qa manual 4th edition final controlled

Fourth Edition Quality Assurance Manual

STARCON International, Inc.

SHOP LOCATION

260 Market Place

Manhattan, IL. 60442

Manual Number Effective Date 7/15/2009

Controlled Manual *** Uncontrolled Manual

This Manual is the property of STARCON International, Inc., and shall not be duplicated in any way without the express written permission of the president of the aforementioned company.

Quality Assurance Manual Fourth Edition

July 15, 2009 Revision 0 of 54

Contents 1 Glossary........................................................................................................................................................................................... 5 2 STATEMENT OF POLICY AND AUTHORITY ................................................................................................................................. 6 3 AUTHORITY AND RESPONSIBILITY ............................................................................................................................................. 7

3.1 SCOPE .......................................................................................................................................................................................................... 7 3.2 REPONSIBILITY ........................................................................................................................................................................................... 7 3.3 PRESIDENT .................................................................................................................................................................................................. 7 3.4 VICE PRESIDENT OF QUALITY CONTROL ............................................................................................................................................... 7 3.5 DIVISION VICE PRESIDENT ....................................................................................................................................................................... 7 3.6 QUALITY CONTROL MANAGER ................................................................................................................................................................. 7 3.7 PROJECT MANAGER .................................................................................................................................................................................. 7 3.8 SUPERVISOR ............................................................................................................................................................................................... 8 3.9 PROJECT Q.C. MANAGER .......................................................................................................................................................................... 8 3.10 MANUAL CONTROL ..................................................................................................................................................................................... 8 3.11 MANUAL REVISIONS ................................................................................................................................................................................... 8

4 ORGANIZATION .............................................................................................................................................................................. 9 4.1 SCOPE .......................................................................................................................................................................................................... 9 4.2 RESPONSIBILITY ......................................................................................................................................................................................... 9 4.3 ORGANIZATION CHART ............................................................................................................................................................................. 9

5 DRAWINGS, DESIGN CALCULATIONS & SPECIFICATION CONTROL .................................................................................... 10 5.1 SCOPE ........................................................................................................................................................................................................ 10 5.2 RESPONSIBILITY ....................................................................................................................................................................................... 10 5.3 DRAWINGS AND SPECIFICATIONS ......................................................................................................................................................... 10 5.4 DESIGN CALCULATIONS .......................................................................................................................................................................... 11 5.5 COMPUTER-GENERATED DESIGN CALCULATIONS ............................................................................................................................ 11

6 MATERIAL CONTROL ................................................................................................................................................................... 12 6.1 SCOPE ........................................................................................................................................................................................................ 12 6.2 RESPONSIBILITY ....................................................................................................................................................................................... 12 6.3 TAKE-OFF SHEET...................................................................................................................................................................................... 12 6.4 PURCHASE ORDER .................................................................................................................................................................................. 12 6.5 RECEIVING INSPECTIONS ....................................................................................................................................................................... 13 6.6 CUSTOMER-PROCURED MATERIALS .................................................................................................................................................... 13 6.7 DOCUMENTATION..................................................................................................................................................................................... 13

7 EXAMINATION AND INSPECTION PROGRAM ........................................................................................................................... 14 7.1 SCOPE ........................................................................................................................................................................................................ 14 7.2 RESPONSIBILITY ....................................................................................................................................................................................... 14 7.3 RELEASE OF MATERIAL ........................................................................................................................................................................... 14 7.4 IN-PROCESS INSPECTION ....................................................................................................................................................................... 14 7.5 FINAL TESTING.......................................................................................................................................................................................... 14 7.6 MANUFACTURER DATA REPORT (MDR) AND STAMPING ................................................................................................................... 15 7.7 CODE SYMBOL STAMP ............................................................................................................................................................................ 15 7.8 NATIONAL BOARD REGISTRATION ........................................................................................................................................................ 15

8 CORRECTION OF NON-CONFORMITIES .................................................................................................................................... 16 8.1 SCOPE ........................................................................................................................................................................................................ 16 8.2 RESPONSIBILITY ....................................................................................................................................................................................... 16 8.3 NON-CONFORMITIES ............................................................................................................................................................................... 16 8.4 RECEIVING INSPECTION ......................................................................................................................................................................... 16 8.5 PROCEDURE ............................................................................................................................................................................................. 16 8.6 NON-CONFORMITY REPORTS ................................................................................................................................................................ 17 8.7 DEVIATIONS............................................................................................................................................................................................... 17

9 WELDING ....................................................................................................................................................................................... 18 9.1 SCOPE ........................................................................................................................................................................................................ 18 9.2 RESPONSIBILITY ....................................................................................................................................................................................... 18 9.3 WELDING MATERIAL STORAGE AND DISTRIBUTIONS ........................................................................................................................ 18



9.4 WELDING PROCEDURE SPECIFICATIONS ............................................................................................................................................ 18 9.5 WELDERS ................................................................................................................................................................................................... 18 9.6 TEST RESULTS.......................................................................................................................................................................................... 19 9.7 JOB FILE ..................................................................................................................................................................................................... 19 9.8 TACK WELDS ............................................................................................................................................................................................. 19 9.9 WELDER RE-QUALIFICATIONS ................................................................................................................................................................ 19

10 NON-DESTRUCTIVE EXAMINATION ........................................................................................................................................... 20 10.1 SCOPE ........................................................................................................................................................................................................ 20 10.2 RESPONSIBILITY ....................................................................................................................................................................................... 20

11 HEAT TREATMENT ....................................................................................................................................................................... 22 11.1 SCOPE ........................................................................................................................................................................................................ 22 11.2 RESPONSIBILITY ....................................................................................................................................................................................... 22 11.3 PROCEDURE ............................................................................................................................................................................................. 22 11.4 RECORDS .................................................................................................................................................................................................. 22

12 CALIBRATION OF MEASUREMENT & TEST EQUIPMENT ........................................................................................................ 23 12.1 SCOPE ........................................................................................................................................................................................................ 23 12.2 RESPONSIBILITY ....................................................................................................................................................................................... 23 12.3 EQUIPMENT ............................................................................................................................................................................................... 23

13 RECORD RETENTION ................................................................................................................................................................... 24 13.1 SCOPE ................................................................................................................................................................................. 24 13.2 RESPONSIBILITY .............................................................................................................................................................. 24 13.3 RECORDS ........................................................................................................................................................................... 24 13.4 JOB FOLDER ...................................................................................................................................................................... 24

14 REPAIRS AND ALTERATIONS ..................................................................................................................................................... 25 14.1 SCOPE ........................................................................................................................................................................................................ 25 14.2 RESPONSIBILITY ....................................................................................................................................................................................... 25 14.3 DEFINITIONS.............................................................................................................................................................................................. 25 14.4 ROUTINE REPAIRS ................................................................................................................................................................................... 26 14.5 REPORTS ................................................................................................................................................................................................... 27 14.6 JOB PACKAGES......................................................................................................................................................................................... 27 14.7 RECOR RETENTION.................................................................................................................................................................................. 27

