII DIVISION 2 (IN ADDITION TO THE ABOVE REQUIREMENTS) 4.5.1

The user of a vessel built to Section VIII Division 2 shall provide Users DesignSpecification that sets forth expected operating conditions, including all designcases, pump curves, required vessel supports, site and site conditions, whether ornot a fatigue analysis is required, the amount of corrosion/erosion, and whetherlethal fluid or gas is to be contained. A Professional Engineer registered in one ormore states of the United States or provinces of Canada and experienced inpressure vessel design must certify this design specification.

4.5.2 The Engineering Manager shall produce a Design Report consisting of calculationsand drawings establishing that the design, as shown on the drawings, complieswith the requirements of this division for the conditions set forth in the UsersDesign Specification. The design report shall be certified by a ProfessionalEngineer registered in one or more states of the United States or provinces ofCanada and experienced in pressure vessel design, as complying with all therequirements of this division.

4.5.3 Revisions to the Design Specification and/or the Design Report must be approvedby the Engineering Manager and reconciled with the Professional Engineer.Revisions shall be handled as described in this section.

4.5.4 Restricted requirements of allowable materials as reflected by the fatigue analysiscurves of this division must be considered where fatigue analysis is required.

4.5.5 Provisions of adequate overpressure protection or nozzles of adequate cross-sectional area for mounting of overpressure protection devices must be considered.

4.5.6 Loadings as required by paragraph AD-110 must be considered.

4.5.7 Offset (joggle) joints are prohibited.

4.6 SECTION VIII DIVISION 3 (IN ADDITION TO THE ABOVE REQUIREMENTS)

4.0 Drawings, Design, and Specification Control Section 4

Revision 0Page 4 of 412/11/02

4.6.1 All requirements for Sections VIII Division 1 and 2 described above shall apply toSection VIII Division 3 construction except as modified below:

4.6.1.1 The Design Specification shall contain the following items:

a. Vessel identificationb. Vessel configurationc. Controlling dimensionsd. Design criteria (i.e., design pressure, pump curves, design temperature,

MDMT, and thermal gradients)e. Operating conditions for all design cases.f. Contained fluid datag. Material selectionh. Loadingsi. Useful operating life expectedj. Fatigue analysisk. Overpressure protection, and any additional requirements specified by

the userl. Installation site

4.6.1.2 The Design Report must include the following:

a. Final and as-built drawings, detail sheets and code calculations.b. Results of fatigue analysis, according to article KDc. Documents of consideration of the effects of heating or heat treatment

during manufacturing, and similarly, the maximum metal temperaturespecified

d. Statement of any openings for which closures have not been installede. Limiting thermal gradients across the vessel section

4.6.1.3 The Designer of a pressure vessel to this division shall be an individualengineer or group of engineers, experienced in high-pressure vesseldesign who performs the required analysis of the vessel.

4.7 Distribution4.7.1 The Engineering Manager maintains a list of all documents for each jobnumber. A transmittal letter accompanies distribution of all controlled documents.

5.0 Material Control Section 5Revision 0Page 1 of 312/11/02

5.1 PURCHASING

5.1.1 A BOM (Exhibit 1) and associated purchase requisitions are prepared by theEngineering Manager and submitted to the QCM for approval. Upon approval, theQCM submits a copy of the requisitions to the Purchasing Manager. PurchaseOrders (Exhibit 3) are then prepared using the requisitions as the basis.

5.1.2 Material for stock is ordered using a PO prepared by the Purchasing Manager andsubmitted to the QCM for approval prior to ordering.

5.1.3 All material will be ordered to SA, SB, SFA, or other acceptable specificationssuch as ASTM. The PO shall contain all the ordering requirements for the materialspecification as well as any additional requirements for the construction Code(Charpy impact tests, UG-79, etc.). The PO shall also reference the job number andrequest CMTRs when required.

5.1.4 A completed copy of the PO shall be submitted to the QCM for approval. Afterapproval, the QCM returns the original PO to purchasing and sends a copy toreceiving inspection and maintains a copy for the job file.

5.2 RECEIVING, STORAGE AND INSPECTION OF PURCHASED CODE MATERIAL

5.2.1 Receiving, storage and inspection of code material is performed per supplementalprocedure ASME 5.0, latest revision.

5.2.2 A coded marking system may be used to identify material. The coded marking ifused, shall be an alpha numeric identification placed on the material. This codedmarking is kept in a log maintained by the QCM that lists all the required markingsfor the material that corresponds to the identification number. Each coded markingnumber is exclusive to one type and lot of material.


5.3 CUSTOMER SUPPLIED MATERIAL

5.3.1 Customer supplied material is received and inspected as described above exceptthat a customer PO is used at receiving inspection.

