Asme QCM

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY ( ALPHA-ECC )
Address : Lot 9, Dong Xuyen Industrial Zone, Rach Dua Ward, Vung Tau City, Baria Vung Tau Province, Vietnam, 70000 Tel : (84. 64) 3611 200 ; Fax : (84. 64) 3611 788
QUALITY CONTROL MANUAL FOR THE SHOP CONSTRUCTION AND FIELD ASSEMBLY OF POWER BOILERS, PRESSURE VESSELS, PARTS AND POWER PIPING IN ACCORDANCE WITH ASME CODE SECTION I, SECTION VIII DIVISIONS 1 AND 2, B31.1 For ASME CERTIFICATION MARK WITH DESIGNATORS S, U AND U2 AND REPAIRS / ALTERATIONS TO METALLIC PRESSURE RETAINING ITEMS IN ACCORDANCE WITH THE NATIONAL BOARD INSPECTION CODE FOR NB R STAMP
2nd EDITION
CONTROLLED COPY CONTROL No. Holder UNCONTROLLED COPY
Revision Rev. 0 1 2 3 4 Date Prepared by QA/QC Manager Ngo Le Thong Ngo Le Thong Ng L Thng Ng L Thng Ng L Thng Reviewed by QA/QC Dept GM Phan Van Quang Phan Van Quang Phan Vn Qung Phan Vn Qung Phan Vn Qung Approved by Director Vu Van Dao Vu Van Dao L Xun Hng L Xun Hng L Xun Hng Accepted By A.I
21-02-2011 17-01-2012 26-04-2012 03-10-2012 14-11-2012
Responsible: QA/QC Dept Document Title
QUALITY CONTROL
Document format: A4 Document status N/A Document Number AL-QC-ASME.01 MANUAL
QUALITY CONTROL MANUAL Sec. I Table of Contents
Section Rev. No. Page
I 4 1 of 1
Section Preface I II III 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 Cover Page Table of Contents Statement of Authority Glossary Organization QC Manual Control
Description
Rev 4 4 2 2 3 3 3 2 3 3 3 2 2 3 2 2 2 2 1 3
Date 14-11-2012 14-11-2012 03-10-2012 03-10-2012 14-11-2012 14-11-2012 14-11-2012 03-10-2012 14-11-2012 14-11-2012 03-10-2012 03-10-2012 03-10-2012 14-11-2012 03-10-2012 03-10-2012 03-10-2012 03-10-2012 14-11-2012 14-11-2012
Drawings, Design Calculations, and Specification Control Material Control Examination & Inspection Program Correction of Nonconformities Welding Nondestructive Examination Heat Treatment Calibration of Measurement and Test Equipment Records Retention Authorized Inspector Field Assembly Repairs and Alternations Special Requirements for Section VIII, Div. 2 Index of Sample Forms
Document Number : AL-QC-ASME.01
SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )
QUALITY CONTROL MANUAL Sec. II Statement of Authority
II 2 1 of 1
This QC Manual will be used for the shop construction and field assembly of Power Boilers, Boiler External Piping and Pressure Vessels and parts in accordance with the ASME Code Section I, ASME Code Section VIII Div.1 & Div.2, and B31.1. Repairs and Alterations to metallic Pressure Retaining 2 Items in accordance with National Board Inspection Code and any applicable jurisdiction requirements, where the item is installed. All Code items will be constructed or field assembled in the full compliance with the Code, this QC Manual. Repairs and Alterations shall be in accordance with National Inspection Code and this QC Manual. No person involved in the implementation of this QC Manual shall deviate from the provisions set forth in this QC Manual. The QA/QC DEPT General Manager has the sufficient and well-defined responsibility, authority and organizational freedom to identify quality problems and to initiate, recommend and provide solutions to those problems. He also has authority to stop work, which in his opinion, further process will result in non-conforming. All review, approval, certification and authorization used in this QC Manual are indicated by initial/ signature and date of responsible personnel. Electronic signatures are not used. In the event that any problem or difference in opinion concerning quality that cannot be resolved within the organization, it shall be brought to my attention for final resolution and this resolution shall be within the limits of Code, NBIC and this QC Manual as applicable.
Le Xuan Hung DIRECTOR
03-10-2012
Date
Section QUALITY CONTROL MANUAL Sec. III Glossary Rev. No. Page
III 2 1 of 2
AI AIA AIS ASME BM Code C of C DEPT ALPHA-ECC Hold Point Item PS&M DEPT MDR GM 2 PE / RPE PM P&W DEPT MRF MTR NB or National Board NCR NDE
Authorized Inspector ASME accredited Authorized Inspection Agency Authorized Inspector Supervisor The American Society of Mechanical Engineers Bill of Material ASME Codes Sec.I, Sec.VIII Div.1 & Div. 2, and B31.1 and Sections and standards referenced therein Certificate of Compliance Departments in COMPANY Southern Petroleum Construction Joint Stock Company Hold point is a designated inspection stage where the next operation cannot proceed without sign-off by the party who designate the hold point Raw materials, sub-assemblies and completed products covered in this Manual. Process Skid & Modules Department Manufacturer's Data Report or Manufacturers Partial Data Report General Manager of Departments Professional Engineer / Registered Professional Engineer Project Manager Production & Workshops Department Material Requisition Form Material Test Report or Certificate of Compliance The National Board of Boiler and Pressure Vessel Inspectors Nonconformance Report Nondestructive Examination (RT, UT, MT, PT and VT)
Section QUALITY CONTROL MANUAL Sec. III Glossary Rev. No. Page
III 2 2 of 2
PRI PUR DEPT PO PQR QCP WL QC Inspector QA/QC DEPT MRIR Welder
Pressure Retaining Item Purchasing Department Purchase Order Procedure Qualification Record Quality Control Procedure Welder Register List Quality Control Inspector in ALPHA-ECC Quality Assurance/Quality Control Department Receiving Inspection Report Welders or Welding Operators unless otherwise described separately Witness point means a designated inspection stage beyond which the next operation can proceed when the specified partys presence is not available after being notified in advance. The notification shall be documented on the Traveler. Record of Welder or Welding Operator Performance Qualification Welding Procedure Specification Radiographic Examination Ultrasonic Examination Magnetic Particle Examination Liquid Penetrated Examination Visual Examination A Manufacturing step or operation that requires a review of records by AI or Customer. The review activity shall be documented by signature and date on the Traveler and affected document. Quality Control National Board Inspection Code
Witness point
WPQ WPS RT UT MT PT VT Review QC NBIC
Section QUALITY CONTROL MANUAL Sec. 1.0 Organization Rev. No. Page
1.0 3 1 of 4
1.1
This section defines the scope of authorities and responsibilities of key personnel in various departments relating to the implementation and promotion of quality activities in the construction of Code Items. The DIRECTOR is responsible for overall Code construction and NBIC repair/ alteration activities within ALPHA-ECC. The Director will delegate authority to various departments. DEPUTY DIRECTOR reports to the Director. His duties and responsibilities shall include but are not limited to. a) To ensure all requirements of bid documents are fully defined to avoid misinterpretation. b) To determine companys resources and capacity are adequate to fully comply with all requirements of tender prior to submission of bid. c) To identify and resolve all differences, uncertainties or any ambiguous information existing in tender, contract document and request for concession or waiver otherwise.
1.1.1 1.1.2
1.1.3 3
The QA/QC DEPT GM reports to the Deputy Director and responsible for coordinating and controlling inspection activities. The responsibility shall include but not be limited to:
a) Regular review of the applicable ASME Code Edition/ NBIC Edition and Addenda and any consequential update of the Manual, and ensure that only controlled copies of the QC Manual are used. b) Verify compliance and execution of this Quality Control Manual at the shop and field. c) Review of Welding Procedure Specification (WPS) and certify Procedure Qualification Records (PQR), and Welder / Welding Operator Performance Qualification (WPQ). 3 d) Review of Nondestructive Examination (NDE) & Heat Treatment Procedures and NDE personnel certification records. e) Safekeeping of ASME Certification Mark and NB Stamps and proper issuance of the National Board Numbers (on request by client to be registered with the National Board). f) Liaison with the Authorized Inspector for the timely execution of inspections and document reviews. Submitting all supplementary procedures to A.I for his review and acceptance.
g) Control of Nonconformities. h) Certifying MDR
Section QUALITY CONTROL MANUAL Sec. 1.0 Organization Rev. No. Page
1.0 3 2 of 4
1.1.4
THE QC INSPECTOR / Site QC Inspector reports to QA/QC DEPT GM. The responsibility shall include but not be limited to:
a) Inspection of incoming material as per Section 4.0 b) Inspection of Dished Head for forming accuracy. c) Examining welds by means of visual inspection. d) Routine inspection of welding and fabrication operation to ensure that: I). Qualified welders are employed in the Code work. II). The correct welding procedure is being used. III). Welding consumables are controlled as described in procedure No.: AL-WCP-04 e) Conducting welder qualification test. f) Reporting Non-Conformities as described in Section 6.0. g) Keeping calibration records of measuring and test equipment. h) Conducting Final inspection and tests. i) j) 1.1.5 Preparing Manufacturers Data Report and Stamping. Ensuring that inspection hold points do not progress, until authorized to do so. PROCESS SKID & MODULES DEPT GENERAL MANAGER The PS&M DEPT GM is responsible for: a) the review and approval of design documents, drawings, fabrication procedures, specifications, Traveler and subsequent revisions to these documents; b) the appointment of a Design Engineer to prepare design calculations and material selection from the applicable Code section to which the item is to be constructed. 1.1.6 ENGINEER Engineer is responsible for: (a) (b) (c) (d) (e) 1.1.7 the preparation and issuance of shop drawing, fabrication procedures, specifications, Traveler and other related documents, including their subsequent revisions; ensuring that any interruption resulting from design or material changes are properly identified. providing effective supervision instructions and make all applicable documents available in the working area in the shop. preparing weld joints for NDE work. conducting hydrostatic tests as per Code requirements.
DESIGN ENGINEER The Design Engineer is responsible for: c) the liaison with the client / design sub-contractor to ensure drawings, design calculation and material selection meet Code requirements and Clients Specification. d) Submission to PE/RPE for certification of Manufacturers Design Report.
Document Number : AL-QC-ASME.01 SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )
Section QUALITY CONTROL MANUAL Sec. 1.0 Organization 1.1.8 Rev. No. Page
1.0 3 3 of 4
PRODUCTION AND WORKSHOPS DEPARTMENT GENERAL MANAGER The P&W DEPT GM reports to Deputy Director and is responsible for the smooth implementation and execution of the Code item fabrication and repairs and alterations at the shop in compliance with the Code requirements. His responsibility shall also include but not limited to: (a) assigning a Foreman to ensure that the production activities be carried out under controlled conditions; (b) controlling shop equipment and devices and maintaining them in proper working conditions; (c) maintaining the proper calibration of shop equipment and measuring devices, and timely updating QA/QC DEPT. with the calibration status.
1.1.9
SITE MANAGER: The Site Manager shall assume the duties of P&W DEPT GM at the field site. The Site QC Inspector designated by the QA/QC DEPT GM takes responsibility for the quality control activity at the site including in-process inspection, control of NDE subcontractor. He shall certify the MDR for fieldwork portion. He is the principal contact with the A.I at field site.
1.1.10 SITE QC INSPECTOR
1.1.11 PURCHASING DEPARTMENT GENERAL MANAGER The PUR DEPT GM reports to Deputy Director and is responsible for preparing purchase orders and the purchase of Code materials. 1.1.12 PURCHASING STAFF The Purchasing Staff is responsible for the implementation of Code material purchases. 1.1.13 MATERIAL CONTROLLER Material Controller reports to QA/QC DEPT GM and is responsible for the handing of the receiving material and prepare for receiving and inspection. 1.1.14 FOREMAN Reports to P&W DEPT GM / Site Manager and is responsible for the assignment of qualified Welder and supervision of fabrication or assembly operation. 1.1.15 STOREMAN The Storeman is authorized to receive incoming materials and welding consumable. The Storeman reports to P&W DEPT GM. He is responsible for the proper identification and storage of stock, incoming materials and welding consumables, and the maintenance of the electrode oven. He will issue material to Welder upon requested. 1.1.16 DOCUMENT CONTROLLER System Document Controller reports to QA/QC DEPT GM and is responsible for the registration and distribution of documents related to this Quality Control Manual (all revisions of this Manual, its associated QCPs, Exhibits, etc.). Project Document Controller reports to PS&M DEPTt GM and is responsible for the registration and distribution of project documents. 1.1.17 ORGANIZATION CHART See Fig. 1.
Section QUALITY CONTROL MANUAL Sec. 1.0 Organization 1.1.18 DELEGATION OF DUTIES Rev. No. Page
1.0 3 4 of 4
Each GM can delegate performance of duties to his qualified subordinates but the responsibility cannot be delegated.
Figure 1. Organizational Chart
DIRECTOR
DEPUTY DIRECTOR
PROCES SKID & MODULES DEPT. GENERAL MANAGER - Engineer - Design Engineer - Project Doc. Controller
PURCHASING DEPT. GENERAL MANAGER - Purchasing Staff
QA/QC DEPT. GENERAL MANAGER - QA/QC Manager - QC Inspector - Welding Engineer - System Doc. Controller - Material Controller - NDE Sub-Contractor
FIELD SITE (See FIG. 2) (See Section 13)
PRODUCTION & WORKSHOPS DEPT. GENERAL MANAGER - Foreman - Storeman
: Administration Line : Communication Line
QUALITY CONTROL MANUAL Sec. 2.0 QC Manual Control 2.1 Scope
2.0 3 1 of 2
This section describes the applicability and control of the QC Program for CODE/ NBIC activities. 2.2 2.2.1 2.2.2 2.2.3 Applicability of QC Program This QC Manual is the primary documentation of the QC Program. Detailed requirements not covered by this QC Manual will be implemented by the related Quality Control Procedures (QCP) which shall not conflict with this QC Manual. QC Program set forth in this QC Manual shall be applied to the Code/ NBIC activities under ASME Certificates/ NBIC certificate held by ALPHA-ECC. Upon agreement with the customer, the portions of this QC Manual may be applied to the fabrication of Non-Code items where the Code Stamping is not a contractual requirement. Control of QC Manual The QC Manual shall be prepared by the QA/QC Manager in accordance with the Code, reviewed by the QA/QC DEPT GM and approved by the Director. The review and the approval shall be indicated by the QA/QC DEPT GM's and the Director's signature/date on the Cover page. The QC Manual shall be submitted to the AI for review and acceptance prior to implementation. The AI acceptance shall be documented with his signature/date on the Cover page. Distribution 1) 2) The QA/QC DEPT GM is responsible for distribution of the QC Manual. Only controlled copies of the QC Manual shall be distributed by the System Document Controller designated by the QA/QC DEPT GM to the related dept(s) in ALPHA-ECC and shall be available to all the personnel concerned. All the controlled copies of the QC Manual to be issued shall be serialized. The QC Manual and all revisions thereto shall be distributed by hand carry to the related depts. The recipient shall sign and date on the Quality Control Manual Distribution Master List (Exh. AL-ASME-01) except for the recipient of uncontrolled copy. Uncontrolled copy may be issued outside the ALPHA-ECC at the discretion of the QA/QC DEPT GM. Uncontrolled copy shall be current at time of issuance but need not be updated.
2.3 2.3.1 2.3.2 2.3.3 2.3.4
3) 4)
5)
Section QUALITY CONTROL MANUAL Sec. 2.0 QC Manual Control 2.3.5 1) Revision Control Rev. No. Page
2.0 3 2 of 2
Revisions to the QC Manual may be requested by ALPHA-ECC personnel, by Code change, by organizational change, etc. and the QA/QC DEPT GM shall be responsible for the final decision and preparation of the revision to the QC Manual. The QC Manual shall be revised by each Section except for the Sample Forms which are revised by page. The revised area of the QC Manual except for typographical correction shall be identified by italic font plus isosceles triangle mark with revision level. This also applies to areas of pictorial information. Revision status of each Section and Sample Form shall be shown on the Table of Contents and Index of Sample Form, respectively. Addition of information on Sample Forms will not require a revision to the QC Manual, but shall be available to the AI for review prior to its use and to be included in the next revision of the QC Manual. However, deletion of information on sample forms is considered a revision. Distribution of revised QC Manual shall be controlled in the same manner as the original. For any revision in the QC Manual, whole manual is issued as revised document. Obsolete copies of the QC Manual shall be returned to the QA/QC Manager and destroyed by the QA/QC Manager. One copy of the obsolete QC Manual, marked with VOID, may be retained by the QA/QC DEPT for historical record. Review of Code Edition and Addenda QA/QC DEPT GM will review ASME Code Edition/ NBIC Code Edition and Addenda after issuance but prior to the effective date for possible revisions of QC Manual or program. The review result shall be documented with signature, date and results on copies of the summary of changes page of the respective Code or using separate review sheet When revisions are required due to changes in ASME Code/ NBIC Code Edition and Addenda, they shall be implemented within 6 months of the Edition or Addenda issue date.
2)
3) 4)
5) 6)
2.4
2.5
Quality Control Manual Edition At the discretion of QA/QC DEPT GM, this QC Manual may be issued wih a new Edition during the time of the triennal ASME joint review. All revision level shall be reverted to zero and all previous revision level indicators shall be removed.
QUALITY CONTROL MANUAL Sec. 3.0 Drawings, Design Calculations, and Specification Control 3.1 Scope
3.0 3 1 of 3
This section describes order entry and control of design calculations, drawings and specifications and revisions thereto. 3.2 Order Entry Upon awarding of a contract to the ALPHA-ECC, the DIRECTOR shall issue the Job Number, identify it as ASME job and inform the PS&M DEPT GM, P&W DEPT GM, and the QA/QC DEPT GM with comments / directions, if any. The Job number shall be shown on all project related documents. Documents supplied by Customer shall be transferred to the related DEPT GMs from DIRECTOR. Either US Customary unit, SI unit or local customary units may be used for compliance with all requirements of the Code, but one system shall be used consistently throughout all phases of construction (e. g. material, design, fabrication and report) unless otherwise permitted by the Code. The system to be used shall be designated on the drawing in accordance with the Customer Specification. Units on the name plate and MDR shall be consistent with fabrication drawings. Alternate units can be shown in parenthesis. Material certified to either SI or US Customary units can be used irrespective of the units used in construction. PS&M DEPT GM is responsible selection of units.
3.2.1
3.2.2 3.2.3
3.3
Customer Specification Specifications supplied by customer shall be reviewed by Design Engineer, before being accepted by PS&M DEPT GM, in order to verify compliance with applicable Code requirements. After being accepted by PS&M DEPT GM, the specification shall be sent to DIRECTOR for approval. DIRECTOR is responsible for further communication with the Customer for the requirements that are not clear or not in compliance with the Code.
3.4
Control of Customer Supplied Documents The PS&M DEPT GM is responsible for review of the customer supplied documents to assure Code compliance. Customer supplied drawings and calculations may be used directly for fabrication. They shall be stamped with Customer Supplied and reviewed by Design Engineer for meeting Code requirements and approved for construction by PS&M DEPT GM prior to their use. Acceptance of drawings and calculations shall be evidenced by PS&M DEPT GM's signature/date on the drawings and calculations. Revisions to the Customer Supplied Documents shall be controlled in the same manner as the original. When design is by Sub Contractor, customer-supplied documents (data sheets, specifications, drawings) shall be provided to the design sub-contractor. The design-subcontractor generated drawings, design calculation and material specification shall be reviewed by Design Engineer and approved by PS&M DEPT GM for the Code compliance and then shall be submitted to the AI for his review. Alpha ECC remains responsible for correctness and completeness of all design documents. For parts of piping, design responsibility may be taken by main boiler / vessel manufacturer. In such case, partial data report shall be identified with the design responsibility.
3.4.1 3.4.2
3.4.3 3.4.4 3.4.5
3 3.4.6 3.4.7
Section QUALITY CONTROL MANUAL Sec. 3.0 Drawings, Design Calculations, and Specification Control 3.5 1) 2) Control of Documents Drawings, Calculations and Specifications Rev. No. Page
3.0 3 2 of 3
3.5.1
General Assembly Drawings, calculations and specifications shall be prepared by the Design Engineer, reviewed and approved for construction by PS&M DEPT GM for Code compliance. Drawings shall contain enough information to ensure proper fabrication. This information will consist of, but not be limited to, design conditions, material specification including grade, type and class, NDE requirements, heat treatment, dimensions, tolerances, Code Section with Edition and Addenda, drawing number etc. Design calculation shall include the evaluation whether the impact test is required or exempted (not require for S), the applicable Code Section and Addenda, calculation methods and calculated thickness etc. Design Engineer shall verify the Code compliance of inspection openings and corrosion allowance according to the applicable Code as required to be described on the MDR. PS&M DEPT GM shall submit the design calculations and drawings to the A.I. for his review prior to the start of fabrication so that the Al may place his inspection points on the TRAVELER in accordance with Section 5.0 of this QC Manual. All design documents shall be registered with and distributed by the Project Document Controller. The Project Document Controller shall keep Document Distribution Master List (Exh : AL-ASME-02) and record the latest revision for each document. The Project Document Controller shall hand deliver new/ revised drawings to the concerned personnel and obtain the signature with date of recipients as record of receipt on the Drawing / Document Distribution List. Computer Aided Design Calculation When computer aided design calculations are used for the design of Code items, the PS&M DEPT GM is responsible for the input of the correct design data and for verifying that the correct output has been obtained and in compliance with Code by alternate methods. The PS&M DEPT GM shall review Code Edition and Addenda to determine whether computer programs are affected or not. All computer program revisions shall be verified in the same manner as the original prior to use. Computer aided calculations shall be made available to the AI. The PS&M DEPT GM provides the A.I with any alternate calculations when requested. Fabrication Documents
3)
4) 5)
6)
3.5.2 1)
2)
3) 3.5.3
1) The PS&M DEPT GM is responsible for issuing the applicable fabrication documents such as work instructions. 2) Fabrication documents with revision level to be used for fabrication shall be listed on the Traveler by the PS&M DEPT GM and distributed to ASME working area. 3) When contractually required, as built drawings shall be prepared by Engineer, approved by PS&M DEPT GM and may be verified by A.I. 3.5.4 Inspection and Test Documents 1) The QA/QC DEPT GM is responsible for issuing the inspection and test documents such as Inspection and Test Procedure, NDE Procedure as described in Section 7.0 and 10.0 of this QC Manual. 2) Inspection and test documents with revision level to be used for fabrication shall be listed on the Traveler.