15 AUTHORIZED INSPECTOR .......................................................................................................................................................... 28 15.1 SCOPE ........................................................................................................................................................................................................ 28 15.2 RESPONSIBILITY ....................................................................................................................................................................................... 28 15.3 AUTHORIZED INSPECTOR ....................................................................................................................................................................... 28 15.4 ACCESS FOR INSPECTOR ....................................................................................................................................................................... 28 15.5 DOCUMENTATION..................................................................................................................................................................................... 28 15.6 FACILITIES ................................................................................................................................................................................................. 28 15.7 THE INSPECTOR ....................................................................................................................................................................................... 28

16 APPENDIX ...................................................................................................................................................................................... 29 16.1 APPENDIX I REQUIREMENTS OF CALIFORNIA DIV. OF OCCUPATIONAL SAFETY AND HEALTH (DOSH) .................................... 29

16.1.1 GENERAL .................................................................................................................................................................................... 29 16.1.2 ROUTINE REPAIRS .................................................................................................................................................................... 29 16.1.3 JURISDICTIONAL ACCEPTANCE .............................................................................................................................................. 29 16.1.4 INSPECTOR ................................................................................................................................................................................ 30 16.1.5 DOCUMENTATION ..................................................................................................................................................................... 30

16.2 APPENDIX II REQUIREMENTS OF CALIFORNIA DIV. OF OCCUPATIONAL SAFETY AND HEALTH ................................................. 31 16.2.1 PRE-APPROVED REPAIR PLAN FOR PT IN LIEU OF HYDROSTATIC TESTING .................................................................. 31 16.2.2 STARCON REPAIR PROCEDURES ........................................................................................................................................... 31

17 EXHIBITS ....................................................................................................................................................................................... 34



TABLE OF CONTENTS

Page Description Rev. Date

1 Title Page 0 7/15/2009

2 Contents 0 7/15/2009

4 Table of Contents 0 7/15/2009

5 Glossary 0 7/15/2009

6 Statement of Policy and Authority 0 7/15/2009

7 Authority and Responsibility 0 7/15/2009

9 Organization 0 7/15/2009

10 Drawings, Design Calculations, and Specification Control 0 7/15/2009

12 Material Control 0 7/15/2009

14 Examination and Inspection Program 0 7/15/2009

16 Correction of Non-Conformities 0 7/15/2009

18 Welding 0 7/15/2009

20 Non-Destructive Examination 0 7/15/2009

22 Heat Treatment 0 7/15/2009

23 Calibration of Measurement and Test Equipment 0 7/15/2009

24 Record Retention 0 7/15/2009

25 Repairs and Alterations 0 7/15/2009

28 Authorized Inspector 0 7/15/2009

30 Appendix 0 7/15/2009

35 Exhibits 0 7/15/2009



1 Glossary A.I. Authorized Inspector

A.S.M.E American Society of Mechanical Engineers

C.I. Commissioned Inspector

C. of C. Certificate of Compliance

CODE A.S.M.E. Code Section I, II (a,b,c,d), V, VIII-Div. 1, IX, NBIC, B31.1 and applicable jurisdictions

MT Magnetic Particle Examination

Material Certification M.T.R. C of C, or letter of compliance

M.T.R. Material Test Report

M.D.R. Manufacturers Data Report

Natl. Bd. National Board of Boiler & Pressure Vessel Inspectors

N.B.C.I. National Board Commissioned Inspectors

N.B.I.C. National Board Inspection Code

NCR Non-Conformity Report

N.D.E. Nondestructive Examination

P.O. Purchase Request Form

PQR Procedure Qualification Record

P.R.I Pressure Retaining Item

PT Liquid Penetrant Examination

Q.C.I. Quality Control Inspector

QC Manager Quality Control Manager

QC Program Quality Control Program

R.I.R. Receiving Inspection Record

RT Radiographic Examination

SA Ferrous Material

SB Nonferrous Material

SFA Welding Filler Material

Traveler Quality Assurance Traveler

UT Ultrasonic Examination

VT Visual Examination

WPQ Welder Performance Qualification

WPS Welding Procedure Specification



2 STATEMENT OF POLICY AND AUTHORITY

This Manual will be used for shop (260 Market Place, Manhattan, IL) and field fabrication of Pressure Vessels in accordance with the A.S.M.E. Code: Section VIII, Division 1, Power Piping and Boiler Assembly in accordance with A.S.M.E. B31.1 and Sect. I, Repairs and Alterations to pressure retaining items in accordance with the NBIC. It is the Policy of STARCON International, Inc. to support Quality Control to the fullest. All Code Items, Repairs, and Alterations fabricated / installed are in full compliance with this Manual, the A.S.M.E. Code, and the N.B.I.C. No person in this organization will deviate from these quality standards set forth. The Quality Control Manager will have sufficient and well-defined responsibility, the authority, and the organization’s freedom to identify quality control problems and to initiate, recommend, and provide solutions to those problems. In the event that the Quality Control Manager and any other department comes to an impasse concerning quality, the President will make the final and binding decision, provided this decision is within the limits of the Code and this Manual.

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3 AUTHORITY AND RESPONSIBILITY 3.1 SCOPE This section covers the interface and responsibility of each person within the STARCON International, Inc. organization.

3.2 REPONSIBILITY Responsibility for this section lies with the President of STARCON International, Inc.

3.3 PRESIDENT The President is responsible for the overall operation of the entire company. The President will delegate authority to various department heads and will be the arbitrator of any conflicts between Quality Control and Production.

3.4 VICE PRESIDENT OF QUALITY CONTROL The Vice President of Quality Control is directly responsible for the overall quality assurance / quality control programs, policies and procedures as well as the implementation of the Quality Control Program. The Vice President of Quality Control reports directly to the President.

3.5 DIVISION VICE PRESIDENT The Division Vice President is directly responsible for all operations within their respective division. The Division Vice President reports directly to the Vice President of Quality Control in all matters relating to the Quality Control Program.

3.6 QUALITY CONTROL MANAGER The Quality Control Manager will have overall responsibility for the implementation of the Q.C. Program and will work closely with all other divisions with the goal of producing quality items. The Quality Control Manager is responsible for assigning Q.C. Inspectors to perform examination(s) and test(s) at the shop / field site. The Quality Control Manager will answer directly to the President. The Quality Control Manager will Be responsible for this Manual and its revisions. The Quality Control Manager or the authorized designee is responsible for the review and acceptance of all drawings and design calculations provided by a subcontractor. The Quality Control Manager may delegate any of the duties prescribed in this manual, but shall retain full responsibility.

3.7 PROJECT MANAGER The Project Manager or the Project Manager’s designee is responsible for preparing the P.O. and the purchase of Code material. The Project Manager reports directly the Division Vice President.



3.8 SUPERVISOR The Supervisor is responsible for the fabrication / installation of the Code item in the shop / field and reports directly to the Project Manager.

3.9 PROJECT Q.C. MANAGER The Project Q.C. Manager is responsible for performing the required examination and test at the shop / field site and will sign off acceptance of same on the Traveler. The Project Q.C. Inspector will answer directly to the Project Quality Control Manager.

