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TABLE OF CONTENTS
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____________________________
_________________________________
QCM Approval
____________________________
_________________________________
Date
Date
PAGE 1 of 1
MANUAL NO________________
EDITION___________________
ASSIGNED TO_______________
PAGE 1 of 2
SECTION 2 - SCOPE
1.
This Quality Control Manual outlines the procedures that will be used by Allied Vessel Fabrication
Ltd. in constructing ASME Code items in accordance with ASME Code Section VIII Division 1 and
Alberta Safety Codes Act and Regulations at shop.
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 shop and field locations.
3.
Construction, repair, alteration and erection of pressure piping systems shall meet the requirements
of Alberta Safety Codes Act and Regulations, ASME B31.3 and customer requirements at shop and
field locations.
PAGE 2 of 2
This Quality Control Manual has been established to assure compliance with the ASME Code, CSA B51,
B31.3 and the Alberta Safety Codes Act and Regulations.
This Quality Control Manual is intended to be used in the construction of pressure vessels in accordance
with the ASME Boiler and Pressure Vessel Code Section VIII Division 1. Repairs and alternation of
pressure vessels in accordance with Alberta Safety Codes Act and Regulation. Construction, repair,
alteration and erection of pressure piping systems in accordance with B31.3 Code and Alberta Safety Codes
Act and Regulations.
The QCM is hereby assigned to administer the program described in this Quality Control Manual. The QCM
has sufficient and 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.
The quality control problems that cannot be resolved by the QCM shall be brought to my attention for the
final resolution. Such resolution will not compromise any applicable codes, standards, Regulatory Authority,
customer requirements or this Quality Control Manual.
The quality control system has my full support and shall be used in all stages, by all personnel engaged in
fabrication, repairs and alternations, construction, testing and manufacturing of referenced above pressure
equipment.
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.
STATEMENT OF AUTHORITY
Signature_____________________________
Name _______________________________
Title ________________________________
Date_________________________________
PAGE 1 of 1
PRESIDENT
Certified
Individual
GENERAL
MANAGER
SHOP / FIELD
MANAGER
PURCHASING
MANAGER
QCM
SUBCONTRACTOR
QCI
SHOP/FIELD
ENGINEERING
(Designer)
SHOP / FIELD
PERSONNEL
SUBCONTRACTORS:
HEAT TREATMENT
NDE MATERIAL TESTING,
ETC.
SHIPPER /
RECEIVER
SECTION 4 DEFINITIONS
PAGE 1 of 4
4.
DEFINITIONS
4.1
4.2
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.
4.3
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.
4.4
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.
4.5
Code: American Society of Mechanical Engineers, latest Edition and Addenda of:
a) Section II Material Specifications Part A, B, C & D
b) Section V Non-Destructive Testing
c) Section VIII Division 1 Rules for Construction of Pressure Vessels
d) Section IX Welding and Brazing Qualifications
e) Section B31.3 Process Piping
4.6
4.7
SECTION 4 DEFINITIONS
PAGE 2 of 4
4.8
CRN: Canadian Registration Number; registration number allotted by the regulatory authority to
design and specifications when accepted and registered.
4.9
CSA-B 51 Canadian Standard Association; Boiler, Pressure Vessel and Pressure Piping Code.
4.10
Examination means quality control functions performed by the manufacturer, fabricator, or erector.
4.11
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.
4.12
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.
4.13
Inspection: means functions performed for the Owner by the Owners Inspector or inspectors
delegate.
4.14
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.
4.15
4.16
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.
4.17
Owners Inspector - 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.
SECTION 4 DEFINITIONS
PAGE 3 of 4
4.18
4.19
PQR: Procedure Qualification Record: The document that records the test results that establish
the properties of a weldment.
4.20
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.
4.21
4.22
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).
4.23
Pressure Vessel: Means a vessel used for containing, storing, distributing, processing or otherwise
handling an expansible fluid under pressure.
4.24
4.25
QMS: Quality Management System for the purpose of directing and controlling an organization
in regards to quality
4.26
4.27
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.
SECTION 4 DEFINITIONS
PAGE 4 of 4
4.28
Registered Design: Drawings, specifications and information required by Section 15, of the Pressure
Equipment Safety Regulation that have been reviewed and registered by ABSA.
4.29 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.
4.30
SNT-TC-1A Latest construction code accepted edition addenda of the American Society for
Qualification in Non-Destructive Testing; Recommended Practice No. SNT-TC-1A: Personnel
Qualification and Certification in Nondestructive Testing.
4.31 WPS: Welding Procedure Specification: This document describes in detail all of the variables,
which are essential, supplementary essential, and non-essential to the welding process employed
by the ASME Code, Section IX.
PAGE 1 of 1
5.
5.1
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.
5.2
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:
1) President
2) QCM
5.3
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 Ltd.
5.4
The contract shall be then presented to the General Manager of Allied Vessel Fabrication Ltd. for
final approval.
PAGE 1 of 2
6.
MANUAL CONTROL
6.1
This section describes the system for preparing, revising and controlling the distribution of this
Quality Control Manual.
