Professional Documents
Culture Documents
AAF INTERNATIONAL
LOUISVILLE INDUSTRIAL PARK
7625 NATIONAL TURNPIKE
UNIT 130
LOUISVILLE, KY 40214
FOR THE FABRICATION OF BOILERS, POWER PIPING AND PRESSURE VESSELS TO
THE REQUIREMENTS OF ASME SECTION I, B31.1, VIII Div. 1, Div. 2, Div. 3
AND
FOR REPAIRS AND ALTERATIONS TO THE NATIONAL BOARD INSPECTION CODE
AND JURISDICTIONAL REQUIREMENTS ON ABOVE LISTED ITEMS AND SECTION
IV BOILERS
ALL THE ABOVE TO BE PERFORMED IN THE SHOP AND AT FIELD LOCATIONS
CONTROLLED BY THE ABOVE LOCATION
11/02/05
REVISION 1
Control Number
Uncontrolled
.
.
i
Table of Contents
Section ii
Page 1 of 1
Revision 1
Section
Title
Rev.
Date
Facing Page
11-02-05
ii
Table of Contents
11-02-05
Statement of Authority
12/11/02
Manual Control
12/11/02
Organizational Chart
12/11/02
12/11/02
Material Control
12/11/02
11-02-05
Correction of Nonconformities
12/11/02
Welding Control
12/11/02
Nondestructive Examination
12/11/02
10
Heat Treatment
12/11/02
11
12/11/02
12
Records Retention
12/11/02
13
Authorized Inspector
12/11/02
14
11-02-05
15
Exhibits
12/11/02
Date
Authorized Inspector
Date
Section 1
Revision 0
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12/11/02
Date
Section 2
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2.1
Revisions to this Quality Control Manual shall be prepared and approved by the QCM
and submitted to the Authorized Inspector (AI) for his review and acceptance prior to
issue. QCM approval and AI acceptance are shown by signature on the Table of Contents
Page.
2.2
Revisions to this manual with the exception of the Exhibits will be by section with the
revision level and date of the section displayed on the Table of Contents and in the upper
right hand corner of each page of the section. Exhibits will be revised individually with
the revision level of each exhibit displayed on the exhibit itself and on the Exhibit index
page. The exhibit page will also list the date of the revision to each exhibit. The revision
level and date of the Exhibit index page will also be displayed on the Table of Contents.
2.3
The QCM will issue controlled copies of the manual to the individuals listed on the
controlled manual holder list, which the QCM maintains. Controlled Manuals will bear a
controlled copy number on the Facing Page that corresponds to an individual on the
controlled manual holder list. Only controlled copies of the Quality Control Manual will
be issued to AAF INTERNATIONAL personnel. The QCM will recall obsolete copies
of controlled manuals and redistribute revised copies after revisions have been installed.
2.4
2.5
2.6
The Engineering Manager shall review all Code Editions and Addenda. If revisions to the
manual are needed they shall be presented to the QCM for his review and approval.
These revisions shall be incorporated into the system within 6 months of the Edition or
Addenda date. The Engineering Managers review shall be documented either by initial
and dating the cover page of the new Edition or Addenda, or by memo.
Section 3
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General Manager
Designer
(Section VIII, Div. 3)
Project Manager
Shop/Field Foreman
Welders
NOTE: Duties may be delegated but responsibility remains with the above titled individual.
Section 4
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4.1
When an order for Code work is received, it is issued a Job Number by the Project
Manager. This Job Number is used to identify all documents related to the Code item
through construction and assembly.
4.2
DESIGN
4.2.1 Upon receipt of an order for Code work, the Engineering Manager shall review the
customer specifications and verify that they are adequate for Code compliance.
Deficiencies must be reconciled prior to the start of design work.
4.2.2 When the customers specification is approved, the Engineering Manager prepares
drawings, detail sheets, design calculations and a Bill of Material (BOM Exhibit 1)
which lists all the material specifications for the material to be used in the item. In
lieu of Exhibit 1, the BOM may be listed on the production drawing.