3.10 MANUAL CONTROL The Manual is written by the Quality Control Manager and first approval of the entire Manual will be by the President of STARCON International, Inc. This approval will be so indicated by the President’s signature on the Statement of Policy and Authority. Revisions to the Manual will be made by the Quality Control Manager. Revisions will be submitted to the A.I. for review and acceptance prior to being placed in the Manual or implemented. Quality Control Manager’s approval and A.I. acceptance of the Manual will be indicated by signatures and date in Table of Contents. The Quality Control Manager shall designate the Manual as controlled or uncontrolled. Uncontrolled Manuals will be up to date on the day they are delivered, after which date they may not have revisions added. The Quality Control Manager will keep a record of who has been issued copies of the Manual. Only controlled Manuals are given to company personnel and the Authorized Inspector and shall be distributed by the Quality Control Manager. Controlled Manuals may be distributed to the client upon request. Controlled Manuals will be numbered and entered in the Manual Log. (see Exhibit 1)

3.11 MANUAL REVISIONS The Manual will be revised by the entire section except for the Exhibits, which will be revised individually as controlled by the Sample Forms Index. Revisions shall be identified on the Table of Contents by the revision number and the date of the revision. The revised text shall be identified by underlining the affected text. At the Quality Control Manager’s discretion, the entire manual may be advanced to a new Edition. In this case, all sections will be reset to 0 revision level. Only the latest revision will be indicated. This Manual will be reviewed for compliance, as applicable Code, Editions and Addenda are released. Review will be by the Quality Control Manager. Evidence of review will be by written memo to file. Approved and revised sections will be delivered by the Quality Control Manager to the field / shop for placement into the Manual. Superseded sections will be removed from the Manual and destroyed. The Quality Control Manager will keep one set of superseded pages on file.

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4 ORGANIZATION 4.1 SCOPE This section covers the organizational chart and the interface of Shop and Field operations. This sets forth the line of communications and shows how departments relate to each other.

4.2 RESPONSIBILITY The President is the one who delegates responsibility and everyone ultimately answers to him.

4.3 ORGANIZATION CHART

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5 DRAWINGS, DESIGN CALCULATIONS & SPECIFICATION CONTROL 5.1 SCOPE This section is concerned with the generation, review, approval, distribution and revisions to drawings, design calculations and specifications. This section covers the Code relation to each of these items. 14.3.3

5.2 RESPONSIBILITY It is the responsibility of the Project Quality Control Manager to generate, review, approve and distribute these documents and to make them available to the A.I. for review.

5.3 DRAWINGS AND SPECIFICATIONS Drawings and specifications may be provided by the customer or by STARCON International, Inc. When drawings or specifications are prepared by customer, the Project Quality Control Manager will be responsible for review of these drawings / specifications to assure Code Compliance can be attained. Drawings and Specifications may be prepared by the Project Manager or a subcontractor. The Project Quality Control Manager will be responsible for final review and approval of the drawings / specifications for Code Compliance. Drawings will contain enough information to ensure proper fabrication. This information will consist of, but not be limited to A.S.M.E Code Specification, Material Specifications, dimensions, welding procedure number, N.D.E. requirements, job number, print number, date, revisions, and sign off by the Project Quality Control Manager. The Project Quality Control Manager will present the drawings to the A.I. for review. After review the Project Quality Control Manager will see that the drawings and specifications are kept by the Supervisor in the job folder. The Project Quality Control Manager will discuss the requirements of the project with the Supervisor. All revisions to drawings and specifications will be handled in the same manner as the original, except distribution. 8.7 Distribution will be handled by the Project Quality Control Manager. The Project Quality Control Manager will hand deliver the revised drawings and specifications to the Supervisor with instructions for the Supervisor to mark the superseded drawings and specification “VOID”. One copy will be maintained on file, the rest will be disposed of by the Supervisor. All revised drawings and specifications will be handled in the same manner as the originals.



5.4 DESIGN CALCULATIONS Design calculations (including those required by UCS79(d)) may be generated by the Project Manager, the subcontractor or supplied by the customer. In any case it will be the responsibility of the Project Quality Control Manager to check these design calculations for Code compliance. The design calculations will have an area set aside which will contain the following information; applicable A.S.M.E. Code Section and Project Quality Control Manager sign-off and date. After sign-off and approval by the Project Quality Control Manager for final review, the Project Quality Control Manager will then make these documents available to the A.I. for his review, sign-off and date. The calculations will be returned to Project Quality Control Manager for filing. 6.4 8.7

5.5 COMPUTER-GENERATED DESIGN CALCULATIONS When computer-generated design calculations are used for Code items, the Project Quality Control Manager is responsible for verifying input of the correct data and the verification that the correct output has been obtained by comparison with manually prepared calculations, or sample calculations when provided in the applicable Code Section. The Project Quality Control Manager will review Code Edition / Addendum to determine if computer programs are affected and also to revalidate revised computer programs. The required revisions will be made within six months of the Edition / Addendum issue date. Computer-generated calculation outputs, shall be available to the A.I. for review and acceptance. The Project Quality Control Manager will provide the A.I. with any manual calculations he may request to verify the computer outputs.

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6 MATERIAL CONTROL 6.1 SCOPE This section covers the ordering, receiving and storage of Code material. Code material includes welding material. 6.5.3 7.4 14.3.4

6.2 RESPONSIBILITY Ordering of material will be the responsibility of the Project Manager. Approval of the P.O. (see Exhibit 4) will be the responsibility of the Project Quality Control Manager, and material storage will be the Supervisor’s responsibility.

6.3 TAKE-OFF SHEET A Take-Off Sheet (see Exhibit 3) will be generated by the Project Manager or designee for each job. The Take-Off Sheet will contain quantity, required material certification, size, and all pertinent information from the design documents, which will be transferred on to the P.O. by the Project Manager or designee. The Project Quality Control manager shall review the Take-Off Sheet against Section II, Sect. I, B31.1 and Section VIII Division 1 of the Code to assure that the required Material Certification and ordering information is indicated. No change or substitution of material shall be made from the Take-Off Sheet without the approval of the Project Quality Control Manager. Any changes will be reviewed by the A.I.

6.4 PURCHASE ORDER The Take-Off Sheet will be used to generate the P.O. (see Exhibit 4). The P.O. will contain the job number. The Project Manager or designee will generate the P.O. using the information as shown on the Take-Off Sheet. The Project Manager will sign the P.O. and forward the Take-Off Sheet and P.O. to the Project Quality Control Manager for final review. The Project Quality Control Manager will check the P.O. for correctness and see that all necessary information required by the material specifications and applicable Code Sections have been established. All materials will be ordered to SA, SB or SFA specifications or other specifications permitted by the applicable Code Section. A copy of the P.O. will be returned to the Project Quality Control Manager and a copy will be placed in the job folder. When vessel shell sections, heads, or other pressure boundary parts of carbon or low alloy steel plate are cold formed by the vendor, the required certification for the part shall indicate whether or not the requirements of UG-79, UG81 and USC 79(e) have been satisfied. This shall be verified at receiving inspection. Note: Calculations required by UCS 79(d) shall be prepared per paragraph 5.4 of this Manual.