5.3.2 Unacceptable material is handled as described in Section 7 of this manual.

5.4 All material and documents described in this section shall be available for the review andacceptance of the AI.


5.6.1 All material shall be certified by the material manufacturer as in compliance withthe material specification listed on the purchase order.

5.6.2 All steel castings shall be fully radiographed. Magnetic castings shall also beexamined by the magnetic particle method on all surfaces.

5.6.3 Only materials approved by this division may be used in construction. Use ofunidentified material by test is not acceptable for this division.


5.7.1 All material shall be certified by the manufacturer as in compliance with thematerial specification listed on the Purchase Order, all special requirements of PartKM of Section VIII Division 3, and all supplementary requirements specified bythe Users Design Specification.

5.7.2 All material shall be tested for notch toughness except for nuts, washers, andmaterial which do not contribute to the integrity of the pressure boundary.Representative samples shall be used for mechanical tests for tension and charpyV-notch tests on applicable materials used for construction to this division.

5.7.3 All pressure retaining materials shall be ultrasonically tested as required by thisdivision.


5.7.3 Procedures for obtaining test specimens for austenitic and non-ferrous alloys shall comply with material specs.

5.7.4 The appropriate Tables in Section II Part D shall be used to determine stress valuesfor ferrous wiring, as well as ferrous and non-ferrous materials used in constructionto this division.

5.7.5 Thickness of materials shall be the thickness dimension of the product formdescribed in Article KM-2 of this division.

6.0 Examination and Inspection Section 6Revision 1Page 1 of 311-02-05

6.1 RESPONSIBILITY

6.1.1 The QCM shall assure compliance with the Quality Control Manual in the shopand field.

6.2 FABRICATION

6.2.1 Code work is controlled by use of the Traveler. The Traveler lists the sequence ofconstruction, examination, and inspection of an object.

6.2.2 Prior to the start of work, the QCM presents the design documents along with theTraveler to the AI for acceptance. At this time the AI will designate any holdpoints he may wish to assign. The review of the QCM and the AI are documentedon the Traveler.

6.2.2.1 No hold point designated by the AI may be bypassed. The QCM isresponsible for notifying the AI of approaching hold points in sufficient timefor the AI to schedule an inspection.

6.2.3 After work begins, Quality Control inspections during fabrication are documentedby initial and date by the Quality Contol Inspector (QCI) in the appropriate blockon the Traveler. AI inspections are documented in the same manner.

6.3 FINAL INSPECTION

6.3.1 When a job is completed, it shall be given a final inspection including a pressuretest required by the appropriate Code of construction. The QCI and the AI shallconduct this final inspection.

6.3.2 During the pressure test, at least one pressure gage directly connected near thehighest point of the vessel and visible to the operator controlling the pressure testshall be used. Dial indicating gages shall have a range of approximately double thetest pressure, but in no case less than 1.5 times or more than 4 times test pressure.

6.0 Examination and Inspection Section 6Revision 1Page 2 of 3

11/02/05

6.3.3 At no time shall the pressure exceed the requirements of Para. PG- 99 for Section 1items.

6.3.4 When the pressure test is satisfactorily completed, the QCI and AI shall initial anddate the appropriate block on the Traveler.

6.3.5 The inspection report shall contain as a minimum: the inspectors name andqualification, date of the inspection, results of inspection and NCR number ifapplicable.

6.4 STAMPING AND DATA REPORTS

6.4.1 The QCM shall maintain custody and control of all Code stamps except that forfield work the stamp may be delivered to the QCI so he may stamp the item. Uponcompletion of the stamping, the stamp is immediately delivered back to the QCMscustody.

6.4.2 For Section I jobs, stamping shall be directly on the object at the locationprescribed in the appropriate Code paragraph. The AI shall witness the applicationof the Code symbol stamp. If Power Piping has an operating temperature greaterthan 800*F, a Data Plate may be used in lieu of direct stamping. Piping with adiameter less than 2 shall be marked in a manner acceptable to the AI so that itmay be adequately traced to the Manufacturers Data Report.

6.4.3 For Section VIII Div. 1 items, a Data Plate may be used. The object may bestamped and/or the Data Plate attached before the final inspection provided prioracceptance of the AI is received.

6.4.4 The appropriate Data Report shall be certified by the QCM and submitted to the AIfor acceptance at the final inspection.

6.0 Examination and Inspection Section 6Revision 1Page 3 of 311-02-05

6.4.5 Items that are to be registered with the National Board shall be issued a NationalBoard Number. These numbers are issued sequentially without skips or gapsstarting with the number 1, and are recorded in the National Board Number Log(Exhibit 5). This log will list the National Board Number, the ManufacturersSerial Number, and the date the Data Report was submitted to the National Boardfor registration. Data Reports for vessels to be registered shall be submitted to theNational Board within 60 days of certification.


6.5.1 Hydrostatic testing shall not be less than 1.25 times design pressure, unlesscalculated pressure is agreed upon with the user. Examination shall be performedat reduced pressure following the pressure test, and shall be witnessed by the AI.

