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QUALITY CONTROL MANUAL

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

Drawings, Design and Specification Control

12/11/02

Material Control

12/11/02

Examination and Inspection

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

Calibration of Measuring and Test Equipment

12/11/02

12

Records Retention

12/11/02

13

Authorized Inspector

12/11/02

14

Repairs and Alterations

11-02-05

15

Exhibits

12/11/02

Quality Control Manager

Date

Authorized Inspector

Date

1.0 Statement of Policy and Authority

Section 1
Revision 0
Page 1 of 1
12/11/02

The Management of AAF INTERNATIONAL is committed to meeting the requirements of


the ASME Code, the National Board Inspection Code (NBIC), the Jurisdiction, and the Quality
Control System outlined in this manual for the fabrication and assembly of Power Boilers to
ASME Section I, of Power Piping to ASME B31.1, of Pressure vessels to ASME Section VIII
Div. 1, Div. 2, Div. 3 and Repairs and Alterations to the above items as well as Section IV
Boilers using the NBIC and jurisdictional requirements.
The Quality Control Manager (QCM) is responsible for the preparation, revision, approval, and
issuance of the Quality Control Manual and the administration and implementation of the
Quality Control System in the shop and field. He has the organizational freedom to identify and
correct Quality Control problems. The QCM shall be the liaison with the Authorized Inspector.
Department Head responsibilities are as outlined in the text of this manual.
Should a disagreement arise between Department Heads and/or Quality Control, the problem
shall be brought to me for resolution in accordance with the requirements of the Code and this
Quality Control Manual.

Date

Vice President and General Manager


Environmental Products Division

2.0 Manual Control

Section 2
Revision 0
Page 1 of 1
12/11/02

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

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

2.5

Uncontrolled manuals may be distributed to outside personnel with the understanding


that they will not be recalled for revision. These manuals shall be marked Uncontrolled
on the Facing Page.

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.

3.0 Organizational Chart

Section 3
Revision 0
Page 1 of 1
12/11/02

General Manager

Engineering Manager Quality Control Manager Purchasing Manager

Designer
(Section VIII, Div. 3)

Quality Control Inspector


(Shop & Field)

Project Manager

Shop/Field Foreman

Welders

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

4.0 Drawings, Design, and Specification Control

Section 4
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12/11/02

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:
-

Drawing number and revision


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

4.2.4 When drawings and calculations are provided by an outside concern, they 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.

4.0 Drawings, Design, and Specification Control

Section 4
Revision 0
Page 2 of 4
12/11/02

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.

4.0 Drawings, Design, and Specification Control

Section 4

Revision 0
Page 3 of 4
12/11/02
4.5

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


4.5.1
The user of a vessel built to Section VIII Division 2 shall provide Users Design
Specification that sets forth expected operating conditions, including all design
cases, pump curves, required vessel supports, site and site conditions, whether or
not a fatigue analysis is required, the amount of corrosion/erosion, and whether
lethal fluid or gas is to be contained. A Professional Engineer registered in one or
more states of the United States or provinces of Canada and experienced in
pressure vessel design must certify this design specification.
4.5.2 The Engineering Manager shall produce a Design Report consisting of calculations
and drawings establishing that the design, as shown on the drawings, complies
with the requirements of this division for the conditions set forth in the Users
Design Specification. The design report shall be certified by a Professional
Engineer registered in one or more states of the United States or provinces of
Canada and experienced in pressure vessel design, as complying with all the
requirements of this division.

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 VIII DIVISION 3 (IN ADDITION TO THE ABOVE REQUIREMENTS)

4.0 Drawings, Design, and Specification Control

Section 4

Revision 0
Page 4 of 4
12/11/02
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

4.6.1.2 The Design Report must include the following:


a. Final and as-built drawings, detail sheets and code calculations.
b. Results of fatigue analysis, according to article KD
c. Documents of consideration of the effects of heating or heat treatment
during manufacturing, and similarly, the maximum metal temperature
specified
d. Statement of any openings for which closures have not been installed
e. Limiting thermal gradients across the vessel section
4.6.1.3 The Designer of a pressure vessel to this division shall be an individual
engineer or group of engineers, experienced in high-pressure vessel
design who performs the required analysis of the vessel.
4.7

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.