6.5 RECEIVING INSPECTIONS Receiving inspection will be performed by the Q.C. Inspector using a copy of the P.O. and applicable material specification and will verify and record material dimensions, job number and Code required markings, and all other pertinent information on theR.IR (see Exhibit 5). The Q.C. Inspector will sign and date the P.O. and R.I.R. indicating acceptance of the materials ordered. One copy of this report will go to the Supervisor and one copy to the Project Quality Control Manager for filling. 6.6 6.5.1. The material certification will be checked for chemical and physicals and will be compared to Section II of the ASME Code for compliance by the Project Quality Control Manager. Review of the material certification will be evidenced by the Project Quality Control Manager’s initials and date on the appropriate document. The Project Quality Control Manager will compare the PO. and Receiving Inspection Report used for receiving with the material certificate in the job folder. 6.5.2 If the material is acceptable, the Q.C. Inspector will mark all material with the P.O. Number, and “ASME” to differentiate it from non-code material. Small parts may be stored in bins or tubs. The bin or tub will be marked with the P.O. Number and the bin or tub marked “ASME”. Storing of Code material in the shop will be in designated areas A field site storage area will be in such a location so as to prevent damage to the material and will be decided by the Supervisor with the Project Quality Control Manager verifying the system. Welding material will be stored in a clean, dry area, and under the control of the Supervisor. Low hydrogen electrodes will be stored in their sealed containers. 6.5.3. If material I found to be non=conforming, it will be handled in accordance with Section 6 of this Manual. 6.5.4. In case the original identification (I.D.) markings are to be removed by cutting, or the material is divided into two or more parts, the heat number and job number shall be used to assure identification of each piece of material during fabrication and subsequent identification of the markings on the completed Code item. Prior to cutting but after layout, the I.D. markings will be transferred to the individual pieces and verified by the Supervisor and the Project Quality Control Manager to provide traceability to the Code required markings recorded on the R.I.R. When material is needed at field / shop site, the Supervisor will request Code material from the Project Quality Control Manager.

6.6 CUSTOMER-PROCURED MATERIALS When materials are supplied by the customer, it is the responsibility of the Project Quality Control Manager to review the supplied materials against the project specifications, and in accordance with section 6.5.

6.7 DOCUMENTATION All documentation for Code material will be made available to the A.I. for the review concurrence.

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7 EXAMINATION AND INSPECTION PROGRAM 7.1 SCOPE This section will describe the process of procuring material from receiving inspection to in-process inspection program, final inspection, stamping and Manufacturer’s Data Reports.

7.2 RESPONSIBILITY Material movement at field / shop locations will be the responsibility of the Supervisor. The inspection program will be the responsibility of the Project Quality Control Manager.

7.3 RELEASE OF MATERIAL The Supervisor will only release material for production which has been cleared through receiving inspection and has “ASME” marked on it.

7.4 IN-PROCESS INSPECTION It is the responsibility of the Project Quality Control Manager to generate the Traveler (see Exhibit 6). The Traveler shall contain the acceptable N.D.E. and Heat Treat Procedures to be used, if applicable. The Project Quality Control Manager will review this Traveler with the Supervisor, A.I. and Q.C. Inspector as applicable, prior to start of fabrication to enable the Project Quality Control Manager and the A.I. to assign “Hold Points:. The Traveler and job file will be kept at the field / shop site by the Project Quality Control Manager. The Q.C. Inspector will monitor the fabrication, N.D.E., and Heat Treatment operations and document these inspections on the Traveler. The Project Quality Control Manager will notify the A.I. prior to his “Hold Points” coming up. When the Q.C. Inspector finds a non-conformance he / she will notify the Supervisor and Project Quality Control Manager by the use of the NCR (see Exhibit 9). These NCR’s will be handled as per section 8 of the Manual.

7.5 FINAL TESTING The Supervisor will be responsible for the final hydrostatic test. The Q.C. Inspector will be responsible for the final inspection of the project. The Project Quality Control Manager will coordinate the final hydrostatic test with the A.I. The Q.C. Inspector will make visual internal and external inspection of the item prior to the final hydrostatic test. Indicating pressure gauges used in testing shall preferably have dials graduated over a range of about double the intended maximum test pressure, but in no case shall the range be less than 1-1’2 times or greater than 4 times the intended test pressure.



7.6 MANUFACTURER DATA REPORT (MDR) AND STAMPING At the time of the final hydrostatic test, the Project Quality Control Manager will review the completed job package to verify Code compliance and provide an applicable and complete MDR to the A.I. The Project Quality Control Manager, having reviewed it for correctness, will sign and date the MDR. Upon completion of the final hydrostatic test and acceptance by the A.I., the MDR will be presented to the A.I. for his signature. The A.I. will witness the affixing of the Code Symbol Stamp. Prior to affixing the Code Symbol Stamp to the A.S.M.E. Nameplate (see Exhibit 11) if used, the Project Quality Control Manager shall check the nameplate data / stamping for correctness. Power Piping Components will be stamped unless >800F or <2” NPS. In all other cases an A.S.M.E. nameplate will be used. (See Exhibit 13)

7.7 CODE SYMBOL STAMP The Code Symbol Stamps will be kept by the Quality Control Manager when not in use. When the Stamps are required at the field / shop site, the Quality Control Manager will issue the Stamps to the location. After use, the Code Symbol Stamps will be returned to the custody of the Quality Control Manager.

7.8 NATIONAL BOARD REGISTRATION National Board serial numbers shall be controlled and issued by the Quality Control Manager. He / She shall maintain a National Board Registration Log (see Exhibit 10) of issuance showing owner and manufacturer’s serial number. National Board serial numbers shall be issued in sequence without skips or gaps of unused number or duplication. The Quality Control Manager shall also maintain and submit to the National Board the original copy of all Manufactures Data Reports required for the item within 60 days of completion.

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8 CORRECTION OF NON-CONFORMITIES 8.1 SCOPE The section will cover the procedure to be followed in the correction of non-conformities.

8.2 RESPONSIBILITY Correction of non-conformities is the responsibility of the Project Quality Control Manager. The Supervisor will be responsible for making necessary corrections of non-conformities one the disposition has been documented.

8.3 NON-CONFORMITIES A non0conformity is any condition which does not comply with the applicable rules of the Code, customer specification or this Manual. There are generally two types of non-conformities. They are those found during receiving inspection and those found during fabrication and testing. 8.3.1 Any person may identify a discrepancy. This condition will be brought to the attention of the Q.C. Inspector and the Project Quality Control Manager. If a condition is deemed as non-conforming it will be tagged with a Hold Tag. (see Exhibit 8) and an NCR will be filled out. A condition, which deviates from the original design or specifications, or a repair to the material or completed welded joints will always be considered as non-conforming.

8.4 RECEIVING INSPECTION Material found to be non[conforming during Receiving Inspection shall be returned to the vendor, repaired, used as is, or used as non-Code material. Material that is to be repaired shall be handle per section 8.5 below.

8.5 PROCEDURE The Project Quality Control Manager shall prepare the procedure used to repair non-conforming items. This procedure shall state all aspects needed to repair the item(s), this shall include WPS, N.D.E. and heat treat as a minimum/ After approval of the Project Quality Control Manager, this procedure shall be presented to the A.I. and, when required, the customer for their review and acceptance prior to the start of the repair. When the corrective action has been taken and the repairs made, the QC Inspector will make an inspection, sign-off the NCR and remove the Hold Tag. The completed NCR will be returned to the Project Quality Control Manager for filing. All welded repairs will be made using a qualified, written WPS and qualified welders. All N.D.E. will be performed as in the original case when the non-conformity was found with the use of the N.D.E.



8.6 NON-CONFORMITY REPORTS Non-conformities shall be documented on a Non-conformity Report. The procedure used to correct non-conformities shall be attached to and become part of the NCR. These documents shall be placed in the job file. All Code-related documentation shall be made available to the A.I. for review. All NCR numbers will be listed on the Traveler.