6.2
The QCM is responsible for the control and implementation of this system. These duties include:
a) The review the Quality Control Manual every 12 months coincident with the issue of any ASME
Code Edition and to revise the Quality Control Manual and or system as necessary to incorporate
any required changes within six months of the issue of the new Edition or Addenda. The review
of Code Editions or Addenda 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 Form (Exhibit 6.1).
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
6.3
The edition number, revision number and date will be shown on each page of the Quality Control
Manual along with number of pages within each section, and revisions will also be indicated by a
triangle, with the revision number in each margin along the changed paragraph.
6.4
Uncontrolled Quality Control Manuals may be used for information only and shall not be used by
Allied Vessel Fabrication Ltd. Personnel. Uncontrolled Copy shall be permanently indicated on the
front page of these Quality Control Manuals.
6.5
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 6.1
PAGE 2 of 2
FABRICATION LTD.
DOCUMENT TRANSMITTAL
To: Please Print Your Company Name
Below:
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 it
to 403-228-4009.
I acknowledge receipt of the documents noted below (destroying
superseded documents)
Print Receivers Name: _______________________________________
Document Number
Date ___________________
Document Title
Revision #
PAGE 1 of 4
This section provides the system for review, approval, distribution and retrieval of drawings, design
calculations, specifications and instructions.
7.2
The QCM is responsible for ensuring the following functions are performed by the subcontract
Engineering (Designer) acting on behalf of Allied Vessel Fabrication Ltd. 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)
EDITION 1 REV 0
PAGE 2 of 4
7.3
7.4
A description of all revisions to drawings will be recorded in the revision block and all revision
items will be identified with a triangle, containing the revision number, adjacent to the revised item.
Revised items will be distributed and issued in the same manner as the original issue.
7.5
If the design specifications and drawings are provided by the owner, or are subcontracted to a
engineering design organization, 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.
7.6
The QCM will maintain a Drawing Index (Exhibit 7.1) detailing the drawing title, drawing
number, revision number, issue, number of copies and person they are assigned to. All essential
documents to outside organizations will be controlled by use of Document Transmittal (Exhibit 6.1).
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
on all drawings followed by the signature and date of person releasing the drawings.
PAGE 3 of 4
CALCULATION
7.7
The QCM is responsible for assigning the job and serial numbers for all vessels. He/she will
maintain a file for each vessel containing design calculations, drawings and specifications.
7.8
The QCM will ensure that the latest Editions and Addenda of the ASME Codes are available in the
shop and field.
APPLICABLE DOCUMENTS/FORMS
Document Transmittal, Exhibit 6.1
Drawing Index
Exhibit 7.1
ABSA FORMS
Design Registration Application, AB-31
Section 7
PAGE 4 of 4
Rev. No.
Drawing
Title
Date
Issued
Copies To
QCM
Copies To Copies To
Shop Mgr. Purch. Mgr.
Copies To
Eng. File
Copies To
ABSA
Copies To
Field
DRAWING INDEX
Drawing Number
Job Number:
PAGE 1 of 7
MATERIAL CONTROL
8.1
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.
8.2
The Purchasing Manager is responsible for the ordering of all material. The Purchasing Manager will
prepare a Purchase Order (Exhibit 8.1) from the approved drawing Bill of Material.. The Purchase
Order will include (as applicable):
a) the Purchase Order number and job number (unless ordered for stock).
b) the material ASME specification number (SA/SB), grade, schedule, dimensions,
c) a request for Material Test Report (MTR) when required,
d) a request for Partial Manufacturers Data Report or Certificate of Compliance for all code
stamped and standard welded parts supplied by a subcontractor,
e) a request for certification to UG-79 and referenced paragraphs for formed items.
f) a request that tack welds be performed to a Welding Procedure Specification qualified to ASME
Section IX.
g) a request for certification for any supplementary test (I.e. 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.
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 Ltd. and the AI
8.3
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 8.2) 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.
8.4
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. Revised calculations and drawings will
be prepared and issued in accordance with this Quality Control Manual.
PAGE 2 of 7
8.6
PAGE 3 of 7
d) 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.
e) Verifying that the MTRS conform to ASME Code Section II same Edition and Addenda as on
the drawing. If the MTRS conform to Section II, the QCI will sign and date the MTR and
indicate the Code Edition and Addenda used.
f) Ensuring that when pipe material, which will have a Heat # and Purchase Order # at each end
and is color coded by a paint strip over the full length, is fabricated as a nozzle: that the
marking is stamped on each nozzle as per color code chart (Exhibit 8.3).
g) 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 Material Sheet in the applicable row for the item.
h) Ensuring that the color code and coded markings detailed in Exhibit 8.3 are posted in the
storage area and the shop.
i) Alternate marking system shall be acceptable to the AI.
8.7 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 re- inspected
and MTRS are verified to the Code Edition/Addenda specified on the construction drawing.