4.2.3 Drawings Shall list the following items as a minimum:
-
4.2.4 When drawings and calculations are provided by an outside concern, they are
reviewed by the Engineering Manager for compliance to Code. Discrepancies are
brought to the attention of the design concern for correction to the requirements of
the Code.
Section 4
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4.2.5 When the Engineering Manager has satisfied himself that the design documents
meet code, he indicates his approval by initialing and dating each document.
4.2.6 After the QCM approves the design documents, he submits them to the AI for
acceptance which is indicated by the AIs initials in the appropriate block on the Traveler
(Exhibit 2 & 2a). After the AI accepts the design documents, the QCM keeps one copy
for the QC file and gives a copy to the Project Manager to place in the job file for
production.
4.3
REVISION CONTROL
4.3.1 Revisions to design documents shall be handled as per paragraph 4.2. Upon final
approval and AI acceptance of the revision, the QCM shall hand carry the revised
documents to the Project Manager and collect the obsolete documents. The
obsolete documents shall be destroyed except that one copy may be maintained for
reference. If an obsolete copy of a design document is maintained for reference, it
shall be marked in a manner acceptable to the AI (e.g. VOID - FOR
REFERENCE ONLY) so that it will not inadvertently be used for production.
4.3.2 The Project Manager maintains master copies of calculations, BOMS and detail
drawings.
4.3.3 All changes made to controlled documents are noted in bold type or by other
suitable means.
4.3.4 Drawing changes shall be noted by (X) with X representing the revision change
letter.
4.4
COMPUTER CALCULATIONS
4.4.1 Calculations performed to computer programs shall be verified by the Engineering
Manager for accuracy prior to use on Code work. They shall also be checked for accuracy
whenever there is a Code change, which affects them.
Section 4
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4.5
4.5.3 Revisions to the Design Specification and/or the Design Report must be approved
by the Engineering Manager and reconciled with the Professional Engineer.
Revisions shall be handled as described in this section.
4.5.4 Restricted requirements of allowable materials as reflected by the fatigue analysis
curves of this division must be considered where fatigue analysis is required.
4.5.5 Provisions of adequate overpressure protection or nozzles of adequate crosssectional area for mounting of overpressure protection devices must be considered.
4.5.6 Loadings as required by paragraph AD-110 must be considered.
4.5.7 Offset (joggle) joints are prohibited.
4.6
Section 4
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4.6.1 All requirements for Sections VIII Division 1 and 2 described above shall apply to
Section VIII Division 3 construction except as modified below:
4.6.1.1 The Design Specification shall contain the following items:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
Vessel identification
Vessel configuration
Controlling dimensions
Design criteria (i.e., design pressure, pump curves, design temperature,
MDMT, and thermal gradients)
Operating conditions for all design cases.
Contained fluid data
Material selection
Loadings
Useful operating life expected
Fatigue analysis
Overpressure protection, and any additional requirements specified by
the user
Installation site
Distribution
4.7.1 The Engineering Manager maintains a list of all documents for each job
number. A transmittal letter accompanies distribution of all controlled documents.
5.1
Section 5
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PURCHASING
5.1.1 A BOM (Exhibit 1) and associated purchase requisitions are prepared by the
Engineering Manager and submitted to the QCM for approval. Upon approval, the
QCM submits a copy of the requisitions to the Purchasing Manager. Purchase
Orders (Exhibit 3) are then prepared using the requisitions as the basis.
5.1.2 Material for stock is ordered using a PO prepared by the Purchasing Manager and
submitted to the QCM for approval prior to ordering.
5.1.3 All material will be ordered to SA, SB, SFA, or other acceptable specifications
such as ASTM. The PO shall contain all the ordering requirements for the material
specification as well as any additional requirements for the construction Code
(Charpy impact tests, UG-79, etc.). The PO shall also reference the job number and
request CMTRs when required.
5.1.4 A completed copy of the PO shall be submitted to the QCM for approval. After
approval, the QCM returns the original PO to purchasing and sends a copy to
receiving inspection and maintains a copy for the job file.
5.2
5.3
Section 5
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5.4
All material and documents described in this section shall be available for the review and
acceptance of the AI.
5.6
5.7
Section 5
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5.7.3 Procedures for obtaining test specimens for austenitic and non-ferrous alloys shall
comply with material specs.
