quality control manual - prt-bmt qc man 3rd ed r-1 8-10-11 u… · quality control manual edition 3...

Section 1 Revision 1

Date: August 10, 2011

BMT-NW Acquisition LLC

60 Tower Boulevard Elma, WA 98541-9161

Title Page

Quality Control Manual

Edition 3

Revision 1

For Design, Assembly and Fabrication of Power Boilers, Pressure Vessels and Power Piping

Fabricated in the Shop and Field Sites in Accordance With

ASME Code Section I to be stamped “S” Or

ASME Code Section VIII Div 1 to be stamped “U” Or

ASME Code Section VIII Div 2 to be stamped “U2” Or

ASME Section I and B31.1 to be stamped “PP” Also

Metallic Repairs and/or Alterations in the Shop and/or Field Sites in Accordance With

The National Board Inspection Code (NBIC) Including Jurisdictional Requirements to be stamped “R”

UNCONTROLED MANUAL ELECTRONIC VERSION


Manual Control Date: August 10, 2011

Page 1

Manual Control 4.1 The QCM shall maintain a list of Manual holders. The QCM will issue copies of the

Manual in accordance with the list of Quality Manual holders. Each Manual will bear the same control number on its Title Page as is shown on the list of Manual holders. Only controlled Manuals will be issued to BMT employees. Uncontrolled Manuals may be issued to personnel outside of BMT.

4.2 The QCM will review new Code Edition/Addenda for impact on this Quality Control

Program and make necessary changes if required. Revisions will be approved by the QCM and submitted to the Authorized Inspector (AI) for their review and acceptance prior to issue. Revision will be by complete section. The QCM will retrieve issued controlled Manuals, make the necessary changes and reissue the controlled Manuals.

4.3 A current controlled copy of the Quality Control Manual is available for use by the AI at

the shop and field sites. 4.4 Approval by the QCM and acceptance by the AI will be indicated by signature and date

on the revised Table of Contents page of the Manual. 4.5 The entire Quality Manual may be reprinted as a new edition with the revision level reset

to “0” at the discretion of the QCM.


Date: August 10, 2011 Page 1

Quality Control Organization Chart

Engineer

QC Manager (QCM)

Production Control Manager

Shipping & Receiving

Purchasing Agent

Quality Control Inspector *

Shop & Field

Foreman

Plant Manager

President

Sr. Vice President

Welding Personnel

* Designee: A qualified individual assigned an activity by the responsible person. Responsibility may not be deligated



Design 6.1 Upon receipt of an order for a Code item to be designed by BMT, the customer's design

specification is reviewed for adequacy by the Engineer and for compliance to Code requirements by the QCM. Any deficiencies are reconciled with the customer prior to starting design work. All Code jobs are assigned a job number by the Production Control Manager. All documents related to the job will reflect the job number. The Engineer will use the assigned job number for the drawings and calculations.

6.2 Upon approval of the customer's design specification, The Engineer will prepare the design

drawings, calculations, and bill of materials (listed on the drawing). Material used in the design shall be specified to a SA or SB material specification or other material permitted by the Code.

6.3 Completed design drawings, calculations, and bill of materials are reviewed and approved by

the Engineer and the QCM. The Production Control Manager will distribute the approved drawings. Any disapproved documents are returned to the Engineer for correction and re-submittal. Dated initials of the QCM show approval on the documents.

6.4 Design drawings will indicate NDE, post weld heat treatment (PWHT), Code nameplate data,

(stamped on shell) (Exhibit 7) weld size and joint configuration, Code Edition and Addenda, Code Cases, Hydro test pressure, impact test, and other engineering notes as required. Calculations shall also indicate Code Edition and Addenda used and formula references. The Engineer shall determine the system of units of measurements used on each job and define SI or US customary units as the primary units to be used during the construction or field assembly of any Code job.

6.5 Access to computer programs used for design calculations shall be through the Engineer.

When requested by the AI, the Engineer shall have the accuracy of computer programs and their revisions checked by running manually calculated test problems.. Completed design calculations shall list the computer program and version used. No hidden calculations are permitted. All formulas shall be shown together with plug in values for formula variables.

6.6 A Design Control Log (Exhibit 13) shall be maintained by the Engineer to document the

design process for VIII-2 Pressure items. 6.7 When design drawings, and calculations are provided to BMT by others, the Engineer and

QCM shall review these documents for compliance to the Code. If in Code compliance, the drawings and calculations will be approved by the Engineer and QCM. Design may also be subcontracted to a designer approved by the Engineer (see 6.11 and 6.12 for ASME Section VIII Div. 2 items). The Subcontractor shall be responsible to comply with sections 6.1, 6.2, 6.3, 6.4, and 6.5 of this Quality Control Manual. Subcontracted design documents will be reviewed and approved by the Engineer and QCM.


Date: August 10, 2011 Page 2 6.8 The QCM is responsible for providing the AI with all design drawings, and calculations prior

to the start of fabrication. 6.9 Revisions to drawings are made, approved, and distributed in the same manner as the

originals. Superseded documents are retrieved and/or removed from production by Production Control Manager. If these documents contain notes, which require their retention, the Engineer will stamp or write on the documents "VOID-FOR INFORMATION ONLY" and retain in the job file.

6.10 The Engineer shall maintain a Design Control Log (Exhibit 13) for ASME Section I

projects which involve other ASME Stamp holders. The log will record distribution and receiving of design information (drawing revisions, calculations, RFI (letters, correspondence, emails), design change requests, etc) between BMT and the Engineer, broker, owner and other ASME Section I Stamp holders (designer/mfg., assembler, parts mfg. and piping fabricator) involved in the project.

6.11 ASME VIII Div. 2 (VIII-2) User’s Design Specification (UDS): 6.11.1 The User, as part of contract with BMT, will provide a User’s Design Specification

(UDS). This specification will include a description of the intended operating conditions in sufficient detail to provide an adequate basis to design, selected materials, fabricate and examine as required to comply with the rules of VIII-2.

6.11.2 The User, as part of the specification, will specify whether or not a fatigue analysis shall

be made for cyclic service. When a fatigue analysis is specified, the User will provide information in sufficient detail so that an analysis for cyclic operation can be carried out in accordance with VIII-2. When the specification states that no fatigue analysis is required, the specification will include a statement that the intended operation satisfied the requirements.

