forward - heneumann.comthe asme boiler pressure vessel code (bpvc). 4. upon receipt of materials,...

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Forward

H.E. Neumann Company has been providing professional services and quality fabrications to its

customers for over 90 years. Our goal is to provide high-quality products to our customers on

time and at competitive prices, while operating with Safety as our primary objective. Meeting

these objectives will ensure our continued growth by fostering customer loyalty and creating

positive brand recognition for attracting new customers.

H.E. Neumann’s quality control policy is implemented to achieve sustained, profitable growth

by providing products which consistently satisfies, and exceeds, the needs and expectations of

our customer. This level of quality is achieved through adoption of a system of procedures that

reflect the competence of the Company to existing customers, potential customer, and

independent auditing authorities.

The quality program is planned to control products from the requirements of a customer order

to include procurement practices, receipt of material, receiving inspection of supplier material,

handling and storage to the eventual shipment of a product to our customer.

Achievement of this policy involves all staff, who are individually responsible for the quality of

their work, resulting in a continually improving working environment for all. This policy is

provided and explained to each employee by the Quality Manager. Employees are

indoctrinated and trained, as necessary, to assure that suitable proficiency is achieved and

maintained throughout our operation systems. Training is performed as “On the Job Training”

under the direct supervision of management. Procedural changes are implemented by training

of any individual(s) affected by the change.

The quality program is documented within this manual and may be supported at any point by

work instructions that may be selected to increase control of a quality function. Work

instructions affecting quality shall be approved by the Quality Manager.

The Quality Control Manual is maintained by the Quality Manager who ensures that the

appropriate items, at the correct revision levels, are issued to all who need them within the

Company.

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Table of Contents

Section 01:

Section 02:

Section 03:

Section 04:

Section 05:

Section 06:

Section 07:

Section 08:

Section 09:

Section 10:

Personnel Responsibilities

Design Controls

Material Controls

Fabrication Inspection

Calibration Controls

Modification & Repairs to Existing Systems

Welding Controls

Subcontractor & Supplier Quality Controls

Non-Conformances

Records Retention

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Section 01: Personnel Responsibilities

Department Manager: Oversees department Quality Control program, assigns projects and

personnel roles and responsibilities, and is the final decision-making authority for any

clarifications, uncertainties, or disagreements.

Project Manager: Responsible for the successful completion of assigned projects per code and

customer requirements, and is the direct line to the customer, vendors, and subcontractors.

Interprets customer requirements, conducts project planning, and ensures application of and

compliance to all standards on their project.

Quality Manager: The Quality Manager is delegated authority and organizational freedom to

identify and evaluate quality problems and to initiate, recommend, or provide solutions.

Reviews ASME code updates as published and revises Quality Control Manual as necessary,

leading regularly scheduled reviews of the manual with the management team. Maintains all

required documentation and logs listed in the manual, trains Quality Control Inspectors, directs

inspection activities, and advises the management team. Works in conjunction with the Project

Manager to ensure project compliance.

Quality Control Inspector: Responsible for ensuring Quality Control standards are enforced and

approved all work for a particular project. The inspector may be an appointed in-house

employee or a subcontractor as assigned by the Project Manager on a per-job basis.

Foreman: Assigns work to and supervises all personnel, including Subcontractor oversight.

Works in conjunction with the Quality Control Inspector, and in some cases may perform the

role of Quality Control Inspector as assigned by the Project Manager. Responsible for

equipment maintenance, stock upkeep, and material receiving from all parties per the

requirements of this manual.

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Section 02: Design Controls

Purpose: This section ensures project design documents are reviewed and approved as

required prior to submission for fabrication. The Project Manager is responsible for

maintaining these requirements and ensuring only the latest applicable documents are present

in the shop and/or field sites.