APPLICABLE DOCUMENTS/FORMS
Purchase Order,
Purchase Requirements by Product,
Color Code and Code Markings,
Material Receiving Report,
Travel Sheet Front,
Material Sheet (Back)
Exhibit
Exhibit
Exhibit
Exhibit
Exhibit
Exhibit
8.1
8.2
8.3
8.4
9.1
9.1
PAGE 4 of 7
Exhibit 8.1
PURCHASE ORDER
PAGE 3 OF 7
P.O. #
JOB#
DATE:
SHIP
TO
SHIPPING METHOD
SHIPPING TERMS
DELIVERY DATE
JOB
UNIT PRICE
LINE TOTAL
SUBTOTAL
SALES TAX
TOTAL
Date:
PAGE 5 of 7
B-
C-
Rolled Plate (Skid Material and Rolled Plate Saddle Pads or Wear Plates)
1) Materials: SA-516-70 or SA-516-70 Normalized (SA-516-70N) as specified on Purchase Order.
2)
3)
4)
5)
6)
D-
30 degree outside bevel-no land A/A [Excluding Saddle Pads or Wear Plates]
Longitudinal seam tack-welded using a Welding Procedure Specification that meets all the requirements of ASME Section IX: oneeighth inch weld gap-no land. [Excluding Saddle Pads or Wear Plates]
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.
Material test reports must be supplied for this item(s).
This item(s) must meet the ASME Section II,_____Edition-____ Addenda material specification, and general specifications applicable
to the product form.
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-____ Addenda material specification, and general specifications applicable
to the product form.
E-
F-
Welding Consumables
1) All welding consumables mus conform to the SFA specification and AWS classification listed on purchase order.
EDITION 1 REV 0
Section: 8
Revision Date July 18, 2012
PAGE 6 of 7
COLOR CODE
RED
WHITE
GREEN
ORANGE
YELLOW
BLUE
COLOR CODE
PAINT CODE
DISC
E164
Plate
Plate
Plate
Plate
Plate
Plate
DIE STAMP
DISC
WHITE
YELLOW
0
1
2
3
4
4N
5
6
Fitting
Fitting
Pipe
Fitting
Fitting
Fitting
Pipe
Pipe
COLOR CODE
DIE STAMP
DISC
GREEN
7
8
9
10
BLUE
SS MATERIAL SPECIFICATIONS
SA 312-304L
SA 240-304L
SA 479-304 NON PRESSURE
SA 182-304
Other materials will have a color stripe as determined by the QCM. Each length of pipe will have a
continuous stripe of the designated color.
Each piece will be die stamped with indicated letter or digit code.
Section 8
PAGE 7 of 7
SERIAL NUM.
VERIFIED
THICKNESS
/ PRODUCT
DIAMETER
QUANTITY
[Note: The markings required by the material specification are described in the material specification and the general specification for the
product form]
SUPPLIER
P.O.
NUMBER
JOB
NUMBER
Initials
Date
EDITION 1 REV 0
PAGE 1 of 6
9.
9.1
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.
9.2
The QCM is responsible for the examination and inspection program. His duties include:
a. Initiating a job file, which includes the Travel Sheet, drawings, calculations, MTRs,
certificates of compliance, NDE reports, Heat Treatment instructions, welder records,
Manufacturers Data Reports, CRN acceptance letter and a photocopy of the name plate.
b. Initiating a Travel Sheet (Exhibit 9.1) for each job and presenting it to the AI prior to the start
of the job so that AI may indicate his / her hold and inspection points. Work shall not proceed
beyond an established hold point until the AI has released the hold by signing the Travel
Sheet.
c. Notifying the AI reasonably in advance of any hold points.
d. Performing any examination functions specified on the Travel Sheet. Signing/dating each
function when is completed.. Welders symbols for specific joints shall be recorded, and
visual examinations of fit-up and for type-one-joint verification shall be documented by
initial to indicate completion or verification, and acceptance.
9.3
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 plate material, pipe and fittings used for vessel shells and
additional components as required 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.
PAGE 2 of 6
9.4
The QCM shall prepare the Manufacturers Data Report, the AB-25.
9.5
The QCM will verify that the nameplate stamping information is complete and correct in the
Nameplate format (Exhibit 9.3). 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 nameplate to the
AI for acceptance and signature on the Manufacturers Data Report.
9.6
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.
9.7
9.10 The AI or the AI Supervisor, reserves the right to audit this program at any time where Code work is
in progress.
APPLICABLE DOCUMENTS/FORMS
Travel Sheet,
Sample Nameplate,
Exhibit 9.1
Exhibit 9.3
ABSA FORMS
Manufacturers Data Report, for pressure vessel AB-25
EDITION 1 REV 0
PAGE 4 of 6
REVIEW DATE:
SERIAL NO.:
JOB NO.:
VESSEL TYPE:
DRAWING NO.:
Seq.
Comments
Item
1.
Calculations in File
2.
3.
Materials Examined
4.
5.
MTRs Checked
6.
WPS(s) Checked
7.
Welder(s) Qualified
8.
9.
10.
11.
Nozzle Orientation
12.