6.11.3 The User will have the UDS certified to be in compliance with the requirements of VIII-

2. This certification must be performed by a Professional Engineer experienced in pressure vessel design and registered in accordance with VIII-2.

6.11.4 Upon receipt of a contract, the Project Engineer shall review the UDS for full compliance

with VIII-2. The User shall be requested to correct any deficiencies in the specification prior to the initiation of any design effort.

6.12 ASME SectionVIII Div. 2 Manufacturer’s Design Report (MDR):


Date: August 10, 2011 Page 3 6.12.1 The Engineer shall be responsible for producing an MDR VIII-2 consisting of

calculations and drawings establishing that the design as shown on the drawings complies with the requirements of VIII-2 for the conditions set forth in the UDS.

6.12.2 The MDR shall include, when required by the fatigue evaluation requirements of VIII-2

and based on the expected operating conditions, an analysis for cyclic operation. The analysis shall be performed in accordance with the requirements of VIII-2.

6.12.3 Calculations included in the MDR shall consider each type of loading listed in VIII-2. 6.12.4 The Manufacturer’s Design Report shall be certified as complying with all applicable

requirements of VIII-2. This certification shall be performed by a Professional Engineer experienced in pressure vessel design and registered as required by VIII-2

6.12.5 A copy of the MDR shall be furnished by the Engineer to the User. 6.12.5.1 A sample of what is required in the MDR is given as follows: 6.12.5.1.1 Final as-built drawings. 6.12.5.1.2 Actual material specifications used for each component. 6.12.5.1.3 Calculations (design-by-rule) including all intermediate steps. 6.12.5.1.4 Calculations (design-by-rule) including all intermediate steps. Assumptions used in

the design. 6.12.5.1.5 The name and version of computer software, if applicable. 6.12.5.1.6 Extensive details of the finite element model (e.g., model geometry, loading

conditions, boundary conditions, material models used, type of numerical analysis, copies of all significant graphical results, validation of the FEA model, analysis of results, and electronic storage of results).

6.12.5.1.7 Results of fatigue analysis.



Materials 7.1 All Purchase Orders (PO) (Exhibit 3) for Code material are prepared by the Purchasing

Agent from the approved bill of materials as listed on the drawing. All Code requirements, including Specification and Type or Grade, special requirements, such as UG-79, required marking and certification as outlined in the applicable ASME material specification shall be listed on the PO. The PO shall be prepared without change from the approved material specifications listed on the drawing. The QCM shall review and approve the PO. No substitution of material is permitted without a formal revision to the drawing bill of materials, calculations and approval by the QCM or the Engineer and concurrence with the AI.

7.2 Only U2 Certificate Holders can supply welded pressure parts to an ASME Section VIII

Division 2 Manufacturer. 7.3 On Section VIII Division 2 construction -20F impact exemption permitted for ASME

B16.5 Flanges shall only apply to flanges that are supplied in the heat-treated condition (normalized, normalized & tempered or quenched & tempered).

7.4 Welding material will be ordered in accordance with approved welding material

specifications and classifications as listed on the Welding Procedure Specification. The Shop and/or Field Foreman will complete a PO for all welding material ordered. The QCM will review and approve all welding filler material POs.

7.5 The completed PO is then forwarded to the selected vendor. All POs are filed in the job

file by the Purchasing Agent. 7.6 All Code materials received at the shop or field site are placed in a Code Material

"HOLD AREA” pending Quality Control receiving inspection documented on the Material Receiving Form (Exhibit 4). The Quality Control Inspector (QCI) using a copy of the PO examines all Code material for dimensions, marking, condition, and quantity. The QCI documents the inspections on the PO, and forwards it to the QCM. For material already in stock, the QCI will re-inspect the material using the Material Receiving Form.

7.7 For Code material for which the material specification requires heat traceability, the

QCM references the heat number on the PO and reviews the required Material Test Report (MTR) chemical and physical test results and other requirements to the material specification requirements. The heat number/slab (product identifier) number marking on the material is verified to the number listed on the MTR.



7.8 When a head is received for the purpose of manufacturing a pressure vessel or part; each

head will be surveyed for shape, thickness, damage, and markings and shall be documented on the Head Thickness Survey Form (Exhibit 14) to determine that the thickness meets the minimum requirement specified in the calculations for fabrication.

7.9 If the material is acceptable, the QCM signs and dates the MTR(s) and PO(s). If any

material is found that does not meet all PO and/or Code requirements, it is returned to the vendor or it is marked "HOLD", retained in a segregated “Hold Area” and handled in accordance with Section 10 of this Manual.

7.10 Prior to cutting Code material, the required identification marking is transferred to

maintain material traceability. In some cases, with the concurrence of the AI, a coded marking may be used. Any system of coded marking used will be documented by the QCI on the PO.



Inspection 8.1 Fabrication of Code items is controlled by means of the Traveler (Exhibit 1,2,2A, or 2B)

prepared by the QCM from the information on the drawings and Bill of Material. 8.2 A Material Documentation Traveler (Exhibit 12) may be amended to the process Traveler

(Exhibit 1,2,2A, or 2B) that will list and document the Code materials used on pressure vessels and/or parts. The QCM lists the sequence of operations, including the Welding Procedure Specification (WPS or SWPS), for each item in the space provided on the Traveler. The sequence includes fabrication, operations examination-tests and QC inspection.

8.3 The QCM will review the Traveler, calculations and drawings with the AI before the start of

fabrication for the designation of AI hold points. He will initial and date the Traveler to document this review. Hold points are set by the AI and shall not be bypassed without the permission of the AI.

8.4 The QCI/QCM shall be responsible for inspection of all fabrication listed on the Traveler.

When fabrication of a Code item is completed, the QCM does the final inspection and initials and dates the Traveler when all Code and contractual requirements are met. The AI will make the internal inspection prior to the hydrostatic test, and external inspection during hydrostatic testing, and when all fabrication is complete.

8.5 The hydrostatic test, supervised by the Shop and/or Field Foreman, will be witnessed by the

QCM or designee and AI and is applied as specified on the drawing and Traveler. The hydrostatic test procedures and equipment with units consistent with the stamping are required. The calibrated pressure gauge(s) used must be in the same units as the drawings and Progress Traveler. The QCM shall document the correct units required.