8.7 DEVIATIONS Deviations from the original design or specification will be handled in the same manner as sections 5.3 and 5.4 for new construction and will be reviewed by the Project Quality Control Manager.

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9 WELDING 9.1 SCOPE This section covers the WPS, PQR, WPQ, weld material distribution, and control of welding processes. All welders and written WPS will be qualified in accordance with Section IX of the Code. All welding will be done in accordance with Section IX with additional requirements of Section I, VIII, Division 1 and ANSI B31.1 and B31.3 as applicable.

9.2 RESPONSIBILITY All WPS will be the responsibility of the Quality Control Manager. The Supervisor will control disbursement of welding materials and all aspects of weld inspection will be monitored by the Q.C. Inspector and or the Project Quality Control Manager.

9.3 WELDING MATERIAL STORAGE AND DISTRIBUTIONS Welding material will be stored in accordance with the manufacturer’s recommendations or the requirements of ASME Section II Part C. Sealed containers of welding materials will be drawn out of storage, inspected for damage, and, once opened, placed in heated ovens or heated containers when such heat is required. The Supervisor will be responsible for the issuing and return of welding material.

9.4 WELDING PROCEDURE SPECIFICATIONS The Quality Control Manager will be responsible for the formulation of Welding Procedure Specifications and revisions to them. When revisions to a WPS are required, the existing WPS shall be revised showing a new revision level and date. Revisions to a WPS can only be done when there is a change in the Non-Essential Variable. Changes in Essential or Supplementary Essential Variables, when applicable, will require the generation and qualification of a new WPS. The Quality Control Manager or an authorized designee shall be responsible for witnessing welding of the test coupons and qualification and certification of the PQR.

9.5 WELDERS The Quality Control Manager, the Project Quality Control Manager or an authorized designee shall be responsible for witnessing welding of the test coupons and qualification and certification of the WPQ for the shop and field. Required testing of coupons may be done at the site or at an outside source. If tested at an outside source, testing will be under full supervision and control of the Quality Control Manager, Project Quality Control Manager or Q.C. Inspector. Each Welder will be assigned a unique identifying symbol by the Quality Control Manager upon successful completion of his qualification test. 9.5.1 All qualified welders’ names symbols, process qualified and date last welded in that process will be maintained in the Welders Database. The process or processes welded by an individual



welder are reported monthly by the Project Quality Control Manager to the Quality Control Manager. The Welder’s Continuity information is maintained by the Quality Control Manager and shall be made available for review by the A.I when requested. The Welder Continuity Report (see Exhibit 7) shall be generated and signed by the Quality Control Manager, thereby certifying continuity information. The Welder will stamp each girth and vertical weld seam joint a minimum distance of every three feet with his unique identifying symbol or a Welder I.D. shall be documented on a drawing or dedicated weld map by the Q.C. Inspector or Project Quality Control Manager. 9.5.2 Copies of the applicable WPS shall be made available at the work site by the Project Quality Control Manager.

9.6 TEST RESULTS The test results of test specimens shall be documented on the PQR or the WPQ as required. When the weld coupon testing is performed by an outside source, steps shall be taken to assure that the test is performed on the correct specimen, and these reports will be reviewed by the Quality Control Manager.

9.7 JOB FILE The WPS, PQR and WPQ will be made a part of the job folder at the shop or field site. All PQR, WPS and WPQ records shall be maintained and filed by the Quality Control Manager.

9.8 TACK WELDS Tack welds used for alignment purpose and not incorporated into the weld shall be removed completely when they have served their purpose by grinding or other suitable means. Tack welds, whether removed or left in place, shall be made using an applicable WPS listed in the Traveler and qualified in accordance with Section IX. Tack welds to be left in place shall be made by welders qualified in accordance with Section IX and shall be examined visually for defects by the QC Inspector, and if found to be defective, shall be removed. The method of base metal preparation used shall leave the welding groove with reasonably smooth surfaces and free from deep notches or irregularities. The surfaces for welding shall be free of all scale, rust, oil, grease or other foreign materials.

9.9 WELDER RE-QUALIFICATIONS Welders will be re-qualified when they have not welded in the specific welding process within six (6) months, or when there is a specific reason to question the ability of the welder to make welds that meet the requirements of the specifications the Project Quality Control Manager requires. When there is a specific reason to question a WPS or welder the A.I. may require re-qualification. All documentation will be made available to the A.I. for review.

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10 NON-DESTRUCTIVE EXAMINATION 10.1 SCOPE This Section will cover the requirements for N.D.E. and documentation of the results as required for code compliance. All NDE shall be performed by one of the following:

10.1.1 A subcontractor and in accordance with the current and applicable requirements of Sec. V of the code.

10.1.2 A Starcon International N.D.T. Technician certified by Starcon International in accordance with the current and applicable requirements of Sec. V of the code.

10.2 RESPONSIBILITY Review and acceptance of NDE procedures and qualifications of those providing the applicable method of NDE shall be responsibility of the Quality Control Manager and or the Project Quality Control Manager. 10.2.1 Starcon International, Inc shall, by written letter, appoint a qualified and certified representative of the company as Starcon International, Inc.’s authorized Level III examiner in accordance with Starcon International, Inc.’s Qualification and Certification of Nondestructive Personnel. If a qualified representative of the company has not been appointed the Quality Control Manager shall, by written letter, appoint a qualified representative of a subcontractor as Starcon International, Inc.’s authorized Level III examiner. 10.2.1.1 The Quality Control Manager and or the Project Quality Control Manager shall verify that all Starcon International Inc. and subcontractor NDE personnel are properly qualified for the method, including their employer’s written practice using the current SNT-TC-1A Recommended Practice as a guide. American Welding Society (AWS) Certified Welding Inspector (CWI) may be used for VT only. 10.2.2 Starcon International, Inc. or the subcontractor will provide their written practice, procedures and qualifications of personnel and the necessary eye examination in accordance with the Code. The Quality Control Manager and/or the Project Quality Control Manager will review these documents to verify that they are in accordance with the Code applicable requirements and this Manual. 10.2.3 N.D.E. test results will be documented on the reader sheet or other form referenced in the applicable N.D.E. procedure. The N.D.E. Examiner will sign and date the Reader Sheet and include data as requested, including his level of qualification. The Project Quality Control Manager will review, sign and date the Reader Sheet and present it to the A.I. for review and acceptance. RT film viewing equipment will be provided to the A.I. N.D.E. reports shall become a part of the job file and shall indicate traceability to the job. 10.2.4 It is the responsibility of the Project Quality Control Manager to designate N.D.E. requirements per the applicable ASME Code section and assign N.D.E. method on the Traveler prior to the start of fabrication or repair / alteration activities.



10.2.5 When requested by the A.I., N.D.E. procedures or personnel will be re-qualified. All N.D.E. procedures shall be demonstrated to the satisfaction of the Authorized Inspector and be accepted by the Quality Control Manager.

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11 HEAT TREATMENT 11.1 SCOPE This section will cover the heat treatment, procedures and records when such heat treatment is required by the Code.

11.2 RESPONSIBILITY All heat treatment will be subcontracted. The Project Quality Control Manager will be responsible for approving the subcontractor and for monitoring or verifying heat treatment. The Project Quality Control Manager will provide instruction to the subcontractor detailing thermocouple placement and method of attachment, heating and cooling rates and the use of charts. The Project Quality Control Manager will review the subcontractor’s heat treatment procedures for Code and specification compliance ad initial date for acceptance.