5.7.4 The appropriate Tables in Section II Part D shall be used to determine stress values
for ferrous wiring, as well as ferrous and non-ferrous materials used in construction
to this division.
5.7.5 Thickness of materials shall be the thickness dimension of the product form
described in Article KM-2 of this division.
6.1
Section 6
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11-02-05
RESPONSIBILITY
6.1.1 The QCM shall assure compliance with the Quality Control Manual in the shop
and field.
6.2
FABRICATION
6.2.1 Code work is controlled by use of the Traveler. The Traveler lists the sequence of
construction, examination, and inspection of an object.
6.2.2 Prior to the start of work, the QCM presents the design documents along with the
Traveler to the AI for acceptance. At this time the AI will designate any hold
points he may wish to assign. The review of the QCM and the AI are documented
on the Traveler.
6.2.2.1 No hold point designated by the AI may be bypassed. The QCM is
responsible for notifying the AI of approaching hold points in sufficient time
for the AI to schedule an inspection.
6.2.3 After work begins, Quality Control inspections during fabrication are documented
by initial and date by the Quality Contol Inspector (QCI) in the appropriate block
on the Traveler. AI inspections are documented in the same manner.
6.3
FINAL INSPECTION
6.3.1 When a job is completed, it shall be given a final inspection including a pressure
test required by the appropriate Code of construction. The QCI and the AI shall
conduct this final inspection.
6.3.2 During the pressure test, at least one pressure gage directly connected near the
highest point of the vessel and visible to the operator controlling the pressure test
shall be used. Dial indicating gages shall have a range of approximately double the
test pressure, but in no case less than 1.5 times or more than 4 times test pressure.
Section 6
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6.3.3 At no time shall the pressure exceed the requirements of Para. PG- 99 for Section 1
items.
6.3.4 When the pressure test is satisfactorily completed, the QCI and AI shall initial and
date the appropriate block on the Traveler.
6.3.5 The inspection report shall contain as a minimum: the inspectors name and
qualification, date of the inspection, results of inspection and NCR number if
applicable.
6.4
Section 6
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11-02-05
6.4.5 Items that are to be registered with the National Board shall be issued a National
Board Number. These numbers are issued sequentially without skips or gaps
starting with the number 1, and are recorded in the National Board Number Log
(Exhibit 5). This log will list the National Board Number, the Manufacturers
Serial Number, and the date the Data Report was submitted to the National Board
for registration. Data Reports for vessels to be registered shall be submitted to the
National Board within 60 days of certification.
6.5
6.6
7.1
Section 7
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IDENTIFICATION OF NONCONFORMITIES
7.1.1 A nonconformity is any condition in material, fabrication, or inspection which does
not meet all the requirements of the Code, material specifications, Design
Specifications, or this manual.
7.1.2 It is the duty of all personnel to report a nonconformance to the QCI or their
immediate supervisor. The QCI shall identify nonconforming material with a
HOLD tag. The HOLD tag will reference the NCR number. The QCI
completes a Nonconformance Report, (Exhibit 6) and enters it into the NCR Log,
(Exhibit 10). If practical, the nonconforming item shall be removed to a segregated
hold area pending resolution.
7.1.3 The QCI presents the NCR to the QCM for review and acceptance.
7.2
DISPOSITION OF NONCONFORMITIES
7.2.1 The QCM presents to the AI all NCRs and their proposed disposition for his
review and acceptance. At this time the AI is given the opportunity to set any hold
points he may deem necessary. There are three general dispositions available for
nonconforming items:
7.2.1.1 Use-as-is, where the nonconforming item is proven adequate, with the
Engineering Managers approval, to meet Code requirements. Any revisions
to drawings, calculations, procurement, or other documentation shall be
handled as described in the applicable section of this manual.
7.2.1.2 Repair or Rework-Where the nonconforming item may be repaired or
reworked to meet Code requirements. Procedures used in this case shall be
approved by the QCM and accepted by the AI. NOTE: the AI shall accept
the method and extent of welded repairs to base metal under any
circumstances. All nonconformng items that are reworked or repaired must
be reinspected.