8.6 Following the successful hydrostatic test of the Code item and with the authorization of the

AI, the applicable Code symbol stamp (S, PP, U, U2 and/or NB) shall be applied to the stamping/nameplate (Exhibit 7) and be attached to the correct vessel by the QCM or designee. The AI and QCM shall verify that the correct Code stamping/nameplate has been applied to the vessel and /or item.

8.7 The QCM will have custody and control of the ASME and National Board Code(s) symbol

stamps. As an alternative to using the full company name for stamping BMT-NW Acquisition LLC is authorized by ASME to use “BMT”.

8.8 The QCM may pre-stamp the applicable Code symbol stamp(s) with the approval of the AI,

on the “U” stamping/nameplate for vessels and/or items fabricated at field sites. These pre-stamped nameplates shall be forwarded to the Shop and/or Field Foreman along with a Transmittal letter signed by the AI and QCM for application to the Vessel and/or item. The



QCM and the AI at the field site shall verify that the correct Code nameplate has been received and applied to the vessel and/or item.

8.9 Upon completion of a shop or field fabricated Code item, the ASME Manufacturer's Data

Report will be completed from the final job records and certified by the QCM. The Manufactures Data Report shall have the same values as those on the nameplate.

8.10 The completed ASME Manufacturer Data Report, with the final job records, will be

presented to the AI by the QCM for the final review and signature.



Fabrication, Welding, NDE & PWHT 9.1 Fabrication

9.1.1 When backing strips are required by VIII-2, they shall be continuous and any splices shall be butt-welded. Circumferential single-welded butt joints with one plate offset to form a backing strip are prohibited.

9.1.2 VIII-2 fabrications require closing spin holes in all heads. Closing spin holes shall

require NDE to be performed when not closed with a nozzle. 9.2 Welding

9.2.1 All welding and documentation used for Code fabrication will be performed using Welding Procedure Specifications (WPS/SWPS) and Welders or Welding Operators qualified in accordance with ASME Section IX and any additional requirements of the applicable Code and contract.

9.2.2 WPSs' will be approved by the QCM. The required test welds are made under the

QCMs supervision and/or direction. Preparation and testing of the required specimens is performed by a qualified testing laboratory to ASME Section IX requirements. The QCM reviews the report of tests submitted by the laboratory, and if acceptable, the QCM prepares and certifies by signature and dates the Procedure Qualification Record (PQR).

9.2.3 Corporate WPSs, PQRs, WPQs, and SWPSs qualified by the following

companies (under the following previous, or other owned companies) may be used by BMT-NW Acquisition LLC (BMT) provided BMT, by signature of QCM revises the WPS to reflect control and ownership for use by BMT. WPSs, PQRs, WPQs and SWPSs from the following are or may be affected:

Ace Tank and Equipment Co. Busby Marine and Tank Inc. Brown-Minneapolis Tank Brown-Minneapolis Tank Co. BMT Acquisition LLC Brown Minneapolis Tank Fabrication Brown-Minneapolis Tank and Fabricating Co. Brown-Minneapolis Tank and Fabricating Company Iteq Storage Systems Inc. Reliable Steel Fabricators Inc. Reliable Steel Inc.



9.2.4 Copies of a qualified WPS/SWPS are provided to the Shop and Field Foreman, for use in making production welds. The QCM will maintain the WPS/SWPS and PQR master file. WPS/SWPS and PQRs are available for review by the AI. The WPS/SWPS shall be available to the Welder/Welding Operator in the work area. WPSs will be revised when there is a change from non-essential variables to supplemental, or essential variables as they apply to the WPS. A new WPS is prepared and qualified when required by a change in supplemental or essential variable.

9.2.5 WPS/SWPS and PQRs are available for review by the AI. The WPS/SWPS shall

be available to the Welder/Welding Operator in the work area. WPSs will be revised when there is a change from non-essential variables to supplemental, or essential variables as they apply to the WPS. A new WPS is prepared and qualified when required by a change in supplemental or essential variable.

9.2.6 All Welders and Welding Operators used for Code welding shall be qualified to

ASME Section IX. The Welder Performance Qualification (WPQ) will be supervised by the QCM, QCI, or designee, as directed by the QCM. Performance tests may be terminated at any point if it becomes apparent that the welder lacks the necessary skills to meet the specifications. A qualified testing laboratory may perform the preparation and testing of the required test specimens. Guided bend tests may be performed by BMT at the direction of the QCM. The report of the test is reviewed by the QCM, and if acceptable, the QCM will prepare and certify the Welder/Welding Operator WPQ.

9.2.7 Copies of the WPQs are provided to the Shop and Field Foreman for their

respective qualified Welders/Welding Operators. The original records are maintained in the QCMs file.

9.2.8 Welders and Welding Operators are re-qualified when a change in performance

essential variable occurs or they have not welded in the specific process for six months, or the AI or QCM have reason to question their ability to make welds that meet the specification.

9.2.9 Each qualified Welder/Welding Operator is listed on a Welder Continuity Log (Exhibit 5) maintained by the QCI, Shop, or Field Foreman. The Log indicates



the date on which the Welder or Welding Operator has welded in each process within a period of six months. The QCM determines from the Log when a Welder or Welding Operator qualification is expiring to ensure that the Welder or Welding Operator performs welding or is properly re-qualified in the process. Welding records will be maintained from the last date tested, or as long as the Welder or Welding Operator is actively employed as a welder for BMT. Welding records will no longer be maintained after a period of six months from the last day the Welder or Welding Operator is separated from their welding position.

9.2.10 The Shop and Field Foremen are responsible for verifying that all production welders and welding operators are qualified, and for instructing each welder in the WPS they are to use, as listed on the Traveler and drawing for each weld.

9.2.11 All tack welds will be made by qualified welders to a qualified procedure and

examined visually for defects, and if found to be defective, shall be totally removed. Tack welds incorporated in welds shall have their ends feather ground prior to incorporation into the final weld. Temporary tacks made by others shall be made using a qualified WPS approved by the QCM and shall be removed prior to welding.

9.2.12 Each qualified Welder and Welding Operator is issued a unique stamp by the

QCM. Each welder shall identify each completed weld with the Welders stamp or identifying symbol adjacent to and at intervals of not more than 3 feet of each weld made. When conditions prevent the stamping of the weld, the Welder or Welding Operator enters the Welder or Welding Operator symbol on the drawing or weld map and the Traveler for each weld the welder makes.