5.0 Material Control

5.1

Section 5
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12/11/02

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

RECEIVING, STORAGE AND INSPECTION OF PURCHASED CODE MATERIAL


5.2.1 Receiving, storage and inspection of code material is performed per supplemental
procedure ASME 5.0, latest revision.
5.2.2 A coded marking system may be used to identify material. The coded marking if
used, shall be an alpha numeric identification placed on the material. This coded
marking is kept in a log maintained by the QCM that lists all the required markings
for the material that corresponds to the identification number. Each coded marking
number is exclusive to one type and lot of material.

5.0 Material Control

5.3

Section 5
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12/11/02

CUSTOMER SUPPLIED MATERIAL


5.3.1 Customer supplied material is received and inspected as described above except
that a customer PO is used at receiving inspection.
5.3.2 Unacceptable material is handled as described in Section 7 of this manual.

5.4

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

5.6

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


5.6.1 All material shall be certified by the material manufacturer as in compliance with
the material specification listed on the purchase order.
5.6.2 All steel castings shall be fully radiographed. Magnetic castings shall also be
examined by the magnetic particle method on all surfaces.
5.6.3 Only materials approved by this division may be used in construction. Use of
unidentified material by test is not acceptable for this division.

5.7

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


5.7.1 All material shall be certified by the manufacturer as in compliance with the
material specification listed on the Purchase Order, all special requirements of Part
KM of Section VIII Division 3, and all supplementary requirements specified by
the Users Design Specification.
5.7.2 All material shall be tested for notch toughness except for nuts, washers, and
material which do not contribute to the integrity of the pressure boundary.
Representative samples shall be used for mechanical tests for tension and charpy
V-notch tests on applicable materials used for construction to this division.
5.7.3 All pressure retaining materials shall be ultrasonically tested as required by this
division.

5.0 Material Control

Section 5
Revision 0
Page 3 of 3
12/11/02

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.

6.0 Examination and Inspection

6.1

Section 6
Revision 1
Page 1 of 3
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.

6.0 Examination and Inspection

Section 6
Revision 1
Page 2 of 3
11/02/05

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

STAMPING AND DATA REPORTS


6.4.1 The QCM shall maintain custody and control of all Code stamps except that for
field work the stamp may be delivered to the QCI so he may stamp the item. Upon
completion of the stamping, the stamp is immediately delivered back to the QCMs
custody.
6.4.2 For Section I jobs, stamping shall be directly on the object at the location
prescribed in the appropriate Code paragraph. The AI shall witness the application
of the Code symbol stamp. If Power Piping has an operating temperature greater
than 800*F, a Data Plate may be used in lieu of direct stamping. Piping with a
diameter less than 2 shall be marked in a manner acceptable to the AI so that it
may be adequately traced to the Manufacturers Data Report.
6.4.3 For Section VIII Div. 1 items, a Data Plate may be used. The object may be
stamped and/or the Data Plate attached before the final inspection provided prior
acceptance of the AI is received.
6.4.4 The appropriate Data Report shall be certified by the QCM and submitted to the AI
for acceptance at the final inspection.

6.0 Examination and Inspection

Section 6
Revision 1
Page 3 of 3
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

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


6.5.1 Hydrostatic testing shall not be less than 1.25 times design pressure, unless
calculated pressure is agreed upon with the user. Examination shall be performed
at reduced pressure following the pressure test, and shall be witnessed by the AI.
6.5.2 Impression stamping on vessel shells is prohibited.

6.6

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


6.6.1 The special testing requirements of Articles KT-1, KT-2, and KT-3 shall be
considered for items constructed to this division.
6.6.2 Stampings and markings shall be as per the requirements of Article KS-1.