QUALITY CONTROL MANUAL Sec. 3.0 Drawings, Design Calculations, and Specification Control 3.5.5
3.0 3 3 of 3
Fabrication, inspection and test documents shall be registered with the Project Document Controller and Distributed by hand carry under the responsibility of the Project Document Controller Quality Control Procedure (QCP) QCP shall be prepared by QC Inspector and Approved by the QA/QC DEPT GM. Revisions of Drawings/Documents
3.5.6 3.5.7
1) Revisions of drawings/documents shall be prepared, reviewed, approved and distributed in the same manner as the original. 2) The revised area of drawings/documents except for typographical correction shall be identified with a vertical line on the right hand margin and the area of pictorial information shall be identified with appropriate method such as cloud mark and revision level. 3) Obsolete copies shall be withdrawn from the work area and physically destroyed or if retained for historical purpose identified with the stamping of "VOID" by the recipient. 4) Revised drawings / calculations must be verified by PS&M DEPT GM. 5) For any revision to drawings or customer specifications, PS&M DEPT GM shall review and verify if design calculations need be revised. Design calculations shall reference the revision No. of drawing. Revisions to the design documents shall be distributed to all concerned and to AI for his review. 3.6 Availability of Documents to the AI All the documents related to Code activities shall be made available to the A.I.
Section QUALITY CONTROL MANUAL Sec. 4.0 Material Control 4.1 Scope Rev. No. Page
4.0 2 1 of 4
This section describes procurement, receiving inspection and control of Code materials including welding materials to assure that only intended materials are used in Code construction. 2 4.2 Responsibility Requisition of materials shall be the responsibility of the PS&M DEPT GM. Purchasing of materials will be the responsibility of the PUR DEPT GM in according with approved procedure. Receiving inspection and review of the Purchase Order will be the responsibility of the QA/QC DEPT GM. 2 4.3 Material Requisition Form (MRF) The Material Requisition Form ( Exh : AL-ASME-06) and the Bill of Material (BM) ( Exh : AL-ASME-07) will be prepared by the Engineer for each contract, reviewed and approved by the PS&M DEPT GM. The MRF and BM will be the part of PO. The Bill of Material (BM) will contain the material specification, grade/class, quantity, size. Prior to approval of the MRF and BM, the PS&M DEPT GM shall assure that the MRF/BM includes all the requirements of the Material Specification of ASME Code Section, construction Codes and Customer Specifications, including Material Certification documentation requirements, that the materials are acceptable for Construction and that all the relevant ordering information as required by the Material Specification is indicated. No change or substitution of material shall be made without revision of the MRF and BM, and any other affected documents and the approval of the PS&M DEPT GM as applicable and it shall be made available to the A.I when requested. One copy of MRF and BM shall be forwarded to the PUR DEPT. 4.4 Purchase Order After having received the approved MRF/BM, the Purchasing Staff will prepare the Purchase Order (Exh : AL-ASME-05) using the information as shown on the MRF and BM. The Purchase Order will contain the Job number. Project Name, MRF and BM numbers with revision. The Purchase Order shall be approved by the DIRECTOR and sent to the proper vendor by PUR DEPT GM with the MRF and BM (if applicable) for purchasing the material. All materials will be ordered to SA or SB specification for which allowable stresses are listed in the Section II Part D for the applicable construction Code, and to SFA specification for welding material, or other specifications allowed by the Code. A copy of the approved Purchase Order with MRF and BM will be forwarded to the QA/QC DEPT to be used during receiving inspection. When vessel shell sections, heads or other pressure boundary parts are cold formed by a subcontractor, the required certification for the part shall indicate whether or not the part has been heat treated. QC Inspector shall ensure that thickness and dimension requirements after forming are within the design requirement and the applicable ASME Code requirement.
Section QUALITY CONTROL MANUAL Sec. 4.0 Material Control Rev. No. Page
4.0 2 2 of 4
The coded marking system, if used by the subcontractors of formed shape or the processors of plate and pipe shall be acceptable to QA/QC DEPT GM of ALPHA-ECC and to the AI. This shall be verified at receiving inspection stage. 4.5 Receiving Inspection The PUR DEPT will receive the material and inform QA/QC DEPT for receiving and inspection. All document provided by the material supplier shall be forwarded to QC Inspector for receiving inspection. The QC Inspector will prepare Material Receiving Inspection Record : MRIR (Exh : AL-ASME-08). Using the Purchase Order with MRF and BM and Code as a guide, the QC Inspector shall perform receiving inspection and fill out the MRIR. The MRIR will contain measurement for dimensions, heat no., slab no., Job number, MTR number, material identification marking taken from the materials and all other pertinent information. The QA/QC DEPT GM shall verify the miscellaneous pressure part for which the Partial MDR is not required for Code compliance per UG-11 & PG-11. 4.6 Identification of the accepted Material The QC Inspector will indicate the acceptable material by attaching the "ACCEPTED" Sticker (Exh : AL-ASME-11) on the material. When small parts are received, they may be placed in the bin or tub and the "ACCEPTED" Sticker will be attached on the tub or bin. For the material from which the "ACCEPTED" Sticker can be easily defaced during handling i.e. for plates, pipes, etc. the QC Inspector may indicate the acceptance of the material by writing the Job number or MRIR number with signature on the surface of the material with paint. All material with large size enough to be marked with ASME close to ID marking (by non deleted ink). If the material is found to be non-conforming, a "HOLD" Sticker (Exh : AL-ASME-11) will be placed upon the material and an NCR shall be generated per Section 9. 2 4.7 Material Certification (MTR) The Material Certification, when required, will be reviewed by the QC Inspector for the traceability of identification numbers on the material and for the compliance with the requirements of the ASME Code and Purchase Order. QA/QC DEPT GM shall verify Code compliance and re-certify (Exh : AL-ASME-11) for the ASTM material produced to an edition other than those listed in Acceptable ASTM Editions of ASME Code Section II Part A or B or different from edition and addenda of the construction Code used. QA/QC DEPT GM stamps ACCEPTED with signature and date on the material certificate will evidence review of the Material Certificate. The QA/QC DEPT GM will review the MRIR with the material certification and he is responsible to make them available to the AI when requested. The QA/QC DEPT GM shall approve the MRIR and returns it to the QC Inspector. If further material testing is required to be performed at receiving inspection or during manufacturing operations, the test shall be arranged by the QC Inspector with a PO & testing specification and the result shall be reviewed/approved by the QA/QC DEPT GM and shall be available to the AI using either a NCR or a Traveler. The report will be referenced and attached to the MTR and form part of the material certification.
QUALITY CONTROL MANUAL
Section Rev. No.
4.0 2 3 of 4
Sec. 4.0 Material Control 4.8 Issuance of Material
Page
Upon receiving the approved MRIR, the QC Inspector shall distribute the copies of the MRIR to PUR DEPT / P&W DEPT GMs for notification of acceptance. A copy of the MRIR will be sent to the PS&M DEPT GM for withdrawal of the accepted material for fabrication work as described in the Traveler. The Storeman shall release only the material accepted and so identified on the MRIR and material to the Foreman. This shall be documented on the Store Issue Voucher (Exh : AL-ASME-10). 4.9 Storage Storage of Code material in the shop will be in the designated areas. A shop storage area will be in such a location as to prevent damage to the material. Welding material will be stored in accordance with manufacturer's recommendation in a clean and dry area and under the control of the Storeman / Material Controller and in a suitable atmosphere when opened. Welding material shall be stored, issued and controlled in accordance with the Welding Consumable Control Procedure ( AL-WCP-04) 4.10 Customer Supplied Material For customer supplied materials, MTR or C of C as required by the material specification and Code shall be provided and Customer supplied material will receive the same cycle of receiving inspection, identification, certification and control according to the paragraph 4.5 through 4.9. using customer supplied documents, MRF, BM for inspection and Code compliance. 4.11 Stock Material Stock material will receive the same cycle of receiving inspection, identification, certification and control according to the paragraph 4.5 through 4.9, before use, except the BM and MRF. Code and drawings are used in receiving inspection. 4.12 Non-Conforming Material If material is found to be nonconforming, it will be handled in accordance with Section 6.0 of this QC Manual. 4.13 Identification Marking In case the original identification markings are to be cut out or obliterated in subsequent operations, or the material is divided into two or more parts, one set of material identification shall be transferred on to each piece of material prior to cutting to the location where the markings will be visible on the completed vessel, or a Coded Marking Control Procedure (AL-CM-17) shall be used to assure identification of each piece of material during fabrication and subsequent identification of the markings on the completed vessel. When the Coded Marking System is used it shall be traceable to the original required marking and shall be acceptable to the A.I. Heat numbers or material identification markings shall be recorded on the Traveler in the event of machining or other operation causes the identification markings to be removed.
Section QUALITY CONTROL MANUAL Sec. 4.0 Material Control Rev. No. Page
4.0 2 4 of 4
Upon completion of machining or other operation, the markings will be re-stamped or etched back onto the material. This shall be verified by the QC Inspector. For plate materials used in the construction of Section I Boilers, one group of plate manufacturer's stamps, consisting of the manufacturer's name, plate identification number, material specification number with grade, class and type as appropriate shall remain visible on shell plate, furnace sheets and heads, except that heads containing tube holes and butt straps shall have visible at least a sufficient portion of such stamps for identification or the Coded Marking System may be used as described earlier in this paragraph. 4.14 Authorized Inspector All documents for Code material will be made available to the A.I. for review.
Section QUALITY CONTROL MANUAL Sec. 5.0 Examination & Inspection Program 5.1 Scope Rev. No. Page
5.0 3 1 of 3
This section describes the control measures of examination, test and inspection through construction process. 5.2 Responsibility Material processing and handling in the shop will be the responsibility of P&W DEPT GM. The Traveler shall be prepared and implemented under the responsibility of PS&M DEPT GM. The planning and performing of examinations and inspections will be the responsibility of the QA/QC DEPT. 5.3 Traveler The Traveler ( Exh : AL-ASME-21 ) which shall contain all applicable processes such as fit-up, welding, NDE, heat treatment, inspection and test, etc. and all applicable procedures to be used, shall be prepared by the Engineer and approved by the PS&M DEPT GM. The Traveler shall be forwarded to the QA/QC DEPT GM or his designee for review and the designation of QC Hold/Witness points. When entry to the completed vessel is not provided, an inspection stage shall be identified on the Traveler for internal examination prior to setting up the final closure weld. 5.3.3 After designation of QC Hold/Witness points, the QA/QC DEPT GM shall submit the Traveler and drawings and any other documents requested to the AI so that he may assign his Hold/Witness/Review points prior to start of fabrication. The Traveler reviewed by the A.I. with his signature/date shall be given to the Engineer to place in the working area with the applicable drawings and procedures referenced on the Traveler for use during fabrication. The revision to the Traveler shall be prepared, reviewed and approved in the same manner as for the original including A.I. review except that the processed page of Traveler shall remain attached to the revised page. If additional Hold/Witness/Review Points are requested by the AI or Customer, they shall be included. Hold/Witness/Review Points shall not be deleted without approval of the QA/QC DEPT GM, A.I. and/or Customer. Upon the satisfactory completion of the each operation, the Engineer shall sign/date on the applicable column to indicate the completed fabrication operation on the Traveler. The Engineer shall also record the identification of materials used and the ID No. of the Welders who welded the joints on the Traveler.
5.3.1
5.3.2
5.3.4
5.3.5
5.3.6
5.3.7 5.3.8
5.4
In-Process Inspection The QC Inspector will monitor the fabrication, NDE and heat treatment operations, and document inspection results on the Traveler and appropriate report form. The QA/QC DEPT GM shall notify the A.I. of all Hold/Witness Points in reasonable advance. The designated Hold Points shall not be bypassed without consent of the party who designated the inspection point. In the event that the AI consents to allow work to proceed through a specified AI Witness Point which is not mandated by the Code without his presence, the QA/QC DEPT GM shall be responsible for documenting this agreement on the Traveler prior to beginning of the work so affected. AI may designate additional Hold Point in such event.
5.4.1 5.4.2 5.4.3
Section QUALITY CONTROL MANUAL Sec. 5.0 Examination & Inspection Program 5.4.4 Rev. No. Page
5.0 3 2 of 3
Upon satisfactory completion of the inspection of the QC Inspector / A.I. / Customer's Hold/ Witness/Review Points, they will sign-off on the applicable column of the Traveler to indicate their acceptance. Related report/record number shall be recorded on the Traveler. If any non-conformance is found during inspection, they shall be handled in accordance with Section 6.0 of this QC Manual and QC Inspector shall record the NCR number on the Traveler. Nonconforming conditions found by a person other than QC Inspector will be notified to the QA/QC DEPT GM. Upon the completion of fabrication operations, the completed Traveler and required reports shall be submitted to the QA/QC DEPT GM for review to assure that all the designated inspections and tests have been completed and conform to the applicable drawings, procedures and customer documents. The QA/QC DEPT GM is responsible for assuring that all Code required inspections by the A.I. have been performed and there is no open NCR. When the review is acceptable, the Traveler and associated records shall be handled in accordance with Section 11.0 of this QC Manual.
5.4.5
5.4.6
5.4.7 5.4.8
5.5
Final Testing The Engineer shall be responsible for conducting the final pressure test as per Hydrotest Procedure AL-HT-15 (AL-HT-15-01). The QA/QC DEPT GM or his designee shall be responsible for monitoring the final pressure test of the Code items. The QC Inspector and the A.I. shall witness and make the examination and inspection on the welded joints and connections of Code items during the final pressure test and document the result on the Pressure Test Report ( Exh : AL-ASME-12). A.I. is given an opportunity to sign the Pressure Test Report. Pressure indicating gauges used in testing shall have dials graduated over a range as described in the applicable Code section. In the event of a pneumatic test for Section VIII, Div.1 construction, the NDE requirements of UW-50 shall be followed before the test. For Section I Boiler, hydrostatic test shall be performed to preclude over pressurization so that the membrane stress of any part shall not be greater than 90% of its yield strength. A pressure relief valve may be used and set to the predetermined pressure of 0.9 x Pmax. Permissible test temperature shall be as per Code and specified in the hydrotest procedure AL-HT-15 (AL-HT-15-01).
5.5.1 5.5.2 5.5.3
5.5.4 5.5.5 5.5.6
5.5.7
5.6
Manufacturers Data Reports and Stamping Upon successful completion of the final pressure test, QC Inspector shall provide a complete MDR and the QA/QC DEPT GM will review it for correctness, and certify the MDR. The MDR signed by the QA/QC DEPT GM will be presented to the AI for his review and signature. The QA/QC DEPT GM will distribute the copy of the MDR to the user or his designated agent, AIA and jurisdiction at the location of installation, as required by the Code. When providing parts to be assembled by another ASME Certificate Holder, it is the responsibility of the QA/QC DEPT GM to assure that the Partial MDR has been forwarded, in duplicate, to the manufacturer of the finished item or, for replacement or repair parts, to the user or his designated agent. The scope of the design responsibility shall be indicated in the Remarks of the Partial MDR.
5.6.1
5.6.2 5.6.3
Section QUALITY CONTROL MANUAL Sec. 5.0 Examination & Inspection Program 5.6.4 Rev. No. Page
5.0 3 3 of 3
Prior to affixing the ASME Certification Mark and/or NB Stamps, the QC Inspector shall check the data on the item or on the Name Plate Marking ( Exh : AL-ASME-14) with the final drawings and related documents to assure all specified requirements have been met. Direct stamping shall not be used on vessels or parts constructed of steel plates less than 1/4 inch (6mm) thickness or of nonferrous plates less than 1/2 inch (13mm) thickness. The ASME Certification Mark and/or NB Stamps shall be applied only with the concurrence of the AI and he will witness the affixing of the ASME Certification Mark and/or NB Stamps. For field assembled boilers and pressure piping, ASME Certification Mark and/or NB Stamps shall be applied in accordance with the requirements of PG-108 and PG-109 respectively by the QA/QC DEPT GM in the concurrence and presence of AI.
5.6.5 5.6.6
5.7
ASME Certification Mark and NB Stamps The QA/QC DEPT GM shall safely keep the Certification Mark and NB Stamps when not in use. When a stamp is requested by the shop, the QA/QC DEPT GM or his designee will hand carry it to the location. Soonest after being used, the ASME Certification Mark and/or NB Stamps shall be returned to the custody of the QA/QC DEPT GM.
5.7.1 5.7.2 3
5.8
Retention of MDR The Manufacturer's Data Report shall be maintained by QA/QC DEPT GM which shows the date issued, type of vessel and manufacturer's serial number. (See Section 11 of this QC Manual for retention).
5.9
Registration with National Board (NB) When the registration of MDR with NB is required, the original MDR shall be sent to NB for registration by the QA/QC DEPT GM within 60 days after signing by the A.I. The MDR shall be the signed and dated with commission number and endorsements of the A.I. holding NB commission. For registration with NB, the serialized NB number shall be assigned by the QA/QC DEPT GM after the completion of the pressure test without prefix or suffix, skips or gaps of unused numbers or duplication of numbers starting with one and shall be recorded in the National Board No. Log (Exh : AL-ASME-18) at the time of completion of final inspection/ pressure test as applicable.
5.10 Authorized Inspector All documents related to Code activities including material certification, examination reports, test records and other fabrication records shall be made available to the Authorized Inspector when requested.
Section QUALITY CONTROL MANUAL Sec. 6.0 Correction of Nonconformities 6.1 Scope Rev. No. Page
6.0 3 1 of 2
This section describes the system for handling of nonconforming items including identification, reporting and disposition in order to prevent their inadvertent use. Nonconformity is any condition which does not comply with the applicable rules of the Code, this QC Manual or other specified requirements. Nonconformity shall be corrected before the item can be considered to comply with Code requirements. 6.2 Identification When nonconforming conditions are found at any stage of fabrication activity, it shall be identified by the QC Inspector by attaching a "Hold" Sticker( Exh : AL-ASME-11 ) to the nonconforming items. Where attaching the Hold Sticker is not practical, it shall be attached to the tub or the bin, and shall be indicated on the Traveler as appropriate. The QC Inspector shall issue a Nonconformance Report ( Exh : AL-ASME-13) The QC Inspector is responsible to record the NCR number on the Traveler or on the Material Receiving Inspection Record (MRIR) for receiving inspection. When an individual other than the QC Inspector detects the nonconforming conditions, the individual shall notify the nonconformance to the QA/QC DEPT so that the activities described above shall be accomplished. Documentation The QC Inspector documents the nonconforming condition on the NCR with the recommended dispositions, if possible. When the NCR is issued it will be recorded on the Non Conformance Report Log (Exh : AL-ASME-22 ) and which is maintained by the QA/QC DEPT GM. 6.4 Segregation The nonconforming items shall be segregated, if practical, from similar acceptable items by the P&W DEPT GM or PUR DEPT GM and further processing shall not be permitted until the final disposition is made. 6.5 Disposition The QA/QC DEPT GM/ PS&M DEPT GM is responsible for providing the final disposition of the nonconforming condition and when needed, the NCR will be sent to the PS&M DEPT GM before the final disposition for the further technical justification or design evaluation. The PS&M DEPT GM is responsible for evaluation of nonconformance and for the development of the recommended disposition of nonconformance in accordance with the requirements of Code and Customer documents. The QA/QC DEPT GM shall review the recommended disposition and make final disposition. A copy of the NCR resulting in a design change shall be distributed to the PS&M DEPT GM for information and use in the reconciliation of the design documents. All NCR's shall be submitted to the A.I. by the QA/QC DEPT GM for his review and concurrence and designation of inspection points (Ref. Para. 6.5.6) prior to the implementation of disposition.
6.2.1
6.2.2 6.2.3 6.2.4
6.3 6.3.1 6.3.2
6.5.1
6.5.2
6.5.3
6.5.4
Section Rev. No.
6.0 3 2 of 2
Sec. 6.0 Correction of Nonconformities 6.5.5
Page
The NCR need not be issued for recurring type welding defects found by NDE or visual inspection during the fabrication process provided the following conditions are met and documented on the appropriate NDE report. a) The welding defects are repaired using the welding repair procedure which has been verified by the AI in advance and impact testing is not the requirement. b) The repair shall be completed before final heat treatment or pressure testing whichever is earlier. c) The repaired area shall be re-inspected/ examined using the original method
6.5.6
When the final disposition is Use As Is, it should be approved by the QA/QC DEPT GM with technical justification and no Code violation, all affected documents shall be revised and approved as the original. When the final disposition is "Repair", the PS&M DEPT GM shall describe the process steps including required inspection for repair work on the NCR or by using the Traveler. It is the responsibility of the P&W DEPT GM to implement the disposition for the In-Process items and of the PUR DEPT GM for the received material. Repaired items shall be examined in accordance with applicable procedures and with the original acceptance criteria unless the alternate acceptance criteria are established on the NCR which meets the Code requirements.