6.5.2 Impression stamping on vessel shells is prohibited.


6.6.1 The special testing requirements of Articles KT-1, KT-2, and KT-3 shall beconsidered for items constructed to this division.

6.6.2 Stampings and markings shall be as per the requirements of Article KS-1.

7.0 Correction of Nonconformities Section 7Revision 0Page 1 of 212/11/02

7.1 IDENTIFICATION OF NONCONFORMITIES

7.1.1 A nonconformity is any condition in material, fabrication, or inspection which doesnot meet all the requirements of the Code, material specifications, DesignSpecifications, or this manual.

7.1.2 It is the duty of all personnel to report a nonconformance to the QCI or theirimmediate supervisor. The QCI shall identify nonconforming material with aHOLD tag. The HOLD tag will reference the NCR number. The QCIcompletes a Nonconformance Report, (Exhibit 6) and enters it into the NCR Log,(Exhibit 10). If practical, the nonconforming item shall be removed to a segregatedhold area pending resolution.

7.1.3 The QCI presents the NCR to the QCM for review and acceptance.

7.2 DISPOSITION OF NONCONFORMITIES

7.2.1 The QCM presents to the AI all NCRs and their proposed disposition for hisreview and acceptance. At this time the AI is given the opportunity to set any holdpoints he may deem necessary. There are three general dispositions available fornonconforming items:

7.2.1.1 Use-as-is, where the nonconforming item is proven adequate, with theEngineering Managers approval, to meet Code requirements. Any revisionsto drawings, calculations, procurement, or other documentation shall behandled as described in the applicable section of this manual.

7.2.1.2 Repair or Rework-Where the nonconforming item may be repaired orreworked to meet Code requirements. Procedures used in this case shall beapproved by the QCM and accepted by the AI. NOTE: the AI shall acceptthe method and extent of welded repairs to base metal under anycircumstances. All nonconformng items that are reworked or repaired mustbe reinspected.

7.2.1.3 Scrap or Return to Vendor, where the item is not to be used further forCode work. If this disposition is selected, the QCI shall clearly mark the

7.0 Correction of Nonconformities Section 7

Revision 0 Page 2 of 2

12/11/02

material or object and remove it from the production area to prevent its inadvertent use. When material is rejected due to lack of certification or because of an incorrect certification the RTV disposition is conditional depending upon the suppliers ability to supply the required certification.

7.2.2 When the disposition has been satisfactorily completed the QCM removes the holdtag (except for scrap or return to vendor) and signs off the NCR. The completedNCR shall be submitted to the AI for acceptance after which it is placed in the jobfile.

7.2.3 NCRs are uniquely numbered and maintained until the job is completed or asdescribed in Section 12 of this manual.

8.0 Welding Control Section 8Revision 0Page 1 of 312/11/02

8.1 GENERAL

8.1.1 All Code welding shall be performed using welding procedures, welders, andwelding operators qualified to the requirements of ASME Section IX and theappropriate Code of construction.

8.2 WELDING PROCEDURES

8.2.1 The QCM is responsible for approving Welding Procedure Specifications (WPS)using certified Procedure Qualification Records (PQR).

8.2.2 The QCM is responsible for ensuring that test coupons are sent to an approved labfor testing. When the test results are returned, the QCM verifies that they meetCode requirements after which he writes and certifies a PQR based on the actualconditions under which the welder performed the test.

8.2.3 Original copies of the WPSs and PQRs are maintained by the QCM. Copies aresubmitted to the Shop/Field Foreman for use by the welders.

8.2.4 WPSs are revised when there is a change in a Non-essential Variable andrequalified when there is a change in an Essential Variable (or SupplementaryEssential Variable when applicable).

8.2.5 WPSs and PQRs are made available to the AI for his review and acceptance. TheAI may require requalification of a WPS at any time for cause.

8.3 WELDERS AND WELDING OPERATORS

8.3.1 Welders and Welding Operators shall be qualified by preparing a test couponunder the supervision of the Shop/Field Foreman. The coupon shall be testedand/or examined as per Section IX and if acceptable, the QCM shall certify aWelder Performance Qualification Record (WPQ) for that Welder or WeldingOperator. Original WPQs are maintained by the QCM and are made available tothe AI for review and acceptance.


8.3.2 Copies of the WPQs shall be submitted to the Shop/Field Foreman.

8.3.3 Welders and Welding Operators shall require requalification if any of thefollowing occurs:

8.3.3.1 A change in a Performance Essential Variable.

8.3.3.2 When he has not used a process for a period of six months.

8.3.3.3 When there is reason to question his ability to make sound welds.

8.3.4 Each qualified Welder and Welding Operator shall be listed on the WelderContinuity Log (Exhibit 7) maintained by the Shop/Field Foreman. The WelderContinuity Log is updated quarterly as a minimum to show the last date a Welderor Welding Operator welded in a specific process. The Shop/Field Foreman isresponsible for notifying Welders and Welding Operators when their qualificationsare close to expiration. The Shop/Field Foreman uses the Welder Continuity Log toassure that only qualified Welders and Welding Operators are assigned to a Codejob.