7.2.1.3 Scrap or Return to Vendor, where the item is not to be used further for
Code work. If this disposition is selected, the QCI shall clearly mark the
Section 7
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material or object and remove it from the production area to prevent its
inadvertent use. When material is rejected due to lack of certification or because
of an incorrect certification the RTV disposition is conditional depending upon
the suppliers ability to supply the required certification.
7.2.2 When the disposition has been satisfactorily completed the QCM removes the hold
tag (except for scrap or return to vendor) and signs off the NCR. The completed
NCR shall be submitted to the AI for acceptance after which it is placed in the job
file.
7.2.3 NCRs are uniquely numbered and maintained until the job is completed or as
described in Section 12 of this manual.
8.1
Section 8
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GENERAL
8.1.1 All Code welding shall be performed using welding procedures, welders, and
welding operators qualified to the requirements of ASME Section IX and the
appropriate Code of construction.
8.2
WELDING PROCEDURES
8.2.1 The QCM is responsible for approving Welding Procedure Specifications (WPS)
using certified Procedure Qualification Records (PQR).
8.2.2 The QCM is responsible for ensuring that test coupons are sent to an approved lab
for testing. When the test results are returned, the QCM verifies that they meet
Code requirements after which he writes and certifies a PQR based on the actual
conditions under which the welder performed the test.
8.2.3 Original copies of the WPSs and PQRs are maintained by the QCM. Copies are
submitted to the Shop/Field Foreman for use by the welders.
8.2.4 WPSs are revised when there is a change in a Non-essential Variable and
requalified when there is a change in an Essential Variable (or Supplementary
Essential Variable when applicable).
8.2.5 WPSs and PQRs are made available to the AI for his review and acceptance. The
AI may require requalification of a WPS at any time for cause.
8.3
Section 8
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WELDING MATERIAL
8.4.1 All welding material is purchased and received as described in Section 5.
8.4.2 All welding materials are stored in a dry storage area and issued to the welder by
the Shop/Field Foreman.
8.4.3 Low hydrogen electrodes are received in sealed containers. When the sealed
containers are opened, the rod shall be placed in a storage oven at a temperature
recommended by the material manufacturer or as per Section II Part C. Only a
quantity sufficient to complete the weld or four hours supply (whichever is less)
shall be issued. Unconsumed electrodes shall be returned to the Shop/Field
Foreman for examination. If the electrodes are damaged, unclean, or exceeding
four hours from time of issue, they shall not be used for Code work. Use of
portable rod ovens shall negate the above time requirement for returning rod.
8.5
Section 8
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PRODUCTION WELDING
8.5.1 The Shop/Field Foreman is responsible for assigning only qualified welders to a
job.
8.5.2 Each welder is issued a unique identification number to be stamped or written at
not more than three foot intervals adjacent to each weld he makes. When
conditions prevent the welder from marking his identification on the weld, he shall
enter his identification on the Traveler.
8.5.3 Tack welds whether removed or left in place shall be made using qualified welders
and procedures. They shall be identified with the welders identification. Tack
welds left in place shall be prepared for inclusion into the final weld. Defective
tack welds shall be removed.
8.6
9.1
Section 9
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NDE PROCEDURES
9.1.1 All NDE disciplines are performed in accordance with written procedures
approved by the QCM and AI. Either the QCM or a contracted Level III Examiner
may write the procedures. NDE procedures shall meet the requirements of the
appropriate Article of ASME Section V.
9.1.2 All NDE procedures shall be demonstrated to the satisfaction of the AI.
9.2
NDE PERSONNEL
9.2.1 The QCM shall review the written practice of the subcontracted NDE organization.
NDE personnel shall be certified to SNT-TC-1A or CP-189 (latest Code accepted
edition). Exceptions to this requirement are noted in paragraphs 9.4 and 9.5. If a
contracted Level III Examiner is used, an appointment letter must be on file
accepting the individual as the certificate holders Level III Examiner.
9.2.2 All NDE personnel qualifications shall be current and shall be made available to
the AI for review and acceptance. The AI may require requalification of NDE
personnel if there is reason to question their ability to adequately perform an
examination.