9.2.13 The Shop/Field Foreman will order filler material as specified on the approved

WPS. Welding material is stored in dry storage space and issued to the shop or fieldwork areas by the Shop/Field Foreman as required by the WPS.

9.2.14 Covered electrodes, such as (but not limited to) low hydrogen, or stainless steel

electrodes will be held in holding ovens maintained at temperatures recommended by AWS, the electrode manufacturer, or Part C of Section II of the ASME Code. Rod ovens will be used with both the shop and fieldwork.

9.2.15 American Welding Society (AWS) Standard Welding Procedure Specifications

(SWPS) Control.

9.2.15.1 It is the responsibility of the QCM for the following:

9.2.15.1.1 Selection and use of AWS SWPS in accordance with Article V of ASME Section IX.

9.2.15.1.2 Assure BMT’s name is certified on each SWPS used.



9.2.15.1.3 Listing the applicable Code Sections(s) and/or any other

fabrication documents that must be followed during welding on the SWPS.

9.2.15.1.4 Reference to the Code Section(s) or fabrication documents may be

added or deleted from a demonstrated SWPS without further demonstration.

9.2.15.1.5 For administering and witnessing the welding of the required weld

test coupon and recording actual conditions of the test for use of demonstration within the limitations of Article V of the ASME Section IX.

9.2.15.1.5.1 For documenting the test results and certification by

signature and date of the completed Supporting Demonstration Records (SDR).

9.2.15.1.5.2 For controlling and assigning the identification number of

the Supporting Demonstration on each SWPS that it supports prior to using the SWPS.

9.2.15.1.5.3 SDRs are submitted to the AI for review and acceptance.

The AI may request requalification of a SDR at any time for just cause.

9.2.16 When using SWPSs for performing repairs or alterations in accordance with the National

Board Inspection Code, the Quality Control Manager shall complete the certification portion on the SWPS form as required in the NBIC. Additionally, the above requirements will be followed except for the requirement of demonstration.

9.3 Nondestructive Examination (NDE) 9.3.1 In the event that NDE is required by either contract or the Code, it is the intent of BMT to

subcontract for these services with a qualified inspection laboratory and/or use qualified in-house personnel. The qualified inspection laboratory’s Level III examiner shall be appointed by BMT’s QCM in a letter as the BMT Level III examiner for the appropriate NDE discipline. A copy of the written practice that meets the current Code accepted edition of SNT-TC-IA, examiner qualifications, and evidence of current visual acuity shall be kept on file by the QCM.

9.3.2 The NDE vendor shall provide examination procedures, approved by the appointed level

III, for review and acceptance by the QCM. The results of required NDE examinations shall be reviewed for compliance by the QCM. These records shall be available to the AI. The AI and QCM shall have the right to require requalification of NDE examiners or procedures for just cause.



9.3.3 B31.1 and VIII-2 Visual Testing Examiners shall be qualified based on the following

minimum requirements:

9.3.3.1 Instruction in the fundamentals of the NDE method. 9.3.3.2 On-the-job training to familiarize the NDE personnel with the appearance and

interpretation of indications of weld defects. The length of time for such training shall be sufficient to assure adequate assimilation of the knowledge required.

9.3.3.3 An eye examination performed at least once each year to determine optical

capability of NDE personnel to perform the required examination. Visual acuity will be a minimum of J1 at a distance of 12 inches. A record of the eye examination will be kept on file.

9.3.3.4 Upon completion of a. and b. above, the NDE personnel shall be given an oral or

written examination and performance examination by the employer to determine if the NDE personnel are qualified to perform the required examinations and interpretation of results.

9.3.3.5 Certified NDE personnel whose work has not included performance of a specific

examination method for a period of 1 year or more shall be recertified by successfully completing the NDE examination and also passing the visual examination.

9.3.3.6 The following may be used as alternatives to the preceding program, as

applicable: SNT-TC-1A, and personnel qualified to AWS QC-1 may be used for visual examination of B31.1 boiler external piping welds. The QCM is responsible for certification of all B31.1 visual examiners.

9.3.4 Base material examination of cut edges is required by MT or PT when constructing to

VIII-2. 9.3.5 For VIII-2 fabrication, all bolts, studs and nuts over 1” nominal bolt size shall be

examined by NDE. See VIII-2 for exact requirements. 9.3.6 For VIII-2 construction, casting quality factors of Div. 1 do not apply. 9.3.6.1.1 All parts of steel casting, regardless of thickness, shall be fully radiographed (See

VIII-2). 9.3.6.1.2 VIII-2 has specific requirements for ultrasonic, magnetic particle, and liquid

penetrant examination of steel castings and plate depending on thickness and magnetic properties.



9.3.7 For VIII-2 construction, where fatigue analysis is mandatory, all welds on the entire pressure vessel shall be examined by MT or PT after hydrostatic test.

9.4 Post Weld Heat Treatment (PWHT)

9.4.1 PWHT required by the Code is performed by a qualified subcontractor whose procedures, calibration records, and heat treat controls are reviewed and approved by the QCM. A PO approved by the QCM will be issued to the PWHT sub contractor. The PO will list all Code requirements for PWHT including references to the PWHT subcontractors written procedure.

9.4.2 All PWHT will be performed in accordance with the PWHT sub contractors

written procedure approved by the QCM. The Procedure will detail the temperature gradients for heating and cooling, placement of thermocouples, time at temperature, record format, etc. PWHT records shall be submitted by the QCM to the AI for review and acceptance.

9.4.3 When items are sent to a subcontractor for PWHT, the QCM will inspect the

items for identification markings prior to shipment. After PWHT the QCM will re-inspect the items for identification and damage. Any items that have lost their identification or are damaged will be handled in accordance with Section 10 of this Manual.



Nonconformance (NCR)

10.1 Nonconformity is any condition that does not meet the Code, the design drawings,

calculations, specifications, or this Quality Control Manual. 10.2 It is the duty of all BMT employees to report nonconformities to their supervisor.

