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SECTION: 1.1 - TITLE PAGEREVISION DATE: 2012-03-12

REVISION NUMBER: 3.0PAGE: 1 of 1

QUALITY MANAGEMENT SYSTEM MANUALFor

CONSTRUCTION, REPAIR AND ALTERATION OF PRESSURE PIPING ASME B31.1 POWER PIPING INCLUDING BOILER EXTERNAL PIPING

AND ASME B31.3 PROCESS PIPING

REPAIR AND ALTERATION OF SECTION I POWER BOILERS, SECTION IV HEATING BOILERS AND SECTION VIII DIVISON 1 PRESSURE VESSELS

PERFORMANCE QUALIFICATION TESTING OF PRESSURE WELDERS AND MACHINE WELDING OPERATORS EMPLOYED BY DCM INTEGRATED SOLUTIONS INC.

IN ACCORDANCE WITH ASME SECTION IX AND APPLICABLE CODE(S) OF CONSTRUCTION, AB 513 AND

THE ALBERTA SAFETY CODES ACT AND REGULATIONS

by

DCM Integrated Solutions Inc.AT FIELD SITES IN ALBERTA CONTROLLED FROM

#184, 2693 Broadmoor Blvd.Sherwood Park, Alberta

T8H 0G1

MANUAL REVISION NO.: 3.0

DATE EFFECTIVE: 2012-03-12

REGISTRATION NUMBER: AQP-21453

MANUAL NUMBER: 04

HOLDER: Eliot (DCM Intranet)

CONTROLLED: UNCONTROLLED:

DCM-MA-AQ-02-A-Confidential - Property of DCM –Do not duplicate, register or distribute in whole or in part, whatever the process may be, without first obtaining the written consent of the DCM Quality director.

SECTION: 1.2 - TABLE OF CONTENTSREVISION DATE: 2012-03-12


SECTION TITLE REV. DATE1.1 TITLE PAGE 3.0 2012-03-121.2 TABLE OF CONTENTS 3.0 2012-03-121.3 ABREVIATIONS AND DEFINITIONS 3.0 2012-03-121.4 COPY OF CURRENT CERTIFICATE OF

AUTHORIZATION PERMITS0.0 2012-03-12

2.0 SCOPE OF WORK 3.0 2012-03-123.0 AUTHORITY AND RESPONSIBILITY 3.0 2012-03-124.0 CONTROL OF MANUALS & REVISIONS 3.0 2012-03-125.0 ORGANIZATION & RESPONSIBILITY 3.0 2012-03-126.0 CONTROL OF SPECIFICATIONS, DESIGN

CALCULATIONS AND DRAWINGS2.0 2011-09-20

7.0 MATERIAL CONTROL 3.0 2012-03-128.0 WORKING METHODS 2.0 2011-09-209.0 REPAIRS AND ALTERATIONS TO BOILERS

AND PRESSURE VESSELS2.0 2011-09-20

10.0 WELDING MANAGEMENT SYSTEM 3.0 2012-03-1211.0 NON-DESTRUCTIVE EXAMINATIONS 3.0 2012-03-1212.0 POST WELD HEAT TREATMENT 3.0 2012-03-1213.0 CALIBRATION OF MEASURING AND

TESTING EQUIPMENT2.0 2011-09-20

14.0 PRESSURE TEST 3.0 2012-03-1215.0 DOCUMENTATION 3.0 2012-03-1216.0 NON-CONFORMITY MANAGEMENT 2.0 2011-09-2017.0 EMPLOYEE TRAINING 3.0 2012-03-1218.0 CONTRACT REVIEW 0.0 2012-03-1219.0 INTERNAL AUDITS 0.0 2012-03-12

A FORMS 3.0 2012-03-12B PROCEDURES 0.0 2012-03-12C PROCESSES 0.0 2012-03-12

APPROVAL:

______________________________________ ___2012-03-12 ____ DCM Integrated Solutions Inc. DATEQuality Assurance Manager

______________________________________ ________________ Authorized Inspector (AI) DATE


SECTION: 1.3 - ABBREVIATIONS & DEFFINITIONSREVISION DATE: 2012-03-12

REVISION NUMBER: 3.0

PAGE: 1 of 4

a. ABREVIATIONS:

AA: ADMINISTRATIVE ASSISTANTABSA: ALBERTA BOILER SAFETY ASSOCIATIONAIA: AUTHORIZED INSPECTION AGENCYAI: AUTHORIZED INSPECTORANSI: AMERICAN NATIONAL STANDARDS INSTITUTEASME: AMERICAN SOCIETY OF MECHANICAL ENGINEERSCE: CHIEF ESTIMATORCGSB: CANADIAN GENERAL STANDARDS BOARDCSA: CANADIAN STANDARDS ASSOCIATIONDE: DESIGN ENGINEERHP: HOLD POINTNDE: NON-DESTRUCTIVE EXAMINATIONPD: PURCHASING DEPARTMENTPIR: PIPING INSPECTION REPORTPM: PROJECT MANAGERPQR: PROCEDURE QUALIFICATION RECORDQA: QUALITY ASSURANCEQAM: QUALITY ASSURANCE MANAGERQCS: QUALITY CONTROL SUPERVISORSRS: SHIPPING/RECEIVING SUPERVISORSS: SITE SUPERVISORTT: THERMAL TREATMENTWPS: WELDING PROCEDURE SPECIFICATIONSWQ: WELDERS QUALIFICATIONWQR: WELDER QUALIFICATION RECORDWOQR: WELDING OPERATOR QUALIFICATION RECORD




PAGE: 2 of 4

b. DEFINITIONS:

ABSAThe regulatory organization delegated by the Province of Alberta to provide pressure equipment safety services under the Alberta Safety Codes Act, and act as the sole Jurisdiction/Regulatory Authority as defined in CSA B-51 Code and is accredited by ASME.

ABSA SAFETY CODES OFFICER (AUTHORIZED INSPECTOR)A person appointed as a Safety Codes Officer for the purpose of administering the Alberta Safety Codes Act and Regulations (Pressure Equipment).

Alberta Safety Codes ActThe Alberta Safety Codes Act; Statutes of Alberta, Chapter S-0.5 as it applies for pressure equipment and the following adopted regulations under the Safety Codes Act:

i. Pressure Welders Regulationsii. Administrative Items Regulationiii. Pressure Equipment Safety Regulationsiv. Pressure Equipment Exemption Order

AlterationAny change in the item described on the original Manufacturer’s Data Report orConstruction Data Report for Piping Systems that requires a change of design calculations or otherwise affects the pressure containing capability of the boiler, pressure vessel or pressure piping system. Non-physical changes such as an increase in the maximum allowable working pressure (internal and external) or design temperature of a boiler, pressure vessel or pressure piping system shall be considered an alteration. A reduction in minimum temperature of a pressure retaining item shall also be considered an alteration.

Authorized Inspection Agency (AIA)An Authorized Inspection Agency is one designated by, or acceptable to a jurisdiction.

Authorized Inspector (AI)An Inspector, employed by the ASME accredited authorized inspection agency, who is qualified by written examination in accordance with the ASME QAI-1 standard. The Authorized Inspector is also a Safety Codes Officer appointed by the Technical Administrator of ABSA, to administer the Alberta Safety Codes Act.

CodeLatest edition and addenda of the American Society of Mechanical Engineers ASME Code:

i. ASME B31.1 Power Pipingii. ASME B31.3 Process Pipingiii. ASME Section I Rules for Construction of Power Boilersiv. ASME Section II Materials

-Part A Ferrous Material Specifications-Part B Nonferrous Material Specifications-Part C Specifications for Welding Rods, Electrodes, and Filler Metals-Part D Properties

v. ASME Section IV Rules for Construction of Heating Boilersvi. ASME Section V Non-Destructive Examinationvii. ASME Section VIII, Division 1 Rules for Construction of Pressure Vesselsviii. ASME Section IX Welding and Brazing Qualificationsix. API-530




PAGE: 3 of 4

CompanyDCM Integrated Solutions Inc. (DCM Inc.)

CRNCanadian Registration Number; registration number allotted by the regulatory authority to designs and specifications when accepted and registered.

CSA B51Canadian Standards Association, latest edition and addenda of B51 Boiler, Pressure Vessel and Pressure Piping Code.

Designated WorkInstallation, alterations or repairs to pressure piping covered by the Boiler and Pressure Vessel Act.

EliotDCM Inc.’s intranet server, this is used for document control and administration of documents. Eliot also has databases for dealing with Instrument Management and Non-Conformities.