General Conditions:

1. All drawings, addendums, and specifications shall be reviewed by the Project Manager

to identify and document customer specifications in addition to standard code

requirements. These may include specific Non-Destructive Examination (NDE), welding

procedure, heat treatment, pressure testing, coordination drawings, field routing

submittals, and/or other requirements.

2. Documented customer requirements to be distributed to the foreman, Quality Control

Inspector, and Quality Manager.

3. Field measurements and calculations shall be submitted to the Project Manager for

review prior to submission for fabrication. When available, field drawings shall be

confirmed via computer calculations and/or drafting program.

4. When dimensioned fabrication drawings are provided by the Customer, Foreman shall

review site and identify critical dimensions to ensure project constructability. These are

to be field verified prior to fabrication. If field dimensions do not align with provided

drawing dimensions, Project Manager is to document the discrepancies and submit RFI

to the Customer representative for disposition. All fabrication to be placed on hold until

final determinations met.

5. Project Manager and Foreman shall review Customer drawings for accuracy,

inconsistencies, and verify constructability. Any concerns or clarifications shall be

submitted to the Customer in a RFI by the Project Manager.

6. Recommendations for the modification of customer supplied designs to be submitted to

the Project Manager whom shall confirm design constructability and mutual benefit.

The recommendation shall then be documented as a submittal and sent to the

Customer for approval.

7. The Project Manager shall be responsible for reviewing and submitting all Company

design documents and revisions to the Customer.

8. Foreman to make recommendations on placement of field joints to best facilitate

installation and minimize field welding. Recommendations are submitted to the Project

Manager for approval prior to submission to the shop Foreman for fabrication.

9. The Project Manager shall maintain all above documents in the job file, including

calculations, drawings, and applicable RFI responses.

10. The Project Manager is responsible for reviewing all design documents and the

distribution of these documents to the shop and/or field Foremen.

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Section 03: Material Controls

Purpose: This section ensures materials adhere to Customer and code requirements prior to

fabrication. All requirements of this section apply to shop and field material deliveries and

fabrication.

General Conditions:

1. The Project Manager shall be responsible for the procurement of all materials used on a

project. The Project Manager shall ensure quoted materials meet specifications and

customer Approved Manufacturer Lists (AML) prior to release.

2. The Project Manager will prepare the material purchase order(s) based on information

provided in the project’s bill of materials, respective material specifications, and/or

estimator take-offs. Information shall include pipe schedules, pressure classifications,

material composition/grade/type specifications, etc.

3. The purchase order shall be annotated to require applicable Material Test Reports

(MTR) for all material to be used as specified by the “Material Specification” Section II of

the ASME Boiler Pressure Vessel Code (BPVC).

4. Upon receipt of materials, assigned Foreman shall confirm ASME Code required

markings are visible and vendor supplied MTRs match heat codes on product per ASME

BPVC Section VIII. The Foreman shall also inspect the material for damage and

dimensional tolerance. Lastly, the Foreman shall confirm all pipe, fittings, flanges, etc.

meet required schedule/pressure classification for the fabrication and as documented

on the purchase order. Upon acceptance, MTRs shall be forwarded to the Project

Manager.

5. Project Manager to ensure material adheres to customer AML and material specification

in ASME BPVC Section II.

6. Project Manager to maintain all MTRs in the job file and include in project closeout

documentation.

7. After acceptance of all material, assigned Foreman shall clearly mark the material with

the respective project number and heat codes. Materials shall be stored in a designated

area for the specific project purchased for.

8. Prior to cutting materials for fabrication, project number and heat code markings shall

be transferred to all cut ends by the Operator under supervision of the Foreman.

9. Upon project completion, excess materials shall be stored in “stock”. Shop Foreman to

confirm all stock materials are properly labelled with heat codes and a copy of the MTR

is in hand. Stock material MTRs shall be kept on record in the fabrication shop and

readily available.

10. When existing “stock” materials are to be used on a project, the shop Foreman shall

confirm MTR is on hand and matches material markings. The MTR shall then be

forwarded to the Project Manager to confirm material acceptance for the project and

grant approval for utilization.