6.5.7 6.5.8 6.5.9
6.5.10 Nonconforming items shall be returned for further fabrication process as described on the original Traveler only after the disposition has been accepted by QA/QC DEPT GM, the AI and /or the Customer. 6.5.11 Upon completion of disposition activity, the QC Inspector shall close it out by confirming with his signature and date, and signature/date of the AI on the NCR. 6.6 Repair of Base Materials When the disposition of a nonconformance requires the repair to base material as defined by the Code, the acceptance by the AI and the customer shall be obtained prior to the start of repair work for the method and extent of repairs. It shall be documented on the NCR. 6.7 Un-Resolved Nonconformity Material or items that cannot be corrected from the nonconforming condition shall be scrapped. 6.8 Authorized Inspector All documents related to the NCR activities will be made available to the AI for his review.
QUALITY CONTROL MANUAL Sec. 7.0 Welding 7.1 Scope
7.0 3 1 of 4
This section describes the control of WPS, PQR, Welder qualification, welding material distribution and welding processes. All Welding Procedure Specification (WPS) and Welders shall be qualified according to the requirements of Section IX of the ASME Code and additional requirements of the applicable Code of construction. 7.2 Responsibility Preparation of all welding procedures and the procedure qualification tests will be the responsibility of the Welding Engineer / QC Inspector. The certification of the PQR and WPQ will be the responsibility of the QA/QC DEPT GM. The P&W DEPT GM is responsible for the control of all welding materials. Actual issuing and storage of welding material will be the responsibility of Storeman. Welding Engineer / QC Inspector is responsible for the full supervision and control of the welding of the test coupons and recording actual data of variables used in the welding for the qualification of welding procedure, welder and welding operator. 3 In addition to the Traveler (see 5.3.1), the Engineer is responsible for the preparation of work instructions for welders and fitters, production weld and NDT maps. It is the responsibility of QC Inspector to monitor and inspect all aspects of production welding, including welding consumables, etc. to ensure full compliance with the Code and WPS. This responsibility shall also include visual inspection of welds (see 8.1), liaison with NDT Sub-contractor for project-specific NDT service, liaison with customers inspector, AI, and other third party (if any) for their hold, witness, review points indicated on the Traveler. 7.3 Welding Procedure Specification The Welding Engineer / QC Inspector will be responsible for the preparation and qualification of Welding Procedure Specifications and revisions to them. When revisions to a WPS are required and the changes are limited to the nonessential variables the existing WPS shall either be revised showing a new revision level and date or a new WPS shall be written. Any changes in essential or supplementary essential variables (only when impact test is required by the applicable construction Code), will require a new qualification test. The Welding Engineer / QC Inspector shall maintain a list of the WPS which have been qualified for ASME Code activities. The WPS designated by the Welding Engineer / QC Inspector and specified on the Traveler or weld map shall be made available to the Welders in the work area. QA/QC Dept General Manager / A.I may request re-qualification of a WPS at any time, when he has reason to question the WPS on making sound welds.
Section QUALITY CONTROL MANUAL Sec. 7.0 Welding 7.4 7.4.1 Welders/Welding Operators (Welder hereafter) Rev. No. Page
7.0 3 2 of 4
The qualification of Welder will be performed under the full supervision and control by the Welding Engineer / QC Inspector in ALPHA-ECC shop. Only qualified Welders shall be assigned to perform Code welding by the Foreman. The Foreman is responsible for assignment and supervision of welders. Each welder will be assigned a unique identifying number upon successful completion of first qualification test by the Welding Engineer / QC Inspector. If a Welder leaves the ALPHA-ECC, unique identifying number shall not be reassigned for at least 1 year. All qualified Welders name, identifying number, qualified position, F-number, pipe diameter, thickness, process and welding date in that process, etc. will be maintained in a Welder Register List (WL) ( Exh : AL-ASME-04) for each project individually. The QC Inspector will update the project-specific WL for any addition or deletion of new Welder or at least every three months. The updated copies of the WL will be given to the Foreman. If the expiration of some Welder's qualification on WL is coming prior to the next update the Foreman shall notify it to the Welding Engineer / QC Inspector to verify the extension of the qualification. Qualified Welder/Welding Operator is listed on Welder Continuity Log ( Exh : AL-ASME-03) which is updated by Welding Engineer / QC Inspector. Welder Continiuty Log shall indicate at least one report of welders activity per month within the every three month period. The weld joint shall be stamped by Foreman with the Welder's unique identification number on base material surface at distance of not more than 3 feet (1 m) of weld which he makes in steel plates 1/4 inch (6mm) and over in thickness and in nonferrous plates 1/2 inch (13mm) and over in thickness, or record Welder's identification number on applicable column of Traveler by Engineer with his signature. For identification of Welders on vessels in which the wall thickness is less than 1/4 inch (6mm) for steel material and less than 1/2 inch (13mm) for nonferrous material, suitable stencil or other surface markings shall be used, or a record of Welder ID shall be indicated on the Traveler by Engineer for each joint, which shall be available to the AI when requested. Documentation of Test Result The results of the qualification test shall be documented on the PQR or the WPQ as applicable. When the testing is performed by an outside laboratory, steps shall be taken to assure that the test is performed on the correct specimen and these test reports shall be documented on the PQR/WPQ by the Welding Engineer / QC Inspector, which are then certified by QA/QC DEPT GM. Test reports provided by the outside source laboratory shall be kept on file by the Welding Engineer / QC Inspector.
7.4.2
7.4.3
7.4.4 3
7.4.5
7.4.6
7.5
7.6
Expiration and Renewal of Qualification The performance qualification of Welder shall be affected when one of the following conditions occurs.
7.6.1
When a Welder has not welded with a process during a period of 6 months or more, his qualifications for that process shall expire; unless, within the six month period, prior to his expiration of qualification. 1) A Welder has welded using manual or semiautomatic welding under the supervision and control of Foreman that will extend his qualification for an additional 6 months. 2) A Welding operator has welded with a machine or automatic welding under the supervision and control of Foreman that will extend his qualification for an additional 6 months.
7.6.2
When there is a specific reason to question his ability to make welds that meet the specification, his qualification which support the welding he is doing shall be revoked. All other qualifications not questioned remain in effect.
Section QUALITY CONTROL MANUAL Sec. 7.0 Welding Rev. No. Page
7.0 3 3 of 4
7.6.3 7.6.4 7.7
The QA/QC DEPT GM or the AI may require re-qualification of the Welder when these reasons are found. Renewal of qualification shall be in accordance with QW-322.2 of the Code Section IX.
Welding Material Distribution
7.7.1 The Storeman will be responsible for issuing and returning of welding material using in accordance with the Welding Consumable Control Procedure ( AL-WCP-04) 7.7.2 Low hydrogen electrodes shall be properly identified and kept in atmosphere controlled storage area under conditions complying with the manufacturer's recommendation. Low hydrogen welding materials shall be dried in the heating oven before being issued for use in the shop according to the manufacturer's recommended time and temperature on the Welding Electrodes Baking and Holding Report (Exh : AL-ASME-16). Electrodes of controlled quantity will be issued to Welders by the Storeman. Remained materials will be returned to the welding material crib at the end of the shift or after the time specified on the Welding Material Issue Record ( Exh : AL-ASME-17) whichever comes earlier. The low hydrogen electrodes once issued and returned will not be used for Code job. 7.7.3 Welding materials not requiring heated storage will be kept in clean and dry storage areas. 7.8 Welding The Foreman shall assign the welder to the job based on WL, WPS and drawings. The Foreman shall maintain the applicable documents to perform the job at the working place of ASME Code job. QC Inspector will record Welder I.D, WPS, Joint No, NDE Method into Welding Summary (Exh : AL-ASME-23) when requested by customer. Engineer will control Traveler based on working assignment. 7.8.1 Tack Weld and preparation for welding Tack welds used to secure alignment shall either be removed completely when they have served their purpose, or their stopping and starting ends shall be properly prepared by grinding or other suitable means so that they may be satisfactorily incorporated into the final weld. Tack welds, whether removed or left in place, shall be made using a qualified WPS. Tack welds to be left in place shall be made by Welders qualified in accordance with Sec. IX and shall be examined visually for defects, and if found to be defective, it shall be removed. The method of base metal preparation used shall leave the welding groove with reasonably smooth surfaces and free from deep notches, striations or irregularities. The surfaces for welding shall be free of all scale, rust, oil, grease or other foreign materials. 7.9 Individual may be contracted by ALPHA-ECC to supply their welding services provided all the following conditions are met. All Code construction shall be the responsibility of the ALPHA-ECC. All welding shall be performed in accordance with the ALPHA-ECCs Welding Procedure Specifications.
7.9.1 7.9.2
QUALITY CONTROL MANUAL Sec. 7.0 Welding
7.0 3 4 of 4
7.9.3 7.9.4 7.9.5 7.9.6
All Welders shall be qualified by the Welding Engineer/ QC Inspector/Site QC Inspector in accordance with this QC Manual and assigned with an identification number. The P&W DEPT GM has the authority for complete and exclusive administrative supervision of all Welders. The Engineer shall provide technical supervision to the Welders. The Foreman has authority to assign and remove Welders at his discretion without involvement of any other organization. The Director shall be responsible for Code compliance of the vessel or part, including Certification Mark stamping and providing Data Report Forms properly executed and countersigned by the Authorized Inspector. The signature of the AI on the cover page indicates the acceptance of this program on behalf of the AIA of record.
7.9.7
7.10 Authorized Inspector The AI shall have the right at any time to call for and witness tests of welding procedure qualification or of the ability of any Welder. All documentation in this section will be made available to the A.I.
Section QUALITY CONTROL MANUAL Sec. 8.0 Nondestructive Examination 8.1 Scope Rev. No. Page
8.0 2 1 of 2
This section describes the requirements for NDE and documentation of the results as required for Code compliance. When Non-Destructive Examination (RT, UT, MT and PT) is needed, it will be subcontracted. Visual Examination required by the ASME B31.1, Section VIII Division 2 will be performed by qualified QC Inspector. 8.2 2 Responsibility QA/QC DEPT GM has the overall responsibility for successful performance of nondestructive examination as required for Code compliance. Preparation and approval of NDE procedures, calibration of the NDE equipment, qualification of NDE personnel and implementation of NDE for RT, UT, MT and PT will be the responsibility of the subcontractor's NDE Level III who is appointed by the QA/QC DEPT GM as a ALPHA-ECC Level III. The NDE will be conducted by qualified personnel of subcontractor in accordance with the written procedures which shall be reviewed by the QA/QC DEPT GM. QA/QC DEPT GM is responsible for the qualification of VT Examiner and preparation of VT procedure in accordance with AASME B31.1, Section VIII Division 2 (Visual Examination Procedure AL-VS-13). 2 8.3 Appointment of Level III The QA/QC DEPT GM shall review the NDE Subcontractors written practice, qualification and certification records of the intended NDE Level III personnel and, when satisfactory, write a letter to that NDE Level III as ALPHA-ECC appointed NDE Level III examiner. This letter will state the methods (RT, UT, MT and PT) he is appointed for and date of expiration of the appointment. 2 8.4 Documentation for the NDE Personnel The subcontractor will provide the written practice which is in accordance with the Code and using the SNT-TC-1A (Code adopted Edition and Addenda) as guide. The QA/QC DEPT GM will review the qualification and certification records of personnel to assure that they are in accordance with the Code and NDE Subcontractors written practice. 8.5 VT Examiner VT Examiner shall be qualified and certified according to the Procedure : AL-VS-13 8.6 2 NDE Procedures NDE procedures shall be written and qualified in accordance with Code requirements and demonstrated to the satisfaction of the AI, when required by the construction Code. When there is a change in one or more in essential variables, the NDE procedure shall be re-qualified. This demonstration shall be documented with the AI's signature on the cover sheet of the procedure. The QA/QC DEPT GM shall certify applicable NDE procedures in accordance with T-150 of ASME Section V. The NDE procedures shall be made available to the NDE operators in the working area. VT procedure shall be provided by the QA/QC DEPT GM.
Section QUALITY CONTROL MANUAL Sec. 8.0 Nondestructive Examination 8.7 Nondestructive Examination Rev. No. Page
8.0 2 2 of 2
The extent and method of NDE for Code items will be decided in accordance with the Code and Customer Specification by the Design Engineer and it shall be described on the fabrication drawing. The QA/QC DEPT GM, when needed, prepares NDE map showing NDE requirement for weld joints and materials with assistance of Design Engineer in accordance with the designated NDE requirements on the drawing. Additional NDE may be required considering the fabrication process. The subcontractor shall perform the applicable nondestructive examination based on the drawing and NDE Map and submit the NDE reports and film to the QA/QC DEPT GM. NDE results will be documented on the appropriate subcontractors report forms. The QA/QC DEPT GM or his designee will verify the results of NDE and if a defect is found, he will notify the results to the Engineer. Nonconforming conditions shall be handled according to the Section 6.0 of this QC Manual. 8.8 Equipment Control The appointed NDE Level III is responsible for the calibration and control of the NDE equipment. He will maintain the list of the NDE equipment and calibration records which will be reviewed by the QA/QC DEPT GM. 8.9 2 Authorized Inspector The reports of all nondestructive examinations including film and interpretation sheets will be filed by the QA/QC Inspector and, after review and acceptance of QA/QC DEPT GM, made available to the AI for his review. All documents including written practice, examination procedures, personnel records, calibration records, etc. will be on file by the QA/QC DEPT GM and made available to the A.I. When there is a specific reason to question the qualification of the procedure or the personnel, the A.I. may ask for re-qualification.
Section Rev. No.
9.0 2 1 of 1
Sec. 9.0 Heat Treatment
Page
9.1
Scope This section describes the requirements of heat treatment. All heat treatment will be subcontracted.
9.2
Heat Treatment The PS&M DEPT GM is responsible to approve the Design Sub-contractor submitted scope of the heat treatment according to the requirement of Code, standards, and Customer Specifications. The Engineer will provide the heat treatment procedure which shall be as a minimum describing the heating and cooling rate, time and temperature, the location and number of thermocouple, method of thermocouple attachment and removal, and instruction to the Heat Treatment Sub-contractor. The PS&M DEPT GM approves the procedure and instruction. Alternatively, the heat treatment procedure / instruction will be submitted by the Heat Treatment Sub-contractor and it shall be reviewed by the Engineer and approved by the PS&M DEPT GM. The QA/QC DEPT GM or his designee shall assure the proper performance of the heat treatment by witnessing, monitoring and document review i.e. furnace loading, method, heating and cooling rate, time and temperature, the location and number of thermocouple, method of thermocouple attachment and removal calibration equipment used in the heat treatment, etc. Before performing the heat treatment, the QC Inspector shall make examination to check the identification marking, stamping or tagging on the Code item. After completion of the heat treatment, the QC Inspector shall make examination to check the identification marking and to verify that there is no damage or unacceptable deformation on the item.
9.2.1
9.2.2
9.2.3
9.2.4 9.2.5
9.3
Record The QA/QC DEPT GM or his designee shall review the heat treatment record and Time-Temperature Chart for conformance with the requirements of the procedure, specification, Code and Customer Specification. The heat treatment record shall include date, serial number of the equipment used, procedure, and furnace loading (including location and number of thermocouples) as a minimum. All the heat treatment records shall be made available to the A.I for his review.
9.3.1
9.3.2
Section QUALITY CONTROL MANUAL Sec. 10.0 Calibration of Measurement and Test Equipment 10.1 Scope Rev. No. Page
10.0 3 1 of 2
This Section describes the system for the calibration of examination, measuring and test equipment used in the fulfillment of Code requirements. Calibration will be carried out by the outside agency 10.2 Responsibility
10.2.1 The QA/QC DEPT GM shall have the responsibility to assure that examination, measuring and test equipment used in the fulfillment of Code requirements have been calibrated when required by the Code and are of proper type, range and accuracy to assure the intended quality of the items. 10.2.2 Calibration of NDE equipment is the responsibility of the NDE Level III 10.2.3 Calibration of equipment shall be accomplished by ALPHA-ECC or government accredited calibration agency. 10.3 Calibration Standard and Frequency The measurement and test equipment shall be calibrated and traceable by marked serial number and controlled in accordance with the national standards or the manufacturer's standards. 10.3.1 The calibration frequency shall be decided and designated in the Measuring Instrument List (Exh No.: AL-ASME-20) by the QA/QC DEPT GM based on the national standard, the Code, and the manufacturers standard. 10.3.2 Pressure gauges shall be calibrated against a standard dead weight tester or calibrated master gage. These pressure gauges shall be calibrated at least every 12 months, except 6 months for ASME Section VIII Div. 2 construction. 10.3.3 The measurement or test equipment shall be replaced or recalibrated at any time when there is reason to believe that they are in error or there is a doubt in the accuracy due to dropping or damage. 10.4 Calibration Control
10.4.1 Calibration status of equipment shall be recorded on the Measuring Instrument List : ( Exh. No. : AL-ASME-20 ) which contains the identification number, name, range, date calibrated and date to be expired for calibration, etc. The QC Inspector is responsible to review and maintain the calibration records issued by the external agency. 10.4.2 The equipment ID number shall be recorded on the inspection and test records, MRIR, etc. as appropriate. 10.4.3 The calibrated equipment shall be identified by the calibration records and by the calibration label ( Exh. AL-ASME-11) or outside agencys label which identifies the expiration date. The QC Inspector shall keep all calibration records until the next calibration. 3 10.4.4 When out of calibration equipment is found being used, the QC Inspector shall evaluate all inspection records since the previous equipment calibration. Items affected by the out of calibration condition shall be documented on the NCR for evaluation and disposition and controlled in accordance with Section 6.0 of this QC Manual.
Section QUALITY CONTROL MANUAL Sec. 10.0 Calibration of Measurement and Test Equipment Rev. No. Page
10.0 3 2 of 2
10.5
NDE Equipment Calibration of NDE equipment shall be done by the NDE Sub-contractor. The QA/QC DEPT GM or his designee shall review and verify these calibration records for Code compliance.
10.6
Authorized Inspector All documents in relation to the calibration will be made available to the A.I. when requested.
Section Rev. No.
11.0 2 1 of 2
Sec. 11.0 Records Retention 11.1 11.2 Scope This section describes the requirements for retention of records. 2 Responsibility
Page
Each DEPT GM is responsible for the transfer of the records to the QA/QC DEPT GM. The System Document Controller is responsible for the retention of the records. 2 11.3 Records
11.3.1 Records are retained according with the Table 1 (Records to be retained). 11.3.2 Quality records specified in Table 1 will be kept for a period and at a place as designated by the applicable Dept GM and shall be available to the AI until he signs the Manufacturer's Data Report. 11.3.3 The Customer's specification may require certain documents to be provided with the product. 2 11.4 Records Retention
11.4.1 Records shall be filed and maintained in a manner to be fully identified, protected from deterioration or damage and to allow access by the AI to specific information contained therein at any time during the period of vessel and parts manufacture. 11.4.2 All record shall be identified by pertinent material or item identification numbers. 11.4.3 After AI signs off the Manufacturers Data Report, all documents or records shall be transferred to the QA/QC DEPT GM for maintenance in accordance with Table 1. 11.5 Authorized Inspector
11.5.1 When the MDR is presented to the AI for review and signature, all other pertinent documents will be presented to him as requested. 11.6 Distribution of MDR The QA/QC DEPT GM shall have the responsibility to distribute the copies of the MDR to the Jurisdiction, Authorized Inspection Agency, A.I. and/or Customers as required by the Code or Customer Specification.
11.7
For ASME Section VIII Div. 2, the retained records described in this section of QC Manual shall be made available to the AIS or to the ASME Joint Review Team during the triennial renewal joint review.
Section Rev. No.
11.0 2 2 of 2
Sec. 11.0 Records Retention
Page
Table 1 : Records to be retained
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Type of Record Design Calculation RT Film RT Reports UT Reports Material Certifications, Material Test Reports and/or Partial Data Reports Heat Treatment Records including PWHT and Test Results Manufacturing Drawings WPS / PQR / Weld Map / Welder Qualification Records for each welder who welded on the vessel NCRs (including the procedures and records of repairs to material,items and assembly) Travelers and inspection records Hydrostatic Test Records with proof test report. Pneumatic Test Records (Sec. VIII, Div. 1, 2) Manufacturers Data Report/ Manufactures Partial Data Report Users Design Specifications Manufacturers Design Reports Tabulation of Material Specification / Manufacturing / NDE Procedures with Qualification Records List of Subcontracted Services and Parts NDE Examiner Certification personnel demonstration Records including
Retention Period (years) Sec I & B31.1 VIII Div.1 3 VIII Div.2 -
5 5 5
3 3 3 3 3 3 3 3 3 3 -