13.
Impact Tests
14.
Internals Checked
15.
16.
17.
18.
19.
Radiography
20.
Other N.D.E.
21.
22.
23.
Hydrostatic Test
24.
CRN Drawing
25.
N.C.R. #
26.
27.
Nameplate Stamping
Manuf. Data Report
Completed & Verified
28.
Nameplate Installation
29.
QCI
Date
AI Hold
Points
AI
Date
Owner
Shell Side
Tube Side
Shell
Side
Gauge #
Tube
Side
Gauge #
CRN#
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
PAGE 5 of 6
Date
Thickness
(BACK)
Welder
Symbol
Fit-Up
Exam.
Weld
I.D.
Shell #1
Shell #2
Shell #3
Shell #4
Shell #5
Shell #6
Head #1
Head #2
Head #3
Fit-Up
Exam.
Verify
Type 1
Joint
Head #4
L
Boot #1 Shell
C
C
Boot #1Head
Boot #2 Shell
C
C
Boot #2Head
Cone
Welder
Symbol
Mat. I.D.
Neck
Fitting
Flange
Repad or Attachment
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
Section 9
PAGE 6 of 6
Pad OD
SECTION 10 WELDING
PAGE 1 of 6
10
WELDING
10.1
This section describes the system for controlling Welding Procedure Specifications, welding
operations and welder/welding operator performance qualifications to ensure compliance with the
ASME Code.
10.2
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 WPS have been
qualified in accordance with ASME Code and registered with ABSA for the work to be performed.
b. Ensuring that WPS requirements are detailed on the drawings.
c. Ensuring that WPS are detailed on WPS Index and Essential Variable Summary (Exhibit 10.1).
10.3
The QCM is responsible for developing and qualifying new WPS. His duties include:
a) Writing the WPS or delegating this to a qualified consultant.
b) Supervising the welding of the test coupon by Welders employed by Allied Vessel Fabrication
Ltd. 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.
SECTION 10 WELDING
PAGE 2 of 6
10.4
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 Welding/Welder Operators. His duties include:
a. Verifying that welders have valid performance qualification card, issued by a Certified Welding
Examiner and have qualified to Allied Vessel Fabrication Ltd.s WPS prior to start of work and
assigning a welder to a specific work, based on the Welder/Welder Operator qualification records
and Welders Log (Exhibit 10.2).
b. Maintaining a Welders Log detailing the process each welder is qualified for, essential variables,
date of expiry of this PQ card (performance qualification card) and weld symbol assigned.
c. Supervising the welding of the test coupons and preparing and certifying the Welders Performance
Record (QW 484 A/B or equivalent) for all welder/welding operators performance tests.
d. Ensuring that welding procedure requirements are followed and that copies of WPS (Welding
Procedure Specification) are available to welders.
e. Visually examining all completed welds.
f. Ensuring that each welder is assigned a welder symbol and welds after completion are identified
with the welders symbol once every 3 feet (0.9 meters) of weld. When die stamping of the ID
symbols is prohibited by Code, the welders ID for each weld shall be recorded on a shop copy of the
drawing and the QCI shall transfer this data to a copy of the drawing that is retained in the Quality
Control Job file. The welder symbol can be reassigned after six months.
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 examined visually 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 10.3) by recording within the specified interval, when each
welder or welding operation uses a welding process.
SECTION 10 WELDING
PAGE 3 of 6
10.5
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 is 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 essential variable.
10.6
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.
b) Issue purchase order as per Section 8.3
10.7
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.
b) Sign Purchase Order and Pack Memo, initial and date all boxes.
10.8
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
seal is broken.
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.
10.9
The AI shall have the right, at any time, to call for a witness re-qualification
tests of the Welding Procedure Specification or any Welder / Welder Operator.
APPLICABLE DOCUMENTS/FORMS
WPS Index and Essential Variable Summary, Exhibit 10.1
Welders Log,
Exhibit 10.2
Continuity Log,
Exhibit 10.3
PAGE 4 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
Comments
EDITION 1 REV 0
SECTION 10 WELDING
PAGE 5 of 6
SYMBOL
PROCESS
/METHOD
BASE
METALS
FILLER METAL
F NUMBER(S)
BACKING
MINIMUM
OD (In)
DEPOSIT
THICKNESS
(In)
POSITIONS
UPHILL /
DOWNHILL
CORED /
SOLID
INSERT BACKING GAS
GTAW
CURRENT
WELDERS LO
WELDERS
NAME / FILE
NUMBER
PAGE 6 of 6
SECTION 10 WELDING
SYMBOL
PROCESS
/METHOD
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
PAGE 1 OF 3
SECTION 11 NONCONFORMITIES
11
NON-CONFORMITIES
11.1
This section describes the system for identifying, documenting and resolving non-conformities
found at receiving, construction, examination or testing.
11.2
A non-conformity 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 Non-Conformity Report (Exhibit 11.1). .