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11. Any material that has lost traceability shall be considered non-conforming and handled

in accordance with Section 09 of this manual.

12. All pipe fabrications that are shipped from the shop shall be accompanied with the

respective MTRs for materials incorporated. Site QC Inspector shall confirm material

traceability to the provided documentation and store in site job file.

13. Customer supplied materials shall undergo the same inspection process as Company

purchased materials. Non-conformities found shall be documented by the Project

Manager and submitted to the Customer for disposition. Any materials delivered to the

Company from a Customer hired third party vendor that are not traceable shall be

rejected.

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Section 04: Fabrication Inspection

Purpose: This section outlines inspection requirements to ensure fabrications meet all

applicable code and Customer requirements prior to commissioning.

General Conditions:

1. At the onset of the project, the Project Manager in conjunction with the Quality Control

Inspector shall establish necessary inspection hold points. Hold points may be

established for any form of inspection, to include but not limited to dimensional

tolerance verification, Non-Destructive Examination, or pressure testing. Work shall not

progress past any hold point until the designated inspection is completed and approved

by the Project Manager and Quality Control Inspector.

2. The Quality Control Inspector shall inspect all work to ensure adherence to design.

Inspection items include materials used, pressure classifications, pipe schedules

dimensional tolerances, fitting and flange placement, etc.

3. Once the work is completed, the Foreman shall coordinate any third-party inspections

of fabrications per code and Customer requirements to ensure compliance. Inspection

requests shall be drafted by the Foreman and submitted to the Project Manager for

approval. Final inspections and third-party records to be reviewed and approved by the

Quality Control Inspector.

4. For fabrication-only contracts and for assemblies labeled as critical by the Foreman

designated in Section 02 of this manual, 100% of dimensions shall be verified in the shop

prior to shipment to the site. Shop foreman shall sign off on shop drawings for

approval, and shall be distributed to appropriate parties.

Pressure Testing:

1. The Project Manager shall complete the respective pressure testing form(s) for the

project to include project number, line number, testing procedure, and test pressures

and temperature per code for rated assembly or specific Customer requirements.

Consult company policy for pressure testing procedural guidelines and project form.

Company SOP shall be utilized in absence of or in conjunction with Customer provided

testing procedure.

2. The Project Manager shall submit pressure testing procedure(s) to the Customer for

their approval. Approved procedure(s) shall be distributed to the Foreman and third-

party testing outfit as applicable by the Project Manager.

3. Pressure gauges used during final pressure tests shall be checked for identification and

damage prior to use. The pressure gauge shall be connected directly to the component

or to a connected pressure line free of intermediate valves. Gauge shall be installed at

the high point of the component; a second gauge may be utilized if required for visibility

to the operating controlling the applied pressure.

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4. Graduated pressure gauges used in all pressure testing shall have a range of at least 1.5

times the test pressure, but not more than 4 times that pressure. Digital pressure

gauges shall have a range of at least 1.1 times the test pressure. Ideal pressure gauge

range is twice test pressure.

5. The Quality Control Inspector shall confirm pressure gauge utilized for the testing is

compliant and accompanied by qualified calibration documents. Copies of calibration

documentation shall be submitted with the pressure testing paperwork for the job file.

6. Final connections made after pressure testing shall be inspected per code.

Non-Destructive Examination (NDE):

1. NDE shall be conducted by qualified personnel in accordance with applicable ASME

Code, including any additional requirements dictated by the Customer.

2. Project Manager shall determine NDE requirements specify on project documentation

per code and any Customer requirements above code minimums.

3. Project Manager shall fill out NDE request form (Attachment A) to be submitted to the

NDE provider.

4. NDE shall be performed by a qualified Subcontractor, with the exception of Visual

Testing (VT) which may be performed by qualified in-house per ASME BVPC Section V

Article IX.