9.3
NDE REPORTS
9.3.1 All NDE reports shall be reviewed by the QCM and submitted to the AI for his
review and acceptance. For field sites, the QCI may review the reports prior to
submittal to the AI.
9.3.2 All NDE film and reports are placed in the job file after AI acceptance.
9.4
VISUAL EXAMINATION
9.4.1 AAF INTERNATIONAL personnel who are qualified and certified in accordance
with the requirements ASME B31.1 may perform visual Examination (VT) for
Power Piping work. VT shall be conducted using an approved procedure. VT
procedures and personnel qualifications shall be made available to the AI for
review and acceptance.
9.5
Section 9
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9.6
9.7
Section 10
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10.1 GENERAL
10.1.1Heat treatment shall be performed by a subcontractor using calibrated equipment
and a procedure approved by the QCM. Time-temperature charts or chronological
temperature lists will be required and these will be reviewed by the QCM for
conformance with the written procedure and Code requirements. The charts and
written procedures shall be available to the AI for review and acceptance.
10.1.2 The QCM shall verify calibration of subcontracted heat treating equipment
including ovens, thermocouples and recording devices. This data shall be made
available to the AI for acceptance.
10.1.3 For heat treatment performed in the field, the QCI may perform the duties of the
QCM.
10.1.4 After AI review and acceptance, heat treatment records are placed in the job file.
10.3 RECEIVING INSPECTION
10.3.1Material shall be examined for identification by the QCI upon its return from heat
treatment. This examination shall be recorded on a Receiving Inspection Report.
Nonconforming material shall be handled as per Section 7 of this manual.
Section 11
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11.1 PROCEDURE
11.1.1 Measuring and test equipment requiring calibration shall be identified with a
unique serial number.
11.1.2 Master gages shall be calibrated annually by a method traceable to national
standards. This calibration shall be documented on a Calibration Record Card
(Exhibit 8).
11.1.3 Working gages shall be calibrated against a master gage prior to each use and at
any time their accuracy is in question. Date of calibration shall be written on the
item.
11.1.4 Linear measuring equipment shall be calibrated by a method and at a frequency
recommended by the equipment manufacturer or by a procedure written by the
QCM and documented on a Calibration Record.
11.1.5 Measuring and test equipment used by outside contractors for Code work shall be
verified for calibration by the QCM.
11.2 DISCREPANT EQUIPMENT
11.2.1 Equipment found to be out of calibration shall be adequately marked and removed
from the work area pending repair or disposal.
11.2.2 Items found to be tested with equipment that was out of calibration shall be
handled as per Section 7 of this manual.
11.3 All records of calibration and calibration procedures shall be made available to the AI for
review and acceptance.
11.4 Control of M&TE is further defined in supplemental procedure ASME 11.1 latest rev.
11.4 SECTION VIII DIVISION 3 (IN ADDITION TO THE ABOVE REQUIREMENTS)
11.4.1Pressure gages and transducers shall be calibrated against a standard dead weight
tester or a calibrated master gage at least every six months.
Section 12
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12.1 All documents used for Code production described in this manual shall be maintained in
the job file until the job is complete. These records shall be reviewed by the QCM for
completion and submitted to the AI for review and acceptance prior to certification of the
Manufacturers Data Report. Code production related records will be maintained for one
year after the job ships.
12.2 RT film along with RT and UT reports for Section I work shall be maintained by the
QCM for 5 years.
12.3 All Data Reports not registered with the National Board shall be maintained by the QCM
for 5 years.
12.4 SECTION VIII DIVISION 2 (IN ADDITION TO THE ABOVE REQUIREMENTS)
12.4.1The Manufacturers Data Report, with applicable partial Manufacturers Data
Report(s), and supplementary sheet(s) attached shall be maintained in a safe
repository for at least ten years or for the intended life of the vessel unless the item
is registered with the National Board.
12.4.2 All records, procedures, and documentation, including the certified Users Design
specification and a copy of the certified Design Report, for each item constructed
to this division shall be identified and maintained on file for a period of 5 years.
After 5 years, these documents shall be offered to the user of the vessel. If the user
declines these documents, they may be discarded.