Immediately after a nonconformity is found, the QCM shall verify the condition and identify the nonconforming material or fabrication by tagging or marking "HOLD" and completing a NCR (Exhibit 6). If practical, the nonconforming item shall be moved to a segregated “Hold Area”. The NCR with a description of the problem and proposed disposition is completed and signed by the Production Control Manager or the Engineer, then submitted to the QCM for approval and the AI for concurrence.

10.3 The following is a list of some possible dispositions for an NCR:

10.3.1 Use-as-is: When the disposition is use-as-is, the QCM will consult with, and obtain the approval from, the Engineer and the concurrence of the AI. Any required revisions to drawings, calculations and procurement documentation will be done as described in the Manual.

10.3.2 Repair/Rework: All repair or rework shall be approved by the QCM and accepted

by the AI, before disposition.

10.3.3 Scrap/Return to Vendor: This disposition requires the QCM to verify with documentation on the NCR that the item has been removed from the work area, and clearly marked "REJECT" to prevent its inadvertent use prior to disposal.

10.4 The QCM will re-inspect the items dispositioned in 10.3.1 and 10.3.2 when the required

action is complete. When the QCM is satisfied that the item meets Code requirements, the QCM will sign that the NCR removes the "HOLD" marking and allow the item to return to its proper sequence of fabrication. Completed NCR’s are returned to the QCM for filing. The QCM will make all NCR's available to the AI for his review and acceptance prior to removal of the “Hold” or mark.



Calibration/Pressure Tests

11.1 Calibration 11.1.1 Each piece of equipment that requires calibration, and is used for measurement, testing,

or examination, shall be identified with a unique serial number. The QCM is responsible for seeing that designated measuring, test, and examining equipment is maintained in calibration. If not calibrated or out of calibration this equipment will be clearly marked "NOT CALIBRATED-DO NOT USE” or “REFERENCE. The QCM will maintain a list of which equipment requires calibration. The Calibration List (Exhibit 8) will show the serial number of the instrument, frequency of calibration, date last calibrated and date due for calibration.

11.1.2 All gages shall be calibrated against a standard dead weight tester or a calibrated master

gage within six (6) months of the test or at any time there is reason to believe that they are in error.

11.1.3 Gages used for pressure testing shall be calibrated against a dead weight tester or

calibrated master gauge annually or if error is suspected and be traceable to NIST. Dial ranges of pressure gages shall be about double the test pressure but not less than 1.5 nor more than 4 times the test pressure.

11.1.4 Calibration records will be maintained by the QCM and made available to the AI upon

request. 11.2 Pressure Tests 11.2.1 Hydrostatic Pressure testing shall be conducted in a safe manner under the direction of

the Shop and/or Field Foreman, and witnessed by the QCM. Prior to the final pressure test, the QCM and AI shall perform an internal and external inspection of the vessel. The Engineer shall develop a written procedure for pneumatic testing.

11.2.2 The specified test pressure shall be noted on the drawing and Traveler. The test medium

shall be water, unless otherwise specified (with the AI's and jurisdictional concurrence), at a recommended temperature of not less than 30 degrees F, above the vessel's minimum design metal temperature (MDMT) and not to exceed 120 degrees F MDMT. The pressure shall not be applied until vessel and its contents are about the same temperatures. The vessel will be filled with water and vented at the highest point so as not to trap any air in the vessel. When full, the vent shall be closed and the hydrostatic pump shall be used to bring the vessel up to test pressure and held for a minimum of ten minutes or by customers’ recommendations. The test gauge mounted directly on the vessel shall be visible to the Pump Operator. Following the test the pressure will then be gradually reduced to the MAWP of the vessel and inspected for leaks and defects by the Shop-Field Foreman and the QCM. When the QCM is confident that the test results are satisfactory the vessel shall then be available for inspection by the AI.



Records 12.1 All records described in this manual are collected at the completion of the job, and

reviewed for completeness and accuracy by the QCM, prior to preparation of the Manufacturer's Data Report.

12.2 Manufacturer's Data Reports, after certification by QCM and the AI, are filed with the

purchaser, Jurisdiction where installed, the AI (upon request), and the National Board (if registered). When Manufacturer’s Data Reports are to be registered with the National Board, The QCM shall submit an original of the complete set of Manufacturer's Data Reports required for the vessel to the National Board within sixty (60) days of Manufacturer's Data Report certification.

12.3 National Board serial numbers assigned to vessels to be registered with the National

board shall be controlled and issued by the QCM. National Board serial numbers shall be issued in sequence without skips and without gaps and without suffix or prefix beginning with number one (NB 1). The QCM shall maintain a record of issuance showing date issued, type of vessel, date stamped date mailed to the National Board, and manufacturer’s serial number.

12.4 All fabrication and production documents, including a copy of the Manufacturer's Data

Report shall be maintained by the QCM as specified in Paragraph 12.5. Manufacturer's Data Reports not registered with the National Board shall be retained for five (5) years.



12.5 BMT shall maintain the following documents uniquely applicable to each completed

ASME Section VIII Div. 1, Section VIII Div. 2, and Section I certified items. The QCM shall maintain a Document Index Log (Exhibit 9) for all Code items as listed below. The Document Index Log, which lists the job number, record retention time, and location of the record storage within the record storage system. The QCM and the AI shall sign the Document Index Log confirming collection of the production documents listed on the Document Index Log in the job file at the time of Manufacturer's Data Report certification. It is not necessary to have a copy of the WPS, PQR, WPQ, Welder Continuity Records, MTRs, Drawings, Calculations, etc. in the job file if these documents are applicable to more than one job. The Document Index Log can list their filing location; such as a Design Calculation File, Drawing File, WPS File, PQR File, MTR File, etc, for multiple copies identical vessels a job file may contain only those documents unique the vessel, such as NDE Reports, Repair Records (as applicable), Process Control Records, Heat Treatment Records, Nonconformance Reports and their dispositions, Hydrostatic Test Reports, and the Manufacturer’s Data Report when not registered: ASME Section I Records (3 years)

• Radiographs • UT test reports • Manufacturers Data Reports

ASME Section VIII Div. 1 Records (3 years) • Manufacturer’s Partial Data Report • Manufacturer’s drawings • Design calculations and proof tests • Material Test Reports and/or material certifications • Welding procedure Specifications and Procedure Qualification Records • Welder Qualification and Continuity Records • NDE Examination Reports • Repair procedure and records (as applicable) • Process control records (Traveler) • PWHT records • Heat treat records and test results • Nonconformance Reports and their disposition • Hydrostatic test records • RT and UT reports