11.3 PROCEDURE The item to be heat treated will be identified in such a manner that after heat treatment the identity will be maintained. Whenever possible or feasible the Project Quality Control Manager or Q.C. Inspector will monitor the heat treatment of the item. In all cases, the Project Quality Control Manager will review the heat treatment records to assure heating rate, holding time at temperature, and cooling rate are in compliance with the procedure. The Project Quality Control Manager shall also verify signature and date of operator or subcontractor’s personnel and the calibration records of equipment used.

11.4 RECORDS All heat treatment records including calibration records will be placed in the job folder and made available to the A.I. for review.

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12 CALIBRATION OF MEASUREMENT & TEST EQUIPMENT

12.1 SCOPE This section will cover the calibration program of measuring and test equipment (M&TE).

12.2 RESPONSIBILITY The Quality Control Manager will be responsible for this program and will have a list of equipment under this program.

12.3 EQUIPMENT The equipment the company will require to be calibrated shall include the pressure gauges used for final testing. 12.3.1 M&TE will be assigned a permanent serial / ID number, calibrated and a record of each calibration will be recorded on the M&TE Calibration Record (see Exhibit 16), or on records provided by calibration subcontractors. These records will contain the serial / ID number, description, range, master standard, tolerances, date calibrated, by whom and date next due for calibration. 12.3.2 Before each final test, the calibration of the gauge(s) will be verified. The gauge number(s) will be recorded on the Traveler. 12.3.3 M&TE will be traceable to a known standard and calibrated at a frequency where experience with the equipment or manufacturer’ recommendation shall be considered. When the M&TE are found to be discrepant, they will be removed and re-calibrated. A copy of the calibration record(s) for applicable M&TE used shall be kept at the job site and made available for review. These M&TE will be re-calibrated when error is suspected. 12.3.4 Pressure gauges will be calibrated annually following initial use or at any time improper calibration is suspected.

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13 RECORD RETENTION 13.1 SCOPE This section will cover the retention of records for field / shop site documentation.

13.2 RESPONSIBILITY The Quality Control Manager will be responsible for the distribution and retention of records.

13.3 RECORDS For ASME Sect. VIII Div. 1 the documents outlined below shall be maintained for a period of at least 3 years. All other records shall be kept for a period of time and at a place as designated by the Quality Control Manager and/or Code requirements. The customer’s specifications may require certain documents to be provided with the item fabricated or repaired.

(1) Manufacturer’s Partial Data Reports (2) Manufacturer’s Drawings (3) Design Calculations (4) Material Test Reports and/or Material Certifications (5) Welding Procedure Specifications and Procedure Qualification Records (6) Welders Qualification Records (7) RT and UT Reports (8) Repair Procedure and Records (9) Process Control Sheets (10) Heat treatment records and test results (11) Post weld heat treatment records (12) Non Conformances and dispositions (13) Hydrostatic test records

13.3.1 For ASME Sect. 1, radiographs and reader sheets shall be maintained for a period of 5 years.

13.4 JOB FOLDER The job folder shall be presented to the A.I. for review prior to presenting the Manufacturer’s Data Report for review and certification.

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14 REPAIRS AND ALTERATIONS 14.1 SCOPE This section is applicable to repairs and alterations to pressure retaining items determined to be within the scope of this Manual. Repairs and alterations may be carried out in the shop or field. Field operations will be handled in the same manner as the shop operations.

14.2 RESPONSIBILITY The Quality Control Manager will be responsible to assure that repairs and / or alterations are carried out in accordance with the National Board Inspection Code, the rules of the local jurisdiction, this Manual and within the scope of STARCON International, Inc.

14.3 DEFINITIONS The following definitions are provided in this section for reason of convenience and to further clarify the scope of work: A. Repairs and alterations will conform to the NBIC part 3. B. Repair — The work necessary to restore an item to a safe and satisfactory operating

condition. C. Alterations — A change in any item described on the original Manufacturer’s Data Report

which affects the pressure containing capability of a pressure vessel. An increase in the maximum allowable working pressure or temperature shall be considered to be an alteration. (see Re-rating)

D. Re-rating — Re-rating by increasing the maximum allowable working pressure (internal or

external) or temperature or a decrease in temperature shall be considered an alteration. Repairs and alterations shall be performed in accordance with the requirements of the National

Board Inspection Code, Jurisdictional Requirements and this Quality Assurance Manual. 14.3.1 The Quality Control Manager and / or the Project Quality Control Manager shall assume overall responsibility for the performance of repairs and alterations and for originating the procedures necessary to direct the course of work. 14.3.2 The method of repair or alteration shall be acceptable to the A.I. The Project Quality Control Manager shall make available to the A.I. proposed procedures for method and extent of repairs or alterations including all examinations and tests to be performed. Under no circumstances shall work be started without authorization of the A.I.



14.3.3 Design engineering shall conform to the requirements of section 5 of this Manual, the National Board Inspection Code and in so far as possible, to the ASME Code Section Edition and Addenda most current and applicable to the work plan. 14.3.4 Materials used in making repairs and alterations shall conform to the applicable section of the Code of Construction. Carbon or alloy steel having a carbon content of more than 0.35% shall not be welded. The procurement, inspection and handling of materials shall be in accordance with section 6 of this Manual. 14.3.5 All welding, non destructive examinations and heat treatment, as required, shall be in accordance with the requirements of the National Board Inspection Code and shall conform to the applicable sections of this Manual. 14.3.6 Pressure test shall conform to the requirements of the National Board Inspection Code and shall be witnessed by the A.I. Repairs shall be pressure tested at a minimum pressure to verify leak tight integrity. Alternate NDE may be performed in lieu of the hydrostatic test as permitted by the National Board Inspection Code provided acceptable to owner, A.I. and Jurisdiction where work is being performed. Alterations shall be pressure tested as required by the original Code of Construction, not to exceed 150% of M.A.W.P. 14.3.7 The “R” Symbol shall be applied only with the knowledge and authorization of the A.I. All repairs or alteration stamping and / or Nameplates (see Exhibits 14 and 15) shall be applied or attached adjacent to the original manufacture’s stamping or nameplate. The Quality Control Manager will have custody and control of the National Board “R” Stamp. 14.3.8 When a repair or alteration requires removal of that part of the item bearing the original Code stamping, the A.I., subject to the approval of the jurisdiction, shall witness the making of a facsimile of stamping, the obliteration of the old stamping and the transfer of such stamping to the new part. When the stamping is on a nameplate, the A.I. shall witness the transfer of the nameplate to the new part. 14.3.9 The original Code Symbol stamping shall not be re-stamped, and any relocation of the original stamping or nameplate shall be described on the applicable National Board “R” Form. 14.3.10 Replacement pressure parts, for which Manufacturer’s Partial Data Reports are required, shall be fabricated and inspected to the requirements of the applicable ASME Code Section, stamped with the applicable Code Symbol and the word “part”, and reported on the appropriate Manufacturer’s Partial Data Report. When such parts are added to the item being repaired or altered, Partial Data Reports submitted herewith shall be part of the completed “R: Form and shall be attached hereto.