5. All NDE shall be performed in accordance with written procedures, approved by the

appointed Level III Examiner qualified in the specific NDE method, which shall be

furnished by the Subcontractor to the Project Manager and kept with the NDE

documentation in the job file. At the Customer’s request, NDE procedures shall be

submitted by the Project Manager for approval prior to commencement of applicable

examination.

6. New NDE service providers shall submit all applicable NDE procedures to the

Department Manager for approval prior to being contracted for services.

7. Quality Control Inspector shall verify NDE personnel have current qualifications prior to

commencing work, and observe the examiners to ensure adherence to applicable

procedure.

8. Quality Control Inspector shall indicate NDE test points and on assembly weld map and

submit to the project manager for approval prior to scheduling NDE Subcontractor.

9. The Project Manager shall review planned NDE testing plan to ensure code and

Customer requirements shall be met. Project Manager to verify minimum number of

welds tested per welder and per line will be met for the respective service.

10. NDE reports shall be interpreted and approved by the designated Quality Control

Inspector, then submitted to the Project Manager for final approval.

11. All NDE reports, including Radiographic Testing (RT) films, shall be maintained in the job

file by the Project Manager and submitted with closeout documentation.

12. In-house examiners shall follow Company VT inspection procedure and accompanying

inspection form, which includes qualification guidelines.

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13. The Quality Manager in conjunction with the Department Manager, or an approved NDE

Subcontractor shall prepare all in-house NDE procedures and revisions to established

procedures. The Quality Manager shall distribute NDE procedures to qualified

examiners and discard all prior revisions. Procedures shall be demonstrated and re-

certification conducted when applicable.

Bolt Torqueing:

1. All bolts in fabricated assemblies shall be torqued per company policy or as dictated by

Customer requirements.

2. Quality Control Inspector shall ensure torqueing equipment is compliant and

accompanied by calibration certificates, to be submitted to the Project Manager for

retention in the job file.

3. Quality Control Inspector shall oversee all final bolt torqueing and ensure proper bolt

marking is conducted per standard.

4. Quality Control Inspector shall fill out company Torque Schedule form and submit to the

Project Manager for approval and retention in the job file. Reference Attachment B.

Closeout:

1. All testing and inspection paperwork shall be submitted to the Project Manager and

retained in the job file.

2. Project Weld Maps to be updated with NDE type and date performed. Reference

Attachment C.

3. Upon completion of required inspections, all shop fabricated components shall be UA

labelled and the shop foreman shall fill out Monthly Union Label Report for submission

to the Project Manager and Business Agent.

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Section 05: Calibration Controls

Purpose: Measuring and testing equipment shall be controlled and calibrated at specified

intervals to maintain accuracy within required tolerances. No undocumented equipment shall

be authorized for use.

General Conditions:

1. The Quality Manager shall be responsible for maintaining all testing and measuring

equipment, ensuring applicable calibrations are kept up-to-date and documentation

retained.

2. The Quality Manager shall dictate calibration intervals based on equipment type and

applicable manufacturers recommendations, codes, and industry standards.

3. The Quality Manager is responsible for issuing, tracking, receiving, and storing testing

equipment. Prior to each transaction the Quality Manager shall inspect the device for

damage, identification, and documentation.

4. Calibration records for equipment used by Subcontractors shall be reviewed by the

Quality Control Inspector prior to use and submitted to the Project Manager for the job

file.

5. Equipment found to be out of calibration or damaged shall be removed from the work

area and clearly marked “DO NOT USE” by the user and returned to the Quality

Manager. Any components tested with this device shall be re-inspected with a

compliant device.

6. All calibration documentation for equipment used shall be stored in the job file and

furnished to the Customer with closeout paperwork.

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Section 06: Modifications & Repairs to Existing Systems

Purpose: Ensure operational safety and overall system integrity and operation.

