Quality Control Manual

ALLIED VESSEL FABRICATION
QUALITY CONTROL MANUAL
EDITION 1 REV 1
Revision Date Dec 01, 2014
PAGE 1 of 2
SECTION 2: TABLE OF CONTENTS
SECTION 1: TITLE PAGE

EXHIBIT 1.1: CERTIFICATE OF AUTHORIZATION
SECTION 3: SCOPE
SECTION 4: STATEMENT OF AUTHORITY
SECTION 5: ORGANIZATION CHART
SECTION 6: DEFINITIONS
SECTION 7: TENDER & CONTRACT
SECTION 8: MANUAL CONTROL
EXHIBIT 8.1 DOCUMENT TRANSMITTAL
SECTION 9: DRAWINGS & DESIGN
EXHIBIT 9.1 DRAWING INDEX
EXHIBIT 9.2 Calculation Index
SECTION 10: MATERIAL CONTROL
EXHIBIT 10.1 Purchase Order
EXHIBIT 10.2 Purchase Requirements
EXHIBIT 10.3 Color Code
SECTION 11: EXAMINATION AND INSPECTION
EXHIBIT 11.1 Travel Sheet
EXHIBIT 11.2 Nameplate
SECTION 12: WELDING
EXHIBIT 12.1 WPS Index
EXHIBIT 12.2 WELDERS LOG
EXHIBIT 12.3 CONTINUITY LOG
SECTION 13: NONCONFORMITIES
EXHIBIT 13.1 Nonconformity Report
EXHIBIT 13.2 HOLD TAG
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EDITION 1 REV 1
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PAGE 2 of 2
SECTION 14: NONDESTRUCTIVE EXAMINATION

EXHIBIT 14.1 Certifying Statement
SECTION 15: HEAT TREATMENT
EXHIBIT 15.1 HEAT TREATMENT
INSTRUCTIONS
SECTION 16: MEASURING & TESTING EQUIPMENT
EXHIBIT 16.1 EQUIPMENT CALIBRATION
LOG
SECTION 17: PRESSURE TESTS
Exhibit 17.1 Pneumatic Test Procedure
Exhibit 17.2 Hydrostatic Test Report
SECTION 18: REPAIRS AND ALTERATIONS
Exhibit 18.1 Repair / Alteration Inspection Checklist
SECTION 19: RECORD RETENTION
PAGEOF
SECTION
REVISION
DATE
(mm/dd/yy
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SECTION 20: AUTHORIZED INSPECTORS
1
13
14
15
16
17
SECTION 21 - PRESSURE PIPING

EXHIBIT 21.1 PRESSURE PIPING SPECIFICATION SHEET
EXHIBIT 21.2 PRESSURE PIPING EXAMINATION CHECK LIST
EXHIBIT 21.3 PRESSURE PIPING EXAMINATION GUIDE
EXHIBIT 21.4 PRESSURE TEST EXAMINATION GUIDE
EXHIBIT 21.5 PIPETHREAD DIMENSIONAL REQUIREMENTS
1
5
6
SECTION 22: MINIATURE VESSELS AND FITTINGS

Exhibit 22.1 Pressure Volume Limits
Exhibit 22.2 Certified Individual Requirements
1
3
4
SECTION 23: INDIRECT FIRED HEATER COILS

Exhibit 23.1: Heater Coil Travel Sheet
Exhibit 23.2: Heater Coil Nameplate
SECTION 24: STANDARD PNEUMATIC TEST PROCEDURE
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____________________________
___
Authorized Inspector Acceptance

____________________________
Date
_____________________________
03/18/2013
QCM
Approval__________________

EDITION 1 REV 1
PAGE 1 of 2
SECTION 1. TITLE PAGE

FOR THE FOLLOWING CONSTRUCTION ACTIVITIES
IN ACCORDANCE WITH THE ALBERTA SAFETY CODES ACT AND
REFERENCED STANDARDS:
SECTION VIII DIVISION 1; PRESSURE VESSELS
MINIATURE VESSELS AND PRESSURE FITTINGS IN ACCORDANCE WITH CSA B51
BY
AT
5302 42 ST. STETTLER AB T0C 2L0
AND
CONSTRUCTION, REPAIR AND ALTERATIONSOF PRESSURE PIPING
IN ACCORDANCE WITH ASME B31.3 AND B31.1
INDIRECT FIRED HEATER COILS
REPAIR AND ALTERATION OF EXISTING PRESSURE VESSELS
AT
5302 42 ST.
STETTLER AB. T0C 2L0
AND FIELD SITES
CONTROLLED FROM THIS LOCATION
MANUAL NO________________
EDITION___________________
ASSIGNED TO_______________________

EDITION 1 REV 1
PAGE 2 of 2
SECTION 1 ALBERTA CERTIFICATION AQP

EXHIBIT 1.1 ALBERTA QUALITY CONTROL PROGRAM CERTIFICATE OF AUTHORIZATION

EDITION 1 REV 1
PAGE 1 of 1
SECTION 3 SCOPE OF WORK
1.
1
This Quality Control Manual outlines the procedures that will be used by Allied Vessel Fabrication
in constructing ASME Code items in accordance with ASME Code Section VIII Division 1 and
Alberta Safety Codes Act and Regulations at: 5302 42 ST. Stettler AB.
2.
Repair and alterations to pressure vessels shall be performed in accordance with the procedures
outlined in this Quality Control Manual, the requirements of Alberta Safety Codes Act and
Regulations at both shop and field locations being controlled from the shop.
3.
Construction, repair and alteration of pressure piping systems shall meet the requirements of Alberta
Safety Codes Act and Regulations, ASME B31.3, B31.1 Codes, as applicable, and customer
requirements at both shop and field locations being controlled from the shop. Construction, repair
and alteration of Indirect Fired Heater Coils designed to ASME B31.3 Code is included in this
Quality Control System at shop and field locations
4.
Miniature pressure vessel construction and the manufacture of category A, E and H pressure
fittings under this Quality Control System shall be in accordance with the requirements of the
Alberta Safety Codes Act and Regulations and the CSA B51 Boiler, Pressure Vessel and Pressure
Piping Code at 5302 42 ST. Stettler Alberta.
5.
Preparation of design calculations, drawings and specifications will be subcontracted to a qualified

engineering and design organization.
6.
All nondestructive examination, heat treatment, calibration of measuring and testing equipment will
be subcontracted to an approved vendor.

EDITION 1 REV 1
PAGE 1 of 1
SECTION 4 STATEMENT OF AUTHORITY
This Quality Control Manual has been established to assure compliance with the ASME Code Section VIII
Division 1, B31.3, B31.1, CSA B51 and the Alberta Safety Codes Act and Regulations.
This Quality Control Manual shall be used by Allied Vessel Fabrication in the construction, repair and/ or
alteration of pressure vessels in accordance with the ASME Boiler and Pressure Vessel Code Section VIII
Division 1. and Alberta Safety Codes Act and Regulations. Construction, repair, and/ or alteration of
pressure piping systems in accordance with ASME B31.3 or B31.1 Code as applicable, and Alberta Safety
Codes Act and Regulations. Miniature pressure vessels and category A, E and H pressure fittings are
constructed in accordance with the Alberta Safety Codes Act, Regulations, and CSA B51 Code.
The QCM is hereby assigned the authority to administer and implement the program described in this
Quality Control Manual. The QCM has sufficient, well-defined responsibility, authority and the
organizational freedom to identify quality control problems, to initiate, recommend or provide solutions to
quality control problems and to ensure implementation of solutions. The QCM shall control the disposition
of non-conforming items and issues until the non-conformance has been removed, assuring Code
compliance.
A Certified Individual (CI) has been qualified and certified, and is responsible for the Alberta Safety Codes
Act compliance of Miniature Pressure Vessels.
The quality control problems that cannot be resolved by the QCM shall be brought to my attention for
resolution without compromise any applicable codes, standards, Regulatory Authority, customer
requirements or this Quality Control Manual.
The quality control system has the full support and endorsement of management, who will ensure that
adequate resources, including qualified personnel, are provided to effectively implement the system.
Any person assigned a responsibility within this Quality Control Manual may delegate the performance of
the activity to another qualified person. However the responsibility remains with the individual assigned.
Signature_____________________________
Name _______________________________
Title ________________________________
Date_________________________________

EDITION 1 REV 0
SECTION 5 ORGANIZATION CHART
PAGE 1 of 1
Certified
Individual
QS
SUBCONTRACTOR QCI
ENGINEERING
SHOP/FIELD
(Designer)
SHOP / FIELD
PERSONNEL
SUBCONTRACTORS:
HEAT TREATMENT
NDE MATERIAL TESTING,
ETC.
SHIPPER
RECEIVE

EDITION 1 REV 1
PAGE 1 of 4
SECTION 6 DEFINITIONS
6.
DEFINITIONS
6.1
Alberta Safety Code Act and Regulations:

a) Alberta Safety Codes Act
b) Pressure Equipment Safety Regulation
c) Pressure Welders Regulation
d) Pressure Equipment Exemption Order
e) Administrative Items Regulation.
6.2
ABSA: ABSA is a regulatory organization delegated by the Province of Alberta to provide pressure
equipment safety services under the Alberta Safety Codes Act, and act as the Sole Jurisdiction
/Regulatory Authority as defined in the CSA B51 Code and as accredited by ASME.
6.3
Alteration: Any change in the item described on the original Manufacturers Data Report. Any
change which affects the pressure containing capacity of a boiler, pressure vessel, piping or fitting.
Non-physical changes such as increase in the maximum allowable working pressure (internal or
external) or design temperature of a pressure item shall be considered an alteration. A reduction in
the minimum design metal temperature of a pressure item shall be considered an alteration.
6.4
AQP: Means Alberta Quality Program number issued by ABSA. A company holding a valid AQP
number from ABSA is qualified to undertake activities that are authorized by the Certificate of
Authorization Permit.
6.5
Code: American Society of Mechanical Engineers (ASME), latest mandatory Edition and Addenda
(at time contract acceptance) of the ASME Boiler and Pressure Vessel Code:
a) Section VIII Division 1 Rules for Construction of Pressure Vessels
b) B31.1, Power Piping
c) B31.3, Process Piping
d) Sections referenced by the construction Section
6.6
Authorized Inspector (AI):

An inspector, regularly employed by the ASME Accredited Authorized Inspection Agency, who is
qualified by written examination in accordance with the ASME QAI-1 Standard. The AI Inspector
shall hold a valid National Board Commission and Endorsement and is also a Safety Codes Officer
appointed to administer the Alberta Safety Codes Act.
6.7
CGSB: Canadian General Standards Board

EDITION 1 REV 1
PAGE 2 of 4
6.8
CRN: Canadian Registration Number; registration number allotted by the regulatory authority to
designs and specifications when accepted and registered.
6.9
CSA B51: Canadian Standard Association, Boiler, Pressure Vessel and Pressure Piping Code.
6.10
Certified Individual (CI): An employee of Allied Vessel Fabrication that is qualified and certified
by Allied Vessel Fabrication in accordance with the Alberta requirements, that coincide with ASME
requirements, to perform the duties of a CI as specified by the ASME Code. The CI is responsible
for Safety Codes Act compliance when the AI is not involved.
6.11 Examination means quality control functions performed by the manufacturer, fabricator, or erector.
6.12
Expansible Fluid:
Expansible Fluid means
a) a vapor or gaseous fluid or
b) a liquid under pressure and at a temperature at which the liquid changes to a gas or
vapor when the pressure is reduced to atmospheric pressure or when the temperature
is increased to ambient temperature.
6.13
Fitting or Pressure Fitting: Fitting means a valve, gauge, regulating or controlling device, flange,
pipe fitting or any other appurtenance that is attached to, or forms part of, a boiler. pressure vessel,
indirect fired heater pressure coil, thermal liquid heating system or pressure piping system.
6.14
Inspection: means functions performed by the Owners Inspector, or the AI.
6.15
Job File: A file which contains all records documenting quality control for the item constructed.
This file shall be assigned a unique number to identify the job.
6.16
NDE: means Nondestructive Examination conducted in accordance with the requirements

of the ASME Section V Code.
6.17
Non-conformance: Any condition which renders an item unacceptable or indeterminate for use
because it does not comply with Code, owners specifications, design specifications or the
requirements of this Quality Control Manual. Examples of non-conformance include physical
defects, test failures, improper documentation, and loss of material identification.
6.18
Owners Inspector (OI) - An Inspector designated by the owner to certify that all required
examinations and testing have been completed. For the inspections of piping systems, OI shall
satisfy them self that the piping system conforms to all Code and customer requirements.

EDITION 1 REV 0
Revision Date March 18, 2013
PAGE 3 of 4
6.19
PQ Performance Qualification: The demonstration of a welder or welding operator skill and

ability to produce welds in accordance with WPS.(see 4.31)
6.20
PQR: Procedure Qualification Record: The document that records the test results that establish
the properties of a weldment.
6.21
Pressure Equipment: means a thermal liquid heating system and any containment for an expansible
fluid under pressure, including but not limited to, fittings, boilers, pressure vessels and pressure
piping systems, as defined in the regulations.
6.22
PESR: means Pressure Equipment Safety Regulation.
6.23
Pressure Piping System: (Under the Jurisdiction of the Safety Codes Act) Pressure piping systems
means pipes, tubes, conduits, fittings, gaskets, bolting and other components that make up a system
for the conveyance of an expansible fluid under pressure and may also control the flow of that fluid.
The Pressure Equipment Safety Regulation does not apply to a pressure piping system that is fully
vented or operating with one or more pressure relief devices with a set pressure not exceeding 15 psi
(103 kPa) and sized so that the operating pressure cannot exceed 15 psi (103 kPa). The Safety Codes
Act and Pressure Equipment Safety Regulation (PESR) do not apply to pressure piping under the
jurisdiction of the Alberta Oil & Gas Conservation Act and Regulations or the Alberta Pipeline Act
and Regulation (see ERCB Directive 077). There is also a partial exemption from some requirements
of the PESR for pressure piping meeting the requirements of PESR paragraph 4(2).
6.24
Pressure Vessel: Means a vessel used for containing, storing, distributing, processing or otherwise
handling an expansible fluid under pressure.
6.25
QC: Quality Control (part of QMS focused on fulfilling quality requirements).
6.26
QMS: Quality Management System for the purpose of directing and controlling an organization
in regards to quality
6.27
QCM: Quality Control Manager

An employee of Allied Vessel Fabrication designated by the President or General Manager to have
the responsibility and authority to maintain this Quality Control System, and the organizational
freedom to recognize quality control problems and provide solutions to those problems.
6.28
Quality Control Inspector; (QCI): An employee of Allied Vessel Fabrication Ltd. designated by
the QCM to perform the quality control duties as defined in this Quality Control Manual. The QC
Inspector reports directly to the QCM on any quality related function.

EDITION 1 REV 0
PAGE 4 of 4
6.29
Registered Design: Drawings, specifications and information required by the Pressure

Equipment Safety Regulation that have been reviewed and registered by ABSA.
6.30 Repair - The work necessary to restore a pressure item (e.g. boiler, pressure vessel, and piping) to a
safe and satisfactory operating condition, providing there is no deviation from the original design.
6.31 SNT-TC-1A Recommended Practice No. SNT-TC-1A. Personnel Qualification and Certification in
Non-destructive Testing. The American Society for Non-destructive Testing, Inc. Latest ASME
Code of construction accepted Edition.
6.32
Welding Procedure Specification (WPS): The document that describes in detail all of the
variables which are essential, supplementary essential, and non-essential to the welding process as
specified by the ASME Code to provide direction to the Welder or Welding Operator for making
production welds in accordance with Code requirements. The WPS shall also reference the
supporting Procedure Qualification Records. The WPS may be revised if there is a change in a nonessential variable. Any change to an essential or supplementary essential variable requires requalification of the WPS (i.e., new or additional PQRs to support the change in essential or
supplementary essential variables).

EDITION 1 REV 0
PAGE 1 of 1
SECTION 7 TENDER & CONTRACT
7.
TENDER AND CONTRACT
7.1
This section describes the method of carrying out a tender and contract review, in order to ensure
that contractual requirements can be met before contract is accepted.
7.2
Upon the receipt of a tender, the General Manager shall define the scope of the project, the time and
tender submissions and the requirements for preparation and review in consultation with the
president and QCM.
7.3
Before accepting the contract, the General Manager shall review the contract to ensure its
conformance with the tender. All discrepancies and deficiencies between the tender and the contract
shall be resolved and accepted by the customer and Allied Vessel Fabrication.
7.4
The contract shall be then presented to the General Manager of Allied Vessel Fabrication. for final
approval.