12.5 SECTION VIII DIVISION 3 (IN ADDITION TO THE ABOVE REQUIREMENTS)
12.5.1 All documentation, procedures, and records for items built to this division shall be
maintained until the Manufacturers Data Report is certified. The records listed in
paragraph KS-320 shall be furnished to the user of the vessel.
Section 13
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13.1 AAF INTERNATIONAL shall maintain a current contract with an ASME accredited
Authorized Inspection Agency (AIA).
13.2 The QCM shall be the liaison with the AIA and the AI. The QCM is responsible for
informing the AI of the progress of work in a timely manner so that he may be present to
conduct inspections on designated hold points and pressure tests.
13.3 The AI and AI Supervisor shall be provided access to the plant where Code work is
performed and to such parts of all plants and facilities which are concerned with the
manufacture, assembly and/or supply of Code parts and material as requested.
13.4 The AI shall have access to all records and documents referenced in this manual.
13.5 The AI shall hold a National Board of Boiler and Pressure Vessel Commission that bears
the A Endorsement.
Section 14
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Section 14
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Section 14
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Section 14
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Pressure test may be a pneumatic test provided the QCI obtains the concurrence of
the INSPECTOR, jurisdictional authority where required and the owner.
Precautionary requirements of the applicable section of the original Code of
construction shall be applied.
b)
As an alternative to the pressure test, NDE methods that verify the integrity of the
repair may be used subject to the concurrence of the INSPECTOR and
jurisdictional authority (where required) prior to performing the examination.
Section 14
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14.9 CALIBRATION
14.9.1The calibration of pressure gauges, measurement, examination and test equipment
and documentation of calibration shall be performed per Section 11 of this manual
and shall be in accordance with the standard used for construction.
14.10 NONCONFORMING ITEMS
14.10.1 A nonconformity is any condition that does not comply with the applicable rules
of the NBIC, construction code, jurisdictional requirements or this Quality Control
System.
14.10.2 The system described in Section 7 of this manual shall be used. All
nonconformitys shall be corrected or eliminated before the repair or altered
component can be considered in compliance with the NBIC.
14.11 ACCEPTANCE, STAMPING & DOCUMENTATION
14.11.1 The QCI shall stamp or attach a Nameplate adjacent to the original stamping in
accordance with the applicable Edition of the NBIC, only when authorized by the
INSPECTOR. Only nameplates shall be used for Section VIII Division 2 and 3
repairs and alterations. After the stamping is performed the QCI shall return the
stamp to the QCM who shall maintain custody and control of the "R" stamp.
14.11.2 Upon completion of repair/alteration activities, the QCI reviews all
documentation for compliance to the NBIC. If acceptable, the QCI shall prepare
and certify the applicable NBIC Report Form from final records.
NBIC REPORT FORM:
a)
FORM R-1 for Welded Repairs,
b)
FORM R-2 for Alterations, or
c)
FORM R-4 Report Supplementary Sheet for
additional data.
Section 14
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14.11.3 The final records and applicable NBIC Report Form are presented to the
INSPECTOR for his review and certification when he is satisfied all Code of
construction and NBIC requirements have been met.
14.11.4 The QCM shall distribute legible copies of the NBIC Report Form together with
attachments to the owner or user, the INSPECTOR, the jurisdiction (if required),
and the AIA responsible for inservice inspection of the pressure vessel. One copy
will be placed in the job file for retention.
14.11.5 If an altered item is registered with the National Board, the original R-2 Report
Forms (with attachments) shall be transmitted to the National Board within 60 days
after certification. R-1 Report Forms may be registered with the National Board at
the discretion of the Quality Control Manager. Registration of R-1 and R-2 Report
Forms shall be documented sequentially on a log showing the Repair/ Alteration
number, description of the item, date certified, and date submitted to the National
Board.
14.11.6 All records referenced in this Section are available for review by the
INSPECTOR.