14.4 ROUTINE REPAIRS Routine repairs shall be in accordance with NBIC part 3. 14.4.1 Identifying — All Routine Repairs shall be identified and accepted by the A.I. before any work commences. It is the responsibility of the Project Quality Control Manager to determine if Routine Repairs are acceptable to the jurisdiction where the pressure-retaining item is installed.



14.4.2 Controlling — The procedures set forth in this manual shall apply to Routine Repairs with the exception of the in-process involvement by the A.I., and the Authorized Inspection Agency responsible for the in-service inspection of the item and stamping, when accepted by the A.I.

14.5 REPORTS The Quality Control Manager shall distribute legible copies of the NBIC Form R’1 and R’2 together with attachments to the owner or user, the Inspector and, when required, the jurisdiction. 14.5.1 All repaired or altered items shall be registered with the National Board. A form “R” number shall be controlled and issued by the Quality Control Manager. The National Board “R” number shall be issued in sequence without skips or gaps. The original National Board Report Form R-1 and R-2 (with attachments) shall be transmitted to the National Board within 60 days of certification. 14.5.2 The Quality Control Manager shall prepare, certify, and present to the A.I. for his signature, the applicable completed “R” Form. 14.5.3 A Repair / Alteration Registration Log (see Exhibit 17) shall be maintained by the Quality Control Manager.

14.6 JOB PACKAGES All completed Code Packages shall be sent to the Quality Control Manager for archiving. These packages shall contain all original documents, when applicable. Only a copy of the completed package will be submitted to the customer.

14.7 RECORD RETENTION Welders continuity records will be maintained for a period of 3 years.

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15 AUTHORIZED INSPECTOR 15.1 SCOPE This section will cover the A.I. (Authorized Inspector) or C.I. (Commissioned Inspector) interfacing with STARCON International, Inc.

15.2 RESPONSIBILITY The Project Quality Control Manager will be responsible for the interface between the A.I., or C.I. and STARCON International, Inc.

15.3 AUTHORIZED INSPECTOR The A.I. or C.I. will be an inspector employed by an ASME/National Board accredited Authorized Inspection Agency, Jurisdiction or Owner User. The A.I. or C.I. shall have been qualified by a written examination under the rules of any state of the United States or Province of Canada, which has adopted the ASME Code and carry a current National Board Commission Card. An Authorized Inspector will also have a valid “A” endorsement.

15.4 ACCESS FOR INSPECTOR The Authorized Inspector or Commissioned Inspector and his Supervisor shall be permitted free access at all times while Code work is being performed to all parts of the shop and field locations that concern the construction or repair / alteration of the item and field site of field erected items during the period of assembly and testing of the item. The Project Quality Control Manager shall keep the A.I. informed of the progress of the work and shall notify him reasonably in advance when the items will be ready for any required test or inspection. The Project Quality Control Manager shall notify the A.I. of all repairs to Code material (by use of an NCR) prior to repairs being started.

15.5 DOCUMENTATION The A.I. or C.I. will have access to all documents related to Code items being fabricated, repaired or altered. A current controlled copy of the Quality Assurance Manual will be made available to the A.I.

15.6 FACILITIES The A.I. or C.I., will be provided a suitable work area and an area for the filing of his documentation.

15.7 THE INSPECTOR When reference throughout the Manual is made to the A.I., this reference is understood to include the NBIC requirements for Repairs and Alterations as related to a C.I.

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16 APPENDIX 16.1 APPENDIX I REQUIREMENTS OF CALIFORNIA DIV. OF OCCUPATIONAL

SAFETY AND HEALTH (DOSH)

16.1.1 GENERAL Repairs and Alterations when performed to Pressure Retaining Items installed in California shall meet the California Jurisdictional requirements as listed in the California Code of Regulations Title 8 Division 1, Chapter 4:

(1) Unfired PV Safety Orders, Subchapter 1, (2) Boiler and Fired PV Safety Orders, Subchapter 2, (3) Circular Letters issued by the Division (PV-2001-1,PV-2006-2, & PV-2006-3), (4) Petroleum Safety Orders – Drilling and Production, Subchapter 14, (5) Petroleum Safety Orders – Refining, Transportation and Handling, Subchapter 15.

The California Division of Occupational Safety and Health(DOSH) shall be provided free access to conduct audits of the Quality System and Code activities upon a valid request from an Owner, User, Inspection Agency, or the National Board.

16.1.2 ROUTINE REPAIRS Routine repairs are NOT allowed on Pressure Retaining Items installed in CA.

16.1.3 JURISDICTIONAL ACCEPTANCE a) A written procedure, submitted to and accepted by the Jurisdiction and the Inspector, are required

prior to the following activities:

1) PWHT not in accordance with the original code of construction. This includes use of the alternative weld procedures and localized PWHT procedures.

2) NDE not in accordance with the original code of construction. 3) Repairs and Alterations: Pneumatic test in lieu or hydro, NDE in lieu of hydro.

b) Written prior acceptance from the Jurisdiction is required on a case by case basis for the following

activities: 1) Using MT or PT to evaluate material prior to welding and to examine welds when RT was

required by the original Code of construction. This applies to alternative weld procedures in lieu of PWHT.

2) The repairs involving unstayed boiler furnace cracks in knuckles or turns of flanges of boiler openings, mechanical repairs of bulged plates, seal welding of riveted joints.

3) Rerates 4) Minimum wall thickness calculations using higher material stress values allowed on later

editions of the ASME Code. 5) When the original Manufacturer’s Data Report cannot be obtained for design basis.

c) Any changes on this document will require acceptance by DOSH prior to implementation.



Submit above procedures to: State of California DOSH Pressure Vessel Unit, 1515 Clay St., Oakland CA 94612. To the attention of Don Cook, Principal Engineer

16.1.4 INSPECTOR The Quality Control Manager shall verify the Inspector holds a valid Certificate of Competency

issued by the California Division of Occupational Safety and Health, and is employed by an Authorized Inspection Agency.

The Inspector shall stamp his/her certificate of competency number adjacent to all welded repairs authorized on air, propane, ammonia, LNG, CNG tanks and boilers.

16.1.5 DOCUMENTATION All repairs and alterations shall be documented on the appropriate National Board “R” form or

equivalent including the Jurisdiction Number of the item, and shall be registered with the National Board within 60 days after certification. Additionally, repairs and alterations performed on boilers, air tanks, and LPG tanks that require a permit to operate shall have the National Board “R” form or equivalent sent to the attention of the Principal Engineer at the Pressure Vessel Unit Headquarters within 21 days after certification..

Approved By:

Date:________________ Quality Control Manager

Accepted By:

Date:________________ DDOSH

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16.2 APPENDIX II REQUIREMENTS OF CALIFORNIA DIV. OF OCCUPATIONAL SAFETY AND HEALTH

16.2.1 PRE-APPROVED REPAIR PLAN FOR PT IN LIEU OF HYDROSTATIC TESTING

STARCON plans to use Solvent Removable Visible Dye Penetrant (PT) in lieu of hydrostatic testing, that have been accepted by California Division of Occupational Safety and Health. This procedure will be used only when hydrostatic testing is not practical and PT will provide meaningful information to determine the soundness of the repair.

The use of this procedure satisfies STARCON the need to notify the California Division of Occupational Safety and Health of the repair, requesting PT in lieu of hydrostatic testing and receive written approval prior to the repair.