8.4 WELDING MATERIAL

8.4.1 All welding material is purchased and received as described in Section 5.

8.4.2 All welding materials are stored in a dry storage area and issued to the welder bythe Shop/Field Foreman.

8.4.3 Low hydrogen electrodes are received in sealed containers. When the sealedcontainers are opened, the rod shall be placed in a storage oven at a temperaturerecommended by the material manufacturer or as per Section II Part C. Only aquantity sufficient to complete the weld or four hours supply (whichever is less)shall be issued. Unconsumed electrodes shall be returned to the Shop/FieldForeman for examination. If the electrodes are damaged, unclean, or exceedingfour hours from time of issue, they shall not be used for Code work. Use ofportable rod ovens shall negate the above time requirement for returning rod.


8.5 PRODUCTION WELDING

8.5.1 The Shop/Field Foreman is responsible for assigning only qualified welders to ajob.

8.5.2 Each welder is issued a unique identification number to be stamped or written atnot more than three foot intervals adjacent to each weld he makes. Whenconditions prevent the welder from marking his identification on the weld, he shallenter his identification on the Traveler.

8.5.3 Tack welds whether removed or left in place shall be made using qualified weldersand procedures. They shall be identified with the welders identification. Tackwelds left in place shall be prepared for inclusion into the final weld. Defectivetack welds shall be removed.


8.6.1 Subcontracted welders shall be in the employ of a manufacturer that possesses avalid U, U2, or U3 Certificate of Authorization issued by the ASME.

8.6.2 No welding shall be performed on metal surfaces when the metal temperature isbelow 60oF.

8.6.3 Finished welds shall be ground or machined to blend with the surface of the partsbeing joined.

9.0 Nondestructive Examination Section 9Revision 0Page 1 of 212/11/02

9.1 NDE PROCEDURES

9.1.1 All NDE disciplines are performed in accordance with written proceduresapproved by the QCM and AI. Either the QCM or a contracted Level III Examinermay write the procedures. NDE procedures shall meet the requirements of theappropriate Article of ASME Section V.

9.1.2 All NDE procedures shall be demonstrated to the satisfaction of the AI.

9.2 NDE PERSONNEL

9.2.1 The QCM shall review the written practice of the subcontracted NDE organization.NDE personnel shall be certified to SNT-TC-1A or CP-189 (latest Code acceptededition). Exceptions to this requirement are noted in paragraphs 9.4 and 9.5. If acontracted Level III Examiner is used, an appointment letter must be on fileaccepting the individual as the certificate holders Level III Examiner.

9.2.2 All NDE personnel qualifications shall be current and shall be made available tothe AI for review and acceptance. The AI may require requalification of NDEpersonnel if there is reason to question their ability to adequately perform anexamination.

9.3 NDE REPORTS

9.3.1 All NDE reports shall be reviewed by the QCM and submitted to the AI for hisreview and acceptance. For field sites, the QCI may review the reports prior tosubmittal to the AI.

9.3.2 All NDE film and reports are placed in the job file after AI acceptance.

9.4 VISUAL EXAMINATION

9.4.1 AAF INTERNATIONAL personnel who are qualified and certified in accordancewith the requirements ASME B31.1 may perform visual Examination (VT) forPower Piping work. VT shall be conducted using an approved procedure. VTprocedures and personnel qualifications shall be made available to the AI forreview and acceptance.

9.0 Nondestructive Examination Section 9Revision 0Page 2 of 212/11/02

9.5 LIQUID PENETRANT EXAMINATION

9.5.1 For other than Section VIII Division 3 vessels, Liquid Penetrant Examination (PT)may be performed by AAF INTERNATIONAL personnel who are qualified andcertified in accordance with the requirements of ASME Section VIII Div.1Appendix 8. PT shall be conducted using a procedure written by the QCM andaccepted by the AI. All PT personnel qualifications shall be made available to theAI for review and acceptance.

9.5.2 Liquid penetrant inspection will be performed in accordance withsupplemental procedure ASME 6. 2 latest rev. Acceptance standards will be per theapplicable code.


9.6.1 Except as exempted in paragraph AF-571, all vessel shall be 100% radiographed.

9.6.2 Offset (joggle) joints are prohibited.


9.7.1 All methods of NDE (i.e., RT, UT, MT, PT, and EC) shall be performed usingwritten procedures in accordance with Section V of the ASME Code.