11.3
Any non-conforming material found the QCM will decide if the item is to be rejected (e.g. by
returning to the supplier) or if the item is to be reworked or repaired to bring it into conformance. If
a decision is made to repair the material or item, a repair procedure will be developed. This repair
procedure shall be approved by the QCM and the method and extent of the repair must be accepted
by the AI before the start of the repair, by signature and date on the Non-Conformity report
disposition section. The QCM shall prepare additional inspection functions on the Travel Sheet when
applicable.
11.4
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 11.2).
11.5
The QCM will prepare a Non-Conformity Report with details of the non-conformity and a hold
notation shall be made on the Travel Sheet listing the Non-Conformity Report number. All proposed
Non-Conformity Report dispositions shall have QCM approval. The Designer shall approve all
proposed dispositions involving design changes. The Designer will prepare revised design
calculations and drawings as outlined in Section 7 of this Manual. After receiving the specified
approvals, all 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.
11.6
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.
11.7
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
Non-Conformity Report and Travel Sheet when applicable.
11.8
The Non-Conformity Report shall be retained in the job file and in a separate Non-Conformity
Report File. The QCM will periodically review all the reports and indicate corrective action if
required.
APPLICABLE DOCUMENTS/FORMS
Nonconformity Report, Exhibit 11.1
Hold Tag,
Exhibit 11.2
PAGE 2 OF 3
SECTION 11 NONCONFORMITIES
NONCONFORMITY REPORT
JOB NUMBER:
SER#
DESCRIPTION OF NONCONFORMANCE:
SIGNATURE OF ORIGINATOR:
DATE:
PROPOSED DISPOSITION:
DESIGNER APPROVAL:
DATE:
QCM APPROVAL:
DATE:
DATE:
DATE:
NONCONFORMANCE RECTIFIED:
DATE:
QCM APPROVAL:
DATE:
DATE:
0005
NCR #
0005
NONCONFORMITY REPORT
JOB NUMBER:
SER#
DATE:
EXHIBIT 11.2
HOLD
DO NOT USE
SIGNATURE:
DATE:
JOB NO.:
THIS ITEM OR PART IS NOT TO BE
USED FOR THE REASONLISTED ON
THE NONCONFORMITY REPORT:
PAGE 3 OF 3
PAGE 1 OF 3
12 NONDESTRUCTIVE EXAMINATION
12.1
This section describes the system of ensuring that nondestructive examination are completed in
accordance with the Construction Code and ASME Code Section V as referenced by the applicable
Construction Code.
12.2
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. He shall ensure that these are
available to AI at his request.
b)
Certifying 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 12.1) kept on file, the NDE Subcontractors Level III Examiner to act as the Level III
Examiner for Allied Vessel Fabrication Ltd. 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.
12.3
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
PAGE 2 OF 3
12.3
12.4
APPLICABLE DOCUMENTS/FORMS
Certifying Statement And Appoint Letter, Exhibit 12.1
PAGE 3 OF 3
______________________________________
(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)
________________________________________
PAGE 1 OF 2
13
HEAT TREATMENT
13.1
This section describes the procedure that will be used to ensure that heat treatment is performed in
accordance with Code and job specifications.
13.2
13.3
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.
13.4
The QCM will issue the written Heat Treatment Instructions (Exhibit 13.1) to the subcontractor
specifying holding time, holding temperature, heating rate, cooling rate, and any special instructions.
13.5
The QCI will ensure that all items to be sent out for heat treatment are properly identified by die
stamping or heat resistant marker.
13.6
The QCI will notify the subcontractor when the vessel is ready for heat treatment and will review the
procedures used by the subcontractor.
13.7
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 will be identified with the vessel (or item) serial number and shall be signed
and dated by the subcontractors representative and the QCI.
13.8
The QCI will file the instructions and time temperature charts in the vessel file which will be made
available for the AI for review.
APPLICABLE DOCUMENTS/FORMS
Heat Treatment Instructions, Exhibit 13.1
PAGE 2 OF 2
PAGE 1 OF 2
14.
14.1
The purpose of this section describes the control and calibration of measuring and testing equipment
to ensure Code compliance.
14.2
The QCM is responsible for the control of measuring the test equipment. His/Her duties include:
a. Ensuring that all gauges and recorders are identified with a serial number and calibration
date.
b. Maintaining calibration records pertaining to measuring and test equipment which will
include a list of all measuring and test equipment for Code use, and an Equipment
Calibration Log (Exhibit 14.1) and calibration reports for each item. (Pressure gauges must
be calibrated against a dead weight tester 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.
14.3
The QCI is responsible for the use of test equipment. His/Her duties 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) Returning all equipment to the storage area after the test.
a) Identifying any equipment that requires recalibration.
14.4
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 documented as nonconformity in accordance with
Section 11 of this Quality Control Manual.
a) In the event the Code Item has left our possession, the QCM would notify the owner of the
nonconformance and the item would be re-inspected or retested, and documented in accordance
with Section 11 of this Quality Control Manual.