5 -
Inspection, Examination and Test Report Results of Production Test Plates (if applicable) As-Built Drawings ( U2 only)
: Until AI signs off the Manufacturers Data Report. : Three (3) years after Stamping.
Section Rev. No.
12.0 2 1 of 1
Sec. 12.0 Authorized Inspector
Page
12.1
Scope This section covers the interface between Southern Petroleum Construction Joint Stock Company ( ALPHA-ECC) and the Authorized Inspection Agency (AIA).
12.2
Inspection Agreement with AIA ALPHA-ECC shall maintain a written Inspection Agreement to provide Code inspection and audit services with an AIA which is accredited by the ASME in accordance with the requirements of latest version of ASME QAI-1.
12.3
Authorized Inspector An Authorized Inspector is a person who is regularly employed by an AIA, has 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 and holding a valid National Board Commission with an "A" endorsement. The AI will monitor Southern Petroleum Construction Joint Stock Company QC system periodically as required by the Code. For repairs / alteration, the Inspector shall have either IS Commission or AR endorsement on their NB commission Card.
12.4
Free Access The AI and AIS shall have free access to all areas of the shop and field sites and documents of ALPHA-ECC including its vendors in order to perform inspection, monitoring and periodic audit as required by the ASME QAI-1 and Code. The QA/QC DEPT GM shall provide full assistance to the AI Supervisor during his audit.
12.5
Documents/QC Manual The AI shall have free access to all documents and records required by the Code and those other documents and records requested to assure Code compliance. The QC Manual including subsequent revisions shall be acceptable to the AI. The QA/QC DEPT GM shall distribute a controlled copy of the QC Manual to AI at the shop and field site where Code activities are being carried out.
12.6
Interface with the A.I. The QA/QC DEPT GM (Site QC Inspector for field site) is the principal contact with the A.I. He is responsible to present or to make available to the AI all documents including Design documents, Traveler, NCR, MDR, etc. as required in the other Sections of this QC Manual. The QA/QC DEPT GM / Site QC Inspector shall notify the AI for his inspection points reasonably in advance. When the purchaser requests another AIA to perform inspection on its project or Code jobs, or whenever the AIA of record cannot provide coverage for inspection at a specific field site, the second AIA shall perform activities under their Certificates of Authorization in compliance with this Manual and Code requirements. The QA/QC Dept GM shall verify the Code activities are within the scope of the 2nd AIAs certificate of authorization. A contract or agreement shall be signed between Alpha ECC and a second AIA for the specific Code work before any inspection with the concurrence, in writing, of AIA of record. The AI of AIA of records signature on the cover page will be the evidence that this program is accepted by the AIA of record.
Section QUALITY CONTROL MANUAL Sec. 13.0 Field Assembly 13.1 Scope Rev. No. Page
13.0 2 1 of 4
This section describes responsibilities and measures to control the field assembly of Code Item. The quality related activities not described in this section shall be in accordance with the requirements in the other applicable Sections of this QC Manual. 13.2 Responsibility The Site Manager appointed by the Deputy Director takes overall responsibility for the operation of the field site controlled by the shop location. The Site Engineer is responsible for control of material and documents such as drawing, WPS, etc. which are supplied by the shop. 2 13.3 Material Control Material shall be purchased, inspected and controlled in accordance with Section 4.0 of this QC Manual. All the material including welding material shall be supplied from the shop with related document at least copies of the MRIR or MTR. The parts fabricated in the shop shall be supplied with clear identification and along with the copies of the processed Traveler or Partial MDR. The material may be supplied to the field site directly from the vendor. In this case, The Site QC Inspector shall be responsible to perform the receiving inspection at the field site in accordance with Section 4.0 of this Manual. The Site Manager or his designee shall designate the material storage area in such a location as to prevent damage to the material. Part fabricated item from shop shall be sent to site along with traveler signed off for the activities completed at shop. 13.4 Drawing Control Drawing, Specifications, etc. shall be supplied by the shop and controlled as specified in Section 3.0 of this QC Manual. The Site Manager or his designee will control the original or revised drawings supplied by the shop. Scope of field activities shall be specified on the drawings. 13.5 Inspection, Examination and Test The Traveler for field assembly work shall be prepared by the Engineer, reviewed by QA/QC DEPT GM for designation of inspection points and approved by PS&M DEPT GM /Site Manager. The Traveler shall be submitted to the AI for the designation of inspection points. Inspection, Examination and Test shall be carried out according to the Section 5.0 of this QC Manual unless otherwise described in this Section. The Site Manager will take the same responsibility of P&W DEPT GM. The Site QC Inspector shall implement each inspection, Examination and Test program in the field site and he will witness the final pressure testing with A.I.
Section Rev. No.
13.0 2 2 of 4
Sec. 13.0 Field Assembly
Page
After successful completion of hydrostatic test, the ASME Certification Mark/ NB Stamp shall be applied in accordance with the requirements of Code/NB by the Site QC Inspector in the concurrence and presence of A.I. When the Certification Mark and NB Stamps are requested by the field site, the QA/QC DEPT GM or his designee will hand carry it to the location and shall be kept in the custody of site QC Inspector. After using the applicable Stamps they will be returned to the custody of the QA/QC DEPT GM. Measurement and test equipment will be calibrated and supplied by the shop. The Site QC Inspector is responsible to notify the A.I. of his impending inspection point. 13.6 Correction of Nonconformities The Site QC Inspector shall issue NCR for nonconforming condition in field site. The NCR shall be sent to the shop for disposition according to the paragraph 6.5 and returned to the field site for A.I. review and implementation of the disposition.
13.7
Welding Control Welding Procedures and Welders shall be controlled as described in Section 7.0 of this QC Manual. The Welding Engineer / QC Inspector in the shop shall provide the WPS. The Welding Engineer / Site QC Inspector is responsible for qualification of welders for field site. The Site QC Inspector is responsible for preparation and maintenance of the WL in the field site. The Site Foreman is responsible for assignment of welders and control of Welding Material Control Room at field site. All welding work and documentation will be performed in the same manner as in the shop. Site Foreman is responsible for protection of weld joints during welding from wind, rain, dust, etc.
13.8
Nondestructive Examination All NDE shall be controlled as specified in Section 8.0 of this QC Manual.
13.9
Heat Treatment The heat treatment shall be controlled as specified in the Section 9.0 of this QC Manual.
13.10
Calibration of Measurement and Test Equipment
The calibrated equipment shall be provided by the shop and controlled in accordance with Section 10.0 of this QC Manual. All equipment when returned from the site shall be recalibrated to ensure they were accurate when used at site. 13.11 2 Records Retention
The Site QC Inspector will be responsible for the retention of records and forwarding the records to the QA/QC DEPT GM.
Section QUALITY CONTROL MANUAL Sec. 13.0 Field Assembly Rev. No. Page
13.0 2 3 of 4
It is the responsibility of the Site QC Inspector to properly complete and certify the field assembly portion of the MDR signed by QA/QC DEPT GM prior to presenting it to the A.I. 2 MDRs shall be prepared in accordance with the provisions specified on Sec. I PG-107 & PG-113.2, Sec. VIII Div.1 U-2 (h) and Sec. VIII Div.2 Para. 1.2.6 respectively. 13.12 Authorized Inspector
The Site QC Inspector will make all Code related document available to the A.I. The Section 12.0 of this QC Manual shall be applied in addition to this requirement. 13.13 Organizational Chart
See Figure 2.
Section QUALITY CONTROL MANUAL Sec. 13.0 Field Assembly Rev. No. Page
13.0 2 4 of 4 | |
Figure 2. Organizational Chart
DIRECTOR
DEPUTY DIRECTOR
QA/QC DEPT. GENERAL MANAGER THE SHOP FIELD SITE SITE MANAGER SITE QC INSPECTOR
NDE SUB-CONTRACTOR SITE FOREMAN SITE ENGINEER
: Administration Line : Communication Line
Section QUALITY CONTROL MANUAL Sec. 14.0 Repairs and Alterations 14.1 Scope Rev. No. Page
14.0 2 1 of 7
This section is applicable for repairs and alterations to be carried out on Boilers, Pressure Vessels and Heat Exchangers at the shop and field sites controlled from the shop. The repairs or alterations can be carried out on ASME Code stamped boilers and vessels (S, U and U2 stamped) and also on other non ASME vessels. The repairs and alternations shall be performed in accordance with the National Board Inspection Code and the applicable Jurisdictional requirements, if any. Before initiating any repairs (including routine repairs) or alterations, prior authorization of INSPECTOR shall be obtained with sufficient information so that INSPECTOR can determine if repair or alteration methods are acceptable. Permitted subcontracted activities are identified in the applicable sections of this manual and those sections have been referenced in this system. Company takes full responsibilities for the work carried out by its subcontractors. 14.2 Definitions Repair is defined as the work carried out to restore pressure retaining items, components and system to a safe and satisfactory operating condition such that existing design requirements are met. Alteration is defined as any change in the item described on the original Manufacturers Data Report or similar other document or drawing, which affects the pressure containing capabilities of the pressure retaining item. Nonphysical changes such as an increase in the maximum allowable working pressure (internal or external) or design temperature shall be considered an alteration. A reduction in minimum temperature such that additional Mechanical Tests are required shall also be considered an alteration. Re-rating refer Alteration above. 2 Routine Repairs Routine repairs are defined in 3.3.2, Part 3 of the NBIC. PS&M DEPT GM is responsible to identify if the required repairs can be identified as Routine Repairs and that the routine repairs are acceptable to jurisdiction where the item is installed. In such case of routine repairs, in-process inspection by AI and jurisdiction may be waived; the repairs shall however be documented on R-1 form with a Routine Repair statement in the remarks column and the form shall be presented to the INSPECTOR for his signatures. All applicable documents are provided to the AI for his review. INSPECTOR shall be an inspector as defined in the NBIC and meeting the requirements of NB-263 and holding the appropriate commission issued by the National Board. He/she shall be currently employed by an Inservice AIA, accredited by the National Board, meeting the qualification and duties of NB369. 14.3 Statement of Authority and Responsibility The authority of control of this manual and implementation of Quality Control System is vested with QA/QC DEPT GM, as described in Section II of this QC Manual. 14.4 Manual Control The preparation, revision and issue of this QC Manual shall be the responsibility of QA/QC DEPT GM. The system has been detailed in Section 2.0 of this QC Manual. 14.5 Organization The Organization Charts (See Figure 1 & 2) and QA/QC responsibilities for carrying out repair and alteration shall be as shown in Section 1.0 of this QC Manual.
Section QUALITY CONTROL MANUAL Sec. 14.0 Repairs and Alterations Rev. No. Page
14.0 2 2 of 7
14.6
Construction Standards When original equipment is constructed to the ASME Code, repairs and alterations shall conform insofar as possible to the section and edition of the ASME Code most appropriate to the work performed. When the original equipment is not constructed to the ASME Code, repairs and alterations shall conform insofar as possible to the edition of the construction standard or specification most appropriate to the work. Where use of original construction code is not possible or practicable, other codes, standards, specifications including ASME Code with latest edition and addenda may be used provided prior concurrence of the INSPECTOR has been obtained. When applicable prior concurrence of Jurisdiction and Owner shall also be obtained for use of standards other than original construction standard. Reference 1.2 of NBIC Part 3 for other requirements.
14.7
Drawings, Design and Specifications On receiving the order for carrying out Repairs or Alteration, it shall be the responsibility of PS&M DEPT GM to identify and confirm whether the required work is categorised as Repair or Routine Repair or Alteration or Rerating in accordance with the requirements of NBIC. He shall also be responsible to ensure that sufficient information has been provided by the owner or user along with the order so that repair or alteration work can progress. He shall ensure availability of the vessel data report, drawings, data sheets and similar other documents required to undertake the repair or alteration work. If data reports are not available and the vessel is registered with National Board (as verified from the vessel name plate/stamping), he shall arrange a copy from the National Board by providing the necessary information like Name of the manufacturer, vessel serial number, year made and NB number. The system of preparation of design calculations shall be as explained in Section 3.0 of this QC Manual. The design calculations for alteration shall be based on the original construction standard or as otherwise specified in 14.6 above. Reference for design shall be based on manufacturers data report and other details like drawings, data sheet etc., given by the owner. Design calculations shall clearly identify the Code/Standard used including their year date and addenda. Drawings for alterations (and when required for repairs) shall be approved by PS&M DEPT GM. In addition to the applicable details given in Section 3.0, the drawings shall also indicate the original construction code, construction Code used for repairs/alterations, applicable National Board Inspection Code addenda and name plate/stamping details. Distribution and revision to the drawings shall be controlled in the manner described in Section 3.0. of this QC Manual. PS&M DEPT GM is also responsible for verifying the identification of the existing materials from the original data reports, original drawings and other such documents. Material specification for the existing material and material to be installed shall be clearly indicated on the drawings. When any material or part is to be replaced during repairs or alteration, Technical specifications for material shall be prepared by Engineer and approved by PS&M DEPT GM as described in Section 4.0, para. 4.3 of this QC Manual. Design Engineer is responsible for selection of units based on the requirements of the owner, units used for the original item and the original construction Code. However one system of units shall be used throughout the repair and alteration process. All design documents shall be submitted to the INSPECTOR for his review.
QUALITY CONTROL MANUAL Sec. 14.0 Repairs and Alterations 14.8 2 Materials and Replacement Parts
14.0 2 3 of 7
Consideration shall be given to the condition of existing material especially in the weld preparation area. If the existing material cannot be verified by the PS&M DEPT GM, QA/QC DEPT GM shall arrange to perform sufficient chemical and hardness tests to identify the material and its weldability. The use of stock material, procurement, receipt inspection, storage, issue and identification of material shall be as described in Section 4.0 of this QC Manual. All materials used in making repairs or alterations shall conform insofar as possible to the requirements of original construction standards or as specified in 14.6 above. The relevant material test reports or certificate of compliance shall be obtained and submitted to the INSPECTOR for his review and acceptance. Carbon or alloy steels having carbon content more than 0.35% shall not be used for items requiring welding. Replacement parts shall meet the requirements of 3.2.2, Part 3 of NBIC. When ASME is the original code of construction, replacement parts subjected to internal or external pressure which require welding and inspection by AI shall be fabricated, inspected and documented as per ASME Code as parts. When original Code of construction is not ASME, replacement parts which require welding shall be fabricated, inspected and documented as per the original construction code and if this is not practicable, such items can be constructed and stamped R by the R symbol stamp holder and documented on Form R-3 of NBIC.
14.9
Repairs and Alterations Method For all repairs and alteration work, prior to start of the activities, QA/QC DEPT GM shall prepare and approve a detailed procedure describing the projected scope of work. The procedure shall as a minimum include repair/alteration methodology, applicable welding procedure specifications, proposed NDT methods and their extent, material, preheat and post weld heat treatment requirements and documentation requirements. Any other special requirements of the NBIC, Construction Code and Owners shall also be included. Based on this procedure and other applicable drawings and documents, QA/QC DEPT GM shall prepare Traveler detailing the stages of operations, reference documents and procedures, format of record. QA/QC DEPT GM shall presents the following to the INSPECTOR for his review and acceptance and to enable him to indicate his inspection points on Traveler: i. Approved design calculations, drawings, materials specifications. ii. Copy of original manufacturers data report. iii. Traveller. iv. Repair/Alteration procedure detailing projected scope of work. v. Applicable WPS, PQR and Welder Qualification test records. vi. Proposed NDE and Heat treatment and applicable procedures. The examination and tests required during repair shall be in accordance with the original construction standard. However, if impossible or impractical, alternative methods as permitted by NBIC and acceptable to the INSPECTOR and the owner may be used. The INSPECTOR shall have access to make such inspections of vessels he deems necessary in order to ensure that Inspections can be performed, and to accept the repair and alterations after final inspection.
QUALITY CONTROL MANUAL Sec. 14.0 Repairs and Alterations
14.0 2 4 of 7
14.10 2
Welding, NDE and Heat Treatment
Welding controls including qualification of welding procedures and welders, control of welding consumables, welders identity & continuity control and shop/field welding controls for repairs and alterations shall be in accordance with Section 7.0 of this QC Manual. The welding procedures and welders qualification shall conform to original construction standard. If this is not possible or practicable, WPS and welders qualified in accordance with ASME Code Sec. IX can be used. Records of approved WPS and welders qualification tests shall be made available to the INSPECTOR for his review and acceptance before carrying out welding work. Standard WPS shown in 2.3, Part 3 of the NBIC can be used without supporting PQR for repairs or for performance qualification. Such WPS shall be documented and certified by QA/QC DEPT GM for use. When required, owners or jurisdictions acceptance will be obtained for use of standard WPS. NDE requirements including technique, extent of coverage, procedures, personnel qualification and acceptance criteria shall be in accordance with original construction standard. Weld repairs and alterations shall be subjected to same NDE requirements as the original welds. When this is not possible or practicable, alternative NDE methods acceptable to the INSPECTOR and owner or jurisdiction as applicable may be used. NDE personnel shall be qualified in accordance with the requirements of original construction standard. When this is not possible or practicable, personnel qualified in accordance with NBIC adopted edition of SNT-TC-1A may be used. Other NDE controls shall be as per Section 8.0 of this QC Manual. Preheat temperature requirements shall be as specified in the applicable WPS. Reference can also be made to Table 2.5.1, Part 3 of NBIC for recommended minimum preheat temperatures. PWHT shall be performed as required by the original construction standard or as per original manufacturers data report. PWHT shall be in accordance with procedure and instructions prepared and approved as detailed in Section 9.0 of this QC Manual. Local PWHT that is not specified by the original construction code may be performed as per NBIC with prior acceptance of the AI and when required by the owner and Jurisdiction. Under certain conditions, when PWHT in accordance with original construction standard is inadvisable or impractical, alternative methods of PWHT or special welding methods as described in 2.5.3, Part 3 of NBIC and acceptable to AI may be used.
14.11
Examination and Tests
All examination and tests required during and after repairs or alterations shall be identified on the Repair procedure and Traveler. Requirements for the pressure tests including test medium, test pressure, holding time, and temperature limits etc. shall be specified in the repair procedure. All pressure tests shall be witnessed by the QA/QC DEPT GM and shall be offered to the INSPECTOR. The extent of Pressure Testing shall be as acceptable to the INSPECTOR and the owner/user. When it is not possible or practicable to pressure test the whole equipment on which repairs or alterations have been carried out, only connecting welds (defined as welds attaching replacement parts and pressure retaining item) may be tested. The metal temperature during Pressure Test shall not be less than 60F (16oC) or more than 120F (49oC). Care shall be taken to ensure that the pressure relief devices on the equipment are either removed or gaged before test. Test pressure shall be held for minimum of 10 minutes prior to the examination. The INSPECTOR shall be afforded the right to carry out the close examination after reducing the pressure to MAWP.
14.0 2 5 of 7
When Liquid Pressure Test is not practicable the QA/QC DEPT GM shall obtain the acceptance of the INSPECTOR and the owner/user for carrying out alternative test as described in Section 4 Part 3 of NBIC. This acceptance shall be obtained and recorded before performing any alternative examination or testing. 14.12 Non-conformities
Any non-conformity noticed during execution of repairs and alterations shall be dealt in accordance with the Section 6.0 of this QC Manual. 14.13 Calibration
All equipment and gauges used for inspection and examination during repair and alterations shall be maintained and calibrated in accordance with the Section 10.0 of this QC Manual. 14.14 Acceptance and Inspection of Repair or Alteration
Repair and Alteration shall be carried out as per the procedure accepted by the INSPECTOR and all the stages identified in the Traveler shall be offered to him in accordance with his designated inspection points. Before acceptance of any repair or alteration, the INSPECTOR shall be afforded right to satisfy himself that all the functions deemed necessary and in compliance with the requirements of the NBIC, have been performed. 14.15 Name Plate and Stamping
The R symbol stamp is at all times the property of National Board and shall be promptly returned on demand. In case the agreement with Authorized Inspection Agency for Inservice has been discontinued or the certificate of authorization has expired and no new certificate has been issued, the R symbol stamp shall be immediately returned to the National Board. 2 The QA/QC DEPT GM shall be responsible for the custody and use of the R symbol stamp. The custody of the R symbol stamp may be temporarily transferred to the Site QC Inspector, when it is required to be used on field sites. Under no circumstances the R stamp shall be given or loaned to any other organization. The R symbol stamp shall always be applied on authorization by the INSPECTOR and in his presence. Stamping and/or name plate for repair/alteration/re-rating/parts fabricated by welding shall be adjacent to the original manufacturer stamping or name plate and shall be as shown in [Exhibit AL-ASME-14]. When repair or alterations requires removal of the part of the item bearing the original code stamping; the AI, subject to approval of the owner, shall witness the making of facsimile copy of old stamping and transfer such stamping on the new part. When the stamping is on the Name Plate the AI shall witness transfer of the Name Plate to the new part. Re-stamping or replacement of original stamp shall only be performed when restamping is permitted by the original code of construction and any relocation of the stamping or the name plate shall be as indicated on the relevant forms in accordance with NBIC. 14.16 2 Report, Distribution and Retention
QA/QC DEPT GM shall ensure that the repair or alteration has been completed in accordance with the procedure and the system described above. He shall verify correctness and completeness of all documents including acceptance of the INSPECTOR for all stages.
14.0 2 6 of 7
The repairs shall be recorded on form R-1 (Report for Repairs). When required, description of the relocation of Code Stamping or Name Plate shall also be reported on form R-1. Reports of the replacement parts (Form R-3 or manufacturers partial data reports) shall also form part of the completed form R-1. Additional data can be recorded on from R-4 and attached to the form R-1. Alterations and Re-rating shall be documented on Form R-2. When required, description of the relocation of Code Stamping or Name Plate shall also be reported on from R-2. Reports of the replacement parts (Form R-3 or manufacturers partial data reports) and copy of the original manufacturers data report (when available) or copy of the report required by other Codes shall also form part of the completed form R-2. Additional data can be recorded on from R-4 and attached to the form R-2. The relevant R1, R2, R3 or R4 Form shall be prepared and certified by QA/QC DEPT GM before submitting the same to AI along with all relevant documents for his review. QA/QC DEPT GM shall also certify the design certificate section of Form R-2. On review and endorsement of the INSPECTOR, the report forms shall be distributed by QA/QC DEPT GM as follows: i. Completed R-1 form along with attachments shall be distributed to the owner/user, the INSPECTOR, Jurisdiction (when required) and the Authorized Inspection Agency responsible for the in-service inspection of pressure retaining item (when applicable). ii. Completed R-2 form along with attachments shall be distributed to the owner/user, the INSPECTOR, Jurisdiction (when required), the Authorized Inspection Agency responsible for the in-service inspection of pressure retaining item (when applicable) and the R certificate holder responsible for design (when applicable). For those R forms not registered with National Board, QA/QC DEPT GM shall retain a copy of the R form together with attachments for a minimum period of 5 years. QA/QC DEPT GM shall maintain a single, sequential log of R form numbers, National Board R Form Log ( Exh : AL-ASME-19 ) assigned for NBIC Report Forms (i.e., R-1, R-2 and R-3) that are registered with National Board. The welder log for welder performed welding involved in this program shall cover the initial qualification up to the date he/she ceased employment with ALPHA-ECC and be maintained for the existence of Alpha-ECC. 14.17 2 National Board Registration
When the repairs or alteration forms are required to be registered with National Board the R form number shall be referenced on the applicable Repair/Alteration reports (Forms R1 & R2). R form numbers will start from R-1 and will be in sequence without any skips and gaps. NB stamp shall not be applied on the R stamp name plates. A sequential log of all the R reports issued shall be maintained by QA/QC DEPT GM indicating Serial number, R form number (only when registered), description of equipment, owner, date repairs certified, and date R form sent to National Board for registration. Form R-1 along with attachments shall be registered with National Board when required by the owner or Jurisdiction. If the original vessel is registered with National Board, Form R-2 along with attachments shall be registered with National Board. If the original vessel is not registered with National Board, Form R-2 along with attachments shall be regsitered with National Board when required by the owner or Jurisdiction. When registration is required, the original copy of the applicable report form shall be regsitered with National Board within 60 days of the certification.
Section QUALITY CONTROL MANUAL Sec. 14.0 Repairs and Alterations Rev. No. Page
14.0 2 7 of 7
15.18
Sample Forms
Sample forms are shown in Section 16.0 of this QC Manual.
Section QUALITY CONTROL MANUAL Sec. 15.0 Special Requirements for Section VIII, Div.2 15.1 Purpose Rev. No. Page
15.0 1 1 of 5
15.1.1 To describe the additional requirements to the preceding Sections of this QC Manual for the shop fabrication/ field assembly of Section VIII Division 2 pressure vessels. 15.2 Responsibilities
15.2.1 The PS&M DEPT GM is responsible for ensuring that all Users Design Specifications, design calculations and construction drawings for the structural and pressure retaining integrity of a vessel or part thereof are according to this QC Manual, Section VIII Division 2. 15.2.2 The QA/QC DEPT GM is responsible for ensuring that fabrication, examination and testing is in accordance with this QC Manual and Section VIII Division 2 requirement, including sub contracted work by others. 15.2.3 It is the responsibility of the user or an agent acting on behalf of the user to provide a Certified Users Design Specification for each pressure vessel to be constructed to this Division. 15.3 1 Design Control
15.3.1 The PS&M DEPT GM is responsible for ensuring that ALPHA-ECCs Customers have provided Certified Users Design Specification as per the requirements of Para 2.2.2 and Annex 2.A, Part 2 of the Code duly certified by an Engineer (as defined an Annex 2.A paragraph 2.A.2.2.b and c) experienced in the pressure vessel design or a Registered Professional Engineer (as defined an Annex 2 paragraph 2.A.2.2.a). A Checklist generated by ALPHA-ECCs Design Engineer shall be used to ensure all the Code requirements have been addressed in the Users Design Specification and reviewed by the PS&M DEPT GM. 15.3.2 The Design Engineer shall prepare Manufacturers Design Report (including design calculation and construction drawing), which shall comply with the requirements of ASME Section VIII Division 2 for the design condition specified in the Certified Users Design Specification and approved by the PS&M DEPT GM. 15.3.3 The Manufacturers Design Report shall be certified by either an Engineer(s) experienced in pressure vessels or Registered Professional Engineer as per the requirements of Para 2.3.3.1 and Annex 2.B of the Code (as defined an Annex 2.B paragraph 2.B.2.2.a, 2.B.2.2.b and c, Part 2 of the Code). 15.3.4 Any revision to both Certified Users Design Specification and Manufacturers Design Report will be reconciled and certified by an Engineer in the Certified Users Design Specification and final Certified Manufacturers Design Report. Registered Professional Engineer or Engineer certifying Manufacturers Design Report shall be other than the one who certified Users Design Specification. 15.3.5 The Certified Users Design Specification and Certified Manufacturers Design Report shall be made available for review by the Authorized Inspector. 15.3.6 The use of computer program for the design or analysis of component, the PS&M DEPT GM is responsible for all technical input into the computer program, and the application of these program in the design process (see paragraph 5.3.6 Section 5 of this QC Manual) and verify the output correctness. 15.4 1 Material Control
15.4.1 Code material requisition using the Material Requisition Form (Exhibit: AL-ASME-06) and BM (Exhibit: AL-ASME-07) shall be prepared by the Engineer (of ALPHA-ECC) and approved by PS&M DEPT GM.
Section QUALITY CONTROL MANUAL Sec. 15.0 Special Requirements for Section VIII, Div.2 Rev. No. Page
15.0 1 2 of 5
15.4.2 The MRF and BM prepared by the Engineer & approved by PS&M DEPT GM shall be based on the Users Design Specification & Approved for Construction drawing. All materials purchased shall be in accordance with Section II and limited to those listed in Section VIII Division 2 and only Code approved materials shall be used in Section VIII Division 2 Construction. 15.4.3 The QC Inspector is responsible for verifying the received materials are in accordance with the PO. He shall verify the material test report are certified by the materials manufacturer and ensure that all the PO, MRF and Code requirements are addressed in material test report. 15.4.4 Substitution of material shall be approved by the user and reconciled with the Users Design Specification and the Manufacturers Design report and shall be re-certified by the RPE/ Engineer(s) as specified in above 15.3. 15.4.5 A Material Traceability List (Exh: AL-ASME-24) shall be made by QC Inspector, identifying each piece of material with a certified test report or, where permitted by ASME Section VIII Div. 2, with a certificate of compliance and the coded marking which assure identification of each piece of material during fabrication and subsequent identification in the completed vessel. 15.4.6 The material used in the vessel shall be represented by test specimens that have been subjected to the same manner of heat treatment, including post weld heat treatment. The kind of number of tests and test results shall be as required by the material specification. The Engineer (of ALPHA-ECC) shall specify the temperature, time and cooling rates to which the material will subject during fabrication. Material from which the specimens are prepared shall be heat treated at the specified temperature within the tolerance established by the Engineer (of ALPHA-ECC) for use in actual fabrication. The total time at temperature shall within at least 80% of the total time at temperature during actual heat treatment of the product and may be performed in a single cycle. Simulation of post weld heat treatment may be applied to the test specimen blanks.
15.4.7 Certificate of Compliance and Material Test Reports a. The QA/QC DEPT GM shall ensure shall ensure all requirements of the material specification, and all special requirements of para. 3.2.6.2, Part 3 of this Division, that are to be fulfilled by the materials manufacturer have been complied with. The QA/QC DEPT GM shall accomplish this by obtaining Certificates of Compliance or Material Test Reports. These documents shall include results of all required tests and examinations, evidence of compliance with the material specifications and additional requirements as applicable. When the specification permits certain specific requirements to be completed later, those incomplete items shall be noted on the material documentation. When these specific requirements have been completed by someone other than the material manufacturer, this completion shall be documented and attached to the material by the QA/QC DEPT GM. b. The QA/QC DEPT GM shall receive a copy of the test report as prepared by the originator of the data and maintain as part of his construction records. c. All conflicts between the material specification and supplemental requirements shall be noted, and compliance with the supplemental requirements shall be certified by the QA/QC DEPT GM.
d. Certification by other than material manufacturer shall be in accordance with Para 3.2.6.2, Part 3 of ASME Section VIII Division 2. e. The material may be marked by any method acceptable to the AI. However, all steel stamping shall be carried out with commercially available Low Stress dies and shall be limited to P No. 1 Group 1 & 2 material with nominal thickness of at least 5 mm and MDMT no colder than -29C.
15.0 1 3 of 5
15.5 1
Examination and Inspection program
15.5.1 ALPHA-ECC Engineer is responsible for preparing Traveler (to be approved by the PS&M DEPT GM) in accordance with the Approved for Construction drawings and the requirements of Section VIII Division 2. The Traveler shall include all the requirement of Table 7.A.1, Annex 7-A of the Code. 15.5.2 Stamping as required by Section VIII Division 2 Annex 2.F shall be applied on the nameplate or directly on vessel using low stress type stamp located on an area designated on a low stress area by Design Engineer of ALPHA-ECC in the Manufacturer Design Report. 15.5.3 All welding shall be subject to in process examination by visual examination at the fit up stage and after back gouging by a qualified QC Inspector who shall visually inspect all welds prior to assembly.
15.5.4 All welds for pressure retaining parts shall be visually examined with applying the acceptance criteria given in Table 7.6, Part 7 of the Code. 15.5.5 Weld seams that will be hidden in the final vessel configuration shall be visually examined prior to final assembly. See Table 7.6 of the Code for Acceptance Criteria.
15.5.6 Type and extend of NDE shall meet the requirement of Table 7.2., Part 7 of the Code. 15.5.7 Personnel performing visual inspection shall have qualification as per Qualification and Certification Procedure AL-VS-16. Visual Examiner
15.5.8 Use of UT in lieu of RT shall comply with the requirements of para 7.5.5, Part 7 of the Code. 15.6 Non Conformance
15.6.1 When the resolution of a nonconformance is use as is that does not comply with the Users Design Specification, the NCR shall be submitted to the user by the PS&M DEPT GM for reconciliation with the Certified Users Design Specification and re-certification by an RPE/ Engineer. 15.6.2 In case of NCR affect Manufacturers Design Report it shall be recertified by Engineer/ Registered Professional Engineer who certified the original. 15.7 Calibration of Measuring and Test Equipment
15.7.1 The frequency of calibration for hydrostatic test gauges shall be at any time when there is reason believe they are in error or six (6) month intervals maximum. 15.8 1 Hydrostatic Testing
15.8.1 Hydrostatic testing of pressure vessel, except vessel in accordance with para 8.1.3, Part 8 of the Code, shall be the greater of (1.25 x MAWP x lowest ratio) or (1.43 x MAWP). The upper limit shall be determined in accordance with para 4.1.6.2, Part 4 of the Code. 15.8.2 Pressure shall be gradually increased until the test pressure is reached. The pressure shall then be reduced at a pressure not less than the test pressure divided by 1.43 and examined by QC Inspector, Clients Representative and AI. 15.8.3 Examination for leakage shall be made of all joints and connections and regions of high stress in accordance with para 8.2.5, Part 8 of the Code.
15.0 1 4 of 5
15.8.4 For all pressure test, as a minimum, the following data shall be recorded by QC Inspector and shall be issued as part of the vessels record required in para 15.9.2 of this Section: a. ALPHA-ECC and identification of the pressure vessel, b. Name of Authorized Inspection Agency, c. Type of test (hydro, pneumatic or hydro-pneumatic), d. Test pressure at the top of the vessel in test position, e. Position of the vessel during pressure testing (horizontal, vertical or normal operating), f. Test fluid and temperature, g. Date of pressure test, h. Reference to written procedure, if used. 15.9 Records Retention
15.9.1 After acceptance by the Authorized Inspector, one copy of the Manufacturers Data Report shall be submitted to the user, enforcement authority in the jurisdiction of installation when required by Law, and upon request, to the Authorized Inspector. 15.9.2 The QA/QC DEPT GM shall be responsible for maintaining the quality following records. The records shall include but are not limited to: Certified Users Design Specification, Certified Manufacturers Design Report, Manufacturers Data Report, Manufacturers Partial Data Report, if any, Manufacturers Construction Records and Partial Data Reports: a. Material test Certification and Material Test Reports, including Document Control Sheet (Material), and a record of any repairs to pressure retaining material that require a radiography examination by the Code include the location of the repairs, examination results and the repair procedures, Fabrication information including all heat treatment requirements, forming and rolling procedure when prepared, an inspection and test plan identifyng all inspection points required by the user, and signed inspection reports, List of any subcontrated services or parts, if applicable, Welding Procedure Specifications / Procedure Qualification Qualification Records / Welding Operator Qualification Records, Pressure parts documentation and certifications, Record of all heat treatments including post weld heat treatment (those records may be either the actual heat treatment charts or a certified summary of heat treatment time and temperature), Results of production test plates, if applicable, NDE Procedures, records of procedure demonstration, and records of personnel certification, Records, Welder
b.
c. d. e. f.
g. h.
15.0 1 5 of 5
i.
All reports stating the results of inspection, nondestructive examination and testing including radiographic examination and radiographic films, ultrasonic examination, magnetic particle examination, liquid dye penetrant examination and hardness tests, All non conformance reports including resolution and detailed description of any repairs including repair procedure, a sketch, photo, or drawing indicating the location and size of the repaired area, Charts or other records of the required hydrostatic, pneumatic, or other tests. Test logs shall include the test date, testing fluid, duration of the test, temperature of test fluid, and test pressure, Dimensional drawing of the as built condition,
j.
k.
l.
are maintained in the Company storage file for at least three years and are available for review by the AI, or AI Supervisor or ASME Review Team for the issue or renewal of Certificates of Authorization. 15.9.3 All records shall be kept in such a way to protect from deterioration, damage and loss. 1 15.9.4 All records shall be fully identified by pertinent material or item identification numbers, e.g. by Index. The record shall include all data on repaired material, items and assemblies. 15.9.5 The above records shall be retained for at least three (3) years after completion of vessel, after this time the records may be offered to the User by the QA/QC DEPT GM, if a rejection is received, these records may be destroyed. 15.9.6 The QA/QC DEPT GM, during manufacturing, shall maintain the records in such a manner so as to allow access to the Authorized Inspector to specific information within a period of no more than twenty-four hours. 15.9.7 All records shall be made available for review by the Authorized Inspector at the time he signs the Manufacturers Data Report. 15.9.8 A complete set of radiographs shall be maintained until the signing of the Manufacturers Data Report and submitted it, upon request, to the user. 15.10 Subcontract activities 15.10.1 All subcontract works such as forming, heat treatment shall be handled by issuing a purchase order with specification approved by QA/QC DEPT GM specifying the Code requirements, required documentation, and acceptance criteria. Received item and documentation shall be inspected /reviewed for Code compliance by the requesting personnel.
Section QUALITY CONTROL MANUAL Sec. 16.0 Exhibit Index of Sample Form Exhibit No. AL-ASME-01 AL-ASME-02 AL-ASME-03 AL-ASME-04 AL-ASME-05 AL-ASME-06 AL-ASME-07 AL-ASME-08 AL-ASME-10 AL-ASME-11 AL-ASME-12 3 AL-ASME-12.1 AL-ASME-13 AL-ASME-14 AL-ASME-16 AL-ASME-17 AL-ASME-18 AL-ASME-19 AL-ASME-20 3 AL-ASME-21 AL-ASME-22 AL-ASME-23 3 AL-ASME-24 Title Rev 0 0 2 1 0 0 0 0 1 0 1 0 1 1 1 1 0 0 0 1 0 0 0 Rev. No. Page
16.0 3 1 of 1
Date 21/02/2011 21/02/2011 23/07/2012 26/04/2012 21/02/2011 21/02/2011 21/02/2011 21/02/2011 23/07/2012 21/02/2011 14/11/2012 14/11/2012 23/07/2012 23/07/2012 23/07/2012 26/04/2012 21/02/2011 21/02/2011 21/02/2011 14/11/2012 21/02/2011 21/02/2011 14/11/2012
Quality Control Manual Distribution Master List Document Distribution Master List Welder Continuity Log Welder Register List Purchase Order Material Requisition Form Bill of Material Material Receiving Inspection Record Store Issue Voucher Rubber Stamp and Sticker Samples Pressure Test Report (ASME Section VIII, Division 1) Pressure Test Report (ASME Section VIII, Division 2) Non Conformance Report Name Plate Marking (5 pages) Welding Electrodes Baking and Holding Report Welding Material Issued Record National Board No. Log National Board R Form. Log Measuring Instrument List Traveler Non Conformance Report Log Welding Summary Material Traceability List
[ Exhibit : AL-ASME-01] Rev. 0
QUALITY CONTROL MANUAL DISTRIBUTION MASTER LIST