EDITION 1 REV 0
PAGE 1 of 2
SECTION 8 MANUAL CONTROL
8.
MANUAL CONTROL
8.1
This section describes the system for preparing, revising and controlling the distribution of this
Quality Control Manual.
8.2
The QCM is responsible for the control and implementation of this system. These duties include:
a) Reviewing the Quality Control Manual every 12 months coincident with the issue of any Code
Edition or Errata and to revise the Quality Control Manual and/or Quality Control System as
necessary to incorporate any required changes within six months of the issue date of the new
Edition or published Errata. The review of Code Edition or Errata shall be documented by
initials and date of the person performing the review on the summary of changes page for each
Code section.
b) The QCMs approval and AI acceptance shall be by signature and date on the Table of Contents.
c)
Approving all proposed changes and ensure that all revisions have been presented to and
accepted by the AI prior to implementation.
d)
Maintaining a list of controlled Quality Control Manual holders showing assigned Quality
Control Manual number and revision status and to distribute revisions to each Quality Control
Manual holder using the Document Transmittal (Exhibit 8.1).
e) The Quality Control Manual shall be revised by section including the Exhibits and the Table of
Contents.
f) The Quality Control Manual Edition shall be updated coincident with each Audit/Review
8.3
The edition number, revision number and revision date will be shown on each page of the Quality
Control Manual along with number of pages within each section, and any revisions will also be
indicated by a delta symbol with the revision number in each margin along the changed paragraph
and the new wording will appear in italic print.
8.4
Uncontrolled Quality Control Manuals may be used for information only and shall not be used by
Allied Vessel Fabrication personnel. Uncontrolled Copy shall be permanently indicated on the
front page of these Quality Control Manuals.
8.5
ABSA AB forms used shall be identified through the Quality Control Manual but will not be shown
as Exhibits. Only the latest ABSA forms will be used.
APPLICABLE DOCUMENTS/FORMS
Document Transmittal, Exhibit 8.1

EDITION 1 REV 0
PAGE 2 of 2
EXHIBIT 8.1 DOCUMENT TRANSMITTAL

ALLIED VESSEL
FABRICATION
DOCUMENT TRANSMITTAL
To:
DATE:
The following copies of controlled documents are forwarded to you for your use. Please
sign and
return this transmittal sheet within 7 days to: jeff@alliedfab.com or fax
to 888 526 - 0274
I acknowledge receipt of the documents noted below (voiding or
destroying superseded documents as applicable)
Print Receivers Name: _______________________________________
Receivers Signature :_________________________________________
Document Number
Document Title
Date ___________________
Revision #

EDITION 1 REV 0
PAGE 1 of 5
SECTION 9 DRAWINGS & DESIGN

CALCULATION
9. DRAWINGS & DESIGN CALCULATION

9.1
This section provides the system for review, approval, distribution and retrieval of drawings, design
calculations, specifications and instructions.
9.2
The QCM is responsible for ensuring the following functions are performed by the subcontract
Designer acting on behalf of Allied Vessel Fabrication or when the design is supplied by the
customer, that the functions are completed by the customer:
a) Review the customer specifications to ensure that the vessel can be designed and constructed in
accordance with the ASME Code, additionally the Designer shall determine the system of units to
be used consistently throughout construction of the Code items. (IE: metric or US Customary)
b)
Verifying drawings to ensure that the following are included as applicable to the Code
of construction;
drawing title
drawing number, revision number with details of revisions
date and job number and/or serial number
detailed drawings showing dimensions and orientations with tolerances where applicable
bill of material with material specification and grade, in consistent units of measurement
material thickness, nozzle details and corrosion allowance
Maximum Allowable Working Pressure (MAWP) at coincident Max. Design Temp. Max.
Allowable External Working Pressure (if a design condition) and Minimum Design Metal
Temp. (MDMT) at MAWP.
Code Edition year
NDE and heat treatment requirements
Weld details and welding procedure specifications
Volume and/ or heating surface area as applicable
Hydrostatic test pressure
CRN
Impact test requirements or exemptions from Impact Testing
Notes identifying additional requirements.
c) Submission of the drawings, specifications, and calculations, in duplicate, to ABSA or

applicable jurisdiction for acceptance and registration. The design Registration application AB31 will accompany the drawings and calculations to ABSA.

EDITION 1 REV 0
PAGE 2 of 5
SECTION 9 DRAWINGS & DESIGNS

CALCULATION
9.3
The design specifications and drawings are subcontracted to a Designer:

a) Prepares design calculations and drawings in accordance with the ASME Code.
b) Coincident with the issue of a New Code Edition and Errata, the Designer reviews the master
document to ensure compliance with any changes to the Code. The program is run using
standard test data from Appendix L Example L-7-2 and visually compare the results in the
formulas to the numbers in the Code example to verify the program is operating correctly. At
this point the program is password protected again.
c) Review of computer programs annually to coincide with Code revisions and to alter the program
to meet Code requirements or if the computer program has any updates or changes.
d) Installation of a safeguard system to prevent tampering with the programs.
e) Prior to reissuing drawings for previously designed vessels or issuing new drawings based upon
the existing design drawing, the Designer will review and revise as necessary, the design
drawings and design calculations to ensure compliance with the latest mandatory Code Edition
and Errata. The Designer sends verification that all designs comply with the latest Code Edition
and Errata.
9.4
A description of revisions to drawings will be recorded in the revision block and all revision
items will be identified with a triangle (delta symbol), containing the revision number, adjacent to
the revised item.
Revised items will be distributed and issued in the same manner as the original issue.
9.5
If the design specifications and drawings are provided by the owner, or are subcontracted to a
designer, the QCM is responsible for:
a) Reviewing and approving by signature and date the drawings and calculations.
b) Ensuring that the drawings representing the design have been accepted and registered by the
jurisdiction where the vessel is to be located.

EDITION 1 REV 0
PAGE 3 of 5
SECTION 9 DRAWINGS & DESIGN

CALCULATION
9.6
The QCM will maintain a Drawing Index (Exhibit 9.1) detailing the drawing title, drawing number,
revision number, and person or department they are assigned to. The Design Calculation Index and
Revision Control Sheet (Exhibit 9.2) will be used to document the contents of calculation packages
for each job, calculation revisions, and the review and approval of drawing revisions against
calculations. All essential documents to outside organizations will be controlled by use of Document
Transmittal (Exhibit 8.1). The QCM is responsible for control of documents at shop and field sites.
He will issue the latest revisions and recall and destroy all superseded documents. One copy of each
superseded document Marked VOID shall be kept in the job file for reference. Issued for
Construction will be stamped or written on all drawings followed by initial and date of person
releasing the drawings.
9.7
The QCM is responsible for assigning the job and serial numbers for all vessels and shall maintain a
file for each vessel containing design calculations, drawings and specifications.
9.8
The QCM will ensure that the latest Editions and Errata of the ASME Codes are available in the
shop and field.
Document Transmittal, Exhibit 8.1
Drawing Index
Exhibit 9.1
Design Calculation Index And Revision Control Sheet, Exhibit 9.2
ABSA FORMS
Design Registration Application, AB-31

EDITION 1 REV 0
Section 9
PAGE 4 of 5
XHIBIT 9.2 DESIGN CALCULATION INDEX AND REVISION CONTROL SHEET

Job Number:
Code Edition:
Calculation Package Revision Level:

DESIGN CALCULATIONS INDEX
Applicable
Calculation Description
Yes
No
Primary Membrane Stress Calcs. (Computer Design Pgm.)
Lifting Lug Calculations
Horizontal Vessel Saddle Calculations
Vertical Vessel Skirt Calculations
Other UG-22 Specified Loadings
Pages
Rev. Level
Vessel Impact Testing Exemption Summary

DESIGN CALCULATIONS REVISION CONTROL AND APPROVAL
Drawing No. & Rev. Level
Calc. Package
Rev. Level
Revised Calcs.
Required
Approval
Date
1 Whenever new drawings are issued that pertain to the calculation package, or whenever drawings are
revised, the current calculations shall be verified and approved as applicable or revised as necessary and
approved.
Drawing Number
Rev. No.
Drawing
Title
Date
Issued
Copies To
QCM
Copies To Copies To
Shop Mgr. Purch. Mgr.
Copies To
ABSA
Copies To
Field
DRAWING INDEX
Copies To
Eng. File
Job Number:

EDITION 1 REV 0
Revision Date March 18, 2013Section 9
XHIBIT 9.1 DRAWING INDEX
PAGE 5 of 5

EDITION 1 REV 1
PAGE 1 of 6
SECTION 10 MATERIAL CONTROL
10.
MATERIAL CONTROL
10.1
This section describes the system of controlling, ordering, receiving, identification and use of all
Code material in compliance with ASME Code and design specification requirements.
10.2
The Purchasing Manager is responsible for the ordering of all material. The Purchasing Manager will
prepare a Purchase Order (Exhibit 10.1) from the approved drawing Bill of Material. The Purchase
Order will include (as applicable):
a) Purchase Order number and job number (unless ordered for stock).
b) material ASME specification number (SA/SB), grade, schedule, dimensions.
c) request for Material Test Report (MTR) for all Code materials,
d) request for Manufacturers Partial Data Report or Certificate of Compliance for all code stamped
and standard welded parts supplied by a subcontractor.
e) request for certification to ASME Code Section VIII, Division 1, paragraph UG-79 and
referenced paragraphs for formed items,( ie. UHA-44) when applicable
f) request that tack welds be performed to a Welding Procedure Specification qualified to ASME
Section IX.
g) request for certification for any supplementary test (ie. impacts).
h) heat treatment requirements.
i) NDE requirements.
j) Statement that all fitting designs must be registered with ABSA.
k) The SFA Specification and AWS Classification on all Purchase Orders for welding consumables
and/or other requirements as qualified by the applicable WPS.
l) A requirement that all Code required material markings must be accurately transferred to formed
material or if a coded marking system is used to maintain traceability to the original Code required
markings and the MTR, the coded marking system used must have prior acceptance by Allied Vessel
Fabrication and the AI.
10.3
The Purchase Order will be issued by Purchasing Manager and the QCM will review prior to issue.
When Code materials are ordered an attachment to the Purchase Order titled Purchase
Requirements by Product Form (Exhibit 10.2) shall be used to convey mandatory requirements.
One copy of the Purchase Order will be issued to the Vendor, one copy will be kept in the Purchasing
File, one copy to the Shipper/Receiver and one copy will be sent to the QCM for the job file.

EDITION 1 REV 1
PAGE 2 of 6
10.4
Material substitutions must be approved by the QCM, the customer, Designer and accepted by the
AI. Approved material changes will be noted on the drawing. If required, revised calculations and
drawings will be prepared and issued in accordance with this Quality Control Manual.
10.5 The Shipper/Receiver is responsible for receiving of all materials.

His duties include:
a) Checking all Code material received against the Purchase Order, packing slip, MTR if required,
and examining the material for visible damage, correct quantity, markings, dimensions, verifying
the thickness, recording the measured thickness for pipe and plate material on the MTR. All code
required markings will be highlighted or identified with the check mark on the MTR's confirming
that the material marking conforms to Code requirements. A certificate of compliance showing a
measured minimum thickness (ie. Vessel heads) shall be accepted as the measured thickness.
b) Identifying all acceptable material with the job number or marking with heat number, either as a
lot (eg. smaller components) or by the piece (eg. larger items, heads, shells, etc.)
c) Accepting the material if it satisfies the Purchase Order requirements, is marked in accordance
with Code requirements and is not damaged. When the Receiver cannot immediately determine if
the material is acceptable, it shall be segregated and the QCI will then determine if the
material meets Code and Purchase Order requirements. Unacceptable material will be rejected.
d) Ensuring that all pipe material is color coded by a stripe over the full length. The Color Code
Chart (Exhibit 10.3) shall be posted in the storage area and the shop area. Pipe material will be
identified with a heat number and supported by the corresponding MTR.
10.6
The QCI is responsible for identification and traceability of all materials.

His duties include:
a) Recording the material specification number, grade, heat number, and verified thickness as
required on the Travel Sheet (Exhibit 11.1) for vessel fabrication. When the materials are examined
prior to fabrication. the QCI shall confirm that the material identification markings match the MTRs
or Manufacturers Partial Data Reports and shall also ensure that all plate material used as a pressure
retaining component and any other material for vessel shells, heads or nozzle reinforcing pads,
remain traceable to the MTR.
b) Examining all material for the purpose of detecting imperfections that would affect the safety of
the Code item and verifying that the material is as specified on the drawings and conforms to
Code requirements. If material defects are detected, if the material is not in full conformance
with Code requirements or if further material testing is required then the material shall be
identified as nonconforming and handled as described in Section 13.

EDITION 1 REV 1
PAGE 3 of 6
c) Ensuring that all identification markings are transferred prior to dividing any plate or pipe
material, so that each piece will be identified on the completed vessel. The identification will
be stamped on carbon steel plate over 1/4 thick and written by water proof marker on other
material and the information will also be recorded on a drawing of the vessel.
d) Verifying that the MTRS conform to ASME Code Section II same Edition as on the drawing.
If the MTRS conform to Section II, the QCI will initial and date the MTR and indicate the
Code Edition used.
e) Ensuring that when pipe material, which is identified with the heat number and Color Coded,
is fabricated as a nozzle that the marking is stamped on each nozzle.
f) Maintain traceability to Code required identification markings for all pressure fittings used
on a Code item. For product form such as couplings or threadolets, if the original fitting
manufacturers markings will be obscured by construction; then, after the fitting is attached
to the Code item all of the original Code required identification markings will be recorded on
the Travel Sheet in the applicable row for the item.
g) Ensuring that the Color Code and Coded Markings detailed in Exhibit 10.3 are posted in the
storage area and the shop.
h) Alternate marking system shall be acceptable to the AI.
10.7
Material purchased for stock, customer supplied material, or excess material remaining from
previous jobs may be used for construction of Code items providing the material is again,
inspected, and MTRS are verified to the Code Edition specified on the construction drawing.
Purchase Order,
Purchase Requirements by Product Form,
Color Code and Code Markings,
Travel Sheet
Exhibit
Exhibit
Exhibit
Exhibit
10.1
10.2
10.3
11.1

EDITION 1 REV 0
PAGE 4 of 6
Exhibit 10.1
Allied Vessel Fabrication
PURCHASE ORDER
PAGE 1 OF
P.O. #
JOB#
DATE:
Billing Address: #107 535- 10Ave SW

Calgary AB T2R 0A8
VENDOR
SHIP
TO
SHIPPING METHOD
Attn: Jeff Hagel

Allied Vessel Fabrication
3808-46 Ave.
Stettler, AB TOC 2L1
Ph:1-403-742-6400
Fax:1-888-526-0274
SHIPPING TERMS
DELIVERY DATE
JOB
UNIT PRICE
LINE TOTAL
SUBTOTAL
SALES TAX
TOTAL
PO is issued as per quote number as referenced above.