7.0 Correction of Nonconformities

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

7.0 Correction of Nonconformities

Section 7

Revision 0
Page 2 of 2
12/11/02

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

8.0 Welding Control

8.1

Section 8
Revision 0
Page 1 of 3
12/11/02

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

WELDERS AND WELDING OPERATORS


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

8.0 Welding Control

Section 8
Revision 0
Page 2 of 3
12/11/02

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


8.3.3 Welders and Welding Operators shall require requalification if any of the
following occurs:
8.3.3.1 A change in a Performance Essential Variable.
8.3.3.2 When he has not used a process for a period of six months.
8.3.3.3 When there is reason to question his ability to make sound welds.
8.3.4 Each qualified Welder and Welding Operator shall be listed on the Welder
Continuity Log (Exhibit 7) maintained by the Shop/Field Foreman. The Welder
Continuity Log is updated quarterly as a minimum to show the last date a Welder
or Welding Operator welded in a specific process. The Shop/Field Foreman is
responsible for notifying Welders and Welding Operators when their qualifications
are close to expiration. The Shop/Field Foreman uses the Welder Continuity Log to
assure that only qualified Welders and Welding Operators are assigned to a Code
job.
8.4

WELDING MATERIAL
8.4.1 All welding material is purchased and received as described in Section 5.
8.4.2 All welding materials are stored in a dry storage area and issued to the welder 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.

8.0 Welding Control

8.5

Section 8
Revision 0
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12/11/02

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

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


8.6.1 Subcontracted welders shall be in the employ of a manufacturer that possesses a
valid U, U2, or U3 Certificate of Authorization issued by the ASME.
8.6.2 No welding shall be performed on metal surfaces when the metal temperature is
below 60oF.
8.6.3 Finished welds shall be ground or machined to blend with the surface of the parts
being joined.

9.0 Nondestructive Examination

9.1

Section 9
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12/11/02

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.

9.0 Nondestructive Examination

9.5

Section 9
Revision 0
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12/11/02

LIQUID PENETRANT EXAMINATION


9.5.1 For other than Section VIII Division 3 vessels, Liquid Penetrant Examination (PT)
may be performed by AAF INTERNATIONAL personnel who are qualified and
certified in accordance with the requirements of ASME Section VIII Div.1
Appendix 8. PT shall be conducted using a procedure written by the QCM and
accepted by the AI. All PT personnel qualifications shall be made available to the
AI for review and acceptance.
9.5.2 Liquid penetrant inspection will be performed in accordance with
supplemental procedure ASME 6. 2 latest rev. Acceptance standards will be per the
applicable code.

9.6

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


9.6.1 Except as exempted in paragraph AF-571, all vessel shall be 100% radiographed.
9.6.2 Offset (joggle) joints are prohibited.

9.7

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


9.7.1 All methods of NDE (i.e., RT, UT, MT, PT, and EC) shall be performed using
written procedures in accordance with Section V of the ASME Code.
9.7.2 Visual NDE examiners physical examination shall be to Jaeger 1 or equivalent.
9.7.3 Qualifications and certifications of NDE personnel employed by subcontracted
material manufacturers, material suppliers, and material organizations shall be
verified as meeting the requirements of this division.

10.0 Heat Treatment

Section 10
Revision 0
Page 1 of 1
12/11/02

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.

11.0 Calibration of Measuring and Test Equipment

Section 11
Revision 0
Page 1 of 1
12/11/02

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.

12.0 Records Retention

Section 12
Revision 0
Page 1 of 1
12/11/02

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.

13.0 Authorized Inspector

Section 13
Revision 0
Page 1 of 1
12/11/02

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.

14.0 Repairs and Alterations

Section 14
Revision 1
Page 1 of 6
11-02-05

14.1 SCOPE OF WORK


14.1.1 Shop and field repairs or alterations to Boilers, Pressure Vessels and Boiler
External Piping are made in accordance with the applicable requirements of the
NBIC, Jurisdictional requirements, and this Manual.
14.1.2 Where any provision herein presents a direct or implied conflict with any
jurisdictional regulation, the jurisdictional regulation shall govern.
14.2 DRAWINGS, DESIGN, & SPECIFICATIONS
14.2.1 Drawings (as appropriate), design calculations (for alterations) and specifications
shall be prepared, reviewed and approved in accordance with Section 4 of this
manual to describe the repair or alteration in sufficient detail prior to performing
the activity. The drawing may be a sketch, which is documented on the Repair
Checklist (Exhibit 9), prepared by the QCM.
14.2.2 The above design documents shall be interpreted by the QCM to provide the basis
for an alteration in accordance with the original Code of construction. When the
Manufacturer's Data Report is required by the original construction standard, a
copy of the original Data Report shall be obtained for use in the design of the
alteration.
14.2.3 For alterations, including re-rating, to pressure vessels the QCM will provide the
INSPECTOR with drawings, calculations, design specifications, design reports,
and any other documentation required to adequately perform the work per Section
4 of this manual. All design calculations shall be completed by the Engineering
Manager and shall meet the requirements of the original Code of construction.
14.2.4 The QCM shall, prior to the start of work, provide the INSPECTOR with
drawings, calculations, procedures, checklists, and any other documents,
including a copy of the original Manufacturer's Data Report, (if available)
necessary for the INSPECTOR to accept the repair or alteration and designate his
Hold Points.