APPLICABLE DOCUMENTS/FORMS
CALIBRATION INTERVAL:
Date of First Use
PAGE 1 OF 3
15
PRESSURE TESTS
15.1
This section describes the system for conducting all pressure tests including hydrostatic, pneumatic,
services and leak. Pneumatic test procedures will be submitted to ABSA Design Survey Section for
acceptance prior to testing. (See Exhibit 15.1 for guidelines for pneumatic test procedure).
15.2
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)
c)
d)
The metal temperature should be at least 30 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. They will be graduated to no less than 1.5 times and no more
than 4 times the test pressure.
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 15.2)
APPLICABLE DOCUMENTS/FORMS
Guidelines for The Preparation of Pneumatic Test Procedure, Exhibit 15.1
Hydrostatic Test Report
Exhibit 15.2
PAGE 2 OF 3
SECTION 15 EXHIBITS
EXHIBIT 15.1
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 has to be submitted to the 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)
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.
SERIAL NUMBER(S):
JOB NUMBER:
VESSEL(S) DESCRIPTION:
RESULTS + COMMENTS:
DATE
Signature of QCM
DATE
Signature of Owners Inspector.
DATE
Signature of AI
PAGE 3 OF 3
PAGE 1 OF 4
16.1
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.
16.2
All repairs and alterations shall be in accordance with Alberta Safety Codes Act and Regulations.
16.3
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-230) may be used to detail the
repair/alteration procedure when suitable.
16.4
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.
16.5
The QCM will ensure that copies of the latest repair/alteration procedure and instructions are
provided to all personnel responsible for the repair/alteration.
PAGE 2 OF 4
If the vessel is still under warranty, the QCM will contact the owner to obtain acceptance of the
proposed work from the manufacturer.
16.7
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 Section of ABSA for acceptance prior to starting work.
16.8
Material for the repair/alteration shall be ordered in accordance with Section 8 of this Manual.
16.9
Examination and inspection will be in accordance with Section 9 of this Manual. The QCM will
develop for each repair/alteration the Repair/Alteration Inspection Checklist (Exhibit 16.1) and
present it to the AI prior to the repair for his/her hold and inspection points.
16.10 When required by the AI, an identification plate will be attached to the vessel, adjacent to the
original name plate with the following information:
a) Name of repair/alteration organization
b) Date and description of repair/alteration
c) MAWP and MDMT
d) Job number
e) CRN number
f) Original MFG Name & Original Vessel S/N
16.11 Non-destructive examination shall be performed according to the applicable ASME Code Section
and Section 12 of this Manual.
16.12 Heat treatment shall be in accordance with the applicable ASME Code Section and Section 13 of this
Manual.
16.13 The repaired/altered vessel shall be hydrostatically tested as indicated on the Repair/Alteration
Report unless specifically exempted by the AI.
PAGE 3 OF 4
APPLICABLE DOCUMENTS/FORMS
Repair / Alteration Inspection Checklist, Exhibit 16.1
PAGE 4 OF 4
Manufacturer / Serial
Number
AI Review:
Review Date
Se
q.
Operations
Repair/Alteration Procedure
Accepted by Authorized Inspector
and Owner
5a
5b
5c
6a
6b
6c
7
8
9
10
11
12
tubesheet/shell-firetube
13
Comments
ABSA
Insp
Owner
Insp.
14
15
16
Hold Points
Rep
Org
OUTLINE SKETCH
(Record Welders Symbols and
Heat No.'s ) Attach Separate
Sketch if required
Gauge
No.'s
Rating
Firetube
Nozzles
Fittings
Flanges
PAGE 1 OF 2
17
RECORD RETENTION
17.1
This section describes the records that will be maintained in accordance with Code requirements and
this Manual as stated in scope.
17.2
The QCM will ensure that the following records (as applicable) are maintained in the job file, for a
minimum of five (5) years.
PAGE 2 OF 2
17.3
Radiographic film may be disposed of after the Manufacturers Data Reports are signed and
accepted by the AI.
17.4
Records documenting Welder / Welder 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 / Welder
Operator have left the employment of Allied Vessel Fabrication Ltd.
PAGE 1 OF 1
AUTHORIZED INSPECTORS
18.1
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.
18.2
The QCM is responsible for liaison with the AI who is an employee of the ASME accredited
Authorized Inspection Agency which is ABSA.
18.3
Allied Vessel Fabrication Ltd. 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.
18.4
A controlled copy of this Quality Control Manual will be available on site for the use of the AI.
PAGE 1 OF 1 7
19
PRESSURE PIPING
19.1
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.
19.2
All pressure piping construction, repair, alteration or replacement shall be in accordance with the
Safety Codes Act, and the ASME piping Codes B31.3 as applicable. ASME Code Boiler External
Piping is not within the scope of this quality system.