Enter this order in accordance with the prices, terms, delivery
method, and specifications listed above.
Please notify us immediately if you are unable to ship as specified.
Authorized by:
Date:

EDITION 1 REV 0
PAGE 5 of 6
EXHIBIT 10.2 PURCHASE REQUIREMENTS BY PRODUCT FORM

A-
Rolled Plate (Shells and rolled Plate Nozzle Reinforcing Pads)

1) Materials: SA-516-70 or SA-516-70 Normalized (SA-516-70N) as specified on Purchase Order.
2) Unless as otherwise shown on PO; 30 degree outside bevel-no land A/A [Excluding Reinforcing Pads]
3) Longitudinal seam tack-welded using a Welding Procedure Specification that meets all the requirements of ASME Section IX: oneeighth inch weld gap-no land. If the purchase order specifies welding of the longitudinal seam that manufactures Partial Data Report
must be supplied for this item.
4) Must conform to ASME Section VIII, Div.1 paragraphs UG-79 and reference paragraphs, ie. UHA-44 when applicable.
5) All ASME Code required material markings must be accurately transferred to this item or, if a coded marking system is used to
maintain traceability to the original Code required markings and material test report for formed items, the coded marking system
must be accepted prior to confirming this order.
6) Material test reports must be supplied for this item(s).
7) This item(s) must meet the ASME Section II,_________Edition material specification, and general specifications applicable to the
product form.
B-
Formed Plate (Heads and Formed Plate Nozzle Reinforcing Pads)

1) Materials: SA-516-70 or SA-516-70 Normalized (SA-516-70N) as specified on Purchase Order.
2) Head, 2:1 Semi Elliptical, 2-Inch Straight Flange.
3) Unless as otherwise shown on PO; 30 degree outside bevel-no land A/A [Excluding Reinforcing Pads]
4) Must conform to ASME Section VIII, Div.1 paragraphs UG-79 and reference paragraphs, ie. UHA-44 when applicable.
maintain traceability to the original Code required markings and material test report for formed items, the coded marking system must
be accepted prior to confirming this order.
7) This item(s) must meet the ASME Section II,__________Edition material specification, and general specifications applicable to the
product form.
C-
Rolled Plate (Skirt Material and Rolled Plate Saddle Pads or Wear Plates)
1) Materials: SA-516-70, SA-516-70 Normalized (SA-516-70N) or SA-36 as specified on Purchase Order.
2) Unless as otherwise shown on PO; square cut A/A
3) Longitudinal seam tack-welded using a Welding Procedure Specification that meets all the requirements of ASME Section IX: oneeighth inch weld gap-no land.
maintain traceability to the original Code required markings and material test report for formed items, the coded marking system must
be accepted prior to confirming this order.
product form.
D-
Pipe
1)
2)
3)
4)
Materials SA-106B seamless pipe or SA-333 Gr.6 seamless pipe as specified on Purchase order.
Material test reports must be supplied for this item(s).
For cut lengths all markings required by the material specifications must be accurately transferred to this item.
This item(s) must meet the ASME Section II,__________Edition material specification, and general specifications applicable to the
product form.
E-
Flanges and Fittings

1) Materials: SA-105 or SA-105 Normalized to Supplementary Requirements S-2 (SA-105N), SA-234-WPB, SA-350-LF2, or SA-420WPL6 as specified on Purchase order.
2) Fitting design must be registered with ABSA for this item(s). Canada Registration Number(s) must be available upon request.
product form.
5) Unless otherwise specified; all Pipe Flanges and Flange fittings shall be in accordance with ASME B16.5-2009.
6) Unless otherwise specified; all Factory- Made Wrought Steel Buttweld Fittings shall be in accordance with ASME B16.9- Latest
Edition.
7) Unless otherwise specified; all Forged Fittings, Socket-Welding and Threaded shall be in accordance with ASME B.16.11-Latest
Edition.
F-
Welding Consumables
1) All welding consumables must conform to the SFA specification and AWS classification listed on purchase order.

EDITION 1 REV 1
PAGE 6 of 6
EXHIBIT 10.3 COLOR CODE and CODED MARKINGS
COLOR CODE FOR PLATE PIPE & FITTINGS

PLATE MATERIAL
SA - 36
CSA G40.21 44W
CSA G40.21 50W
SA 516 - 70N
SA - 516 - 70
PIPE MATERIAL SPECIFICATIONS

SA - 420 WPL 6
SA - 350 LF2
SA - 333 GRADE 6
SA - 234 WPB
SA - 105
SA - 105N
SA - 106 GRADE B
SA - 53B (ERW)
COLOR CODE
DIE STAMP
DISC
RED
WHITE
GREEN
ORANGE
YELLOW
36
44
50
70N
70
Plate
Plate
Plate
Plate
Plate
COLOR CODE
DIE STAMP
DISC
0
1
3
2
5
5N
6
4
Fitting
Fitting
Pipe
Fitting
Fitting
Fitting
Pipe
Pipe
BLUE
WHITE
YELLOW
Other materials will have a color stripe or die stamp as determined by the QCM. Each length of pipe will
have a continuous stripe of the designated color.

EDITION 1 REV 0
SECTION 11 EXAMINATION AND INSPECTION
PAGE 1 of 5
11.
EXAMINATION AND INSPECTION
11.1
This section describes the system of inspection and examination required to verify that fabrication
has been completed in accordance with ASME Code and this Quality Control Manual.
11.2
The QCM is responsible for the examination and inspection program. His duties include:
a. Creating and maintaining a job file, which includes the Travel Sheet, drawings, calculations,
MTRs, certificates of compliance, NDE reports, Heat Treatment instructions including time/
temperature chart, Hydro-Test report, Manufacturers Data Reports, CRN acceptance letter
and facsimile of name plate stamping.
b. Initiating a Travel Sheet (Exhibit 11.1) for each job and presenting it, along with drawings,
specifications, and calculations, to the AI prior to the start of fabrication so the AI may
indicate hold and inspection points. Work shall not proceed beyond an established hold point
until the AI has released the hold by initial and date on the Travel Sheet.
c. Notifying the AI reasonably in advance of any hold points.
d. Performing any examination functions specified on the Travel Sheet, initialing and dating
each function on the Travel Sheet when completed. Welders symbols shall be recorded on
the Travel Sheet if stamping is not allowed on item otherwise, the item shall be hard stamped.
Visual examinations of fit-up and for type-one-joint verification shall be documented by
initial to indicate completion or verification, and acceptance.
11.3
In addition to the examination and inspection functions on the Travel Sheet, the QCM will ensure
that:
a. All applicable material is identified on the Travel Sheet with specifications and heat numbers
and that these heat numbers are transferred and remain traceable throughout construction.
b. The material contains no visible scars or defects.
c. MTRs are available for all pressure retaining plate material used for shell, heads, repads,
pipe used for vessel shells, nozzle necks and any additional components as may be requested
by the customer.
d. Alignment tolerances are maintained during construction.
e. Weld details are correct.
f. Non-destructive examination is performed in accordance with Section 12 of this Quality
Control Manual and the Code.
g. Heat treatment charts comply with instructions.
h. The correct hydrostatic test pressure is applied.

EDITION 1 REV 0
PAGE 2 of 5
SECTION 11 EXAMINATION AND INSPECTION
11.4
The QCM shall prepare the AB-25; Manufacturers Data Report.
11.5
The QCM will verify that the nameplate (Exhibit 11.2) stamping information is complete
and correct. After the hydrostatic test has been witnessed by AI, and accepted, the QCM will certify
the Manufacturers Data Report and present it along with the job file and nameplate to the AI for
acceptance and signature on the Manufacturers Data Report.
11.6
The QCM is responsible for ensuring that the completed nameplate is installed on the correct vessel.
Prior to installing the nameplate, the vessel serial number on the nameplate will be verified as
matching the serial number which is die stamped on the vessel shell, or nameplate bracket.
Note: Manufacturers Data Reports shall not be changed or altered after they have been signed by
the QCM and the AI. If errors are found, a corrected Manufacturers Data Report must be completed
and certified.
11.7
The QCM will distribute the Manufacturers Data Report, with all attachments, to:
a) The AI
b) The customer or designated agent
c) The job file
d) The jurisdiction where the vessel will be located, if other than Alberta.
11.8 The AI or the AI Supervisor, reserves the right to audit this program at any time where Code work is
in progress.
Travel Sheet,
Sample Nameplate,
Exhibit 11.1
Exhibit 11.2
ABSA FORMS
Manufacturers Data Report, for pressure vessel AB-25

EDITION 1 REV 0
PAGE 3 of 5
XHIBIT 11.1 TRAVEL SHEET (FRONT)

DO NOT START CONSTRUCTION WITHOUT AI REVIEW
AI REVIEW:
REVIEW DATE:
SERIAL NO.:
JOB NO.:
DRAWING NO.:
Seq.
TRAVEL SHEET REVISION NO.: 0
Item
1.
Calculations in File
2.
Release of Appd Dwg.
3.
Materials Examined
4.
Heat Numbers Recorded
5.
MTRs Checked
6.
WPS(s) Checked
7.
Welder(s) Qualified
8.
Thicknesses Verified &

Recorded
9.
Shell(s) & Head(s) Fit-up

Inspection
10.
Nozzles & Fittings Fit-up

Inspection
11.
Nozzle Orientation
12.
Nozzle & Flange Rating

Checked
13.
Impact Tests
14.
Internals Checked
15.
Final Internal Inspection
16.
Weld Sizes Checked
17.
Welder I.D. Checked
18.
Final External Inspection
19.
Radiography
20.
Other N.D.E.
21.
Final Ext. Prior to

P.W.H.T.
22.
PWHT Chart Checked
VESSEL TYPE:
REV. NO.:
Comments
QCI
TRAVEL SHEET INITIATED BY:

Date
AI Hold
Points
AI
Date
Owner
Shell Side
Tube Side
Gauge #
23.
Hydrostatic Test
24.
CRN Drawing & CRN #
25.
N.C.R. #
26.
27.
Nameplate Stamping
Manuf. Data Report
Completed & Verified
28.
Nameplate Installation
Gauge #
29.
The AI shall be presented with the Travel Sheet prior to construction so that he can designate additional inspection points and/or Hold Points.
Any revisions shall be marked with a delta symbol with revision number and described at the bottom of this page.
* Denotes an A.I. Inspection Point
** Denotes an A.I. Hold Point

EDITION 1 REV 0
PAGE 4 of 5
Date
XHIBIT 11.1 TRAVEL SHEET
(BACK)
MATERIAL THICKNESS VERIFICATION AND IDENTIFICATION

Description
Thickness
Material Spec.
& Grade
Heat & Plate Identifier

or I.D. Number
WELD I.D. / WELDER SYMBOLS / FIT-UP

Weld
WPS
Welder
Symbol
Fit-Up
Exam.
Weld
I.D.
Welder
Symbol
Fit-Up
Exam.
Verify
Type 1
Joint
Shell #1
Shell #2
Head #1
Head #2
ATTACHMENT AND / OR NOZZLE MATERIAL THICKNESS VERIFICATION AND IDENTIFICATION

Mark
Mat. I.D.
Neck
Fitting
Flange
Repad or Attachment
WELDER SYMBOLS / FIT-UP/WPS

Cat. B
Cat. C
Cat. D
Spec.-Grd.
Thk./Rating
Heat# or ID
Spec.-Grd.
Thk./Rating
Heat# or ID
Spec.-Grd.
Thk./Rating
Heat# or ID
Spec.-Grd.
Thk./Rating
Heat# or ID
Spec.-Grd.
Thk./Rating
Heat# or ID
Spec.-Grd.
Thk./Rating
Heat# or ID
Spec.-Grd.
Thk./Rating
Heat# or ID

EDITION 1 REV 0
PAGE 5 of 5
Pad OD
EXHIBIT 11.2 NAME PLATE

EDITION 1 REV 0
SECTION 12 WELDING
PAGE 1 of 6
12
WELDING
12.1
This section describes the system for controlling all Welding Procedure Specifications, welding
operations and Welder/Welding operator performance qualifications to ensure compliance with the
ASME Code.
12.2
The QCM is responsible for control of all Welding Procedures Specifications (WPS). His duties
include:
a. Reviewing the job specifications, prior to the start of construction, to verify that the WPS has been
qualified in accordance with ASME Code and registered with ABSA for the work to be performed.
b. Ensuring that the correct WPS and joint requirements are detailed on the construction drawings for
each weld joint.
c. Ensuring that WPS are detailed on WPS Index and Essential Variable Summary (Exhibit 12.1).
12.3
The QCM is responsible for developing and qualifying any new WPS. His duties include:
a) Preparing the WPS, or delegating this to a qualified consultant.
b) Supervising the welding of the test coupon by a Welder employed by Allied Vessel Fabrication to
ensure that it conforms to the WPS.
c) Recording the test data on the Procedure Qualification Record (PQR).
d) Subcontracting the testing of the coupons to a recognized material testing laboratory.
e) Reviewing the results and certifying the PQR.
f) Submitting the WPS and PQR with the test results to the ABSA in duplicate, for registration.

EDITION 1 REV 0
SECTION 12 WELDING
PAGE 2 of 6
12.4
The QCM is responsible for the Welder/Welding operator performance qualification testing and the
maintenance of Welder/Welding Operator qualification records. Additionally the QCM shall instruct,
assign and supervise Welder/Welding Operators. His duties include:
a. Verifying that Welders have a valid performance qualification card (PQ card), issued by a Certified
Welding Examiner, have qualified to Allied Vessel Fabrication WPS prior to start of their assigned
Code work, based on the Welder/Welding Operator qualification records and Welders Log (Exhibit
10.2).
b. Maintaining the Welders Log (Exhibit 12.2), detailing the process each welder is qualified for,
essential variables, date of expiry of the PQ card and weld symbol assigned.
c. Supervising the welding of the test coupons and preparing and certifying the Welder Performance
Record (QW 484 A/B or equivalent) for all Welder/Welding Operators performance tests.
d. Ensuring that welding procedure requirements are followed and copies of WPS are available to all
Welders for information.
e. Visually examining all completed welds.
f. Ensuring that each Welder is assigned a Welder ID symbol and all welds, after completion, are
identified with the Welders symbol at least once for every 3 feet (0.9 meters) of weld. When die
stamping of the ID symbol is prohibited by Code, or customer requirements, the Welders ID for
each weld shall be recorded on a shop copy of the drawing and the QCI shall transfer this data onto
the QC drawing and/ or Travel Sheet as retained in the Quality Control Job file. The Welder symbol
may be reassigned after six months of inactivity.
g. Ensuring that all tack welds are made using WPS qualified to ASME Code Section IX; tack welds, if
left in place, are done by welders qualified to ASME Code Section IX. Tack welds done by
subcontractors shall be completely removed.
h. Verifying tack welds which are not completely removed are properly prepared for incorporation into
the final weld and have been examined visually by the QCI for defects; if found defective they will
be completely removed.
i. Ensuring that all weld repairs to materials are referred to AI for acceptance prior to the repair.
j. Updating the Continuity Log (Exhibit 12.3) by recording within the specified interval, when each
welder or welding operation uses a welding process.

EDITION 1 REV 0
SECTION 12 WELDING
PAGE 3 of 6
12.5
A Welder or Welding Operator shall be re-qualified whenever any of the following criteria exists.
1)
He has not welded using a process he had qualified for a period of six months or more.
2)
Whenever, for a specific reason, the QCM or the AI may require re-qualification.
3) Whenever there is a change in any of the Welders or Welding Operators performance
qualification essential variables outside of the range of qualification.
12.6
The Purchasing Manager is responsible for ordering welding consumables based on inventory levels.
His duties include:
a) Verifying that all Purchase Orders for welding consumables specify SFA specifications and AWS
classifications and/or other requirements as qualified by the applicable Welding Procedure
Specifications.
b) Issue purchase order as per Section 10.
12.7
The Shipper/Receiver is responsible for receiving welding consumables. His duties include
a) Verifying that welding consumables are identified with the correct SFA specifications and AWS
classifications , and marking acceptable material with a check mark made with a black marking
pen (felt marker) to signify that the designated consumables are verified as acceptable for use.
12.8
The Shop Manager is responsible for:
a) Ensuring that low hydrogen and alloy electrodes are kept in heated storage in accordance with the
Electrode Manufacturers specifications (typically between 200 F and 300 F) after the container
has been opened.
b) Ensuring that welders are issued with sufficient electrodes for no longer than two hours work period
and that electrodes removed from the oven for more than four hours will not be used for Code work;
those electrodes will be placed in a container marked: NON - CODE.
c) Ensuring that submerged arc welding flux is stored in accordance with the manufacturers
recommendation. Hoppers and temporary storage containers if used, shall be labeled to indicate the
type of flux they contain.
12.9
The AI shall have the right, at any time, to call for and witness re-qualification
tests of the Welding Procedure Specification and any Welder / Welding Operator.
WPS Index and Essential Variable Summary, Exhibit 12.1
Welders Log,
Exhibit 12.2
Continuity Log,
Exhibit 12.3

EDITION 1 REV 0
PAGE 4 of 6
SECTION 12 EXHIBIT 12.1 WPS INDEX & ESSENTIAL VARIABLE SUMMARY
EDITION 1 REV 0
SECTION 12 EXHIBIT 12.2 WELDERS LOG
PAGE 5 of 6
W.P.S.
Process &
Identifier & Weld Deposit
Revision No. Thickness
Base Metal
Thickness
Range
PWHT
Impact
Tested &
Temp.
P No.
Position
WPS Consumables
WPS INDEX & ESSENTIAL VARIABLE SUMMARY

Comments
WELDERS
FILLER
PROCESS
BASE
NAME / FILE SYMBOL /METHOD METALS METAL F
NUMBER(S)
NUMBER
BACKING
MINIMUM
OD (In)
DEPOSIT
THICKNESS
(In)
POSITIONS
UPHILL /
DOWNHILL
WELDERS LOG
CORED /
SOLID
INSERT
BACKING GTAW
GAS
CURRENT
GMAW EXPIRY DATE

X-FER
P.Q. CD.