14.0 Repairs and Alterations

Section 14
Revision 1
Page 2 of 6
11-02-05

14.3 REPAIR AND ALTERATION METHODS


14.3.1The repair and alteration methods shall be performed in accordance with the
requirements of this manual.
14.3.2QCM and AAF Engineering Manager must approve alterations and repairs
proposed by the vendor.
14.3.3The user of a Section VIII, Division 2 item shall prepare a Repair Plan that is
reviewed and certified by a Professional Engineer per RC-2082. Work involved
in a repair to these items shall be compatible with the Users Design Specification
and the Manufacturers Design Report. The Repair Plan shall then be submitted to
the AIA whose inspector will sign the R-1. Alterations to Section VIII, Division 2
or Division 3 items shall be in accordance with NBIC Para RC-3025.
14.4 MATERIALS
14.4.1Materials shall be controlled as described in Section 5 of this manual. The QCM
shall verify the identification of existing materials from the original construction
documentation or by additional testing of the materials.
14.5 METHOD OF PERFORMING WORK
14.5.1The method of performing repairs and alterations shall be handled as described
throughout this manual. The INSPECTOR shall perform the duties and have all the
opportunities described throughout this manual for the Authorized Inspector, to
assure compliance to the NBIC. The method of repair or alteration shall have prior
acceptance of the QCM and the INSPECTOR.
14.5.2The QCM shall arrange access to the Code item for the INSPECTOR so he may
make any inspections he deems necessary to accept the repair or alteration. The
QCM keeps the INSPECTOR informed of the progress of work so that he will be
available to see his Hold Points.

14.0 Repairs and Alterations

Section 14
Revision 1
Page 3 of 6
11-02-05

14.6 WELDING, NDE, AND HEAT TREATMENT


14.6.1WELDING
14.6.1.1 The QCM shall be responsible to assure that the welding, welders and
welding operators are performed and qualified in accordance with the
original construction Code used. The Standard Welding Procedures
Specifications referenced in the applicable Edition and Addenda of the
NBIC may be used. With the exception of the Standard Welding
Procedures, all procedure qualifications and welders/welding operator's
qualification records shall be certified by the QCM and available for
review by the INSPECTOR. It is also the QCM's responsibility to assure
that the welders and welding operators maintain their qualifications per
Section 8 of this Manual.
14.6.2HEAT TREATMENT
14.6.2.1 Preheat shall be performed as stipulated per the qualified Welding
Procedure Specification.
14.6.2.2 Postweld heat treatment shall be performed as required by the original
construction code and per Section 10 of this manual.
14.6.2.3 Alternatives to postweld heat treatment may be used if PWHT is
inadvisable or impractical, and it is acceptable to the INSPECTOR.
Examples of these alternative methods of postweld heat treatment or
special welding methods are described in the applicable Edition of the
NBIC.
14.6.3NONDESTRUCTIVE EXAMINATION (NDE)
14.6.3.1 Weld repairs and alterations shall be subjected to the same NDE
requirements as with the original construction code of the pressure
retaining item. Where this is not possible or practical, alternative NDE
methods acceptable to the INSPECTOR and the jurisdiction (where
required) may be used.