Project : Job No. : Product Code :
English Version Vietnamese Version
Doc. No. Rev. No. Page of
Revision
No. Manual Holder 0 1 2 3 4 5 6 7 8 9 Remark
Instruction : Place a check mark in the upper box of the appreciate revision level when the revision is sent out Place a check mark in the lower box when the acknowledgement is received.
DOCUMENT DISTRIBUTION MASTER LIST

English Version Vietnamese Version
Doc No. Rev. No. Page of
Distribution Department : _____________________________________________________________________ Rev. No. Name Document Doc. No. Date Issued Qty Date Distribution Receiving Deprt. Signature Remarks
WELDER CONTINUITY LOG S THEO DI TH HN
Doc. No./Ti liu s: Rev. No./ LPH Page/ Trang of
Year / Nm 20..
Welder ID M s Welder Name H tn Th hn Qualification date Ngy ph chun Jan. T1 Feb. T2 Mar. T3 Apr. T4 May T5 Jun. T6 July T7 Aug. T8 Sep. T9 Oct. T10 Nov. T11 Dec. T12 Remark Ch thch
Prepared by QC Inspector/Nhn vin QC chun b ............................. ............ ...............................................................Date / Ngy thng: Review and Approved by QA/QC DEPT GM Trng phng Qun l Cht lng xem xt v ph duyt .................. ............ ...............................................................Date / Ngy thng:
WELDER REGISTER LIST DANH MC NG K TH HN