15.0 Exhibits
Section 15
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Exhibit#
Title
Revision
Date
Bill of Material
12/11/02
2 & 2A
Traveler
12/11/02
Purchase Order
12/11/02
12/11/02
12/11/02
Nonconformance Report
12/11/02
12/11/02
Calibration Record
12/11/02
Repair Checklist
12/11/02
10
NCR Log
12/11/02
11
12/11/02
12
12/11/02
Section 15
Revision 0
Job Number___________
Page 2 of 14
Exhibit
1
BILL OF MATERIAL
ITEM #
DRAWING NUMBER
& REVISION
MATERIAL
SPECIFICATION
DESCRIPTION
REMARKS
Section 15
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Exhibit
2
TRAVELER
JOB NUMBER________________________________
SERIAL NUMBER_____________________________
MAWP___________________________________
MDMT___________________________________
HEATING SURFACE___________________________
NDE_____________________________________
CAPACITY____________________________________
PWHT____________________________________
CODE STAMP_________________________________
HYDRO/PNEUMATIC TEST_________________
DESCRIPTION
Initial Review of Job
Drawings/Specs.
Calculations
Material ID
MTR Review
Fabrication Insp.
PWHT Review
NDE Review
Pressure Test/
Final Inspection
Nonconformities
Code Stamping
Final Review
Data Report
Revision
Revision
Revision
REMARKS
QUALITY CONTROL
MANAGER
HOLD
POINT
AUTHORIZED
INSPECTOR
Remarks________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
Quality Control Manager Approval_______________________________________________
Authorized Inspector Acceptance_________________________________________________
Section 15
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Exhibit 2a
TRAVELER
Weld Joint Fit Up Sheet
Job Number:
Sheet ___of___
Comments:
Q.C.
A.I.
Joint
Identification
Weld Fit Up
Alignment
Root Welding
Back Gouging
Completed
Weld
NDE
Welder
Stamp
Procedure
Section 15
Revision 0
Page 6 of 14
Exhibit
4
PO #
SUPPLIER
MATERIAL MARKING
DIMENSIONS
ACC/REJ
Section 15
Revision 0
Page 7 of 14
Exhibit 5
MFR SN
DESCRIPTION
DATE SUBMITTED TO NB
Section 15
Revision 0
Page 8 of 14
Exhibit
6
NONCONFORMANCE REPORT
JOB #___________________________
NCR#___________________________
DATE___________________________
DESCRIPTION OF NONCONFORMANCE________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
FOUND BY_________________________________________________________________________________________
PROPOSED DISPOSITION_____________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
QC MANAGER __________________________________________________________
ENGINEERING MANAGER_______________________________________________
AI ACCEPTANCE________________________________________________________
ACTUAL DISPOSITION ______________________________________________________________________________
___________________________________________________________________________________________________
___________________________________________________________________________________________________
____________________________________________________________________________________________________
QC MANAGER APPROVAL _______________________________________________
AI ACCEPTANCE ________________________________________________________
REMEDIAL ACTION __________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
REMARKS __________________________________________________________________________________________
____________________________________________________________________________________________________
Section
15
Revision
0
Page 9 of 14
Exhibit
7
JAN - MAR
GMA
W
GTAW
SMAW
APR - JUN
GMA
W
GTAW
SMAW
JUL - SEPT
GMA
W
GTAW
SMAW
OCT - DEC
GMA
W
GTAW
SMAW
Section
15
Revision
0
Page 11 of 14
Exhibit
9
REPAIR CHECKLIST
JOB NUMBER________________________________
NDE_____________________________________
PWHT____________________________________
PRESSURE TEST__________________________
WPS_____________________________________
WELDER ID______________________________
DESCRIPTION
REMARKS
QUALITY CONTROL
MANAGER
HOLD
POINT
AUTHORIZED
INSPECTOR
Initial Review
Material ID
MTR Review
Fitup Inspection
Root Weld
Back Gouge
Completed Weld
NDE
PWHT
Pressure Test
Noncomformities
R Stamping
Final Review
NB Repair Form
Material Tabulation_______________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
Remarks________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
Quality Control Manager Approval_______________________________________________
Authorized Inspector Acceptance_________________________________________________
Section 15
Revision 0
Page 12 of 14
Exhibit 10
NCR LOG
NCR NUMBER
JOB NUMBER
DATE OPENED
DATE CLOSED
Section 15
Revision 0
Page 13 of 14
Exhibit 11
DESCRIPTION