9.7.2 Visual NDE examiners physical examination shall be to Jaeger 1 or equivalent.

9.7.3 Qualifications and certifications of NDE personnel employed by subcontractedmaterial manufacturers, material suppliers, and material organizations shall beverified as meeting the requirements of this division.

10.0 Heat Treatment Section 10Revision 0Page 1 of 112/11/02

10.1 GENERAL

10.1.1Heat treatment shall be performed by a subcontractor using calibrated equipmentand a procedure approved by the QCM. Time-temperature charts or chronologicaltemperature lists will be required and these will be reviewed by the QCM forconformance with the written procedure and Code requirements. The charts andwritten procedures shall be available to the AI for review and acceptance.

10.1.2 The QCM shall verify calibration of subcontracted heat treating equipmentincluding ovens, thermocouples and recording devices. This data shall be madeavailable to the AI for acceptance.

10.1.3 For heat treatment performed in the field, the QCI may perform the duties of theQCM.

10.1.4 After AI review and acceptance, heat treatment records are placed in the job file.

10.3 RECEIVING INSPECTION

10.3.1Material shall be examined for identification by the QCI upon its return from heattreatment. This examination shall be recorded on a Receiving Inspection Report.Nonconforming material shall be handled as per Section 7 of this manual.

11.0 Calibration of Measuring and Test Equipment Section 11Revision 0Page 1 of 112/11/02

11.1 PROCEDURE

11.1.1 Measuring and test equipment requiring calibration shall be identified with aunique serial number.

11.1.2 Master gages shall be calibrated annually by a method traceable to nationalstandards. This calibration shall be documented on a Calibration Record Card(Exhibit 8).

11.1.3 Working gages shall be calibrated against a master gage prior to each use and atany time their accuracy is in question. Date of calibration shall be written on theitem.

11.1.4 Linear measuring equipment shall be calibrated by a method and at a frequencyrecommended by the equipment manufacturer or by a procedure written by theQCM and documented on a Calibration Record.

11.1.5 Measuring and test equipment used by outside contractors for Code work shall beverified for calibration by the QCM.

11.2 DISCREPANT EQUIPMENT

11.2.1 Equipment found to be out of calibration shall be adequately marked and removedfrom the work area pending repair or disposal.

11.2.2 Items found to be tested with equipment that was out of calibration shall behandled as per Section 7 of this manual.

11.3 All records of calibration and calibration procedures shall be made available to the AI forreview and acceptance.

11.4 Control of M&TE is further defined in supplemental procedure ASME 11.1 latest rev.


11.4.1Pressure gages and transducers shall be calibrated against a standard dead weighttester or a calibrated master gage at least every six months.

12.0 Records Retention Section 12Revision 0Page 1 of 112/11/02

12.1 All documents used for Code production described in this manual shall be maintained inthe job file until the job is complete. These records shall be reviewed by the QCM forcompletion and submitted to the AI for review and acceptance prior to certification of theManufacturers Data Report. Code production related records will be maintained for oneyear after the job ships.

12.2 RT film along with RT and UT reports for Section I work shall be maintained by theQCM for 5 years.

12.3 All Data Reports not registered with the National Board shall be maintained by the QCMfor 5 years.


12.4.1The Manufacturers Data Report, with applicable partial Manufacturers DataReport(s), and supplementary sheet(s) attached shall be maintained in a saferepository for at least ten years or for the intended life of the vessel unless the itemis registered with the National Board.

12.4.2 All records, procedures, and documentation, including the certified Users Designspecification and a copy of the certified Design Report, for each item constructedto this division shall be identified and maintained on file for a period of 5 years.After 5 years, these documents shall be offered to the user of the vessel. If the userdeclines these documents, they may be discarded.


12.5.1 All documentation, procedures, and records for items built to this division shall bemaintained until the Manufacturers Data Report is certified. The records listed inparagraph KS-320 shall be furnished to the user of the vessel.

13.0 Authorized Inspector Section 13Revision 0Page 1 of 112/11/02

13.1 AAF INTERNATIONAL shall maintain a current contract with an ASME accreditedAuthorized Inspection Agency (AIA).

13.2 The QCM shall be the liaison with the AIA and the AI. The QCM is responsible forinforming the AI of the progress of work in a timely manner so that he may be present toconduct inspections on designated hold points and pressure tests.

13.3 The AI and AI Supervisor shall be provided access to the plant where Code work isperformed and to such parts of all plants and facilities which are concerned with themanufacture, assembly and/or supply of Code parts and material as requested.

13.4 The AI shall have access to all records and documents referenced in this manual.

13.5 The AI shall hold a National Board of Boiler and Pressure Vessel Commission that bearsthe A Endorsement.

14.0 Repairs and Alterations Section 14Revision 1Page 1 of 611-02-05

14.1 SCOPE OF WORK

14.1.1 Shop and field repairs or alterations to Boilers, Pressure Vessels and BoilerExternal Piping are made in accordance with the applicable requirements of theNBIC, Jurisdictional requirements, and this Manual.