CONTRACT REVIEW
19.3
The General Manager shall review the contract / order before acceptance to ensure that requirements
are adequately defined. When requirements are inadequately defined there is no written contract /
order, the General Manager shall contact the client to ensure requirements are stated and agreed
upon, and shall record the information in the job file. He/She 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
PAGE 2 OF 17
i) Allied Vessel Fabrication Ltd. has the capability to meet all contract / order requirements.
j) The lot sizes are established
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
19.4
Design drawings, calculations and specifications shall be prepared in accordance with the ASME
B31.3 Piping Codes. These may be prepared by the Owner or by a subcontracted engineering firm
experienced in ASME pressure piping design. Spool drawings may also be prepared by Allied Vessel
Fabrication Ltd. when others do not supply these.
19.5
Reviewing the customers specifications to ensure that the piping system can be designed and
constructed in accordance with B31.3 Code.
b)
Preparing design calculations and design drawings in accordance with the B31.3 Piping Code.
c)
Reviewing and approving the design drawings and design calculations by signature and date.
d)
1) material description including ; material specification, grade, dimensions, schedule, type and
rating,
PAGE 3 OF 17
19.5
2)
Reviewing and approving for construction, any spool drawings prepared by Allied Vessel
Fabrication Ltd. from owners design specifications and drawings.
19.6
Maintaining a Drawing Index listing the drawing title, number and revision, copies issued
and the name of person to whom they were issued.
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.
PAGE 4 OF 17
19.7
19.8
If the owner has not prepared design specifications, and the piping system meets the following
criteria;
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)
The QCM is responsible for the control of all documents and drawings. His / Her
duties include:
a)
b)
Obtain written 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 each item is identified with the job number.
Job File
e)
f)
Obtaining the owners approval for any revisions, and submitting the final as built
drawings to the owner along with all pertinent records
PAGE 5 OF 17
19.9
The QCI shall be responsible for the handling of drawings, specifications and
documents at job sites. His / Hers duties include:
a)
b)
Forwarding the job file to the General Manager when the job is complete.
MATERIAL CONTROL
19.10 All material shall be controlled as per Section 8 of this Quality Control Manual except as modified
below.
NOTE: All material receiving, identification / verification and code requirements defined in this section,
and Section 8, 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.
19.11 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.
19.12 The QCI is responsible for the receiving and storage of material at site. His /
Her duties include:
a) Checking all incoming material against the Purchase Order / Owners material list, and packing
slip for;
visible damage
correct dimensions, and
3) correct material markings, specification and grade, size, schedule, rating, name
of manufacturer or trademark, etc as applicable.
4) material receiving report
1)
2)
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 purchase
order number; acceptance shall be indicated by initial and date on the MTR.
c) Segregating and marking acceptable material in accordance with Section 8 and paragraph 19.14
of this Quality Control Manual.
PAGE 6 OF 17
19.13 Any material / item that does not meet above requirements shall be considered a nonconformity and
shall be processed in accordance with Section 11 of this Quality Control Manual.
19.14 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 8.2. If required by the owners specifications, an alternate color code
may be used or material specification and grade 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) verify that all material left at end of project is fully identified and itemized
WELDING CONTROL
19.15 Welding activities and consumables shall be controlled in accordance with Section 10 of this Quality
Control Manual. Welding tasks shall be assigned by QCI based upon the qualifications documented
on the Welders log that is provided by the QCM.
PAGE 7 OF 17
review all completed records for compliances with Code, Owners specifications and
this Quality Control System, and
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.
19.18
The QCI is responsible for the implementing the examination program on site. Under the direction
of QCM, He / She shall;
a)
initiate a Job File, and maintain all applicable records detailed in paragraph 19.21 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
shall be documented on the Pressure Piping Examination Checklist (Exhibit 19.2)
Additional examination may be documented on the back of the check list when
necessary.
PAGE 8 OF 17
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 and prior to test against design specifications and
drawings using the Pressure Piping Examination Guide (Exhibit 19.3),
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 Ltd.
and present the form to the Owners Inspector for his / her certification. 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 Ltd. Oil &
Gas Inc, 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 General Manager.
PRESSURE TESTS
19.19
The QCM is responsible for the implementation and control of this section His /
Her duties include;
a) Preparing the written test procedure for all pressure tests in accordance with the
B31.3 Code, and job specifications.
b) Ensuring that the test procedure is accepted by the Owners representative before test.
c) submitting all proposed pneumatic test procedures to the ABSA Design Survey
department for acceptance before the test.
PAGE 9 OF 17
PRESSURE TESTS
19.19
19.20
RECORD RETENTION
19.21
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.
d.
e.
NDE reports
f.
g.
h.
Nonconformity Reports,
i.
j.
PAGE 10 OF 17
RECORD RETENTION
19.21
k.
l.
material lists, spool lists, Purchase Orders generated by Allied Vessel Fabrication Ltd.,
m.
n.
as built drawings.
Threaded piping shall be designed and constructed within the specific service limitations of
ASME
Pressure Piping Codes B31.3. 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:
PAGE 11 OF 17
19.23
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).
19.24
The Designer is responsible for the design of mechanically assemble 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:
PAGE 12 OF 17
Ensuring that the design and assembly of flanged joints complies with ASME B31.3
paragraphs 312, 335.1 and 335.2.
The QCM shall ensure that the applicable Allied Vessel Fabrication Ltd. 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 19.5 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.