ASME Section VIII Div. 2 Records (3 years) a) User's Design Specification b) Manufacturer's Design Report c) Manufacturer's Data Report d) Manufacturer's Construction Records and Partial Data Reports 1) Tabulated list of all material used for fabrication with Materials Certifications and Material Test Reports, and a record of any repairs to pressure retaining material that require a radiographic examination by the rules of this Division. The record of the repairs shall include the location of the repair, examination results, and the repair procedures. 2) Fabrication information including all heat treatment requirements, forming and rolling procedure when prepared, an inspection and test plan identifying all inspection points required by the user, and signed inspection reports 3) List of any subcontracted services or parts, if applicable 4) Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), weld map and welder or welding operator qualification test results 5) Record of all heat treatments including post weld heat treatment (these records may be either the actual heat treatment charts or a certified summary description of heat treatment time and temperature) 6) Results of production test plates, if applicable 7) NDE procedures, records of procedure demonstrations, and records of personnel certifications 8) All reports stating the results of inspection, nondestructive examinations and testing including radiographic examination, ultrasonic examination, magnetic particle examination, liquid dye penetrant examination and hardness tests 9) All non-conformance reports including resolution and a detailed description of any repairs including repair procedures, a sketch, photo, or drawing indicating the location and size of the repaired area 10) Charts or other records of required hydrostatic, pneumatic, or other tests. Test logs shall include the test date, testing fluid, duration of the test, temperature of the test fluid, and test pressure 11) Dimensional drawings of the as-built condition

12.6 The QCM shall conduct an annual audit to verify compliance of record storage. The

results of the audit shall be documented on the Document Index Log and made available to the AI.



Authorized Inspector (AI)

13.1 The Authorized Inspector (AI) is the third party Inspector required by the Code. The AI

works for an ASME accredited Authorized Inspection Agency (AIA) and holds a current “A” National Board new construction commission. BMT will maintain a current contract with an AIA for all Code activities.

13.2 When requested by the AI, hold points will be inserted on the Traveler for those

operations the AI wishes to witness before, during and after fabrication of a Code vessel or part.

13.3 The QCM for the shop and all field sites shall be the liaison with the Authorized

Inspector and is responsible for keeping him advised of the progress of the work so that he can make his designated inspections. The AI and the Authorized Inspector Supervisor shall have free access to all locations where work is being performed, and shall be furnished with all drawings, calculations, specifications, procedures, Travelers, repair record, test reports and all other documents as are required to perform their duties.

13.4 All NCR’s for Code work are submitted to the AI for his review and acceptance. 13.5 The QCM will notify the AI sufficiently in advance of hold points so that he can be there

to personally witness the activity. 13.6 The final records, together with the completed Manufacturer's Data Report, are submitted

by the QCM to the AI for his review and signature. The Code symbol stamp is applied only when authorized by the AI and when all fabrication and inspections are complete.



Repairs and Alterations

14.1 SCOPE

This section of the Manual describes the controls for repairing and altering pressure-retaining items in accordance with the National Board Inspection Code (NBIC) and Jurisdictional laws. The other sections of this QC Manual apply except as modified by this section and as applicable to the work being performed.

14.2 DEFINITIONS 14.2.1 AUTHORIZED INSPECTOR - as referenced in this section may be one of the following

NB commissioned Inspectors dependent on circumstance.

• The Authorized Inspector employed by the Authorized Inspection Agency of "record" (i.e., contractually arranged Authorized Inspection).

• Employed by an authorized insurance carrier, • Employed by a State/City to perform certificate inspection, • Employed by a qualified Owner-User Agency.

For repair/alterations an NB Commissioned Inspector shall be utilized. For repair/alteration either the “Inservice” Inspector or “AIA” Authorized Inspector may be utilized. The Inspector (CI) in this section of this manual shall be an “IS” National Board Commissioned Inspector or “A” National Board new construction Commissioned Inspector with the “Ar” endorsement. 14.2.2 ALTERATION

1) A physical change to a boiler or pressure vessel which affects its' pressure retaining capability (i.e., requires design consideration). This is typically identifiable by comparison to significant information listed on the Original Equipment Manufacturer's (OEM) Data Report.

2) A non-physical change that would increase the maximum allowable working pressure (MAWP) or lower MDMT to the extent that impact testing would be required. (NOTE - this also constitutes a RERATE).

14.2.3 REPAIR (to in-service equipment) - A repair is the work necessary to restore a vessel to

a safe and satisfactory working condition, provided that in all cases the Code design is not altered, and the repair construction will follow the Construction Code to which the item was originally fabricated.



14.2.4 Routine repairs for which the requirements for in-process involvement by the Inspector

and stamping may be waived as determined appropriate by the Jurisdiction and the Inspector.

14.2.5 R-1/R-2 REPORT - A document certified by BMT and the NB Commissioned Inspector

certifying that a vessel repair or alteration was in accordance with NBIC and Jurisdictional requirements.

14.3 BMT performs repairs/alterations to Code vessels and Routine Repairs, in accordance

with the requirements of the National Board Inspection Code (NBIC), ASME Section VIII, Division 1, VIII-2 and Section I Jurisdictional requirements and this Manual as applicable. BMT also makes alterations to vessels in accordance with the above. All design information, applicable drawings, design calculations, specifications and instructions shall be prepared or obtained, controlled and interpreted in accordance with the original Code of construction.

14.4 For “R” stamped work, either system of units (US customary or SI metric) may be used

for repairs and alterations, however only one system shall be used consistently throughout the repair/alteration, and the original Code of construction shall be the basis for selecting the units of measurement. Hydrotest procedures and equipment with units consistent with the stamping are required. The pressure gage(s) used must be in the same units as the hydrotest Traveler / drawing, instruction sheet / procedure. The contemplated repairs, including those of a routine nature (as defined in the NBIC), will be described to the AI (and in-service Inspector when applicable) by the QCM. No repair or alteration shall be started without the authorization of the AI. For Routine Repairs the AI may waive the inspection and stamping. The work including evidence of AI authorization shall be documented on the Traveler. Hold points are set by the AI and shall not be bypassed without the permission of the AI. The QCM will, prior to the start of work, provide the AI with records such as drawings, procedures, repair plan(s), Travelers and any document necessary to define the scope of work, including a copy of the OEM Code Data Report (when available) and R Form for the vessel. The scope of intended work will also be acceptable to the jurisdiction, where required. Welders continuity records shall be retained back to the last date tested in the process.