14.1.2 Where any provision herein presents a direct or implied conflict with anyjurisdictional regulation, the jurisdictional regulation shall govern.

14.2 DRAWINGS, DESIGN, & SPECIFICATIONS

14.2.1 Drawings (as appropriate), design calculations (for alterations) and specificationsshall be prepared, reviewed and approved in accordance with Section 4 of thismanual to describe the repair or alteration in sufficient detail prior to performingthe activity. The drawing may be a sketch, which is documented on the RepairChecklist (Exhibit 9), prepared by the QCM.

14.2.2 The above design documents shall be interpreted by the QCM to provide the basisfor an alteration in accordance with the original Code of construction. When theManufacturer's Data Report is required by the original construction standard, acopy of the original Data Report shall be obtained for use in the design of thealteration.

14.2.3 For alterations, including re-rating, to pressure vessels the QCM will provide theINSPECTOR with drawings, calculations, design specifications, design reports,and any other documentation required to adequately perform the work per Section4 of this manual. All design calculations shall be completed by the EngineeringManager and shall meet the requirements of the original Code of construction.

14.2.4 The QCM shall, prior to the start of work, provide the INSPECTOR withdrawings, calculations, procedures, checklists, and any other documents,including a copy of the original Manufacturer's Data Report, (if available)necessary for the INSPECTOR to accept the repair or alteration and designate hisHold Points.


14.3 REPAIR AND ALTERATION METHODS

14.3.1The repair and alteration methods shall be performed in accordance with therequirements of this manual.

14.3.2QCM and AAF Engineering Manager must approve alterations and repairsproposed by the vendor.

14.3.3The user of a Section VIII, Division 2 item shall prepare a Repair Plan that isreviewed and certified by a Professional Engineer per RC-2082. Work involvedin a repair to these items shall be compatible with the Users Design Specificationand the Manufacturers Design Report. The Repair Plan shall then be submitted tothe AIA whose inspector will sign the R-1. Alterations to Section VIII, Division 2or Division 3 items shall be in accordance with NBIC Para RC-3025.

14.4 MATERIALS

14.4.1Materials shall be controlled as described in Section 5 of this manual. The QCMshall verify the identification of existing materials from the original constructiondocumentation or by additional testing of the materials.

14.5 METHOD OF PERFORMING WORK

14.5.1The method of performing repairs and alterations shall be handled as describedthroughout this manual. The INSPECTOR shall perform the duties and have all theopportunities described throughout this manual for the Authorized Inspector, toassure compliance to the NBIC. The method of repair or alteration shall have prioracceptance of the QCM and the INSPECTOR.

14.5.2The QCM shall arrange access to the Code item for the INSPECTOR so he maymake any inspections he deems necessary to accept the repair or alteration. TheQCM keeps the INSPECTOR informed of the progress of work so that he will beavailable to see his Hold Points.


14.6 WELDING, NDE, AND HEAT TREATMENT

14.6.1WELDING

14.6.1.1 The QCM shall be responsible to assure that the welding, welders andwelding operators are performed and qualified in accordance with theoriginal construction Code used. The Standard Welding ProceduresSpecifications referenced in the applicable Edition and Addenda of theNBIC may be used. With the exception of the Standard WeldingProcedures, all procedure qualifications and welders/welding operator'squalification records shall be certified by the QCM and available forreview by the INSPECTOR. It is also the QCM's responsibility to assurethat the welders and welding operators maintain their qualifications perSection 8 of this Manual.

14.6.2HEAT TREATMENT

14.6.2.1 Preheat shall be performed as stipulated per the qualified WeldingProcedure Specification.

14.6.2.2 Postweld heat treatment shall be performed as required by the originalconstruction code and per Section 10 of this manual.

14.6.2.3 Alternatives to postweld heat treatment may be used if PWHT isinadvisable or impractical, and it is acceptable to the INSPECTOR.Examples of these alternative methods of postweld heat treatment orspecial welding methods are described in the applicable Edition of theNBIC.

14.6.3NONDESTRUCTIVE EXAMINATION (NDE)

14.6.3.1 Weld repairs and alterations shall be subjected to the same NDErequirements as with the original construction code of the pressureretaining item. Where this is not possible or practical, alternative NDEmethods acceptable to the INSPECTOR and the jurisdiction (whererequired) may be used.


14.6.3.2 The NDE personnel shall be qualified in accordance with therequirements of the original Code of construction. When this is notpossible or impractical, NDE personnel may be qualified in accordancewith SNT-TC-1A (latest accepted Edition).

14.7 REPLACEMENT PARTS

14.7.1At this time AAF INTERNATIONAL does not intend to fabricate and supplyParts as defined in the NBIC.