General Conditions:

1. Prior to any work being conducted, Foreman is to verify systems to be worked on are

de-energized and void of any liquids and volatiles. Proper safety and environmental

protocols are to be set in place to protect each accordingly. If work to be conducted is

to be a “hot-tap”, refer to company policy for required guidelines.

2. Work is to be performed per standard fabrication procedures in accordance with

applicable code. Quality Control Inspector shall ensure work adheres to all applicable

sections of this manual.

3. While work is being conducted, if any personnel find potential non-conformities in the

existing system they shall alert the Foreman immediately to set a hold point and

implement stop-work authority if applicable. The Quality Control Inspector shall review

the concern and document accordingly to the Project Manager, who shall submit to the

Customer for disposition.

4. Non-Destructive Examination (NDE) shall be performed to all work per code and

Customer requirements. Follow Section 04 of this manual.

5. Repairs and alterations shall be pressure tested as allowable. Specific pressure test type

will be predicated on the service and existing conditions. The Project Manager shall

determine pressure testing procedure based on site conditions and Customer

requirements.

6. If site conditions inhibit pressure testing, alternate NDE methods may be utilized to

verify work integrity. The Quality Manager and Project Manager shall determine test

method to be used and submit to the Customer for approval.

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Section 07: Welding Controls

Purpose: This section ensures qualified operators and welding procedures are enforced for all

fabrications and proper welding materials are utilized.

General Conditions:

1. All piping welds shall be made using a procedure qualified to ASME Boiler Pressure

Vessel Code (BPVC) Section IX requirements.

2. The Foreman shall be responsible for assigning work to welders in order to make most

efficient and cost-effective use workforce and minimize multiple welders working on the

same line. The Quality Control Inspector and/or Project Manager may provide guidance

on assignments to facilitate this process.

3. Throughout the course of the work, the Quality Control Inspector and Foreman shall

conduct periodic inspections of welders to ensure essential requirements laid out in the

approved Welding Procedure Specification (WPS) is being followed.

4. Prior to start of any project, the Project Manager shall determine if the customer has

any specific WPS requirements to be utilized and have a new/revised WPS published as

necessary. If essential variables are modified, the procedure and personnel shall be

requalified prior to work commencement.

5. Copies of the WPS, Procedure Qualification Record (PQR), and Welder Performance

Qualification (WPQ) utilized on a project shall be issued to the Foreman by the Project

Manager on a per-project basis and posted in work areas for welder’s use.

6. Joint preparations may be prepared by any means such as grinding, gouging, machining,

flame cuttings, etc. as long as the final weld prep is reasonably smooth and true. The

weld prep shall be free of cadmium and chrome plating, slag, mill scale, dirt, rust, oils,

paints, etc. that would interfere with the welding process. The joint prep shall be

cleaned prior to welding for a minimum distance of ¼” from the welding edge.

7. Inter-pass Cleaning: Remove slag and oxide using grinder, wire brush or chipping hammer, as needed. The welder shall perform a visual inspection of each weld pass. Any visible cracks, lack of fusion, porosity, and slag inclusions shall be removed before depositing the next bead or layer.

Procedure & Welder Qualifications:

1. All welding shall be conducted with an approved Welding Procedure Specification (WPS)

and accompanying Procedure Qualification Record (PQR) for the respective welding

required. Welders shall also have an approved Welder Performance Qualification

(WPQ) on the procedure in use before performing the work. All records shall be

maintained by the Quality Manager, Project Manager, and Department Manager; and

copies of procedures and qualifications used retained in all respective job files.

2. A WPS may be updated with informational data or non-essential variables without

requiring re-qualification.

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3. WPS may be prepared by in-house CWI or approved Subcontractor. All PQR and WPQ

testing shall be performed by an approved third-party per ASME BPVC Section IX.

4. All PQR and WPQ coupons must be prepared in shop or in an approved UA shop under

Company Quality Control Inspector supervision.