14.0 Repairs and Alterations

Section 14
Revision 1
Page 4 of 6
11-02-05

14.6.3.2 The NDE personnel shall be qualified in accordance with the


requirements of the original Code of construction. When this is not
possible or impractical, NDE personnel may be qualified in accordance
with SNT-TC-1A (latest accepted Edition).
14.7 REPLACEMENT PARTS
14.7.1At this time AAF INTERNATIONAL does not intend to fabricate and supply
Parts as defined in the NBIC.
14.8 PRESSURE TESTS
14.8.1The pressure tests shall be applied by the Shop/ Field Foreman as specified on the
Repair Checklist and witnessed by the QCI and the INSPECTOR. The QCM shall
be responsible for all activities relating to pressure testing of repairs or alterations.
14.8.2 Repairs shall be pressure tested at 80% of the maximum allowable working
pressure (MAWP) stamped on the PRI or operating pressure, whichever is greater,
using water or other liquid medium. Alterations shall be pressure tested as required
by the original Code of construction.
14.8.3 The pressure test shall be held for a minimum of 10 minutes prior to examination
by the QCI and INSPECTOR.
14.8.4 When contamination of the pressure vessel contents by liquids is possible or when
pressure testing is not practical, other methods shall be used as follows:
a)

Pressure test may be a pneumatic test provided the QCI obtains the concurrence 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.

14.0 Repairs and Alterations

Section 14
Revision 1
Page 5 of 6
11-02-05

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.

14.0 Repairs and Alterations

Section 14
Revision 1
Page 6 of 6
11-02-05
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.

14.12 NATIONAL BOARD COMMISSIONED INSPECTOR (INSPECTOR)


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

A Jurisdictional AIA. b)The AIA on contract/agreement by this


organization, to perform repair or alteration inspection per the NBIC. c)
The Authorized Inspection Agency which insures the pressure retaining
item.

14.13 ROUTINE REPAIRS


14.13.1 Prior to performing routine repairs this organization shall determine whether
Routine Repairs are acceptable to the jurisdiction where the work is to be
performed. The jurisdiction may mandate specific additional requirements not
directly specified in the NBIC. For Routine Repairs, in-process inspection and
stamping may be waved at the discretion of the INSPECTOR. Routine Repair
shall be documented in the Remarks section of the R-1.

15.0 Exhibits

Section 15
Revision 0
Page 1 of 14

Exhibit#

Title

Revision

Date

Bill of Material

12/11/02

2 & 2A

Traveler

12/11/02

Purchase Order

12/11/02

Receiving Inspection Report

12/11/02

National Board Number Log

12/11/02

Nonconformance Report

12/11/02

Welder Continuity Log

12/11/02

Calibration Record

12/11/02

Repair Checklist

12/11/02

10

NCR Log

12/11/02

11

Job Number Log

12/11/02

12

Master Cal Log

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
Revision 0
Page 3 of 14
Exhibit
2

TRAVELER
JOB NUMBER________________________________

SHEET _______________ OF ________________

SERIAL NUMBER_____________________________

MAWP___________________________________

NATIONAL BOARD NUMBER___________________

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

(See Weld Joint Fit-up Sheet)

Remarks________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
_______________________________________________________________________________________________________
Quality Control Manager Approval_______________________________________________
Authorized Inspector Acceptance_________________________________________________

Section 15
Revision 0
Page 4 of 14
Exhibit 2a

TRAVELER
Weld Joint Fit Up Sheet
Job Number:

Sheet ___of___

Comments:

Q.C.
A.I.
Joint
Identification

(H Denotes Hold Point)


Material
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

JOB NO. _____________

RECEIVING INSPECTION REPORT


BOM
ITEM #

PO #

SUPPLIER

MATERIAL MARKING

DIMENSIONS

INSPECTOR & DATE

ACC/REJ

Section 15
Revision 0
Page 7 of 14
Exhibit 5

NATIONAL BOARD NUMBER LOG


NB#

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

WELDER CONTINUITY LOG


YEAR ____________
NAME
ID#

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_____________________________________

NATIONAL BOARD NUMBER___________________

PWHT____________________________________

MANUFACTURERS SERIAL NUMBER___________

PRESSURE TEST__________________________
WPS_____________________________________
WELDER ID______________________________

SKETCH OR DESCRIPTION OF REPAIR ON BACK

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

JOB NUMBER LOG


JOB NUMBER

CUSTOMER & PO NUMBER

DESCRIPTION

DATE JOB NO.


ASSIGNED