Job FileA file that contains all Code records and documents, which are essential to ensure the quality of the product. This file shall be assigned the number of each job. This number shall be a means of identifying each job file.

JurisdictionAs applicable to this Quality Manual, a municipality, state, provincial, federal or other enforcement or regulatory body having jurisdiction at the location of an installation establishing the mandatory applicability of the Code rules, in whole or in part, within their jurisdiction.

ManualWhen used within this document it refers to; Quality Management System Manual.

Manufacturer’s Data ReportA document in an accepted form by which a manufacturer certifies that a boiler, pressure vessel, fired-heater pressure coil and boiler external piping has been manufactured in accordance with a particular section of the ASME Code or Regulation. The document provides for a technical description of the item, and for counter signature by an authorized inspector where required.

Non-ConformityAny condition which renders an item unacceptable or indeterminate for use because it does not comply with the ASME Code, the Alberta Safety Codes Act and Regulations or this Quality Management System Manual. Examples of nonconformities include physical defects, improper documentation, and loss of material identification.

Procedure Qualification Record (PQR)A document that records the test results that establishes the properties of the weldment used to support the Welding Procedure Specification(s).




PAGE: 4 of 4

Quality Control (QC) InspectorAn employee of DCM Inc. that has the responsibility and authority to maintain a Quality Management System and to have the organizational freedom to recognize Quality Management System problems and to provide solutions to those problems.

Quality Control Supervisor (QCS)When used within the Manual may also refer to the PM, SS, QAM for small projects.

RegulationPressure Equipment Safety Regulation

Revision/Approved/Reviewed/Accepted/CertifiedWhen used within the Manual require a signature or initials, as well as the date.

Routing SheetForm containing the description of the designated work and the controls required by the contract specifications. When a significant number of controls are required an Inspection and Test Plan (form DCM-GU-AQ-02-A) will be annexed to the Routing Sheet

Small ProjectAny project for Designated Work that does not require the presence of a full time, dedicated Quality Control Supervisor as determined by the Quality Assurance Manager.

SNT-TC-1A“Recommended Practice for Non-destructive Testing Personnel Qualification and Certification” published by the American Society of Non-destructive Testing.

Welding ExaminerAn employee of DCM Inc. designated by the Quality Control Manager to perform the duties as defined in this manual. The Welding Examiner reports directly to the Quality Control Manager. The Welding Examiner must hold a valid Welding Examiner Certificate of Competency issued pursuant to the Pressure Welders Regulation.

Welding Procedure Specification (WPS)The document that describes in detail all of the variables which are essential, supplementary essential and non-essential to the welding process as specified by the ASME Code to provide direction to the welder or welding operator for making production welds in accordance with Code requirements. The WPS may be revised if there is a change in a non-essential variable. Any change to an essential or supplementary essential variable requires re-qualification of the WPS.

WQR/WOQRThe document (AB-76A/AB-76B) that records the testing conditions, qualification limits and test results of the Welder (AB-76A) or Machine Welding Operator (AB-76B) for a performance qualification test conducted in accordance with ASME Section IX.


SECTION: 1.4 – COPY OF CURRENT CERTIFICATEOF AUTHORIZATION PERMITS

REVISION DATE: 2012-03-12REVISION NUMBER: 0.0

PAGE: 1 of 2


SECTION: 1.4 – COPY OF CURRENT CERTIFICATEOF AUTHORIZATION PERMITS


PAGE: 2 of 2


SECTION: 2.0 – SCOPE OF WORKREVISION DATE: 2012-03-12


PAGE: 1 of 2

2.1 This Quality Management System Manual describes the Quality Management System as it applies to:

DCM Integrated Solutions Inc.#184, 2693 Broadmoor Blvd.Sherwood Park, AlbertaT8H 0G1

2.2 The objective of this program is to foresee, detect and correct non-conformities and to ensure that the installation, alteration and repairs of pressure piping or the repairs and alterations to existing boilers, heating boilers and pressure vessels (designated work) are executed in accordance with the Alberta Safety Codes Act and the project specifications.