EDITION 1 REV 0
PAGE 6 of 6
SECTION 12 EXHIBIT 12.3 CONTINUITY LOG
CONTINUITY LOG
WELDERS NAME
FILE NUMBER
SYMBOL
PROCESS
YEAR:
JAN. - MAR.
APR. - JUN.
JUL. - SEPT.
OCT. - DEC.
Note: There must be confirmation of welding process use (i.e., continuity) in every three-month period in
order to ensure that a six-month gap in continuity has not occurred

EDITION 1 REV 0
PAGE 1 OF 3
SECTION 13 NONCONFORMITIES
13
NONCONFORMITIES
13.1
This section describes the system for identifying, documenting and resolving nonconformities
that could be found at receiving, construction, examination, testing or any other area in regards to
Code items.
13.2
A nonconformity is any condition, which does not meet the requirements of the Code, job
specifications or this Quality Control Manual. Repairs to weld metal that are identified by planned
quality control examination shall be completed in accordance with the Code, this Manual, and the
job specifications but need not be documented on a Nonconformity Report (Exhibit 13.1).
13.3
With any nonconforming material found, the QCM will decide if the item is to be rejected (e.g.
returned to the supplier), or if the item will be reworked and/or repaired as required to then assure
conformance. If a decision is made to repair the material or item; a repair procedure will be
developed, be approved by the QCM and must be accepted by the AI showing signature and date on
the Nonconformity Report, before the start of the repair. The QCM shall prepare additional
inspection functions on the Travel Sheet when applicable.
13.4
When non-conformity is found during construction an immediate hold shall be placed on that portion
of work affected, and the QCM shall be informed immediately. The non-conformity item will be
identified with a Hold Tag (Exhibit 13.2).
13.5
The QCM will prepare a Nonconformity Report with details of the nonconformity and a hold
notation shall be made on the Travel Sheet listing the Nonconformity Report number. All proposed
Nonconformity Report dispositions shall have QCM approval. The Designer shall approve all
proposed dispositions involving design changes. If required, the Designer will prepare revised design
calculations and drawings as per Section 9 of this Manual. After receiving the specified approvals,
and when required, the Nonconformity Reports indicating design changes, repairs, re-work, material
substitution, or use as is dispositions shall be submitted to the AI for acceptance of the proposed
disposition.
13.6
During any repair or re-work the QCM will ensure that the specified examinations are completed,
and that the AI is notified sufficiently in advance of any additional inspection or hold points.
13.7
The Hold Tag shall only be removed after the non-conformity has been resolved to the satisfaction
of the QCM, AI and the Owners Inspector, and they have indicated acceptance by signing off the
Nonconformity Report and Travel Sheet when applicable.
13.8
The Nonconformity Report shall be retained in the job file and also in a separate Nonconformity
Report File. The QCM will periodically review the Nonconformity Reports and initiate corrective
action if required as to prevent recurrence.
Nonconformity Report, Exhibit 13.1
Hold Tag,
Exhibit 13.2

EDITION 1 REV 0
PAGE 2 OF 3
SECTION 13 NONCONFORMITIES
XHIBIT 13.1 NONCONFORMITY REPORT

NCR #
JOB NUMBER:
SER#
DESCRIPTION OF NONCONFORMANCE:
SIGNATURE OF ORIGINATOR:
DATE:
PROPOSED DISPOSITION:
DESIGNER APPROVAL:
DATE:
QCM APPROVAL:
DATE:
AUTHORIZED INSPECTOR ACCEPTANCE:
DATE:
OWNERS INSPECTORS ACCEPTANCE:
DATE:
NONCONFORMANCE RECTIFIED:
DATE:
QCM APPROVAL:
DATE:
AUTHORIZED INSPECTOR ACCEPTANCE:
DATE:
OWNERS INSPECTORS ACCEPTANCE:
DATE:

EDITION 1 REV 0
SECTION 13 HOLD TAG
EXHIBIT 13.2
HOLD
DO NOT USE
SIGNATURE:
DATE:
JOB NO.:
THIS ITEM OR PART IS NOT TO BE

USED FOR THE REASONLISTED ON
THE NONCONFORMITY REPORT:
NONCONFORMITY REPORT NO.:
WHEN THE NONCONFORMITY HAS

BEEN RESOLVED IN ACCORDANCE
WITH SECTION 13 OF THE QUALITY
CONTROL MANUAL THIS TAG MAY
ONLY BE REMOVED BY THE QUALITY
CONTROL DEPARTMENT
HOLD TAG COLOR RED
PAGE 3 OF 3

EDITION 1 REV 0
PAGE 1 OF 3
SECTION 14 NONDESTRUCTIVE EXAMINATION
14
NONDESTRUCTIVE EXAMINATION
14.1
This section describes the system of ensuring that nondestructive examination is completed in
accordance with the Construction Code and ASME Code Section V as referenced by the applicable
Construction Code.
14.2
The QCM is responsible for appointing all NDE subcontractors. His duties include:
a) Reviewing the subcontractors personnel qualifications and certifications, Written Practice and NDE
procedures that are approved by a Level III Examiner for compliance with the Code and the latest
Construction Code accepted Edition/Addenda of SNT-TC-1A. The QCM shall accept the
qualifications, certifications, calibrations, Written Practice and NDE procedures for use at Allied
Vessel Fabrication also ensuring that these are available to AI at his request.
b) Verifying that all personnel performing NDE shall be qualified and certified in accordance with their
employers Written Practice and appointing, using the Certifying Statement and Appointment Letter
(Exhibit 14.1), to kept on file, the NDE Subcontractors Level III Examiner to act as the Level III
Examiner for Allied Vessel Fabrication. There shall be evidence that the Level III Examiner has
accepted the appointment.
c) Ensuring that all examinations are done under the supervision of a Level II or Level III Examiner.
d)
Ensuring that all interpretations are done by a Level II or Level III Examiner.
e) Ensuring and certifying on the Certifying Statement and Appointment Letter that all qualified NDE
procedures for Code required Ultrasonic Examination (UT), Magnetic Particle (MT), and Liquid
Penetrant (PT) are demonstrated to the satisfaction of the AI prior to use. Any change in NDE
procedure essential variables shall require re-qualification of the procedure and demonstration to the
satisfaction of the AI prior to the use of the revised procedure.
14.3
The QCI is responsible for liaison with the NDE subcontractor. His duties include:
a) Reviewing the qualifications of the NDE Examiners for conformance to this Quality Control
System.
b) Notifying the NDE Examiners of NDE requirements

EDITION 1 REV 0
PAGE 2 OF 3
SECTION 14 NONDESTRUCTIVE EXAMINATION
c) Identifying the welds to be examined; if spot RT is required, choosing the location of the spot
when the AI has been notified in advance and cannot be present or otherwise make the selection and
it shall be as per UW-52.
d) Maintaining traceability of NDE reports to their locations on the Code item either by marking the
weld ID on the Code item or, by recording the necessary information on a copy of the construction
drawing and/or the Travel Sheet that will be retained in the job file.
e) Reviewing all radiographic film and reports to confirm that the film identification, density,
sensitivity and the documentation of examination and interpretation are in accordance with Code
requirements. If acceptable the radiographic reports shall be accepted by signature and the
radiographic film and reports shall be made available to the AI for review and acceptance.
f) Filing all NDE reports and forwarding these to the QCM when the job is completed.
14.4
The AI may require re-qualification of NDE examination or procedure for cause.
Certifying Statement And Appoint Letter, Exhibit 14.1

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PAGE 3 OF 3
EXHIBIT 14.1 CERTIFYING STATEMENT

AND APPOINTMENT LETTER
I have reviewed the:

Written Practice
(Edition Number and Revision Number of Written Practice)
NDE Procedures
(Method and Edition Number and / or Revision Number of Written Procedures)
And personal certification records and vision
Examination records of all examiners that will perform
NDE at Allied Vessel Fabrication Ltd.
For:
_____________________________________________________________________________________
(Name and Address of NDE Company)
It is my opinion that the specified NDE procedures are in accordance with ASME Section V Requirements as referenced by the
applicable construction Code and that the Written Practice complies in all respects with the requirements of the construction
Code accepted Edition/ addenda of SNT-TC-1A. Based Upon my review of the above referenced documents I hereby certify
that personnel performing and evaluating NDE have been qualified and certified in accordance with their employers written
practice and that the demonstration of the procedure(s) to the satisfaction of the AI, as required by the ASME Code, Section V,
paragraph T-150, has been completed as specified within the (Name of Company) written Quality system.
Therefore:
_________________________________________
(Name of NDE Company)
are hereby appointed

to perform
______________________________________
(RT, UT, PT, MT, ET, VT, and or LT)
For:
______________________________________________________________________________________________________
(Name of the Manufacturer)
Appointment of Level III Examiner
_________________________________________is by this statement appointed to act as the Level III Examiner on behalf of:
(Name of Level III Examiner)
_________________________________________ in the following methods: _______________________________________
(Name of the Manufacturer)
(RT,UT,PT,MT,ET,VT, and/orLT)
_________________________________________
(Signature of QCM
(Date)
________________________________________
(Appointment Expiry Date)
Level III Examiner Acceptance of Appointment

I hereby accept the appointment as indicated above
________________________________________

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PAGE 1 OF 2
SECTION 15 HEAT TREATMENT
15
HEAT TREATMENT
15.1
This section describes the procedure that will be used to ensure that heat treatment is performed in
accordance with Code and job specifications.
15.2
Heat Treatment of Code items will be subcontracted.
15.3
The QCM will review and accept the subcontractors facilities and written procedures and ensure
that the furnace instrumentation is properly calibrated. The acceptance and approval of facilities and
procedures shall be documented on a copy of the subcontractors procedures that are maintained on
file.
15.4
The QCM will issue the written Heat Treatment Instructions (Exhibit 15.1) to the subcontractor
specifying holding time, holding temperature, heating rate, cooling rate, and any special instructions.
15.5
The QCI will ensure that all items to be sent out for heat treatment are properly identified by die
stamping or heat resistant marker.
15.6
The QCI will notify the subcontractor when the vessel is ready for heat treatment and will review the
procedures used by the subcontractor.
15.7
After completion of heat treatment, the QCI will inspect the vessel for proper identification and any
damage, and review all time temperature charts for legibility and compliance with written
instructions. The charts and instruction sheet will be identified with the job number, vessel (or item)
serial number and shall be signed and dated by the subcontractors representative and the QCI.
15.8
The QCI will file the instructions and time temperature charts in the vessel file which will be made
available for the AI for review.
Heat Treatment Instructions, Exhibit 15.1

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SECTION 15 HEAT TREATMENT
PAGE 2 OF 2
JOB NO.:
DESCRIPTION:
EXHIBIT 15.1 HEAT TREATMENT INSTRUCTIONS

DATE:
DWG. AND LINE NO.
DIAMETER
TYPE OF HEAT TREATMENT:
THICKNESS
MATERIAL
LENGTH
WEIGHT
PWHT
HEATING
Temperature to be raised from 800F (425C) to ________F (_____C) at a maximum rate of

__________F (__________C) per hour. NOTE: THIS VALUE MUST NEVER EXCEED 400F (222C) PER
HOUR.
[Calculated rate = 400 degrees F/hr. (222 degrees C/hr.) Divided by the maximum metal thickness of the shell or head
plate in inches]
HOLDING
Temperature to be held at a minimum of ________F (________C) for ____________ minutes.

[Holding time to be determined by Table UCS-56 for Nominal Thickness as specified in UW-40(f)]
COOLING
Temperature to be lowered from _________F (_____C) to 800F (425C) at a maximum rate of

_______F
(__________C) per hour. NOTE: THIS VALUE MUST NEVER EXCEED 500F (280C) PER HOUR.
[Calculated rate = 500 degrees F/hr. (280 degrees C/hr.) Divided by the maximum metal thickness of the shell or head
plate in inches]
From 800F (425C) items may be cooled in still air.

Additional requirements:
Job number and description required on heat treatment charts along with the operators signature & date.
Reporting of thermocouple attachment method and location, and verification of furnace thermocouple calibration is
required.
A sufficient number of thermocouples shall be located to control and maintain uniform distribution of temperature on
all vessels and parts. Thermocouples shall be directly attached to the item or provision shall be made for
thermocouple placement at bottom, centre and top of the furnace charge in accordance with the ASME Code.
During the heating period, there shall not be a greater variation in temperature throughout the portion of the vessel
being heated than 250F (140C) within any 15 ft. (4.6 m) interval of length. An adequate number of thermocouples
must be used to ensure this Code requirement is met. This limitation is also applicable to the temperature variations
between the different thicknesses of various vessel components.
During the holding period, there shall not be a greater difference than 150F (83C) between the highest and lowest
temperature throughout the portion of the vessel being heat treated, except where the range is further limited by
these instructions.
If Capacitor Discharge welding is used to attach thermocouples an ASME Code Section IX Welding Procedure
Specification is required (WPS qualification is not required), and the energy output must be limited to 125 WattSeconds. No other welding is permitted on vessels or parts. [0.5 X Capacitance in farads X Voltage 2 = W-Sec.]
The method of thermocouple removal shall not damage the heat treated item.
QCI Signature:
Date:
Thermocouple Attachment Method:
Location(s):
Furnace Heat Number:

Furnace Operator Signature:
Date:

EDITION 1 REV 0
PAGE 1 OF 2
SECTION 16 MEASURING AND TESTING EQUIPMENT
16.
MEASURING AND TESTING EQUIPMENT
16.1
The purpose of this section describes the control and calibration of measuring and testing equipment
to ensure Code compliance.
16.2
The QCM is responsible for the control of measuring the test equipment with duties that include:
a. Ensuring that all gauges and recorders are identified with a serial number and calibration
expiry date.
b. Maintaining calibration records pertaining to measuring and test equipment which will
include a list(s) of all measuring and test equipment for Code use, and an Equipment
Calibration Log (Exhibit 16.1) and calibration reports for each item. (Pressure gauges must
be calibrated against a standard dead weight tester or a calibrated master gauge that has a
calibration record traceable to national standard.) The maximum interval between
calibrations shall be twelve months. If the item has not been used since the last calibration,
the QCM upon satisfactory examination of the gauge will change the calibration date to one
year, from the date of use.
16.3
The QCI is responsible for the use of test equipment with duties that include:
a) Examining the equipment for visible damage and calibration status.
b) Recording the date of first use of equipment after calibrations, on the Equipment Calibration Log.
c) Ensuring that the range of the gauge is between 1.5 and 4 times the test pressure.
d) Cleaning, inspecting and returning all equipment to the storage area after the test.
a) Identifying any equipment that requires recalibration.
a) Code items that are inspected or tested with measuring and test equipment found to be out of
calibration shall be re-inspected or re-tested, and the measuring and test equipment documented
as a nonconformity in accordance with Section 13 of this Manual. If the Code item has been
shipped, the user or his designated agent shall be notified.
Equipment Calibration Log, Exhibit 16.1

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Page 2 of 2
EXHIBIT 16.1 EQUIPMENT CALIBRATION LOG

EQUIPMENT CALIBRATION LOG
EQUIPMENT DESCRIPTION:
IDENTIFICATION NO.:
Calibration Date
CALIBRATION INTERVAL:
Calibration Record Verified
Date of First Use
Calibration Expiry Date
Calibration Requirements And Instructions:

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PAGE 1 OF 3
SECTION 17 PRESSURE TESTS
17
PRESSURE TESTS
17.1
This section describes the system for conducting all pressure tests including hydrostatic, pneumatic,
services and leak. Pneumatic test procedures, as required, (See Section 24) will be submitted to
ABSA Design Survey Section for acceptance prior to testing. (See Exhibit 17.1 for guidelines for
pneumatic test procedure).
17.2
The QCM is responsible for the implementation of this system in accordance with the following
procedures:
a) All hydrostatic tests performed in the shop/field will be undertaken with maximum regard to
personnel safety. All unauthorized personnel will stay clear of the area where the test is being
performed.
b) The AI will witness the hydrostatic test.
c) Air will be vented from the vessel as it is filled.
d) The metal temperature should not less than 32 degrees F and at least 30 degrees F above the
MDMT but not exceed 120 F for ASME Code Section VIII Division 1 pressure vessels.
e) The pressure will be increased gradually to the test pressure as stated on the accepted drawings
and held
1) for a minimum of 15 minutes for an item without nozzle reinforcing pads, or
2)
for a minimum of 60 minutes when the item has nozzle reinforcing pads.
f) Following the application of the hydro test pressure an inspection shall be made of all joints and
connections. This inspection shall be made at a pressure not less than required by the applicable
construction Code. The pressure will be held for a sufficient time for the AI to complete the
inspection
g)
Two pressure gauges will be used and shall have a range of not less than 1.5 times and not more
than 4 times the test pressure. One gauge will be mounted directly on the item without
intervening valve.
h) Results of all pressure tests, including a record of pressure gauges used, shall be documented on
the Travel Sheet and the Hydrostatic Test Report (Exhibit 17.2)
Guidelines for The Preparation of Pneumatic Test Procedure, Exhibit 17.1
Hydrostatic Test Report
Exhibit 17.2

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PAGE 2 OF 3
SECTION 17 EXHIBITS
EXHIBIT 17.1
GUIDELINES FOR THE PREPARATION OF PNEUMATIC TEST PROCEDURE
Due to the large energy storage in compressed gas and hence the potential hazard of a sudden release of this
energy, pneumatic testing should be avoided if at all possible.
The testing procedure, when required, shall be submitted to ABSA for acceptance before any testing can be
carried out.
The testing procedure must be accompanied by detailed justifications why a standard hydrostatic test is not
feasible.
In addition to strict adherence to the respective Code Sections (e.g. ASME Section VIII Division 1, Para
UG-100 or ASME B 31.3, Para 345.5), the testing procedure should contain as a minimum the following
information:
1)
List of all personnel within the testing area and designated personnel in charge of testing.
2)
Test boundaries of the pressure system with specified maximum pressure x volume (PV) limits,
including listings of piping and/or equipment to be included in the test.
3)
Test site preparations and related precautions undertaken including removal of unauthorized
personnel, isolation of test site, etc.
4)
Test media, pressure source and pressure and temperature ranges of testing.
5)
Provision of Safety Relief Valves which must be sized to handle the maximum output of the pressure
source to avoid excessive testing pressure.
6)
Material specification involved in the test. For materials whose resistance to brittle fracture at low
temperature has not been enhanced, test temperature above 60 F (16 C) may be considered in
reducing the risk of brittle fracture during a pneumatic testing.
7)
Exposure of all joints including weld joints, threaded/flanged connections, etc. All post-weld heat
treatment shall be completed. Should a piping system be tested, all equipment and pressure vessels
shall be disconnected from the piping or isolated by blinds or other safe means.
8)
Method of testing with details of pressure steps, holding time inspection
9)
Precautions taken to prevent gas expansion temperature drop and thermal stresses due to temperature
gradients.
10)
Reference should be made to the Canadian Registration Numbers (CRN) of the system/vessel to be
tested.
methods etc.

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PAGE 3 OF 3
SECTION 17 - HYDROSTATIC TEST REPORT

Exhibit 17.2
HYDROSTATIC TEST REPORT
DATE
SERIAL NUMBER(S):
JOB NUMBER:
VESSEL(S) DESCRIPTION:
HOLDING TIME @ TEST PRESSURE:
GAUGE SERIAL #(S) + CALIBRATION DATE:
RESULTS + COMMENTS:
DATE
Signature of QCM
DATE
Signature of Owners Inspector.
DATE
Signature of AI

EDITION 1 REV 0
PAGE 1 OF 4
SECTION 18 - REPAIRS AND ALTERATIONS OF PRESSURE

VESSELS
18
REPAIRS AND ALTERATIONS SHOP/FIELD
18.1
This section describes the system for controlling the repairs and alterations of pressure vessels. All
other sections of this Manual apply except as modified below.
18.2
All repairs and alterations shall be in accordance with Alberta Safety Codes Act and Regulations.
18.3
The QCM will develop a written procedure for all repairs and alterations containing as minimum the
following information:
a) Vessel description
b) Year built
c) (A) number
d) CRN number
e) Original Manufacturer
f) Owners name
g) Location of vessel
h) Detailed description of the repair/alteration procedure
i) Weld details
j) Welding procedure number
k) Material used (specification number, grade, size)
l) NDE requirements
m) PWHT requirements
n) Pressure test requirements
The Boilers and Pressure Vessels Repair and Alteration Report, (AB-40) may be used to detail the
repair/alteration procedure when suitable.
18.4
The QCM shall obtain acceptance of the repair or alteration procedure from the AI and the owners
approval before starting work. The AI may require that the repair procedure be submitted to Design
Survey Section of ABSA for acceptance.
18.5
The QCM will ensure that copies of the latest repair/alteration procedure and instructions are
provided to all personnel responsible for the repair/alteration.

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PAGE 2 OF 4

VESSELS
18.6
If the vessel is still under warranty, the QCM will contact the owner to obtain acceptance of the
proposed work from the manufacturer.
18.7
For alterations, the Designer will prepare detailed design calculations and drawings in accordance
with applicable Code Section. The QCM will submit the alteration procedure, design calculations
and drawings to the Design Survey Department of ABSA for registration prior to starting work.
18.8
Material required for repair/alterations shall be ordered and controlled in accordance with Section 10
of this Manual.
18.9
Examination and Inspection will be in accordance with Section 11 of this Manual. The QCM will
develop the Repair/Alteration Inspection Checklist (Exhibit 18.1) for each repair or alteration and
present it to the AI prior to the job starting for sign on along with indicating hold and inspection
points.
18.10 When required by the AI, a repair/alteration name plate will be attached to the vessel. The name
plate (Exhibit 11.2), will be modified to suit on an as-needed bases and attached adjacent to the
original name plate with the following information:
a) Name of repair/alteration organization
b) Date and Altered or Re-Rated or Repaired, as applicable
c) MAWP and MDMT
d) Job number
e) CRN number
f) Original Manufacturers Name and Original Vessel Serial Number
18.11 Non-destructive examination shall be performed according to the applicable ASME Code Section
and Section 14 of this Manual.
18.12 Heat treatment shall be in accordance with the applicable ASME Code Section and Section 15 of this
Manual.
18.13 The repaired/altered vessel shall be hydrostatically tested as indicated on the Repair/Alteration
Report unless specifically exempted by the AI.

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PAGE 3 OF 4

VESSELS
18.14 Upon satisfactory completion of the repair/alteration, the QCM will complete and certify the Boilers
and Pressure Vessels Repair/Alteration report (AB-40) and present it to the AI for his acceptance.
18.15 The QCM will assign a separate job number and file for each repaired / altered item.
The file will contain the following information:
a. Drawings
b. Calculations
c. Repair/alteration procedure
d. Purchase Order
e. Material Test Reports
f. NDE records
g. Heat treatment records
h. Repair/Alteration Checklist
i. Boilers and Pressure Vessels Repair and Alteration Report with Manufacturers Partial Data
Reports
j. Non-conformity Report
k. Nameplate stamping facsimile
l.
Manufacturers Partial Data Report with attachments
m. Hydrostatic Pressure Test records
Repair / Alteration Inspection Checklist, Exhibit 18.1

EDITION 1 REV 0
EXHIBIT 18.1 REPAIR/ALTERATION INSPECTION CHECKLIST
PAGE 4 OF 4
Manufacturer / Serial
Number
Boiler / Vessel Title

AI Review:
Alberta (A) Number
Review Date
Indicate Sequence Numbers and Hold Points Which Are Applicable By *
Se
q.
Operations
Hold Points
Repair/Alteration Procedure
Accepted by Authorized Inspector
and Owner
Welding Procedure Specifications

Registered for Welding to be done
Welders Have Valid Alberta P.Q.

Card for work to be done
Cracks MT/PT check after removial
5a
Material to be used - check

against PO/Drawing
material identified with corrected
SA/SB specifications and
examined
for
defects
5b
5c
material test reports checked

against specifications
6a
Fit Up Shell courses -flush

patches -heads
6b
6c
7
8
9
10
11
12
tubesheet/shell-firetube
13
Rep
Org
ABSA
Insp
Owner
Insp.
nozzles & fittings

Radiographic Examination
Ultrasonic Examinmation MT/PT
Internal Visual after welding
External Visual after welding
Heat Treatment
Hardness Test
Gauge
No.'s
Hydrostatic Pressure Test
14
Alternative Test (Specify)
15
Alberta Repair/Alteration Form AB40 complete

Repair/Alteration Nameplate
Attached
16
Comments
OUTLINE SKETCH
(Record Welders Symbols and
Heat No.'s ) Attach Separate
Sketch if required
MATERIAL USED IN REPAIR / ALTERATION

Item
Mat.'l
Plate
Thk.
Sch.
Spec
&
Head
Heat
&
Plate
#
Shell/Patches
Heads/End
Tubesheet
Firetube
Nozzles
Fittings
Flanges
Rating

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PAGE 1 OF 2
SECTION 19 - RECORD RETENTION
19
RECORD RETENTION
19.1
This section describes the records that will be maintained in accordance with Code requirements and
this Manual as stated in scope.
19.2
The QCM will ensure that the following records (as applicable) are maintained in the job file, for a
minimum of five (5) years.
a) Manufacturers Data Report with attachments

b)
Manufacturers Partial Data Report with attachments.
c)
Design specifications for design and field construction of pressure piping systems (AB-96)
d)
Drawings, design calculations and any applicable proof test records in the CRN File
e)
Pressure Piping Data Reports (AB-83)
f)
Material Test Reports and/or material certification
g)
NDE reports
h)
Heat Treatment records and test results.
i)
Physical test reports (CVN, hardness, etc.)
j)
Nonconformity report and Dispositions
k)
WPSs and PQRs as recorded on the construction drawing in the WPS File
l)
Post Weld Heat Treatment Records
m)
Hydrostatic Test Reports
n)
Material lists, spool lists, purchase orders generated by Allied Vessel Fabrication
o)
As built drawings
p) Travel Sheet
q)
Completion of Construction Form (AB-81) for piping
r)
Repair/Alteration Form (AB-40) for repairs and alterations
s)
Repair/Alteration Inspection Checklist.
t) Facsimile of stamped of Nameplate

u) Repair Procedures and Records as defined in Section 18
v) Pressure part documentation and certification

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PAGE 2 OF 2
SECTION 19 - RECORD RETENTION
19.3
Radiographic film may be disposed of after the Manufacturers Data Reports are signed and
accepted by the AI.
19.4
Records documenting Welder / Welding Operator performance qualification and the continuity of
those qualifications shall be maintained by the QCM for as long as the qualifications remain valid,
and for a minimum of three years after the qualifications have expired or the Welder / Welding
Operator have left the employment of Allied Vessel Fabrication.

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PAGE 1 OF 1
SECTION 20 - AUTHORIZED INSPECTORS

20
AUTHORIZED INSPECTORS
20.1
The purpose of this section is to describe the provisions made within this Quality Control Manual to
allow the AI and the AI Supervisor to perform their duties in accordance with the Code and the
Alberta Safety Codes Act.
20.2
The QCM is responsible for liaison with the AI who is an employee of the ASME accredited
Authorized Inspection Agency which is ABSA.
20.3
Allied Vessel Fabrication shall arrange for the AI and the Authorized Inspector Supervisor to have
free access to such parts of all plants as are concerned with the supply or manufacture of materials
for Code items, when so requested. The AI and the Authorized Inspector Supervisor shall be
permitted free access, at all times while work on Code items is being performed, to all parts of the
facility and field sites (including subcontractors) that concern the construction of Code items and to
all documentation related to the construction of Code items.
20.4
A controlled copy of this Quality Control Manual will be available on site for the use of the AI.

EDITION 1 REV 0
PAGE 1 OF 17
21
PRESSURE PIPING
21.1
The purpose of this section is to describe the system for controlling the construction, repair,
alteration or replacement of pressure piping systems. All other sections of this Quality Control
Manual shall apply for pressure piping, except as modified below.
21.2
All pressure piping construction, repair, alteration or replacement shall be in accordance with the
Safety Codes Act, and the ASME piping Codes B31.1 and/or B31.3 as applicable. ASME Code
Boiler External Piping is not within the scope of this quality system.
CONTRACT REVIEW
21.3
The General Manager shall review the contract / order before acceptance to ensure that requirements
are adequately defined. When requirements are inadequately defined or there is no written contract /
order, the General Manager shall contact the client to ensure requirements are clearly stated, agreed
upon, then record the information in the job file and will ensure that;
a) the scope of work is defined, including the applicable ASME Code and service (for example
ASME Code B31.3 service category),
b) when drawings are provided by the owner, that owner has approved the drawings for
construction,
c) when drawings are provided by the owner, that the material list including ASTM / ASME
material specification numbers, grades, schedules, classes and sizes (as applicable), is provided,
d) the required Welding Procedure Specifications (owner or contractors) are specified and qualified
for the job,
e) the degree and type of NDE and type of pressure test is defined, and responsibility for these
requirements is assigned,
f) the responsibility for quality control functions is defined,
g) the responsibility for material procurement is defined,
h) the responsibility for registering the drawings of the pressure piping system exceeding an
aggregate internal volume of 500 liters (18 cubic feet) with ABSA has been assigned, and that
Allied Vessel Fabrication has the capability to meet all contract / order requirements.

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PAGE 2 OF 17
21.3.1 When part of the pressure piping involved in a contract is to be subcontracted, the QCM shall ensure
that;
a) the subcontractor has a valid Alberta Quality Program and Welding Procedure Specifications
suitable for the scope of subcontract work,
b) the contract review procedure is conducted with the subcontractor,
c) the Owner and/or Owners Inspector is advised so that the necessary inspections can be
conducted, and
d) a certified Pressure Piping Construction and Test Data Report (form AB-83), for the
subcontracted work, is received and incorporated into the records required by the contract and this
Quality Control System
NOTE: The General Manager shall make the owner aware that under the Alberta Pressure
Equipment Safety Regulations (PESR) paragraph 11(1), the owner must have the Authorized Quality
Control Program for the scope of work if the owner assumes responsibility for Quality Control
functions such as material receiving inspection, material traceability, Welder supervision and
Welders records, control of N.D.E. on site, conducting pressure tests, and preparing quality control
records. If the owner does not have an Authorized Quality Control Program for any of these
functions, the General Manager shall make the Owner aware that all requirements of this quality
system must be met. The Owner should also be made aware that the design of a pressure piping
system constructed for use in Alberta must be registered when the aggregate internal volume of the
piping, that is not exempt from PESR requirements by PESR paragraph 4(2), exceeds 500 liters [see
PESR paragraph 14(1)].
DRAWINGS, DESIGN CALCULATIONS AND SPECIFICATION CONTROL
21.4
Design drawings, calculations and specifications shall be prepared in accordance with the ASME
Codes and the Alberta Safety Codes Act. These may be prepared by the Owner or by a
subcontracted Designer experienced in ASME pressure piping design. Spool drawings may also be
prepared by Allied Vessel Fabrication when not supplied by others.
21.5
The Designer is responsible for the following functions:

a)
Reviewing the customers specifications to ensure that the piping system can be designed and
constructed in accordance with ASME Code.
b)
Preparing design calculations and design drawings in accordance with the applicable ASME
Code.
c) Reviewing and approving the design drawings and design calculations by initial and date.
d) Verifying that the design drawing contains the following information;

EDITION 1 REV 0
PAGE 3 OF 17
1) material description including; material specification, grade, dimensions, schedule, type

and rating,
2)
design pressure and maximum / minimum design temperature of system, and if

applicable, ASME Code B31.3 service category,
3) nondestructive examination and extent (i.e. random, 100% )

4) test pressure and medium,
5) heat treatment temperature and holding time if applicable,
6) construction details, supports, etc.,
7) Welding Procedure Specification information (e.g. WPS Numbers / electrode
classification) and welding details for each weld, and
8) any additional job requirements.
Spool Drawings
e) Reviewing and approving for construction, any spool drawings prepared by Allied Vessel
Fabrication from owners design specifications and drawings.
Drawing and Specification Distribution
f)
21.6
Maintaining a Drawing Index listing the drawing title, number, revision, number of copies
issued and the name of person or department they were issued to.
The Designer shall be responsible for verifying that the design drawings and specifications have
been submitted in duplicate to the ABSA Design Survey department with the General Engineering
Requirements for Design and Construction of Pressure Piping Systems form (AB-96) and Design
Registration Application form (AB-31) for the system that exceeds 500 liters in aggregate internal
volume of pressure piping that is not exempt from PESR requirements by PESR paragraph 4(2). If
the design documents are to be submitted by the owner, the Designer shall request written
verification of the design registration from the owner (e.g., copy of the registered AB-96 form). For
piping systems exempt from PESR requirements by PESR paragraph 4(2) or 500 liters or less in
aggregate internal volume when not exempt, the submission of designs for registration is not
mandatory; however all pressure piping systems must comply with the requirements of the
applicable Code of construction. All design drawings for pressure piping systems that exceed 500
liters in aggregate internal volume of pressure piping that is not exempt from PESR requirements by
PESR paragraph 4(2) shall be stamped by Registered Professional Engineer.