5. The Quality Manager shall review all PQR and WPQ testing reports and if acceptable

certify and issue the qualification. The Quality Manager may elect to have an approved

Subcontractor certify the qualifications.

6. The Quality Manager shall issue each qualified welder a unique identification number.

This number shall be used to identify each weld completed by the welder and each weld

shall be labelled by the welder with their respective number. The Quality Manager shall

maintain a master welder log to include welder identification numbers, procedures the

welder is qualified on, and all respective qualification and expiration dates

7. The Operator shall not label the weld in any fashion that may damage its profile or

integrity (i.e. stamps).

8. The Quality Control Inspector shall record all welder identifications for each weld on an

accompanying weld map for the project. The weld map shall be submitted to the

Quality Manager for approval, and passed along to the Project Manager for retention in

the job file and submission to the Customer with closeout documentation. Reference

Attachment C for sample weld map.

9. Company WPQ are valid for 1-year from the testing date for the specific WPQ.

Maintenance criteria to keep a WPQ active as follows:

a. 1-year continuity with Radiographic Testing (RT) films taken and approved on

project work with respective WPS.

b. Annual RT testing on any WPS a welder is qualified on but has not utilized on a

project requiring RT Non-Destructive Examination (NDE).

c. If a qualified welder has a break in service, continuity paperwork may be

furnished to the Quality Manager for review and maintain welder WPQ if

approved. Any break in service of more than 1-year shall require retesting.

10. The following occurrence shall result immediate expiration of a welder’s WPQ, which

shall be update on the welder log by the Quality Manager. An Operator’s individual

WPQ only or all WPQs on record may be revoked at the Quality Manager’s discretion.

a. The qualified WPS has been updated with an essential variable based on ASME

BPVC Section IX

b. Welder fails 3 NDE within 12-month period, or 2 exams on a single project.

c. More than a 1-year break in service from the Company

d. The Quality Manager reserves the right to revoke a WPQ at any time for any

specific reason that brings the welders ability to perform the work to question.

Materials:

1. Welding materials shall be purchased and received per guidelines in Section 03 of this

manual. The Quality Control Inspector shall verify welding materials meet WPS

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requirements, inspect containers for damage, confirm SFA number, and lot number

traceability.

2. Welding materials shall be stored in their original containers in a dry storage area

designated by the Foreman, and shall be issued out to welders by the Foreman.

3. The Quality Control Inspector shall track filler metal lot numbers used on each project.

4. Welders are responsible for keeping track of filler metal identification issued to them

and stored in their portable rod ovens, if applicable. The Quality Control Inspector may

conduct periodic checks to ensure welders maintain proper accountability.

5. All low hydrogen electrodes shall be stored in an electrode oven after opening. Low

hydrogen electrodes include may electrode whose last digit is a 5, 6 or 8 (i.e. E7018,

E308-15, E8015-B2). These electrodes are purchased in hermetically sealed cans. When

a can is opened, the welder is to take only what they will use in less than four hours and

immediately put the rest of the can in the oven. After four hours, if the welder has any

unused electrodes, they should return them to the oven and take a fresh supply of hot

electrodes from the oven. The temperature of the oven should be maintained at 250°F,

or per manufacturer’s recommendation, and must remain on continuously day and

night and weekends. The rods are not to cool to room temperature once they have

been removed from the sealed cans. At no time, should the ovens be used for anything

other than keeping low hydrogen electrodes warm. 6. Unconsumed coated electrodes shall be examined by the Foreman for condition,

cleanliness, and identification, then stored in a heated oven open acceptance.

Unacceptable electrodes shall be scrapped.

Inspection:

1. Preliminary inspection shall be conducted by the Operator to ensure all materials are

correct and identification transferred to components as required. The Operator shall

check all weld joints and filler materials for proper preparation, alignment, cleanliness,

and conformance with the details of the WPS.