Project / Tn D n : Job No. / M s Cng vic: Product Code / Quy phm Sn phm:
Filler Metal. F-No. S F Current Polarity Dng, cc hn Date of Test Ngy kim tra Expire Date Ngy ht hn Welding Process Qu trnh hn Position For Plate T th hn tm Position For Pipe T th hn ng
Doc. No./ Ti liu S: Rev. No./ LPH: Page / Trang of
ID No. M s
Welder Name H tn Th hn
Backing Lt y
Base Material P-No. S P
Size DIA C ng knh (mm)
THK. Chiu dy (mm)
Remarks Ch thch
Legend Ch gii :
(*) Unassigned metal of similar chemical composition to these metals / Kim loi khng ch nh c thnh phn ha hc tng t cc kim loi ny. O.D : OUTSIDE DIAMETER (ng knh ngoi) O : OVERHEAD POSITION (hn trn) W : WITH (c) U-H : UPHILL (leo) W.O : WITHOUT (khng c) D-H : DOWNHILL (tt) All : ALL POSITIONS (mi t th han) DIA: DIAMETER (ng knh) THK: THICKNESS (chiu dy)
F : FLAT POSITION (hn sp) H : HORIZONTAL POSITION (hn ngang) V : VERTICAL POSITION (hn ng) Prepared by / Ngi son: ALPHA-ECC Name / H tn : Sign.:/ Ch k Position / Chc v: Date / Ngy thng:
Approved by / Ngi ph duyt: ALPHA-ECC Name / H tn : Sign.:/ Ch k Position / Chc v: Date / Ngy thng: Name / H tn : Sign.:/ Ch k Position / Chc v: Date / Ngy thng: Name / H tn : Sign.:/ Ch k Position / Chc v: Date / Ngy thng:

Southern Petroleum Construction J.S Company
Purchase Order
Number: ---------------------------------Supplier: Address: Tel: Attn: PO Date: Packing: Project name: Product code: Fax: Delivery Date: Ship Via:
Dong Xuyen Industrial Zone, Rach Dua Ward, Vung Tau City, S.R. Viet Nam Tel: +8464 3611200 Fax: +8464 3611788
Delivery Terms: Payment Terms: Job No:
Shipping Instruction: Bill to: Southern Petroleum Construction J.S Company (ALPHA-ECC) Southern Petroleum Construction J.S Company (ALPHA-ECC) Dong Xuyen Industrial Zone, Rach Dua Ward, Dong Xuyen Industrial Zone, Rach Dua Ward, Vung Tau City, S.R. Viet Nam Vung Tau City, S.R. Viet Nam Tel: +8464 3611 200 Fax: +8464 3611 788 Tel: +8464 3611 200 Fax: +8464 3611 788 VAT Reg. No: 3500-582908 1. Scope of Supply: PIPE AND FITTINGS Item Description MRF no. Size UOM Qty Unit Price Total (SGD) Remark
TOTAL (USD): 2. List of Goods and Technical Requirement: Material Requisition Form number ( MRF No.) : Bill of Material number ( B.M No.) : List of goods: Technical Requirement: The goods shall be manufactured in strict accordance with EN 10204 3.1
Reference Document:(Standard Terms & Conditions are specified in accordance with the attachment herein shall apply) For and on behalf of ALPHA-ECC Signature: Name: Designation: Date: ____________________________ ____________________________ ____________________________ ____________________________ Signature: Name: Designation: Date: For and on behalf of Supplier ____________________________ ____________________________ ____________________________ ____________________________
Page 1 of 4

Purchase Order
Number: ----------------------------------
ALPHA-ECC'S GENERAL TERMS AND CONDITIONS FOR PURCHASE ORDER

1. DEFINITIONS: 2. Purchaser shall mean Southern Petroleum Construction J.S Company (ALPHA-ECC) named in the Purchase Order. Supplier shall mean any firm, company or entities the Purchase Order is issued to. Goods shall mean the goods, commodities to be purchased as stipulated in the Purchase Order. Purchase Order shall mean an order issued by Purchaser for ordering or purchasing of goods. Unless otherwise agreed in writing, Purchase Order shall take effective from date on its face. The trade terms herein used, such as EXW, FOB, CFR and CIF shall be construed or interpreted in accordance with Incoterms 2000, ICC unless otherwise agreed. The delivery time of the Goods in the Purchase Order shall be of the essence. As soon as possible but not later than 02 working days upon the delivery date, the Supplier shall send the following documents in English language to the Purchaser by Express Courier at the Supplier's expenses in one (1) set of originals: i) ii) iii) Duly signed commercial invoice with itemized and total prices issued by the Supplier; Packing list showing the content of each case or lot, dimension, gross and net weight. Certificate of Origin issue by Chamber of Commerce;
NOTICE OF DELIVERY AND DOCUMENTS: -
iv) Supplier's/Manufacturers Letter of Warranty or Certificate of Warranty for normal operation of the Commodity, covering 12 months from the date of installation/ 18 months from the date of delivery; Any storage fees or other relevant cost, expenses arising out due to non or late receipt of the delivery details and/or shipping documents by the Purchaser from the Supplier/the Suppliers agent as well as due to incorrect shipping documents shall be at the Suppliers account.
3.
PAYMENT: The payment of SGD3,000.00 (Singapore Dollars Three thousand only) representing 100% (hundred percent) of the contract value shall be made by telegraphic transfer to the Suppliers account within 05 (five) business days after Purchasers due receipt of Suppliers Commercial Invoice by the Supplier to the Purchaser.
4.
CANCELLATION WITH CAUSE Purchaser reserves the right to cancel this order partially or entirely, in event materials or work specified fail to confirm to the warranty as to quality (see 5 below), in event Supplier fails to make deliveries as specified in this order or Purchasers supplemental schedules or in event Supplier breaches any other terms or conditions of this order. In the event of such cancellation, Purchaser, without prejudice to any other rights available to it for breach of contract, shall have the right: (a) to refuse to accept delivery of material or performance of work; (b) to return to Supplier any materials already accepted, to recover from Supplier all payments made therefor and for freight, storage, handling and other expense incurred by Purchaser and to be relieved from liability for any future payments to Supplier; (c) to recover any advance payments to Supplier for undelivered or returned materials of work to be performed and; (d) to purchase elsewhere and charge Supplier with any resultant losses. However, Supplier shall not be liable for undelivered or returned materials of work to be performed and delays or defaults in delivery due to causes beyond its.
5.
WARRANTY
Page 2 of 4

Purchase Order
Number: ---------------------------------Guarantee Period: -
Upon the Goods being delivered the Supplier shall give to the Purchaser a guarantee to cover the Goods and their workmanship for a period of eighteen (18) calendar months after being Delivered or twelve (12) months from the date of installation whichever is earlier. The Supplier will pass to the Purchaser all Goods' manufacturer's guarantees. The guarantee provided under Clause 5 shall cover any necessary repairs performed at the Supplier's workshop. If repair of the Goods at the Supplier's workshop is not practicable, the Supplier shall authorize the Purchaser to undertake the repairs elsewhere and submit to the Supplier invoices for such authorized repairs and then shall be reimbursed by the Supplier at document costs provided thereof. Should the Purchaser require the Supplier to undertake the necessary repairs on a location other than the Supplier's yard, the Purchaser shall be required to pay for the reasonably additional costs incurred. For this circumstance, the Purchaser shall submit the supported documents for evidence of payment claims.
Guarantee for Repairs:
Page 3 of 4