APPLICABLE DOCUMENTS/FORMS
Pressure Piping Specification Sheet,
Pressure Piping Examination Checklist,
Pressure Piping Examination Guide,
Pressure Test Examination Guide,
Sample-Pipe Thread Assembly Dimensional Requirements,
Exhibit 19.1
Exhibit 19.2
Exhibit 19.3
Exhibit 19.4
Exhibit 19.5
PAGE 13 OF 17
Owner:
Contractor
:
Plant Location:
Item
No.
Line
No.
Material List
Mat'l Spec.
Description
& Grade
Design
Pressure
Design
Temp.
Min. / Max.
Corr.
All.
AQP:
Job
Piping Sketch (Reference attached drawings if appropriate)
Sch./
Rating
Code
ASME
B31.3
Service (e.g.,
Normal,
Cat. D, M, K)
Severe
Cyclic
Yes/No
Test
Pressure
Test
Medium
NDE Contractor:
Post Weld Heat Treatment Time/Temp.:
Hardness
Testing
Other Requirements
Approved by Owner:
Date:
Approved by Contractor:
Date:
Comments:
Date:
PAGE 14 OF 17
FUNCTION
SIGNATURE OR INITIAL
AND DATE
Q.C
INSPECTOR
Welders qualified for WPSs and have valid Performance Qualification cards.
Welders Log completed. WPS reviewed with Welders.
10
11
All deficiencies recorded and signed off by Q.C.I. and Owners Inspector
before test.
12
13
14
15
16
OWNERS
INSPECTOR
PAGE 15 OF 17
Fittings; tees, return bends, reducers, couplings and weld-o-lets etc. Correct schedule and
material specification.
Valves; installed correctly, flow direction, accesses, rising stems free from obstructions,
clearance for removal adequate.
Bolts, Studs, Nuts; length and material correct. Studs at least flush with heads (max.
Thread exposure beyond nut should be about 2 threads)
QCI Signature:
Date:
Q.C. INSP.
PAGE 16 OF 17
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.
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:
Q.C. INSP.
EDITION 1 REV 0
PAGE 17 OF 17
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
.2639
.4018
.4078
.5337
.5457
.6828
.7068
.7235
.7565
1.1375
1.2000
1.2500
1.3000
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
*1 Minor Diameter at Small End of Pipe - given as information for use in selecting tap drills.
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
EDITION 1 REV 0
PAGE 1 OF 2
20
CONSTRUCTION OF FITTINGS
20.1 The purpose of this section is to describe the special procedures and controls for the construction and
inspection of small vessels and registered category H pressure fittings in accordance with Alberta Safety
Codes Act and Regulations, and CSA B51.
20.2 Category H pressure fittings will be manufactured in accordance with this written quality system
with the following additions and/ or exceptions:
a. The Controller 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 manufacturer 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 QCM must obtain a copy of the
registered Statutory Declaration for the item and confirm that it meets the specifications
indicated. The QCM will conform 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 the AI at testing to the results of the testing.
d. A Travel Sheet (Exhibit 9.1) shall be initiated for each fitting or concurrent batch of pressure
fittings manufactured. The QCI is responsible to initiate Travel Sheet and Material Sheet and
sign off all applicable inspection tasks as they are completed.
EDITION 1 REV 0
PAGE 2 OF 2
e. Category 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 shown in the example below will be die stamped in 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 a part of the marking):
CRN
MAWP
PSI
MDMT
-20 DEG.F
YEAR BUILT
SN
AT
AT
DEG.F
PSI
Exhibit 9.1
Exhibit 9.1
2.
Oil level
A visual check-Is maintenance up to date, last oil change is still current
There is a proper oil flow to Dies
Check Dies- if there are Burrs or Noticeable wear
Replace if necessary
Read both P&ID & BOM to assure proper material is being used
Double check Heat numbers are recorded on all fittings to be used
Inspect pipe and fittings for internal obscurities, and/or external damage
Use only PTFE Pipe Joint Tape (Jet Lube Product) and Threaded Sealing Compound TF-15
(Jet Lube Product TFE)
Thread A
a.
b.
Test nipple to assure Dies and all other threaded components are in good working order
Check threads on test nipple to see if they are acceptable
i.
c.
d.
e.
f.
Screw hand tight into fitting, depending on size use Exhibit 19.5 Dimensional
Requirements
Measure the cut: There are many different ways to take pipe measurements.
Mark the cut: Using your tape measure, mark the pipe to be cut to the correct length with a
suitable marker, such as a paint stick.
Cut the pipe
Ream the pipe
i.
ii.
When pipe has been cut to length, remove all burrs, External burrs (caused by multiwheel cutters) prevent the threading tool from starting on the pipe and therefore must
be removed usually with a file.
Internal burrs must be removed. Failure to remove internal burrs:
1. Restricts the bore of the pipe, causing excessive pressure loss;
2. Causes turbulent flow in pipe, which can cause in a water hammer condition
and cause local erosion of the pipe; and
3. Allows