14.8 PRESSURE TESTS

14.8.1The pressure tests shall be applied by the Shop/ Field Foreman as specified on theRepair Checklist and witnessed by the QCI and the INSPECTOR. The QCM shallbe responsible for all activities relating to pressure testing of repairs or alterations.

14.8.2 Repairs shall be pressure tested at 80% of the maximum allowable workingpressure (MAWP) stamped on the PRI or operating pressure, whichever is greater,using water or other liquid medium. Alterations shall be pressure tested as requiredby the original Code of construction.

14.8.3 The pressure test shall be held for a minimum of 10 minutes prior to examinationby the QCI and INSPECTOR.

14.8.4 When contamination of the pressure vessel contents by liquids is possible or whenpressure testing is not practical, other methods shall be used as follows:

a) Pressure test may be a pneumatic test provided the QCI obtains the concurrence ofthe INSPECTOR, jurisdictional authority where required and the owner.Precautionary requirements of the applicable section of the original Code ofconstruction shall be applied.

b) As an alternative to the pressure test, NDE methods that verify the integrity of therepair may be used subject to the concurrence of the INSPECTOR andjurisdictional authority (where required) prior to performing the examination.


14.9 CALIBRATION

14.9.1The calibration of pressure gauges, measurement, examination and test equipmentand documentation of calibration shall be performed per Section 11 of this manualand shall be in accordance with the standard used for construction.

14.10 NONCONFORMING ITEMS

14.10.1 A nonconformity is any condition that does not comply with the applicable rulesof the NBIC, construction code, jurisdictional requirements or this Quality ControlSystem.

14.10.2 The system described in Section 7 of this manual shall be used. Allnonconformitys shall be corrected or eliminated before the repair or alteredcomponent can be considered in compliance with the NBIC.

14.11 ACCEPTANCE, STAMPING & DOCUMENTATION

14.11.1 The QCI shall stamp or attach a Nameplate adjacent to the original stamping inaccordance with the applicable Edition of the NBIC, only when authorized by theINSPECTOR. Only nameplates shall be used for Section VIII Division 2 and 3repairs and alterations. After the stamping is performed the QCI shall return thestamp to the QCM who shall maintain custody and control of the "R" stamp.

14.11.2 Upon completion of repair/alteration activities, the QCI reviews alldocumentation for compliance to the NBIC. If acceptable, the QCI shall prepareand certify the applicable NBIC Report Form from final records.

NBIC REPORT FORM:a) FORM R-1 for Welded Repairs,b) FORM R-2 for Alterations, orc) FORM R-4 Report Supplementary Sheet for

additional data.


14.11.3 The final records and applicable NBIC Report Form are presented to theINSPECTOR for his review and certification when he is satisfied all Code ofconstruction and NBIC requirements have been met.

14.11.4 The QCM shall distribute legible copies of the NBIC Report Form together withattachments to the owner or user, the INSPECTOR, the jurisdiction (if required),and the AIA responsible for inservice inspection of the pressure vessel. One copywill be placed in the job file for retention.

14.11.5 If an altered item is registered with the National Board, the original R-2 ReportForms (with attachments) shall be transmitted to the National Board within 60 daysafter certification. R-1 Report Forms may be registered with the National Board atthe discretion of the Quality Control Manager. Registration of R-1 and R-2 ReportForms shall be documented sequentially on a log showing the Repair/ Alterationnumber, description of the item, date certified, and date submitted to the NationalBoard.

14.11.6 All records referenced in this Section are available for review by theINSPECTOR.

14.12 NATIONAL BOARD COMMISSIONED INSPECTOR (INSPECTOR)

14.12.1 An individual who holds a valid and current National Board Commission. TheINSPECTOR shall be employed by one of the following:

a) A Jurisdictional AIA. b)The AIA on contract/agreement by thisorganization, to perform repair or alteration inspection per the NBIC. c)The Authorized Inspection Agency which insures the pressure retainingitem.

14.13 ROUTINE REPAIRS

14.13.1 Prior to performing routine repairs this organization shall determine whetherRoutine Repairs are acceptable to the jurisdiction where the work is to beperformed. The jurisdiction may mandate specific additional requirements notdirectly specified in the NBIC. For Routine Repairs, in-process inspection andstamping may be waved at the discretion of the INSPECTOR. Routine Repairshall be documented in the Remarks section of the R-1.