2. All weld beads or layers shall be visually checked before depositing a weld bead or layer

over the previous layer. All defects found by visual inspection shall be removed and/or

repaired before depositing the next weld layer.

3. Preheat temperature shall be maintained in accordance with the applicable WPS and

randomly verified by the Operator and QC Inspector.

4. Additional inspection measures are outlined in Section 04 of this manual for final

acceptance.

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Section 08: Subcontractor Quality Control

Purpose: Ensure compliance to code and Customer requirements by all contributors involved

on a project.

General Conditions:

1. Suppliers of products, materials and services, where unspecified by a Customer contract, are selected on their ability to meet the company’s requirements given due consideration to the quality, statutory obligations, timescale and cost. A list of approved Suppliers and Subcontractors is maintained which is compiled on the following criteria:

a. Previous performance in supplying to similar specifications and requirements. b. Stocking of high volume standard items conforming to a relevant British

Standard, or supplied with a statement of conformity. c. Compliance with an approved third-party product/quality registration scheme. d. Recommendation by other similar purchasers or manufactures of equipment. e. A trial order and evaluation of performance.

2. All materials shall be inspected per Section 03 of this manual.

3. All Subcontractor work must be inspected and approved by the Quality Control

Inspector prior to acceptance and release.

4. Subcontractors shall accompany all return shipment with required documentation

based on service provide, to be reviewed by the Quality Control Inspector for

completeness, correctness, and compliance.

5. Upon acceptance, the Quality Control Inspector shall forward all documentation to the

Project Manager for retention in the job file.

Site Work:

1. For Subcontractor work performed in the shop or field location, the Foreman shall

oversee their work performed and the Quality Control Inspector shall conduct periodic

inspections to ensure compliance to specifications and code.

2. The Quality Control Inspector shall conduct a final inspection of completed work and

review all required documentation prior to releasing the contractor from the location.

The Quality Control Inspector shall notify the Project Manager of work completion and

forward Subcontractor documentation for retention in the job file.

3. Foreman to receive and sign all Subcontractor time sheets and submit to the Project

Manager for the job file.

Offsite Work:

1. Subcontracted tasks sent out of the shop for work may include, but not limited to, heat

treatment, coatings, and non-destructive examination.

2. Any components sent out to a Subcontractor for work shall be labeled with the job

number and other necessary designations such as drawing number, line number, etc. for

tracking and end-user identification by the Foreman.

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3. Upon returned receipt of components sent out for work, the Quality Control Inspector

shall inspect each item for damage and identification.

4. Any non-conformances found during receipt inspection shall be immediately reported to

the Project Manager and the component shall be appropriately labelled and segregated

per Section 09 of this manual.

5. The Foreman shall notify the Project Manager of accepted receivables.

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Section 09: Non-Conformances

Purpose: A non-conformance encompasses any condition that does not meet code, design

documents, or the requirements of this manual. All employees are responsible for reporting

non-conformities to their respective foreman, who shall notify the Project Manager.

General Conditions:

1. When a non-conformance is identified, it shall be documented by the responsible party

and submitted to the Quality Manager and Project Manager.

2. Work pertaining to non-conforming items shall seize and hold point initiated until a

disposition has been reached and approved of by the Project Manager. The component

shall be marked as “NON-CONFORMING” and stored in a segregated area awaiting

disposition.

3. The project manager shall determine if disposition of the non-conformity may be

decided by the Company or submitted for Customer response on a per-case basis.

a. Generally, non-conformances in Customer supplied materials or directly

resulting from Customer supplied drawings shall be submitted to the Customer

for disposition.

b. Generally, non-conformances in Company purchased materials or in fabrication

shall receive disposition from the Project Manager.