14.5 Material used in the repair/alteration of an item shall comply with the original

Manufacturers Data Report, if available. If not available, the material must conform to the applicable Code of construction. If a copy of the original Manufacturers Data Report or drawings/documentation from original manufacturer is not available, material may be identified by verification of material markings on the vessel or vessel nameplate or by taking a sample of the material and having it tested by a qualified laboratory (chemical and physical tests) to establish the material properties. If the existing material cannot be verified (unknown), BMT shall perform a chemical analysis and hardness testing, as a minimum, of the unknown material to verify its weldability and strength or may elect to qualify a weld procedure. If there is a question with regard to the weldability characteristics of the material, then competent technical advice should be obtained.



14.6 PWHT, when required, shall be performed in accordance with the code of construction,

however the alternatives including required NDE listed in the NBIC may be utilized with concurrence of the AI and the owner. Original requirements for NDE will be adhered to and handled per the Code and this Manual.

14.7 All alterations of Code vessels (for design, material procurement, receipt and handling,

process/welding control, inspection and testing) will be handled identically with provisions for new fabrication. The work shall be documented on a Traveler. For alterations, calculations shall be completed prior to the start of any physical work. All design calculations shall be completed by an organization experienced in the design portion of the standard used for construction of the item. All calculations shall be made available for review by the AI accepting the design.

14.8 Completed work will be accepted and documented by the QCM and AI in accordance

with this Manual. Upon completion of the work the “R” Report Form including routine Repairs, will be completed from the final records and certified by the QCM. The completed "R" Form, together with the final records, will be presented to the AI for their review and signature. Routine Repairs shall be documented on Form R-1 on line 10, for Remarks, which states “Routine Repair”.

14.9 The QCM shall maintain an R-log list of R Forms registered with the National Board.

The log shall show the R Form number, type of object, date certified and date registered. An original of the R Form shall be mailed to the NB within 60 days of certification. An original Form R-1 or Form R-2 (if the pressure-retaining items is not registered with the National Board) together with their attachments may be registered with the National Board. If the pressure-retaining item is registered with the National Board, an original Form R-2 together with attachments shall be registered with the National Board. All “R” Forms not registered with the National Board, shall be retained for five (5) years.

14.10 After completion of the appropriate “R” Form a nameplate (Exhibit 6) shall be attached

adjacent to the original equipment nameplate or stamping. Repair or alteration nameplates will comply with requirements delineated in the NBIC. Nameplate attachment requires the prior concurrence of the Inspector. As an alternative to using the full company name for stamping BMT-NW LLC is authorized by the National Board to use “BMT”.

14.11 When completed, a copy of the National Board R Form will be distributed as follows:

(1) Customer (2) AI upon request (3) In-service Inspection Agency (4) Jurisdiction (5) National Board (when altered, and only if originally registered with the NB)



14.13 Repair/Alteration of Section VIII, Division 2 vessels or parts require a detailed repair/

alteration Plan that is reviewed and certified by a Registered Professional Engineer.



Exhibits

Exhibit # Exhibit Title

1 Traveler

2

Traveler

2A Traveler 2B Sub Traveler

3

Purchase Order

4

Material Receiving Form

5

Welder Continuity Log

6

Non Conformance Report

7

Name Plate / Stamping

8

Calibration Log

9 Document Index Log

10 BMT VT Certification

11 Intentionally left blank

12 Material Documentation Traveler

13 Design Control Log

14 Head Thickness Survey Form * Note; Actual exhibited forms in use may be revised without revising the exhibited forms in the Quality Control Manual provided the use of the form does not change as described in the Quality Control Manual. All revised forms will be updated during the next formal QC Manual revision.


Exhibit 1 August 10, 2011

TRAVELER Customer: Job # ASME/NBIC Section Code Edition: Addenda: Drawing # Vessel # Nat’l Bd. No. DESCRIPTION OF WORK Internal Review Repair QC: Date: Routine Repair AI: Date: Alteration Via Telecom H= AI Hold Point Page 1 Of

Fit-up Fit-up Final weld Inspection Point QC DATE AI DATE

Weld Joint Identification

WPS Number

Welder Symbol QC Date AI Date QC Date AI Date

Drawing Review Calculation Review Material Documentation Material Identification Dimensions NDE None

RT UT PT MT

Heat Treatment

None

Internal Inspection Pressure Test PSI °F Head Thickness Shell Thickness

Impacts required Test Gauge used Remarks

Section 15 Revision1 Exhibit 2


Traveler DO NOT START CONSTRUCTION WITHOUT SIGNED AI REVIEW TRAVEL SHEET REVISION NO.:

QC REVIEW: REVIEW DATE:

SERIAL NO.: JOB NO.: VESSEL TYPE:

DRAWING NO.: DWG. REV.: TRAVEL SHEET REVIEW AI: DATE: Seq. Item Comments Q.C.I. Date A.I. Date Owner A.I. Hold

Points Date

1. Calculations in File

Release of App’d Dwg.

2.

3.

Heat Numbers

ecorded R

4.

MTRs Checked

5.

WPS(s) Checked

5A Verified

5B Verified

5C Verified

Welder(s) Qualified

6.

7.

Thicknesses Verified & Recorded

8.

Shell(s) & Head(s) Fit-up Inspection

9.

Nozzles & Fittings Fit-up nspection I

10.

Nozzle Orientation

11.

Nozzle & Flange Rating Checked

12.

Internals Checked

Final Internal Inspection

Shell Side

13.

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

Tube Side 14.

Weld Size Checked

15.

Welder I.D. Checked

16.

Final External nspection I

17.

Radiography

18.

Other N.D.E.

19.

Final Ext. Prior to P W H T

20.

PWHT Chart Checked

21.

Hydrostatic Test Shell Gauge #

Side

Tube Gauge # Side

22.

N.C.R. #

23.

Nameplate Stamping

24. Manuf. Data Report

ompleted & Verified C

25. Nameplate Installation

26.