STARCON is still responsible for notification and approval of the repair plan, by the Inspector.

The Inspector may require changes in the repair plan, and if so, STARCON will be responsible for proper notification and approval by California Division of Occupational Safety and Health. The description of the repair will be noted on the R-1 form.

16.2.2 STARCON REPAIR PROCEDURES

16.2.2.1 STARCON Repair Plan 1 – TUBE SECTION REPLACEMENT (P1, P4, P5A, P5B or P8 Material) 1. Cut out the leaking or damaged tube section 2. Visually inspect existing tube ends for corrosion, cracking 3. Record wall thickness using UT measurement at least one inch from the existing end and

must be at least 90% of the original nominal thickness. 4. Fit and weld root pass of the new tube section 5. PT root pass 6. Complete circumferential weld 7. PT final weld in lieu of hydrostatic test

16.2.2.2 STARCON Repair Plan 2 –TUBE WINDOW WELD REPAIR (P1, P4, P5A, P5B or P8 Material) 1. Remove the leaking or damaged tube section by preparing for a window patch 2. Visually inspect existing tube ends in the window for corrosion, cracking 3. Record wall thickness using UT measurement at least one inch from the existing end and

must be at least 90% of nominal thickness. 4. Weld inside the back of the tube using GTAW process for root pass. 5. PT inside back of the tube 6. Fit and weld root pass of the window patch 7. PT root pass 8. Complete window weld 9. PT final weld in lieu of hydrostatic test



16.2.2.3 STARCON Repair Plan 3 – PINHOLE LEAK REPAIR (P1, P4, P5A, P5B or P8 Material) 1. Grind the pinhole to prepare for groove weld repair 2. UT map the area for proper weld thickness 3. PT test the pinhole area for cracks prior to welding 4. Weld circumferential groove weld 5. PT final weld in lieu of hydrostatic test

16.2.2.4 STARCON Repair Plan 4 – WELD BUILD UP OF TUBE WALL THICKNESS (P1, P4, P5A, P5B or P8 Material)

1. UT map the area to identify limits of wall thinning 2. PT thin area for cracking prior to welding 3. Weld build up area using stringer beads 4. Blend grind weld build up to tube OD with no sharp risers and UT measure area 5. PT final weld in lieu of hydrostatic test

16.2.2.5 STARCON Repair Plan 5 – SOCKET WELDED DRAIN / VENT VALVE REPLACEMENT (P1, P4, P5A, P5B or P8 Material)

1. Remove existing socket weld by grinding or scarfing 2. Remove valve 3. Visually inspect pipe ends for cracking or corrosion 4. Record wall thickness of pipe ends 5. Fit and gap valve for socket weld 6. Replace socket weld 7. PT final weld in lieu of hydrostatic test

16.2.2.6 STARCON Repair Plan 6 – WELD BUILD UP OF SHELL, HEAD, OR NOZZLE WALL THICKNESS (P1, P4, P5A, P5B or P8 Material)

1. UT map the area to identify limits of wall thinning 2. PT the identified thin area for cracking prior to welding 3. Weld build up area using stringer beads not to exceed 100 sq. in. area and not to exceed

25% of nominal wall thickness. 4. Weld build-up shall not be in tube hole areas of tubesheet or rivet holes 5. Blend grind weld build up to the contour of the vessel and UT measure for adequate wall

thickness 6. PT final weld in lieu of hydrostatic test

16.2.2.7 STARCON Repair Plan 7 – SEAL WELD OF TUBE ENDS ON FIRETUBE BOILERS (P1) 1. Fit up tube to tubesheet weld with tube protruding a maximum of 1/8” 2. Weld one (1) pass seal weld using a qualified welding procedure 3. Tube welding must not exceed 5% of the total tube in the tubesheet 4. PT final weld in lieu of hydrostatic test



16.2.2.8 STARCON Repair Plan 8: REPLACEMENT OF PRESSURE VESSEL NOZZLES (P1, P4, P5A, P5B OR P8 MATERIAL)

NOTE: This procedure is applicable to nozzles of NPS 3 and smaller. 1. Remove existing nozzle weld by grinding or scarfing. 2. Remove nozzle and inspect shell / head for corrosion or cracking. 3. Verify that the head wall thickness meets the minimum required thickness as shown on the

Manufacturer’s Data Report, the minimum required thickness of the shell to be verified by calculation.

4. Establish Preheat in accordance with the applicable Welding Procedure. 5. Weld root pass. 6. From inside of vessel, back-gouge root pass and perform backing weld. 7. PT or MT the backing weld to determine acceptability. 8. Complete welding of cover passes from outside of vessel. 9. PT or MT OD of final weld in lieu of hydrostatic test.

APPROVAL:________________________________________ DATE:________ QUALITY CONTROL MANAGER

ACCEPTANCE: __________________________________ DATE:________ DOSH

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17 EXHIBITS Exhibit No. Exhibit Description Revision Date

1 Manual Log 0 8/29/2006

2 Deleted

3 Take-Off Sheet 0 7/31/2008

4 Purchase Order Form 0 7/31/2008

5 Receiving Inspection Report 0 7/31/2008

6 Quality Assurance Traveler 0 7/31/2008

7 Welder Continuity Report 0 7/31/2008

8 Hold Tag 0 8/29/2006

9 Non-Conformity Report 0 7/31/2008

10 National Board Registration Log 0 8/29/2006

11 (A.S.M.E.) Name Plate 0 8/29/2006

12 Deleted

13 (A.S.M.E.) Stamping Arrangement for B31.1 0 8/29/2006

14 (Repair) Name Plate 0 8/29/2006

15 Alteration or Rerate Name Plate 0 8/29/2006

16 M & TE Calibration Record 0 7/31/2008

17 Repair / Alteration Registration Log 0 8/29/2006

18 A.S.M.E. Certificate of Authorization

19 N.B.B.P.V.I. Certificate of Authorization

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Exhibit 1

Manual Log

Issued To Date Issued Manual Number

Edition Confirmation Date Received

Exhibit Index 3.10



Exhibit 3

Take-Off Sheet

Exhibit Index 6.3



Exhibit 4

Purchase Order Form

Exhibit Index 6.2 6.4



Exhibit 5

Receiving Inspection Report

Exhibit Index 6.5



Exhibit 6

Quality Assurance Traveler



Exhibit Index 7.4



Exhibit 7

Welder Continuity Report

Exhibit Index 9.5.1



Exhibit 8

Hold Tag

Exhibit Index 8.3.1



Exhibit 9

Non-Conformity Report

Exhibit Index 7.4



Exhibit 10

National Board Registration Log

Serial No. Owner NB # Date of Mfg.

Date Submitted

Exhibit Index 7.8



Exhibit 11

(A.S.M.E.) Name Plate

Exhibit Index 7.6



Exhibit 13

(A.S.M.E.) Stamping Arrangement for B31.1

Exhibit Index 7.6



Exhibit 14

(Repair) Name Plate

Exhibit Index 14.3.7



Exhibit 15

Alteration or Rerate Name Plate




Exhibit 16

M & TE Calibration Record




Exhibit 17

Repair / Alteration Registration Log

Serial No. N.B. Reg. #

Date of Repair or Alteration

Date Submitted

“R” Number

Owner STARCON Job No.

Comments




Exhibit Index



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