4. Four primary forms of disposition may be issued:

a. Accept as-is: The non-conformance may be accepted as-is as long as code

requirements, customer requirements, and design intent shall be met. Any

revisions to design resulting from the non-conformance shall be submitted to the

Customer for approval by the Project Manager. Accompanying documentation

shall be maintained in the job file.

b. Repair: Repairs may be made to the non-conforming components to bring up to

standard. The Quality Control Inspector shall conduct final inspection of all

repairs, which must be approved before the hold designation from the work may

be removed. NOTE: For non-conformances found during Non-Destructive

Examination, repairs shall be made and tracers examined per code.

c. Scrap: Any non-conformances deemed as scrap shall be clearly labeled

“REJECTED” and segregated into a scrap storage area.

i. Assemblies: Components from a non-conforming assembly may be

salvaged at the direction of the Quality Manager or Project Manager.

Salvaged components are to be inspected by the Quality Manager as a

material item or sub-assembly. These components will undergo standard

inspection protocol as applicable and the Quality Manager may designate

them as “accepted” and return components to the work site or into

“stock” if criteria are met.

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ii. Materials: The Project Manager shall return any non-conforming material

to the Supplier in quick fashion to receive a replacement or credit for the

item(s).

d. Stock: Materials that may not conform to specific job requirements, but are

otherwise acceptable for fabrication, may be designated as “stock” and

incorporated accordingly for future use. Material’s accompanying MTR shall be

filed in the shop stock documents and the shop Foreman shall ensure the

material is properly marked with job and heat code numbers.

5. Upon designating a non-conforming item as “accepted” or “repaired”, the Quality

Control Inspector shall remove the “NON-CONFORMING” marking and annotate project

documentation accordingly on shop drawings to maintain visibility.

6. The Project Manager shall maintain record of all non-conforming reports and

dispositions in the job file.

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Section 10: Record Retention

Purpose: Maintain document trail of all projects for Company records that are accessible for

service or for the Customer at their request.

General Conditions:

1. The Project Manager shall collect all job records annotated in this manual and review

them at the completion of the job for completion, correctness, and compliance. Upon

final review, the Project Manager shall update the job file accordingly and prepare

project closeout documentation for the Customer.

2. Completed job files shall be maintained by the department for a minimum of 5 years,

and made available to the Customer at their request.

3. The following records shall be maintained and issued to the Customer during project

closeout:

a. Final approved drawings, if applicable

b. WPS & PQR records used during fabrication

c. WPQ record for each welder on the project

d. Completed weld map(s) for the project

e. MTRs for all materials used on the project

f. Test equipment calibration certifications

g. Final pressure test reports with accompanying procedures

h. Final torque schedules

i. NDE reports, including RT films

j. Heat treatment records

4. The following records shall be maintained, but not issued to the Customer unless

requested at closeout:

a. Design calculations

b. Non-conformance reports and dispositions

c. Subcontractor timesheets and back-up documentation

of 21

Attachments

Attachment A:

Attachment B:

Attachment C:

Non-Destructive Examination Request Form

Bolt Torque Schedule

Weld Map Sample

NDE

Provide

r:Cu

stom

er:

Locatio

n:

Site Con

tact:

Line

Num

ber

Material

Descriptio

nCo

mpo

nent /

Weld ID

Welde

r ID

Size

Sche

dule

Thickn

ess

RTMT

PTUT

NON‐DESTR

UCT

IVE EX

AMINAT

ION (N

DE) REQ

UEST

Acceptan

ce Criteria:

Draw

ing Num

ber:

Date Req

uested

:Job Num

ber:

PO Num

ber:

Flan

ge

Num

ber

Flan

ge

Size

Bolt

Qua

ntity

Bolt Size

Gaske

t Ch

ecke

dTo

rque

Ve

rified

Ope

rator

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

FT/LB

Custom

er:

Locatio

n:

Foreman

:

Supe

rvisor

Date :

Job Num

ber:

Draw

ing Num

ber:

Torque

Sche

duled

Commen

ts

BOLT TORQ

UE SC

HED

ULE

SAMPLE

A

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