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PAGE 4 OF 17
21.7
If the owner has not prepared design specifications, and the piping system meets the following
criteria;
a) for a new piping system when the aggregate internal volume of piping that is not
exempt from PESR requirements by PESR paragraph 4(2) is 500 liters or less, or
b)
21.8
repairs or alterations to existing piping systems, when aggregate internal volume

of piping that is not exempt from PESR requirements by PESR paragraph 4(2) is 500
liters or less; then the Designer shall prepare a Pressure Piping Specification Sheet
(Exhibit 21.1) to fulfill the specification requirements of paragraph 21.4 and 21.5.
The Designer shall obtain approval of these specifications from the Owner before
construction.
The QCM is responsible for the control of all documents and drawings with duties to include:
a)
Releasing all drawings by stamping (or writing) ISSUED FOR CONSTRUCTION

on the drawing, and initialing/dating each drawing.
b)
Obtaining approval from owner before making any proposed changes.
c)
Initiating a Job File and ensuring that all design specifications, owners material lists,
P.O.s etc. are kept in this file, and is identified with the job number.
Job File
Drawing and Specification Distribution

d)
Issuing drawings, specifications, Welding Procedure Specifications, P.O.s material

lists and applicable quality control forms to each Quality Control Inspector.
e)
Recalling and destroying all superseded documents. Alternatively, these may be

marked VOID and kept in Job File.
f)
Obtaining the owners approval for any revisions, and submitting the final as built
drawings to the owner along with all pertinent records

EDITION 1 REV 0
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21.9
The QCI shall be responsible for the handling of drawings, specifications and
documents at job sites with duties including:
a)
Maintaining job file(s) at site containing drawings, specifications, Welding Procedure

Specifications, P.O.s material lists and applicable quality control forms and
documents. Issuing drawings and specifications to site personnel. Collecting and
marking VOID on, or destroying all superseded documents.
b)
Forwarding the job file to the QCM when the job is complete.
MATERIAL CONTROL
21.10 All material shall be controlled as per Section 10 of this Quality Control Manual except as modified
below.
NOTE: All material receiving, identification / verification and code requirements defined in this section,
and Section 10, also apply to Owner supplied material. When the owner supplies material, it shall be
checked by the QCI upon receipt against the Owners Material list.
21.11 Any proposed material substitution must be approved in writing by the Owner and Designer of the
pressure piping system. Revised drawings and specifications shall be prepared and issued in
accordance with this section of the Quality Control Manual.
21.12 The QCI is responsible for the receiving and storage of material at site with duties that include:
a) Checking all incoming material against the Purchase Order / Owners material list, and packing
slip for;
visible damage
2) correct dimensions, and
3) correct material markings, specification and grade, size, schedule, rating, name
of manufacturer or trademark, etc as applicable.
1)
b) Checking MTRS against the material markings and verifying that all material markings match
those described on the MTRS and confirming that the MTRS are identified with the job number;
acceptance shall be indicated by initial and date on the MTR.
c) Segregating and marking acceptable material in accordance with Section 10 and paragraph 21.14
of this Quality Control Manual.

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21.13 Any material / item that does not meet above requirements shall be considered a nonconformity and
shall be processed in accordance with Section 13 of this Quality Control Manual.
21.14 The QCI is responsible for identification and traceability of all material at site.
He / She shall;
a) ensure that the correct color code is provided to site personnel,
b) mark each acceptable pipe for its full length with a paint strip using the color coding
shown in Exhibit 10.3. If required by the owners specifications, an alternate color code
may be used or material specification, grade and heat number shall be marked on each
piece, and each cut off prior to cut,
c) verify that the above identification is maintained on each piece of pipe throughout
construction, repair or alteration,
d) ensure piping spools received at site are identified with the line number, spool number or
job number, and that spool lists are supplied with each shipment. (a certified Pressure
Piping Construction and Test Data Report form AB-83] is required)
e) When pressure vessels and skid package units form part of the pressure piping at field
sites, the QCI will visually examine each pressure vessel and skid package upon arrival
and will notify Owner's Inspector if damage is suspected. The ABSA Safety Codes
Officer shall be notified when system has been completed to enable him to verify the
pressure vessel installation. He shall also be informed immediately if any pressure vessel
is damaged.
f) verify that all material left at end of project is fully identified and itemized
WELDING CONTROL
21.15
Welding activities and consumables shall be controlled in accordance with Section 12 of this
Quality Control Manual. Welding tasks shall be assigned by the Field Manager or the QCI based upon the
qualifications documented on the Welders log that is provided by the QCM.

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EXAMINATION AND INSPECTION SYSTEM

21.16 Under the piping, Codes, inspection applies to functions performed by the Owners Inspector; and
examination to functions done by Allied Vessel Fabrication. It is the Owners responsibility to
provide an inspector who shall inspect the piping to verify that all examination requirements have
been completed in accordance with the Code and Owners design specifications. Inspection by the
Owner does not relieve Allied Vessel Fabrication from the responsibility of performing all
examinations required by Code, Owners specifications and this Quality Control System.
21.17 The QCM is responsible for the examination program and shall;
a) ensure that each individual assigned to perform quality control functions is competent
and fully understands all applicable requirements referred to in this Quality Control
Manual,
b) issue Quality Control Manuals, Owners specifications, drawings, WPS, quality control
forms, ABSA forms, material lists, Purchase Orders, calibration records, and all other
required documents pertaining to the job to the QCI prior to start of work,
c) review all completed records for compliances with Code, Owners specifications, this
Quality Control System, and if required, forward the Completion of Construction
Declaration Form (AB-81) to ABSA prior to operation of the piping system,
d)
forward a certified Pressure Piping Construction and Test Data Report for Piping System (AB-83) to the
owner with any additional records required by the contract.
21.18
Under the direction of QCM, the QCI is responsible for the implementing the examination
program on site and shall;
a)
initiate a Job File, and maintain all applicable records detailed in paragraph 21.21 in this
file,
b) prior to starting fabrication, notify the Owners Inspector of the job and obtain
inspection hold points,
c)
perform all the examinations required by the construction Code. These examinations
may be documented on the Pressure Piping Examination Checklist (Exhibit 21.2)
Additional examination may be documented on the back of the check list when
necessary.

EDITION 1 REV 0
PAGE 8 OF 17

21.18
d)
sign and date each function on the Pressure Piping Examination Checklist when all
examinations have been satisfactorily completed,
e)
communicate with the Owners Inspector to arrange for inspection and sign off, when
the inspection hold points are reached,
f)
examine each system after completion, prior to test against design specifications and
drawings using the Pressure Piping Examination Guide (Exhibit 21.3),
g) prepare and certify the Alberta Pressure Piping Construction and Test Data Report (AB83) for all spools and /or completed system constructed by Allied Vessel Fabrication and
present the form to the Owners Inspector for certification. If required, prepare and sign
the Completion of Construction Declaration Form (AB-81) for piping systems over 500
liters in aggregate internal volume constructed by Allied Vessel Fabrication, or sign the
Pressure Piping Specification Sheet indicating completion for piping systems with an
aggregate internal volume of 500 liters or less,
h) verify that the as built drawings have been revised to incorporate all changes and that
the changes have been approved by the Owner, and
i)
forward the Job File, drawings, reports and radiographs to the QCM.
PRESSURE TESTS
21.19 The QCM is responsible for the implementation and control of this section with duties that include;
a)
Preparing the written test procedure for all pressure tests in accordance with the
applicable Code, and job specifications.
b) Ensuring that the test procedure is accepted by the Owners representative before test.
c) For pressure piping systems over 500 litres in aggregate internal volume, submitting all
proposed pneumatic test procedures to the ABSA Design Survey department for
acceptance before the test.
d) For pressure piping systems equal to or less than 500 litres in aggregate internal volume,
if pneumatic testing is required (as determined in accordance with the construction
Code), ensuring that the pneumatic test procedure used is consistent with the ABSA
standard procedure (Section 24) and that all safety precautions in the procedure are
enforced. When the procedure described in Section 24 is followed, acceptance by ABSA
Design Survey department is not required.
e) Distributing the test procedure to site personnel.

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PAGE 9 OF 17
PRESSURE TESTS
21.20
a)
The QCI s Duties Include;

Notifying the Owners Inspector, reasonably in advance of any pressure test.
b) Witnessing all pressure tests, verifying that the tests were performed in accordance
with the approved procedures, job specifications and noting or high lighting the spool
drawings as to track the testing.
c)
Examining the system before the test and after completion using the Pressure Test
Examination Guide (Exhibit 21.4).
RECORD RETENTION
21.21
The QCM will ensure that the following records are maintained in the engineering file,
identified by job number, for a minimum of five years;
a.
design specifications,
b. Drawings,
c.
Pressure Piping Construction and Test Data Report
d.
Material Test Reports (MTRs)
e.
NDE reports
f.
Physical test reports (e.g., mechanical or hardness tests),
g. heat treatment records

h. Nonconformity Reports,
i. Welders records and weld identification maps,
j. Welding Procedure Specifications,

EDITION 1 REV 0
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RECORD RETENTION
21.21
k. pressure test procedures and reports
l. material lists, spool lists, Purchase Orders generated by Allied Vessel Fabrication,
m. copy of NDE Examiner certificates, and
n. as built drawings.
ADDITIONAL REQUIREMENTS FOR MECHANICALLY ASSEMBLED PIPING

DRAWINGS, DESIGN CALCULATIONS AND SPECIFICATION CONTROL
21.22 Threaded piping shall be designed and constructed within the specific service limitations of ASME
Pressure Piping B31.1 and B31.3 Codes, as applicable. Repairs and alterations of threaded piping
will be completed in accordance with the Alberta Safety Codes Act and Regulations and, insofar as
possible, in accordance with above Codes of construction. Threaded piping is specifically not
permitted under the following service conditions:
For ASME B31.1 Applications

Wherever severe erosion, crevice
corrosion, shock or vibration is expected to
occur, and at temperatures over 925
degrees F. Outside of these exclusions
nominal pipe size and thickness limitations
govern.
For ASME B31.3 Applications

Severe cyclic service conditions (except as
permitted in par. 314.2).
Threaded piping should be avoided wherever
severe erosion, crevice corrosion, or cyclic
loading may occur.

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PAGE 11 OF 17
21.23 In addition to the previous conditions, for ASME B31.3 applications, threaded piping shall be
designed and constructed for normal fluid service and Category D fluid service only (fluid service
categories are defined in ASME B31.3, paragraph 300.2).
21.24 The Designer is responsible for the design of mechanically assembled pressure piping systems in
accordance with construction Code requirements and when applicable, referencing the mechanical
assembly procedures on the construction drawing. Some specific duties related to mechanically
assembled piping include:
FOR B31.1 APPLICATIONS
a) Ensuring that whenever threaded piping is utilized for B31.1 construction that as a minimum (in
accordance with paragraph 114.3) standard weight pipe is used, and for steam service over 250
psi or water service over 100 psi and 220 degrees F the pipe shall be seamless having a minimum
tensile strength of 48,000 psi and a weight at least equal to Schedule 80. Paragraph 114.2.1 also
further limits the use of threaded joints in steam and hot water service to a specified maximum
nominal pipe size, dependent upon the maximum pressure.
b) Ensuring that when threaded piping is utilized in specific piping systems for various service
conditions, that the service related requirements of paragraph 122 are met and that whenever
threaded piping is utilized for toxic or flammable fluids or gases the pipe thickness is no less
than extra strong, regardless of pressure.
a) Verifying that threaded piping layout minimizes stress on joints and that special
consideration is given for stresses due to thermal expansion. Additionally, the QCM
shall confirm that there are provisions made to counteract forces that would tend to unscrew
the joints.
b) Ensuring that threaded flanges in which the pipe ends project through to serve as the
gasket surface are used only for Category D fluid service.
c) Verifying the following design requirements, for taper-threaded joints;
(1) that the minimum thickness of male components shall be in accordance with
Table 314.2.1 and its notes as specified in ASME B31.3
(2) female threaded components shall be at least equivalent in strength and
toughness to threaded components listed in Table 326.1 of ASME B31.3 and
otherwise suitable for the service, and

EDITION 1 REV 0
PAGE 12 OF 17
21.24
(3) couplings having straight threads may be used for Category D fluid service only,
and only with threaded mating components.
f)
Ensuring that the design and assembly of tubing joints complies with ASME B31.3
paragraphs 315.1, 315.2 and 315.3 and 315.4.
g)
Ensuring that the design and assembly of flanged joints complies with ASME B31.3
paragraphs 312, 335.1 and 335.2.

21.25 The QCM shall ensure that the applicable Allied Vessel Fabrication Threaded Piping
Procedure is referenced on the construction drawing and that the referenced Threaded Piping
Procedure specifies;
a) fluid service or range of fluid service that the procedure is applicable to, applicable pipe
materials, pipe sizes and minimum wall thickness to be used,
b) pipe thread assembly dimensional requirements (e.g., the sample of dimensional
requirements illustrated in Exhibit 21.5 may be appropriately modified to include within
the threaded piping procedure),
c) drill sizes for pipe taps, and
d) type of pipe joint sealant to be used.
Pressure Piping Specification Sheet,
Pressure Piping Examination Checklist,
Pressure Piping Examination Guide,
Pressure Test Examination Guide,
Sample-Pipe Thread Assembly Dimensional Requirements,
Exhibit 21.1
Exhibit 21.2
Exhibit 21.3
Exhibit 21.4
Exhibit 21.5
ABSA Alberta Government (Municipal Affairs) Forms

General Engineering Requirements for Design and Construction of Pressure Piping Systems, AB-96

Pressure Piping Construction and Test Date Report AB-83
Completion of Construction Declaration Form AB-81

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PAGE 13 OF 17
XHIBIT 21.1 PRESSURE PIPING SPECIFICATION SHEET

PRESSURE PIPING SPECIFICATION SHEET
(For Construction/Repair/Alteration of Pressure Piping Systems Less Than or Equal to 500 Litres, Aggregate Internal Volume)
Owner:
Contractor
:
AQP:
Plant Location:
Item
No.
Line
No.
Job
Material List
Mat'l Spec.
Description
& Grade
Design
Pressure
Design
Temp.
Min. / Max.
Piping Sketch (Reference attached drawings if appropriate)

(use for recording RT Nos. & Welder Symbols)
Sch./
Rating
Corr.
All.
Code
ASME
B31.3
Service (e.g.,
Normal,
Cat. D, M, K)
Severe
Cyclic
Yes/No
Test
Pressure
Test
Medium
(Note: Pneumatic tests must have prior acceptance from ABSA.)
Welding Procedure Specification Nos:

Numbers:
Line
MT / PT
Radiography
No.
Extent %
Extent %
NDE Contractor:
Hardness
Testing
Ultrasonic - Other NDE

Description / Extent %
Other Requirements
Post Weld Heat Treatment Yes/N.A.:
Post Weld Heat Treatment Time/Temp.:
PWHT Contractor:
Approved by Owner:
Date:
Approved by Contractor:
Date:
Comments:
WORK COMPLETED AND ACCEPTED (AB-83 completed)

Contractor Signature:
Date:

EDITION 1 REV 0
XHIBIT 21.2 PRESSURE PIPING EXAMINATION CHECKLIST
PAGE 14 OF 17
PRESSURE PIPING EXAMINATION CHECKLIST

JOB NUMBER:
NO.
FUNCTION
SIGNATURE OR INITIAL
AND DATE
Q.C
INSPECTOR
DRAWINGS: ABSA registration over 0.5 Cu. M. Approved by Owner.