Section 15 Revision1 Exhibit 2


Exhibit 1 Traveler INPROCESS VERIFICATION AND IDENTIFICATION WELD I.D. / WELDER SYMBOLS / FIT-UP

Description

Quality Control

DATE

A uthorized Inspector Date

Weld I.D.

Symbol

Fit-Up

Weld I.D.

Symbol

Fit-Up

Shell #1 L - C -

Shell #2 L - C -

Shell #3 L - C -

Shell #4 L – C –



Head #1 C –

Head #2 C –

Head #3 C –

Head #4 C –

Boot #1 Shell L – C –

Boot #1 Head C –

Boot #2 Shell L – C –

Boot #2 Head C –

Cone L – C –

ATTACHMENT AND / OR NOZZLE VERIFICATION AND IDENTIFICATION WELDER SYMBOLS / FIT-UP Mark Mat. I.D. Neck Fitting Flange Repad or Attachment Cat. B Cat. C Cat. D Pad OD

Spec.-Grd. Thk./Rating

Heat# or ID


Heat# or ID


Heat# or ID


Heat# or ID


Heat# or ID


Heat# or ID


Heat# or ID

Section 15 Revision1 Exhibit 2A


EXHIBIT 2A

Master Traveler Customer Job Work Order Number Address: Serial Number Shop or Field Ship to: “S” “PP” “Repair” “Alteration” Nat’l Board Number(s) Drawing Number(s) Drawing (Rev level and date) Customer PO# Drawing (Rev level and date) Starting Date Equipment Description Delivery Date Authorized Inspectors Review prior to Fab. Date

QUALITY CONTROL AUTHORIZED INSPECTOR

HOLD POINT

Initial Date HOLD POINT

Initial Date

CALCULATION REVIEW CONSTRUCTION DRAWING REVIEW WELDING PROCEDURE REVIEW WELDERS QUALIFICATION REVIEW MATERIAL CODE IDENTIFICATION FINAL INTERNAL INSPECTION PT MT EXAM (when reqd) RT UT EXAM (when reqd) PWHT COMPLETE (when reqd) NCR’S COMPLETE (when reqd) TYPE OF PRESS. TEST HYDROSTATIC PNEUMATIC OTHER (Describe in Remarks) PRE-PRESS. TEST PSIG FINAL PRESS. TEST PSIG TEST GAUGE SN’S & DATA PLATE / STAMPING VERIFIED DATA PLATE / STAMPING COMPLETE DATA REPORTS SIGNED

REMARKS: Describe important information such as impact testing, special service, and nameplate

NUMBER OF DRAWINGS IN SHOP AND A/I Hold Points Summary


Exhibit 3 Date: August 10, 2011

Page 1

Material Receiving Form Section 15Revision 1

Date: August 10, 2011Exhibit 4Date:

Vendor PO Number # CTNS # of items Description Location Recvd By

Amount Accepted

Amount Rejected

Section 15Revision 1

Exhibit 5Date: August 10, 2011

r

r

r

r

WELDER CONTINUITY LOG

EMPLOYEE NAME: EMPLOYMENT DATE: T N/AERMINATION DATE:EMPLOYEE NO.: STAMP NO.:

2009 January Febuary march April May June July August Septembe October November DecemberGMAWFCAWSMAWSAWGTAWJOB#JOB NAME

January Febuary march April May June July August Septembe October November DecemberGMAWFCAWSMAWSAWGTAWJOB#JOB NAME



PROCEDURE QUALIFICATION DESCRIPTION Date PROC. QUALIFICATION DESCRIPTION Date


Exhibit 6Date: August 10, 2011Nonconformance Report

NCR# :Job# : Prepared By:

Material @ Receiving Work in progress Repair or Alteration

1. Define the nonconformity.

By: Date:2. Recommended Disposition

By: Date:QCM: Date:AI: Date:

3. Final Disposition Reference:Item # : Rev. # :

Repair Material Drawing # : Rev. # :

Rework Fabrication

Return

Scrap

Use as IsApproved By:QCM: Date:

Accepted By:AI: Date:

Corrective Action Required


Exhibit 7 Date: August 10, 2011

BMT Serial No._________ Ref. Pg. 109.2

NB

Gauge Calibration List Section 15Revision 1


Serial # Frequency Calibrated Date Calibrated/ By Date Due



Document Index LogJob # Retention time Record location Date stored QCM Signature Date AI Signature Date

Section 15 Revision 1 Exhibit 10


BMT B31.1 and VIII-2 Visual Examination Certification To Who it may concern, I hereby certify __________________________ as a Certified Examiner based on oral and/or written signed exam.

year 2007 2008 2009 2010 date

Section 15 Revision 1 Exhibit 12


Material Documentation Traveler TRAVEL SHEET REVISION NO.:

QC REVIEW: REVIEW DATE:

SERIAL NO.: JOB NO.: VESSEL TYPE:

DRAWING NO.: DWG. REV.: TRAVEL SHEET REVIEW AI: DATE: Seq. Item Comments Q.C.I. Date A.I. Date Owner A.I. Hold

Points Date

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

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

11.

12.

13.

14.

15. 16. 17. 18. 19.

Design Control Log Section 15Revision 1Exhibit 13


ProjectBMT Job Number

Design Control Number Date Comments

1

This documet may be modified without revising the Quality Control Manual.

Section 15

Revision 1 Exhibit 14

Date: August 10, 2011 Head Thickness Survey Form

0° 1.

2.

3.

90° 4.

5.

6.

180° 7.

8.

9.

270° 10.

11.

12.

1, 2, 3 Semi Eliptical Head

4, 5, 6

LOCATION % OF R 0 0.00 1/32 0.124 1/16 0.174 3/32 0.213 1/8 0.242 3/16 0.292 ¼ 0.331 3/8 0.390 ½ 0.433 5/8 0.464 ¾ 0.484 7/8 0.496 C NTERLINE E 0.500

10, 11, 12

7, 8, 9

Head meets required thickness: ____Head meets required shape/radius: ____ Head meets material marking requirements: ____ MTRs checked: _____ Head inspected for damage: ______, Describe: _______________________ Head Heat Numbers: __________________, _________________________ Number:_____________________________________________________ Notes: _______________________________________________________

_____________________________________________________________

_____________________________________________________________ This form may be modified without revising the Quality Control manual.

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