Purchase Order
Number: ---------------------------------6. INDEMNITY:
In addition to and without prejudice to the generality of these Conditions, the Supplier undertakes to keep the Purchaser indemnified against any damage to or loss of the Supplier's property and against any claims for loss or injury to any person or to the property of any person by reason of the negligence or any act or omission on the part of the employees, subcontractors, or agents of the Supplier arising out of the execution of this Purchase Order. 7. LATE DELIVERY AND LIQUIDATED DAMAGES In case the Supplier fails to deliver/release the Goods by the Delivery date required, the Supplier shall pay the Purchaser a liquidated damage equal to zero point five percent (0.5%) of the Contract Price per each calendar day commencing from required delivery date up to actual day the Goods delivered/ released; provided however, that the total accumulated liquidated damage amount shall not in anyway exceed ten percent (10%) of each overdue shipment of the Goods. Such amount is an approximation of loss and damage incurred by the Purchaser due to the late delivery by the Supplier, and does not construe as a penalty under any circumstances 8. TAXES: The Supplier shall be responsible for any taxes or fees imposed or levied by any other foreign governments relating the performance of the Purchase Order and shall indemnify and hold Purchaser harmless from and against any liabilities arising out of due to failure of Supplier to fulfill this obligation. Unless otherwise provided, in the event that the Supplier is foreign contractor and do not apply the Vietnamese Accounting System, the Purchaser agree to take responsibilities to pay all Vietnamese Withholding Taxes arising out of or in relation to supply of Services or Goods under Purchase Order. 9. APPLICABLE LAW AND ARBITRATION: The Purchase Order and all questions concerning its formation, validity, interpretations and performance shall be governed under the laws of the Socialist Republic of Vietnam. Any disputes arising out of or in connection with any Purchase Order which could not settled through negotiation between the two Parties shall be finally settled by the Vietnam International Arbitration Center under Vietnam Laws. The place of Arbitration shall be in Ho Chi Minh City, the language of Arbitration shall be English. The costs of Arbitration shall be borne by the lost party. The award made in accordance with the provisions of this Condition shall be final and binding upon two parties. 10. FORCE MAJEURE: No failure or omission by either the Supplier or the Purchaser to carry out or observe any of the stipulations, conditions or obligations to be performed hereunder shall, except as herein expressly agreed to the contrary, give rise to any claim against the other party or be deemed to be a breach the Purchase Order if such failure or omission arises from a cause reasonable beyond the control of the party claiming force majeure.
Page 4 of 4
MATERIAL REQUISITION FORM

Item No. Material Material Specification Year of Edition General Specification Size Quantity Pressure class Rating Dimension Standard Supplier Condition Chemical Analysis Mechanical Properties Marking Hydro Static test End use Material test report Supplementary Requirement Alternate Acceptable ASTM Edition Note : The coded marking system, if used, shall be approved by ALPHA-ECC before use. Prepared by:............................................................................................................. ............. Date: ............................................................... (1) (2)
Doc. No. Rev. No.
Ref. BM
Page
of
( 3)
(4)
(5)
(6)
Approved by: ......................................................................................................................... Date: ...............................................................
BILL OF MATERIAL
Project : Job No. : Product Code : No. Description Material Ref. MFR No. :
Specification
Unit
Qty
MRF Item
Remarks
Prepared by Name : Sign : Position : Date : Name : Sign : Position : Date :
Reviewed by Name : Sign : Position : Date :
Approved by
[ Exhibit : AL-ASME-08] Rev. 0 MATERIAL RECEIVING AND INSPECTION RECORD

Doc. No. Rev. No. Project : Job No. : Product Code : No. Description MRF Item MRF No. BM No. Unit Qty Heat No. Certificate No. Acc/ Reject Remarks Page of 0
PREPARED BY NAME : I NAME :
APPROVED BY
SIGNATURE :
SIGNATURE :
DATE :
DATE :
STORE ISSUE VOUCHER

Receiver : ________________________________________________ SIV No.: ________________ Date : ___________________________________________________________________________
No.
Description
Unit
Qty
Prepared by Foreman Name : Sign : Date :
Approved by Workshop Mgr. Name : Sign : Date :
Issued by Storeman Name : Sign : Date :
ACCEPTED
Signature Date Job. No.
CERTIFICATE TRUE COPY

REJECT
CONTROLLED DOCUMENT HOLD

UNCONTROLLED DOCUMENT
AS-BUILT
APPROVED FOR CONSTRUCTION VOID

CUSTOMER SUPPLIED
CALIBRATION
ASME ORIGINAL
I. re-certify that this material is acceptable for ASME Sect. II SA Edition Add
Equip. No. Exp. Date
PRESSURE TEST REPORT

(ASME Section VIII, Division 1)
Serial No: Item Name: MAWP: Test Pressure: Code Applied:
............................................................... ............................................................................ ............................................................... Item No: ............................................................... ............................................................................................................................................ ............................................................................................................................................ ............................................................................................................................................
TEST DETAILS
Test Medium: Test Temp. : Test Pressure: Holding Pressure:
............................................................... ............................................................................ ............................................................................................................................................ .................................. Time From .................................To ............... Duration: ................... .................................. Time From................................ To .............. Duration: ..................
Pressure Gauge No. 1: .................................. Range: ...................... Re-cal. Date : .. . Pressure Gauge No. 2: .................................... Range: .................... .. Re-cal. Date : ... .. Tested Date: ............................................................................................................................................ Test Result: Accept Reject
Remark:
.................................................. QC Inspector
................................................... Authorized Inspector
.................................................. Client Authorized Representative
[ Exhibit : AL-ASME-12.1] Rev. 0
PRESSURE TEST REPORT

(ASME Section VIII, Division 2)
Date of Test: /.../... Serial No: Item Name: MAWP: Test Pressure (Top): Code Applied: Hydrotest Procedure: Type of Test: ............................................................... ............................................................................ ............................................................... Item No: ............................................................... ............................................................................................................................................ Minimum Maximum . ASME Section VIII, Division 2, Edition Addenda : ............................... AL-HT-15-01, Revision : 0 Hydrostatic Pneumatic TEST DETAILS Position of Vessel: Test Medium: Test Temp. : Test Pressure: Holding Pressure *: . ............................................................... ............................................................................ ............................................................................................................................................ .................................. Time From .................................To ............... Duration: ................... .................................. Time From................................ To .............. Duration: .................. Hydrostatic - Pneumatic
Pressure Gauge No. 1: S/N............................. Range: ...................... Re-cal. Date : .. . Pressure Gauge No. 2: S/N............................... Range: .................... .. Re-cal. Date : ... .. Tested Date: ............................................................................................................................................ Test Result: Accept Reject
: For visual examination/inspection
Remark:
.................................................. QC Inspector
................................................... Authorized Inspector ( Name of AIA .)
.................................................. Client Authorized Representative
NON CONFORMANCE REPORT

Contract No .............................. . To ............................... Clients: Vessel: Summary of Nonconformance: Item No:
Date: .............................................................. NCR No:
Corrective Action Recommended
__________________ Approved by: Disposition Use as is Repair/Rework Scrap Other QA/QC DEPT. GM
_______________ PS&M DEPT. GM Distribution Contract File
_______________ A.I.
Production & Workshops Dept. GM Q.C Inspector
Result
Corrective Action by: ........................................................ Sign: .......................................... Date: .............................. Verified by: ....................................................................... Sign: .......................................... Date: .............................. Confirmation/ close out:
...................................... Authorized Inspector: Date:
. ....................................... QA/QC DEPT GM Date:
[ Exh hibit : AL-ASM ME-14] Rev. 1 Page : 1 of 5
Note: 1: NB symb stamp and NB numbe to be stamped only if re bol er equired regis stration with National Boa ard 2: Do not sh how this Max Allowable External Wo x. orking pressu if not a de ure esign require ement.
Note: bol er equired regis stration with National Boa ard 1: NB symb stamp and NB numbe to be stamped only if re 2: Do not sh how this Max Allowable External Wo x. orking pressu if not a de ure esign require ement.
Note: bol er equired regis stration with National Boa ard 1: NB symb stamp and NB numbe to be stamped only if re 2: Max. Allo owable Exter rnal Working pressure req quired only w when specifie as a desig requireme ed gn ent.
N.B. NAME PLATES FOR RE . EPAIR
N.B. NAME P PLATES F FOR ALT TERED
N.B. NAM PLAT FOR RE-RAT N ME TES R TED
N.B. N NAME PL LATES F FOR PAR RT
[ Exhibit : AL-ASME-16] Rev.1
WELDING ELECTRODES BAKING AND HOLDING REPORT BO CO SY QUE HN

Project / Tn D n : Job No. / M s Cng vic :
Size (mm) C Baking Time Thi gian sy In / Vo Out / Ra
Doc. No. Ti liu s Rev. No. LPH Page Trang

Holding oven Time / Thi gian trong l Remarks Ch thich
of
No. S
Date Ngy
Batch No. S m liu
Qty in (kg) Khi lng
Brand / Type Mc / Loi
Controlled by Storeman / Th kho kim sot Name / H tn : Sign / Ch k : Date / Ngy:
Checked by P&W Dept. General Manager / Trng phng Sn xut kim tra Name / H tn : Sign / Ch k : Date / Ngy:
[Exhibit: AL-ASME-17] Rev.1
Project Name (Tn D n) Job No. (M s Cng vic) AWS Class. (Chng loi vt liu hn) Brand Name (Mc vt liu hn)
WELDING MATERIAL ISSUE RECORD H S CP PHT VT LIU HN

Q'ty, KG (S lng, Kg) Issue (Nhn) Return (Tr li)
Doc. No. (S ti liu) Page (Trang) Time (Thi gian) of
Size (C)
Lot No. (S m liu vt liu hn)
Issue (Nhn)
Return (Tr li)
Welder I.D. Th hn S:
Remark (Ghi ch)
Date (Ngy)
Storeman (Th kho)
Workshop Manager (Trng xng)
NATIONAL BOARD NO. LOG

National Board No. Type of Stamp Issued Date Manufacturers Serial Number
Date mailed
Remark
NATIONAL BOARD R Form LOG

R No. Assigned Repair / Alt Date Issued Original MFG Serial Number
Original NB Number
Date mailed
[ Exhibit : AL-ASME-20 ] Rev. 0
MEASURING INSTRUMENT LIST

No. Instrument name Control No. Manuf. Model Spec. Serial No. Cal. Date
Doc. No. Page No. Rev. No. Cal. Freq. Expir. Date. Remark of
P.O No.:
CUSTOMER
TRAVELLER
PROJECT NAME NAME / ITEM No.: Job No:
APPLICABLE DOCUMENT LIST REV.
TRAVELLER No. PROCESS NAME

REV. PREPARED BY APPROVED BY Q.C
INSPECTION A.I
DOCUMENT NAME
DOCUMENT NO. A B C D E
1
2 NOTE 1. Temporary attachment shall be controlled as follows. - Use same material as the pressure retaining part - Use one of the WPS's specified in this cover sheet - Shall be welded by a qualified welder - Removal area shall be marked by paint marker - Removal area shall be examined by MT before final DI/VI. 2. All nozzle openings shall be examinated by MT before fit-up of nozzle neck 3. Examination group 1b in table 7.1 ABBREVIATION MI : MATERIAL INSPECTION MK : MARKING D/I : DIMENSION INSPECTION V/I : VISUAL INSPECTION PWHT : POST WELD HEAT TREATMENT RT : RADIOGRAPHIC TESTING MT : MAGNECTIC TESTING UT : ULTRASONIC TESTING V : VERIFICATION H : HOLDING POINT MFG : MANUFACTURE DEPARTMENT Q.C : QUALITY CONTROL A.I : AUTHORIZED INSPECTOR R : REVIEW POINT W : WITNESS POINT
VERIFICATION FOR DOCUMENT REVISION
Project Name:
Item : Job Number :
OPERATION DESCRIPTION FABRICATION FOR SHELL

1 SHELL TO HEAD MFG Q.C DWG NO. WELD No. : WPS No. : HEAT / LOT , RECORD No. etc 2 SHELL TO SHELL SA516M Gr.485 / SA516M Gr.485 DWG NO. WELD No. : WPS No. : : WM-AL-2088-VAN-01 LS.1 WPS-001-AL Heat No. MFG Q.C DWG NO. WELD No. : WPS No. : HEAT / LOT , RECORD No. etc Heat No. : A.I Heat No. MFG Q.C A.I : A.I
1 M.I
2 MK
V
3 CUTTING
V
4 BENDING and FIT-UP

V H
5 WELDING
V H
6 D/I and V/I

V H
7 RT
8 UT
9 MT
V H H
V H
V H
V H H
HEAT / LOT , RECORD No. etc 3 SHELL TO HEAD
V H H
V H
V H
V H H
Traveller No.:
Rev.
Page : 1 of 1
Project Name:
Item : Job Number :
OPERATION DESCRIPTION INTERNAL VISUAL INSPECTION
MFG
QC
A.I
CLIENT
REMARK
44
45
EXTERNAL VISUAL INSPECTION
46
NOZZLE REINF. PAD LEAK TEST
47
HYDROTEST
48
BLASTING AND PAINTING
49
STAMPING AND MDR REVIEW
50
AFFIXING THE NAME PLATE
Traveller No.: T
Rev.
Page : 1 of 1
NON CONFORMANCE REPORT LOG

No. NCR No. PJT. Name / No. Description Disposition Issued Date Closing Date
Result
Remark
[Exhibit : AL-ASME-23] Rev. 0
WELDING SUMMARY
Project : Job No. : Product Code
ITEM: SHOP DRAWING No : NDE / WELD MAP : Weld No. Weld Type Pre-Heat FIT-UP Date Date WELDING OPERATION Welder No Process WPS MATERIAL PWHT Report
Doc. No. : Rev.: Page : 1 1 of 1
REPORT No:
NDT Report Number MT UT RT OTHERS
REMARK
COMPANY: NAME: SIGNATURE: DATE:
ALPHA-ECC
CLIENT
A.I
[Exhibit:ALASME24]Rev.0
MATERIAL TRACEABILITY LIST

Project : Job No. : Product Code Drawing No. Rev. Item No. Type of Material Dimension Material Specified Heat No.
Doc. No. : Rev.:

Page : 1 of 1
Cert. No. of Mill Sheet
Cert. code (internal cert. no)
=== END === * Item no.: 1, 2, 3 HE 300 B - fabricated from plate. Prepared by : Engineer : Approved by QC Inspector :
Page1of1

Asme QCM

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Asme QCM

Enviado por

Direitos autorais:

Formatos disponíveis

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY ( ALPHA-ECC )

21-02-2011 17-01-2012 26-04-2012 03-10-2012 14-11-2012

Responsible: QA/QC Dept Document Title

Document format: A4 Document status N/A Document Number AL-QC-ASME.01 MANUAL

QUALITY CONTROL MANUAL Sec. I Table of Contents

Section Rev. No. Page

Document Number : AL-QC-ASME.01

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )

QUALITY CONTROL MANUAL Sec. II Statement of Authority

Section Rev. No. Page

Le Xuan Hung DIRECTOR

Document Number : AL-QC-ASME.01

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )

Document Number : AL-QC-ASME.01

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )

WPQ WPS RT UT MT PT VT Review QC NBIC

Document Number : AL-QC-ASME.01

g) Control of Nonconformities. h) Certifying MDR

Document Number : AL-QC-ASME.01

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )

1.1.10 SITE QC INSPECTOR

Document Number : AL-QC-ASME.01

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )

Figure 1. Organizational Chart

PURCHASING DEPT. GENERAL MANAGER - Purchasing Staff

FIELD SITE (See FIG. 2) (See Section 13)

PRODUCTION & WORKSHOPS DEPT. GENERAL MANAGER - Foreman - Storeman

: Administration Line : Communication Line

Document Number : AL-QC-ASME.01

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )

QUALITY CONTROL MANUAL Sec. 2.0 QC Manual Control 2.1 Scope

Section Rev. No. Page

2.3 2.3.1 2.3.2 2.3.3 2.3.4

Document Number : AL-QC-ASME.01

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )

Document Number : AL-QC-ASME.01

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )

Section Rev. No. Page

3.4.3 3.4.4 3.4.5

Document Number : AL-QC-ASME.01

Document Number : AL-QC-ASME.01

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )

Section Rev. No. Page

Document Number : AL-QC-ASME.01

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )

Document Number : AL-QC-ASME.01

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )

QUALITY CONTROL MANUAL

Section Rev. No.

Sec. 4.0 Material Control 4.8 Issuance of Material

Document Number : AL-QC-ASME.01

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )

Document Number : AL-QC-ASME.01

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )

5.4.1 5.4.2 5.4.3

Document Number : AL-QC-ASME.01

5.5.1 5.5.2 5.5.3

5.5.4 5.5.5 5.5.6

Document Number : AL-QC-ASME.01

Document Number : AL-QC-ASME.01

SOUTHERN PETROLEUM CONSTRUCTION JOINT STOCK COMPANY( ALPHA-ECC )

6.2.2 6.2.3 6.2.4

6.3 6.3.1 6.3.2