Approved for Construction (signed & dated).
Owners Inspector notified.
Registered Welding Procedure Specifications, Q.C. Manual and Forms

available at site, Job File started.
Welders qualified for WPSs and have valid Performance Qualification cards.
Welders Log completed. WPS reviewed with Welders.
Material checked against P.O., drawings, and specifications. Identification

confirmed. Colour coding applied.
Sample of each Welders work examined, including root spacing, alignment,

cleaning, joint preparation, preheat and electrode control.
Nondestructive Examination completed. Reports and radiographs reviewed,

signed by Level II or III, Radiograph I.D. detailed on drawings.
Visual Examination of all completed welds. Welders I.D. stamped and

recorded on drawings.
Heat Treatment verified and recorded on drawings.
10
Each system checked against specifications and drawings before test.
11
All deficiencies recorded and signed off by Q.C.I. and Owners Inspector
before test.
12
Pressure Test checked. Gauge calibration verified, gauge #s recorded.
13
System checked after test. Deficiencies recorded and corrected.
14
Construction data reports (AB-83) prepared and signed by Q.C.I. and

Owners Inspector.
15
Declaration form (AB-81) submitted to ABSA
16
As built drawings accepted by Owner.
OWNERS
INSPECTOR

EDITION 1 REV 0
XHIBIT 21.3 PRESSURE PIPING EXAMINATION GUIDE
PAGE 15 OF 17
PRESSURE PIPING EXAMINATION GUIDE
Q.C. INSP.
EXAMINATION PRIOR TO PRESSURE TEST (PUNCHING)

1. Pipe Material; schedule and specification correct.
2. Flanges; ratings, schedule and material specification correct.
3.
Fittings; tees, return bends, reducers, couplings and weld-o-lets etc. Correct schedule and
material specification.
4. Valves; identification Manufacturers name tag, etc., correct.

5.
Valves; installed correctly, flow direction, accesses, rising stems free from obstructions,
clearance for removal adequate.
6. Lubrication fittings, drains, etc., installed as required.

7.
Bolts, Studs, Nuts; length and material correct. Studs at least flush with heads (max.
Thread exposure beyond nut should be about 2 threads)
8. Gaskets are correct type, material, size, etc.

9. All welding satisfactory and traceable to Welders symbol.
10. Seal welding complete - threads covered.
11. All attachment welds satisfactory.
12. All N.D.E., heat treatment complete, records filed.
13. Guide anchors and shoes required installed correctly. (High temp. lines)
14. Line supports adequate - supports to be checked against drawings.
15. Spring hangers - correct type, correct installation.
16. Lines have adequate allowance for expansion.
17. Bellows type expansion joints - correct type, pressure rating and correct installation.
18. Required cold spring applied.
19. Orifice runs have specified straight length of pipe - located correctly etc.
20. All deficiencies recorded on Punch List.
QCI Signature:
Date:

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PAGE 16 OF 17
XHIBIT 21.4 PRESSURE TEST EXAMINATION GUIDE

PRESSURE TEST EXAMINATION GUIDE
Q.C. INSP.
PRESSURE TEST PREPARATION

1. All punch list items corrected.
2. Test blinds correct thickness.
3.
All items which could be damaged by test isolated or removed (control valves, pressure relief
valves, instruments, expansion joints, etc.)
4. Equipment with internals (e.g., filters) that could be damaged is isolated as required.
5. Vents and drains correctly installed.
6. Open and Closed position of all valves verified.
7. Shipping bars in place - bellows.
8. Hanger stops in place.
PRESSURE TEST COMPLETION

1. All temporary blinds (blanks) removed.
2. Temporary gaskets changed for correct gaskets.
3. Temporary supports removed.
4. Shipping bars removed from bellows.
5. Spring hanger stops removed - cold setting checked.
6. Pressure Relief Valves UV or V symbol and correct set pressure and capacity installed.
7.
Safety valve vents are correct size - adequately supported - drain holes and or weather
hoods installed.
8. Screens for pumps and compressors installed (initial start-up and permanent screens).
QCI Signature:
Date:

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PAGE 17 OF 17
PIPE THREAD ASSEMBLY DIMENSIONAL REQUIREMENTS
ASME STANDARD, B1.20.1 TAPER PIPE THREAD DIMENSIONS
Because of the taper, a pipe can only screw into a fitting a certain distance before it jams, unlike threading a
nut on a bolt. The standard specifies this distance, the effective thread (F). It also specifies another distance,
the engagement, which is the distance the pipe can be screwed in by hand without much effort. For
workers, instead of these distances, it may be more convenient to know how many threads (i.e., turns) to
make by hand and how many with a wrench (e.g., provided in the two right columns in the table below).
The table shows the distances and number of turns called for in the standard. A tolerance of plus or minus
one turn is allowed. All dimensions are in inches except for columns specifying number of threads.
NOMINAL
PIPE
SIZE
(NPS)
NUMBER
OF THREADS
PER INCH
O. D.
OF PIPE
D
1/8
1/4
3/8
1/2
3/4
1
1-1/4
1-1/2
2
2-1/2
3
3-1/2
4
27
18
18
14
14
11.5
11.5
11.5
11.5
8
8
8
8
.405
.540
.675
.840
1.050
1.315
1.660
1.900
2.375
2.875
3.500
4.000
4.500
MINOR DIA.
LENGTH OF
PITCH DIA. AT
AT SMALL
EFFECTIVE
START OF EXT.
END OF
THREAD,
THREAD E
PIPE *1
EXTERNAL F
0.3339
0.4329
0.5676
0.7013
0.9105
1.1441
1.4876
1.7265
2.1995
2.6195
3.2406
3.7375
4.2344
.36351
.47739
.61201
.75843
.96768
1.21363
1.55713
1.79609
2.26902
2.71953
3.34062
3.83750
4.33438
Example Hand Engagement plus Wrench Makeup Lengths not

necessarily equal to Length of Effective Thread
LENGTH OF
ENGAGEMENT
TIGHTENED
BY HAND
WRENCH
MAKEUP
LENGTH
0.180
0.200
0.240
0.320
0.340
0.400
0.420
0.420
0.436
0.682
0.766
0.821
0.844
0.111
0.167
0.167
0.214
0.214
0.261
0.261
0.261
0.261
0.250
0.250
0.250
0.250
.2639
.4018
.4078
.5337
.5457
.6828
.7068
.7235
.7565
1.1375
1.2000
1.2500
1.3000
HAND
WRENCH
TIGHT
MAKEUP
THREADS THREADS
4.86
3.60
4.32
4.48
4.75
4.60
4.83
4.83
5.01
5.46
6.13
6.57
6.75
3
3
3
3
3
3
3
3
3
2
2
2
2
*1 Minor Diameter at Small End of Pipe - given as information for use in selecting tap drills.

EDITION 1 REV 0
Revision Date July March 18, 2013
PAGE 1 OF 5
SECTION 22 - CONSTRUCTION OF MINIATURE VESSELS AND FITTINGS
22
22.1
CONSTRUCTION OF MINIATURE VESSELS AND FITTINGS

The purpose of this section is to describe the special procedures and controls for the construction and
inspection of miniature vessels and registered category A, E and H pressure fittings in
accordance with the Alberta Safety Codes Act and Regulations, and CSA B51.
22.2
Supplementary to the requirements of CSA B51, the following items will be submitted for design
registration as pressure vessels in accordance with the regulations under the Alberta Safety Codes
Act:
a)
c)
e)
22.3
steam jacketed sterilizers,

steam jacketed kettles,
compressor bottles,
b)
d)
f)
autoclaves,
air cooled heat exchanger headers,
hairpin type heat exchangers.
Pressure Vessels categorized by CSA B51 and the ASME Code [Section VIII, Division 1, paragraph
U-1(j)] as Miniature Pressure Vessels will be manufactured in accordance with all of the
requirements this Quality Control Manual, CSA B51 and the ASME Code with the following
additions and/or exceptions:
a) Any pressure vessel that is not provided with a quick actuating closure, or required by the ASME
Boiler and Pressure Vessel Code to be fully radiographed, and where the pressure vessel does not
exceed the pressure-volume limits described in sub-paragraphs 1 through 3 below shall not be
required to be inspected by the AI;
(1) 5.0 cu. ft. (0.15 cu. m.) in capacity and 250 psi. (1725 kPa) design pressure, or
(2) 3.0 cu. ft. (0.085 cu. m.) in capacity and 350 psi. (2415 kPa) design pressure, or
(3) 1.5 cu. ft. (0.0425 cu. m.) in capacity and 600 psi. (4140 kPa) design pressure.
(NOTE: Straight-line interpolation for intermediate volumes and design pressures is permitted,
as illustrated in Exhibit 22.1.)
b) The QCM has the responsibility of assuring that the quality control, the detailed examinations,
and the tests required by this Quality Control Manual and by the Code are completed. Some of
the Code specified responsibilities are summarized in Section VIII, Division 1, paragraph UG90.
c) The duties, responsibilities, activities and certification of the Certified Individual are described in
the Certified Individual Requirements (Exhibit 22.2) document.
d) The Travel Sheet (Exhibit 11.1) shall be initialled and dated by the QCI, as each examination
function is completed. On the back side of the Travel Sheet the material tabulation details (i.e.,
verified thickness and material identification markings) and Welders symbols for specific joints
shall be recorded, and fit-up visual examination records shall be initialled but not dated to
indicate completion and acceptance.
e) The QCM shall ensure that the correct hydrostatic test pressure is applied to the completed vessel
as specified on the approved drawing.

EDITION 1 REV 0
PAGE 2 OF 5
f) Each item registered as a vessel will be identified with a nameplate (Exhibit 11.2), or through
direct stamping in compliance with ASME Code Section VIII, Division 1, paragraph UG-116
with the addition of the CRN number. The QCM shall ensure that all data on the nameplate or
stamping is in accordance with the Manufacturers Data Report and the approved drawing.
g) The QCM shall ensure that the correct nameplate is attached to the proper vessel.
h) The QCM shall prepare and certify the CSA B51 Manufacturers Data Report for Miniature
Pressure Vessels (AB-24) and all other documents pertaining to the completion of the vessel.
i) Upon verification of compliance with all applicable Code requirements the Certified Individual
shall sign the Manufacturers Data Report for Miniature Pressure Vessels Certificate of
Compliance, prior to his release of control of the pressure vessel.
j) The QCM will distribute the Manufacturers Data Report to;
(1) the user or his designated agent,
(2) the job file, and
(3) the jurisdiction where the vessel will be installed.
Note: For Miniature vessels without AI inspection, manufacturers are advised to confirm acceptance of
these vessels with the jurisdiction at the location of installation. Some jurisdictions do not permit
installation of small vessels without the ASME Code certification mark.
22.4
Category A, E and H pressure fittings will be manufactured in accordance with this Quality
Control System with the following additions and/or exceptions:
a) The Designer will complete the Statutory Declaration (AB-41) for all items that qualify as
pressure fittings, and submit this document in triplicate along with a Design Registration
Application (AB-31) to ABSA Design Survey. Before the manufacture of pressure fittings for
installation in other jurisdictions, the applicable jurisdiction should be contacted to determine
requirements for design and construction.
b) If the design is the property of the customer, then the Designer must obtain a copy of the
registered Statutory Declaration for the item and confirm that it meets the specifications
indicated. The Designer will confirm that a CRN has been issued in accordance with the
requirements of CSA B51.
c) ABSA Design Survey may require that unusual designs be proof tested in accordance with
ASME Code Section VIII, Division 1, paragraph UG-101. The QCM shall arrange to have these
tests witnessed by the AI. The test will be documented on a Proof Test Report, which will be
signed by the QCM and AI attesting to the results of the testing.

EDITION 1 REV 0
PAGE 3 OF 5
d)
All pressure fitting design registrations expire 10 years after the issue date. Prior to starting
construction of a pressure fitting the QCM shall verify that the CRN was issued or re-issued within
10 years. If the existing CRN is more than 10 years old the design shall be re-submitted.
e)
A Travel Sheet (Exhibit 11.1) shall be initiated for each fitting or concurrent batch of
pressure fittings manufactured. The QCI is responsible to initiate the Travel Sheet and sign off all
applicable inspection tasks as they are completed
f)
In instances where a Category H Fitting Containing Lethal Substances is to be manufactured,
fabrication inspection by the AI is required by CSA B51 Figure 1(c). The required fabrication
inspection shall be conducted in accordance with Section 11 of this Quality Control Manual.
g) Each Category A and Category H pressure fitting constructed to a Standard that contains
specific marking requirements shall be marked in accordance with the Code or Standard of
construction. Category A pressure fittings that are constructed to a proprietary design shall be
marked as follows (using MSS SP-25 as a guide):
AVF
MAWP _____ PSI AT ___ DEG. F
S A-106 Gr. B
HT. NO. _________
4 NPS
CA.______.
h)
Category E and H pressure fittings that are not miniature pressure vessels will, as a
minimum, be marked in accordance with specification MSS SP-25. Where possible the full
identification and marking as shown in the example below will be die stamped on the fitting or on a
nameplate attached to the fitting (if corrosion allowance affects the pressure rating of the fitting then
the rated corrosion allowance will be part of the marking):
AVF
CRN _________
S/N _________
MAWP______ PSI AT ______ DEG. F
MDMT _____ DEG. F AT _____ PSI
YEAR BUILT _______
CA._____
i) Miniature pressure vessels registered as category E or H pressure fittings (e.g., strainers,

separators, etc.) will be identified with a nameplate (Exhibit 11.2), or through direct stamping in
compliance with ASME Code Section VIII, Division 1, paragraph UG-116 with the addition of the
CRN number.

EDITION 1 REV 0
PAGE 4 OF 5
j) A CSA B51 Manufacturers Data Report for Miniature Pressure Vessels (AB-24) shall be used to
document the compliance of miniature pressure vessels registered as category E or H pressure
fittings. When this form is used to document pressure fitting compliance there is no requirement for
a Certified Individual to sign the Manufacturers Data Report for Miniature Pressure Vessels. Up to
5 days consecutive production of identical items may be documented on a single report.
k)
22.5
The QCM will distribute the Manufacturers Data Report to;

(1) the user or his designated agent, and
(2) the job file.
The AI or the Authorized Inspector Supervisor reserves the right to audit this Quality Control System
for Code compliance, at any time, while Code work is in progress.
Travel Sheet, Exhibit 11.1

Miniature Pressure Vessel Pressure Volume Limits, Exhibit 22.1
Certified Individual Requirements, Exhibit 22.2
ABSA/Alberta Government (Municipal Affairs) Forms
Statutory Declaration, AB-41

CSA B51 Manufacturers Data Report for Miniature Pressure Vessels, AB-24

EDITION 1 REV 0
PAGE 5 OF 5
EXHIBIT 22.1 MINIATURE PRESSURE VESSEL- PRESSURE VOLUME

LIMITS

EDITION 1 REV 0
PAGE 1 OF 1
EXHIBIT 22.2 CERTIFIED INDIVIDUAL REQUIREMENTS

The purpose of this document is to describe the duties, responsibilities, activities and certification of the
Certified Individual.
The General Manager of Allied Vessel Fabrication is responsible for verifying the qualifications of a
prospective Certified Individual and for the certification and appointment of the Certified Individual.
The responsibilities of Allied Vessel Fabrication relative to the Certified Individual are as follows:
a) Ensuring that the Certified Individual is knowledgeable regarding the Allied Vessel Fabrication
Quality Control System and ASME Section VIII, Division 1 and referenced Code Sections.
b) Verifying that the Certified Individual has the requisite knowledge, acquired through training
and/or experience, commensurate with the scope and complexity of the required oversight
activities. Or providing the additional training necessary to fulfil this requirement.
c) Maintaining records of the training, experience and certification of the Certified Individual.
d) Evaluating, on an annual basis, the knowledge and ability of the Certified Individual to perform
the required duties. Continued certification shall be documented and may be based upon;
(1) continued satisfactory performance, or
(2) re-training and re-certification.
e) Providing the Certified Individual with all documentation (e.g., drawings, Travel Sheet,
procedures, specifications, MTRs, etc.) necessary for him to perform his oversight activities.
f) Requiring the Certified Individual to participate in annual audits conducted by the Authorized
Inspection Agency and the triennial joint review.
g) Re-certifying the Certified Individual every three years.
The duties of the Certified Individual are as follows:
a) Reviewing the documentation for each miniature pressure vessel to be certified, to verify that the
examination, testing and material requirements of ASME Section VIII, Division 1 have been
met.
b) Witnessing all miniature vessel pressure tests.
c) Performing oversight of QCM and QCI activities relative to miniature pressure vessel
construction.
d) Signing miniature pressure vessel Manufacturers Data Reports after the QCM has certified the
Manufacturers Data Report for Allied Vessel Fabrication.