15.0 Exhibits Section 15Revision 0Page 1 of 14

Exhibit# Title Revision Date

1 Bill of Material 0 12/11/02

2 & 2A Traveler 0 12/11/02

3 Purchase Order 0 12/11/02

4 Receiving Inspection Report 0 12/11/02

5 National Board Number Log 0 12/11/02

6 Nonconformance Report 0 12/11/02

7 Welder Continuity Log 0 12/11/02

8 Calibration Record 0 12/11/02

9 Repair Checklist 0 12/11/02

10 NCR Log 0 12/11/02

11 Job Number Log 0 12/11/02

12 Master Cal Log 0 12/11/02

Section 15Revision 0

Job Number___________ Page 2 of 14Exhibit 1

BILL OF MATERIAL

ITEM # DRAWING NUMBER& REVISION

MATERIALSPECIFICATION

DESCRIPTION REMARKS

Section 15Revision 0Page 3 of 14Exhibit 2

TRAVELERJOB NUMBER________________________________ SHEET _______________ OF ________________

SERIAL NUMBER_____________________________ MAWP___________________________________

NATIONAL BOARD NUMBER___________________ MDMT___________________________________

HEATING SURFACE___________________________ NDE_____________________________________

CAPACITY____________________________________ PWHT____________________________________

CODE STAMP_________________________________ HYDRO/PNEUMATIC TEST_________________

DESCRIPTION REMARKSQUALITY CONTROL

MANAGERHOLDPOINT

AUTHORIZEDINSPECTOR

Initial Review of JobDrawings/Specs.CalculationsMaterial IDMTR ReviewFabrication Insp. (See Weld Joint Fit-up Sheet)PWHT ReviewNDE ReviewPressure Test/Final InspectionNonconformitiesCode StampingFinal ReviewData ReportRevisionRevisionRevision

Remarks________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

Quality Control Manager Approval_______________________________________________

Authorized Inspector Acceptance_________________________________________________

Section 15Revision 0Page 4 of 14Exhibit 2a

TRAVELERWeld Joint Fit Up Sheet

Job Number: Sheet ___of___ Comments:

Q.C.

A.I. (H Denotes Hold Point)

JointIdentification

MaterialIdentification Weld Fit Up Alignment Root Welding Back Gouging

CompletedWeld NDE

WelderStamp Procedure

Section 15Revision 0

JOB NO. _____________ Page 6 of 14Exhibit 4

RECEIVING INSPECTION REPORT BOMITEM # PO # SUPPLIER MATERIAL MARKING DIMENSIONS INSPECTOR & DATE ACC/REJ

Section 15Revision 0Page 7 of 14

Exhibit 5

NATIONAL BOARD NUMBER LOGNB# MFR SN DESCRIPTION DATE SUBMITTED TO NB


NONCONFORMANCE REPORTJOB #___________________________

NCR#___________________________

DATE___________________________

DESCRIPTION OF NONCONFORMANCE________________________________________________________________

___________________________________________________________________________________________________

___________________________________________________________________________________________________

___________________________________________________________________________________________________

FOUND BY_________________________________________________________________________________________

PROPOSED DISPOSITION_____________________________________________________________________________

___________________________________________________________________________________________________

___________________________________________________________________________________________________

___________________________________________________________________________________________________

QC MANAGER __________________________________________________________

ENGINEERING MANAGER_______________________________________________

AI ACCEPTANCE________________________________________________________

ACTUAL DISPOSITION ______________________________________________________________________________

___________________________________________________________________________________________________

___________________________________________________________________________________________________

____________________________________________________________________________________________________

QC MANAGER APPROVAL _______________________________________________

AI ACCEPTANCE ________________________________________________________

REMEDIAL ACTION __________________________________________________________________________________

____________________________________________________________________________________________________

____________________________________________________________________________________________________

REMARKS __________________________________________________________________________________________

____________________________________________________________________________________________________


WELDER CONTINUITY LOGYEAR ____________ JAN - MAR APR - JUN JUL - SEPT OCT - DECNAME ID# GMA

WGTAW SMAW GMA

WGTAW SMAW GMA

WGTAW SMAW GMA

WGTAW SMAW


REPAIR CHECKLISTJOB NUMBER________________________________ NDE_____________________________________

NATIONAL BOARD NUMBER___________________ PWHT____________________________________

MANUFACTURERS SERIAL NUMBER___________ PRESSURE TEST__________________________

WPS_____________________________________

WELDER ID______________________________

SKETCH OR DESCRIPTION OF REPAIR ON BACK

DESCRIPTION REMARKSQUALITY CONTROL

MANAGERHOLDPOINT

AUTHORIZEDINSPECTOR

Initial ReviewMaterial IDMTR ReviewFitup InspectionRoot WeldBack GougeCompleted WeldNDEPWHTPressure TestNoncomformitiesR StampingFinal ReviewNB Repair Form

Material Tabulation_______________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

Remarks________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

Quality Control Manager Approval_______________________________________________

Authorized Inspector Acceptance_________________________________________________

Section 15 Revision 0

of 14 Exhibit 10

NCR LOGNCR NUMBER JOB NUMBER DATE OPENED DATE CLOSED

Section 15Revision 0Page 13 of 14

Exhibit 11

JOB NUMBER LOGJOB NUMBER CUSTOMER & PO NUMBER DESCRIPTION DATE JOB NO.

ASSIGNED