EDITION 1 REV 0
PAGE 1 OF 4
SECTION 23 CONSTRUCTION OF INDIRECT FIRED HEATER COILS
23.1
The purpose of this section is to describe the special procedures and controls for the
construction and inspection of indirect fired heater coils. All construction of indirect fired heater
coils shall be in accordance with the Alberta Safety Codes Act and Regulations, CSA B51 and
ASME Code B31.3. All other sections of this Quality Control Manual shall apply, except as
specifically modified within this section. Retention of the applicable Indirect Fired Heater Coil
records of construction will be as specified within Section 21, for pressure piping constructed to
ASME B31.3 Code.
23.2 The design, construction, installation, inspection and testing of indirect fired heater coils shall
be in accordance with the Alberta Safety Codes Act and Alberta Energy Resources Conservation
Board (ERCB) requirements, as applicable [for Alberta pipeline service, reference ERCB Directive
077 Pipeline Requirements & Reference Tools.
23.3 The Designer shall be responsible for verifying that the design drawing and specifications
have been submitted in duplicate to the ABSA Design Survey department accompanied by a Design
Registration Application (AB-31) for all indirect fired heater coil designs. The Designer shall ensure
that each indirect fired heater coil design has been issued a CRN number.
23.4 All material shall be ordered to an ASME SA/SB specification, with a request for Material
Test Reports for all pressure retaining components (e.g., pipe, return bends, flanges, etc.).
23.5 Inspection by the AI is mandatory.
23.6 The QCM shall initiate an individual Indirect Fired Heater Coil Travel Sheet (Exhibit 23.1)
for each coil to be constructed. This document is to be presented to the AI prior to the start of
construction. With the acceptance of the AI, the inspection and hold point designation that must
occur prior to commencing construction may be completed by telephone or fax. Contact must be
made with the AI, either verbally or by return fax, prior to construction.
23.7 The AI shall be notified reasonably in advance of any hold points. Work shall not proceed
beyond an established hold point until the AI has released the hold by initialling and dating the
Indirect Fired Heater Coil Travel Sheet.
23.8 The QCM shall prepare the Manufacturers Data Report For Indirect Fired Heater Coils (AB28) and verify that the nameplate information is complete and correct. Nameplates, (Exhibit 23.2)
for coils shall be completely hand stamped with all required information and presented to the AI.
After the AI has found the pressure test acceptable, the QCM will certify the Manufacturers Data
Report and then present it to the AI for acceptance.
23.9 After signing the Manufacturers Data Report the AI will apply the Alberta A number to
the nameplate for heater coils that are to remain in Alberta. The QCM is responsible for ensuring
that the completed nameplate is installed on the correct coil assembly.

EDITION 1 REV 0
SECTION 23 CONSTRUCTION OF INDIRECT FIRED HEATER COILS
Indirect Fired Heater Coil Travel Sheet (Exhibit 23.1)

Heater Coil Sample Nameplate (Exhibit 23.2)
ABSA/Alberta Government (Municipal Affairs) Forms
Design Registration Application, (AB-31)

Manufacturers Data Report For Indirect Fired Heater Coils, AB-28
PAGE 2 OF 4

EDITION 1 REV 0
PAGE 3 OF 4
EXHIBIT 23.1 INDIRECT FIRED HEATER COIL TRAVEL SHEET

DO NOT START CONSTRUCTION WITHOUT AI REVIEW
AI REVIEW:
REVIEW DATE:
SERIAL NO.:
JOB NO.:
DRAWING NO.:
1.
Calculations in File
2.
Release of Appd Dwg.
3.
Materials Examined
4.
Heat Numbers
Recorded
5.
MTRs Checked
6.
W.P.S. Checked
7.
Welders Qualified
8.
Thicknesses Verified
and Recorded
9.
Fit-up Examination(s)
Fit-up Acceptable
9.
Impact Tests
11.
Welds Examined
12.
Welder I.D. Checked
13.
Final External
Inspection
14.
Radiography
15.
Other N.D.E.
16.
Final Ext. Prior to

P.W.H.T.
17.
PWHT Chart Checked
18.
Hydrostatic Test
19.
CRN Drawing
20.
N.C.R. #
21.
Nameplate Stamping
22.
Data Report (AB-28)

completed
23.
Nameplate Installation
COIL TYPE:
DWG. REVISION NO.:
Item
Seq.
TRAVEL SHEET REVISION NO.:
Comments
Coil
No. 1
Gauge #
Coil
No. 2
Gauge #
Q.C.I.
TRAVEL SHEET INITIATION BY:

Date
A.I. Hold
Points
A.I.
Date
Owner
Date
CRN#
The Authorized Inspector shall be presented with the Travel Sheet prior to construction so that he can designate additional
inspection points and/or Hold Points. Any revisions shall be marked with a delta symbol with revision number and described at the
bottom of this page.
* Denotes an A.I. Inspection Point ** Denotes an A.I. Hold Point

EDITION 1 REV 0
EXHIBIT 23.2 HEATER COIL NAMEPLATE
PAGE 4 OF 4

EDITION 1 REV 0
PAGE 1 OF 6
SECTION 24 STANDARD PNEUMATIC TEST PROCEDURE
24.1
The purpose of this section is to provide guidance in the development of a standard

pneumatic test procedure for piping systems of 1677 kJ of stored energy (equivalent to 500
litres (18 cubic feet) in aggregate internal volume and 2172 kPa internal pressure) , when
hydrostatic testing is not feasible.
General
24.2
All Pneumatic testing of process piping shall be in accordance with ASME B31.3 and
subject to the provisions of ASME B31.3 paragraph 345.1(b), which requires the Owner to
determine that a hydrostatic leak test is impracticable. The test must be carried out
following the requirements of the construction Code as applicable (for example, ASME
Section VIII Div. 1 UG-100, B31.3-2010 paragraph 345.5) and any other relevant safety
regulations such as the Occupational Health and Safety Regulation
24.3
This standard procedure shall have been accepted by ABSA before pneumatic testing
commences. Provision for pneumatic testing of piping systems up 1677 kJ of stored
energy (equivalent to 500 litres internal volume and 2172 kPa internal pressure) is included
as a standard testing procedure in this quality system.
Limitations of Standard Procedure

24.4
The standard pneumatic test procedure is limited to stored energy of 1677 kJ. If the stored
energy exceeds 1677 kJ, then a job specific pneumatic test procedure shall be submitted to
ABSA for review and acceptance prior to the test.
24.5
The 1677 kJ stored energy threshold was calculated using the equation in ASME
PCC-2-2008, Part 5, Article 5.1, Mandatory Appendix II, with the following pressure and
volume parameters:
Test Medium: air or nitrogen
Test pressure: 2172 kPa (315 psi);
Volume: 0.5m3 (18 ft3);
the component to be tested is comprised of P-1 or P-8 material;
the testing temperature is 16.7C (30F) above MDMT;
Note if MDT is not specified then low temperature limits must be considered (test
temperature would be 16oC or 60oF).
Linear interpolation of the pressure-volume values is permitted providing that the stored
energy value (1677kJ) of the standard pneumatic test is not exceeded. If the stored energy
value is not exceeded the intention of the standard pneumatic test is still met.

EDITION 1 REV 0
PAGE 2 OF 6
Standard Pneumatic Test Procedure Volume Limits

Test procedure limits are calculated using method A or method B below based on the Design
Pressure and the volume of the system undergoing testing. The calculation outcome will result in
relatively higher volume for lower pressure and conversely lower volume for higher pressure while
maintaining accumulated stored energy of 1677 kJ.
Step 1
Define piping system DESIGN PRESSURE (DP) and VOLUME (V) including volume of vessels that
will be tested with this piping system.
Step 2
Use the value of DP defined in step 1 to calculate the volume limit (V1) for the test applying one of
the following two methods:
Method A
If Imperial units are used, calculate V1 using DP in psi
3436
V1 = ------------------------------------------------------(DP +14.7) [1- (14.7/(DP+14.7))0.286]
[ft3]
Or, if SI units are used, calculate V1 using DP in kPa

670838.8
V1 = ------------------------------------------------------(DP +100) [1- (100/(DP+100))0.286]
[m3]
Method B
Calculate V1 using values from table 1 and apply the following interpolation
(VA VB) x (DPB DP)
V1 = VB + ---------------------------------------DPB DPA
[ft3] or [m3]
Where:
DP
design pressure in psi or kPa
DPA the first smaller pressure value in the table 1 than the step 1 DP value
DPB the first larger pressure value in the table 1 than the step 1 DP value
VA
the corresponding table 1 volume listed in same row as DPA
VB
the corresponding table 1 volume listed in same row as DPB
For Volume Limit (V1), Method B is showing from 0 to 3 % lower values than Method A.

EDITION 1 REV 0
PAGE 3 OF 6
Step 3
If V=< V1 The standard pneumatic test procedure may be used without submitting to ABSA Design
Survey for review and registration as this procedure is included in the quality system.
If V> V1 the pneumatic test procedure shall be submitted to ABSA Design Survey for review and
acceptance.
Table 1
Imperial Units
Design
Pressur
e
psi
15
20
25
30
40
50
75
100
125
150
175
200
225
250
275
300
315
325
350
375
400
450
500
600
700
800
900
1000
1500
2000
Volume
ft3
615.90
441.00
342.92
273.68
194.50
145.27
90.11
66.07
50.77
41.39
34.21
29.58
25.80
22.84
20.47
18.52
18.0
16.90
15.52
14.35
13.33
11.66
10.35
8.43
7.10
6.11
5.37
4.73
2.97
2.21
SI Units
DPA & VA
DPB & VB
Design
Pressure
kPa
103
138
172
207
276
345
517
689
862
1034
1207
1379
1551
1724
1896
2068
2172
2241
2413
2586
2758
3103
3447
4137
4826
5516
6205
6895
10342
13790
Volume
m3
17.440
12.488
9.710
7.750
5.508
4.114
2.552
1.871
1.438
1.172
0.969
0.838
0.731
0.647
0.580
0.524
0.500
0.478
0.440
0.406
0.378
0.330
0.293
0.239
0.201
0.173
0.152
0.134
0.084
0.063

EDITION 1 REV 0
PAGE 4 OF 6
Example how to apply interpolation:

Using Imperial units, table 1 shows that:
DPA = 150 [psi]
DPB = 175 [psi]
VA
= 41.39 [ft3]
VB
= 34.21 [ft3]
Apply the following equation from Step 2 Method B:
(VA VB) x (DPB DP)
V1 = VB + ---------------------------------------[ft3]
DPB DPA
(41.39 34.21) x (175 160)
V1 = 34.21 + ---------------------------------------- [ft3]
175 150
V1 = 38.5
[ft3]
The stored energy for the pneumatic test may be calculated using the method provided in
PCC-2, Part 5, Article 5.1 Mandatory Appendix II:
If the calculated E is > 1677 kJ, the pneumatic test procedure must be submitted to Design
Survey for review and registration prior to conducting the test.
The stored energy may be calculated using the following formula providing that nitrogen or
air is used as the test medium:
E=2.5 x Pat x V [1 (Pa/Pat)0.286 ]
E = stored energy, J (ft-lbs)
Pa = absolute atmospheric pressure, 101 kPa (14.7 psia)
Pat = absolute test pressure, (psia)
V = total volume under test pressure, m3 (ft3)
Testing Design Basis & Requirements
24.6
The test pressure shall be 110 percent of design pressure.
A pressure relief device shall be provided, having a set pressure not higher than 110% of the test
pressure. The pressure relief device shall be sized to relieve the maximum output of the pressure
source to prevent excessive testing pressure. The two required gauges and the pressure relief
device shall be installed on a manifold located at the remote location (outside of the restricted
distance) where pressurization will be controlled. There will be no intervening valves between the
pressure gauge and relief device, and the pressurization manifold. Test manifold(s) and
temporary test piping shall have been designed for a pressure not less than the pressure relief
device set pressure and shall have been hydrostatically tested in accordance with ASME B31.3.

EDITION 1 REV 0
PAGE 5 OF 6
24.7
Particular care must be taken to minimize the chance of brittle failure during a pneumatic
leak test. Consideration should be given to the temperature depression that can occur
during sudden system depressurization. The metal temperature shall be maintained at a
minimum of 17 degrees C (30 degrees F) above the design minimum (metal) temperature
for the piping. (See B31.3 Par. 345.5.1 and Fig. 323.2.2).
Test Procedure
24.8
Prior to the test, a pneumatic test procedure and pressure test report will be prepared by
the QCM.
24.9
Testing Unless specified otherwise, the test gas will normally be air. Inert gases, such as
nitrogen, may be used provided that the safety concerns of an oxygen deficient atmosphere
are considered. When testing with an inert gas such as nitrogen in an enclosed area, care
should be taken to ensure that adequate ventilation is provided in the event there are leaks.
Caution should also be exercised when leak-testing inert gas filled systems. To detect
leaks, the bubble forming solution shall produce a film that does not break away from the
area being tested, and the bubbles formed shall not break away rapidly due to air drying or
low surface tension. Household soap or detergents are not permitted as substitutes for
bubble testing solutions. The bubble forming solution shall be suitable for use at the test
temperature.
a)
The owner/manufacturer/AQP holder is responsible to establish the minimum safe distance

limit for personnel to stay away from the piping system during the pneumatic test. Safe
distance based on PCC-2 Article 5.1, Mandatory Appendix III and using the standard
pneumatic test values for the stored energy is a minimum of 30 m. The owner/AQP holder
may reduce this safe distance limit by installing properly designed barriers, or placing the
test item in an engineered enclosure, or by taking other measures to minimize the risk of
harm to personnel. The owner is responsible for the safety of all personnel during the
designated test.
b)
All personnel not directly involved with the pneumatic test shall be evacuated from the area.
Rope or ribbon barriers shall be used to keep personnel from entering the area. No
personnel shall be allowed within the barriers during pressurization, during hold times
above 172 kPa. (25 psig.) while the system is stabilizing and strains are equalizing, and
whenever the system pressure is greater than design pressure, until the test is complete
and the pressure is reduced to the design pressure.
c)
Wrap all flanged connections with masking tape. Make a small hole for leak testing.
d)
Carefully pressurize the system to 172 kPa. (25 psig.) and hold for at least 10 minutes, so
that the system can stabilize. Before entering the restricted area personnel will ensure that
there can be no accidental pressurization of the system.
e)
The bubble forming solution shall be applied to all flange bolt holes and leak test holes in
masking tape, all welds, threaded connections and other possible leak sources by flowing
spraying or brushing. The number of bubbles produced in the solution by application
should be minimized to reduce the possibility of masking bubbles caused by leakage. Mark
all leaks for repair.

EDITION 1 REV 0
PAGE 6 OF 6
f)
Depressurize carefully and repair all leaks found. Repeat the leak test (steps c to e) until
the system is gas tight at 172 kPa. (25 psig.). No personnel should be within the restricted
distance between the time the system is leak free at 172 kPa. (25 psig.) and when the
system is lowered to the Design Pressure at step k).
g)
Increase the pressure to 345 kPa. (50 psig.) and thereafter in increments of 345 kPa. (50
psig.) until the test pressure is reached. The pressure shall be increased gradually in
steps, providing enough time for the pressurized piping system to equalize strains.
h)
The minimum hold time at each increment shall be 10 minutes. During each hold period,
check for leakage from the remote pressurizing location by monitoring the ability of the
system pressure to remain constant during the hold time. The pneumatic test report shall
be completed, denoting all hold pressures. The time shall be logged at each step.
i)
A minimum of two calibrated pressure gauges shall be used to monitor the pressure. The
pressure gauge ranges shall be not less than 1.5 times nor more than 4 times the final test
pressure.
j)
If a leak is detected at any time; the leak is to be marked, the system safely depressurized,
the leak repaired and the test begun again (step c).
k)
Once the required test pressure is reached, the pressure is to be held for a minimum of 10
minutes.
l)
The pressure shall be slowly reduced to design pressure and the system tested for leaks
(step d). Before entering the restricted area personnel will ensure that there can be no
accidental pressurization of the system. If no leaks are detected, the test is successfully
completed.
24.10 Depressurizing The system will be slowly and safely depressurized.

24.11 After Testing The QCI and the Owners Inspector will sign the test report stating that they
have witnessed and accepted the test.

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