2.3 The Quality Management System, as described in this manual, applies to the designated work.

2.4 ABSA is the Jurisdiction.

2.5 The scope of authority covered by the Quality Management System is defined as follows:

a. The installation, alteration and repair of boiler external pressure piping that is subject to the ASME B31.1 Power Piping and the B31.3 Process Piping Codes and the Alberta Safety Codes Act and the project specifications;

b. Repairs and Alterations to AB 513 existing power boilers, heating boilers and pressure vessels in accordance with the Alberta Safety Codes Act and Regulations, and insofar as possible, with ASME Section I, ASME Section IV or ASME Section VIII, Division 1, and AB 513 as applicable;

c. Performance qualification testing of pressure welders and machine welding operators employed by DCM Inc. or one of its named affiliate companies, in accordance with ASME Section IX and the Alberta Safety Codes Act and Regulations;

at Field Sites controlled from the above noted address.

2.6 Removed

2.7 Named Affiliate Companies:

The following represents the names of affiliate companies on behalf of DCM Integrated Solutions Inc. under the scope of this Quality Control Program:

DLI Inc., #184, 2693 Broadmoor Blvd., Sherwood Park, AB, T8H 0G1 Solimec Construction Inc., 8315 Devonshire, Mont-Royal, QC H4P 2L1 Dawcolectric Inc., 8315 Devonshire, Mont-Royal, QC H4P 2L1 JYNT Fabrication Inc., 1420 rue Joliot-Curie, Boucherville, Québec, J4B 7L9

Note: All forms and pertinent documentation in accordance with this Quality System Manual shall be issued in the name of DCM Integrated Solutions Inc.

2.8 Performance Qualification Testing of Pressure Welders and Machine Welding Operators

Para. 2.8 describes the procedure that will be used by DCM Inc. to conduct renewal performance qualification tests of Welders and Machine Welding Operators employed by DCM Inc. in accordance with the Alberta Safety Codes Act and Regulations and ASME Section IX.


SECTION: 2.0 – SCOPE OF WORKREVISION DATE: 2012-03-12


PAGE: 2 of 2

a. Welders/Machine Welding Operators shall be examined using welding procedures registered with ABSA.

b. Welders/Machine Welding Operators must be qualified using guided bend tests or by radiographic examination. Radiographic examination must not be used for the GMAW short circuit process.

c. DCM Inc. shall conduct performance qualification testing for our own employees or named affiliate companies only. DCM Inc. recognizes that when performance qualification cards are issued they are the property of the Welder/Machine Welding Operator and are valid if the Welder/Machine Welding Operator leaves the employment of DCM Inc. or its affiliated companies.

d. DCM Inc. shall subcontract all heat treatment and non-destructive examination.

2.9 Welding Examiner Qualifications

Para. 2.9 details the minimum qualifications of Welding Examiners who conduct and supervise performance qualification testing of Welders/Machine Welding Operators.

a. The Quality Assurance Manager is responsible for appointing the Welding Examiner(s). The QAM’s duties include:

i. Verifying that the Welding Examiner(s) has the necessary qualifications, experience, ability and education.

ii. Maintaining a file for each Welding Examiner containing all relevant documentation including a letter of appointment signed by a company official and accepted by signature of an ABSA Safety Codes Officer.

iii. Monitoring the standards employed by the Welding Examiner.iv. Providing written notification to ABSA, if any Welding Examiner’s employment is

terminated.

b. The Welding Examiner must hold a valid Welding Examiner Certificate of Competency issued by ABSA.

2.10 ABSA Safety Codes Officer

Para. 2.10 establishes the rights and responsibilities of the ABSA Safety Codes Officer.

a. The Quality Assurance Manager or designate is responsible for liaison with the ABSA Safety Codes Officer.

b. The ABSA Safety Codes Officer has access to areas where performance qualification testing of Welders/Machine Welding Operators is conducted. He/she has access to all documents and materials pertaining to Welder/Machine Welding Operator performance qualification tests described in this Quality Management System Manual.


SECTION: 3.0 - AUTHORITY & RESPONSIBILITYREVISION DATE: 2012-03-12


PAGE: 1 of 1

3.1 This manual certifies that Quality Management System, as described in this manual, is mandatory at DCM Inc. and that all pressure piping installation, alteration or repairs to existing boilers, heating boilers and pressure vessels are executed in full conformance with the Alberta Safety Codes Act, AB-518 document, and the project specifications.

3.2 The Quality Assurance Manager (QAM) is responsible for the application of the Quality Management System. The QAM will prepare, revise, approve, distribute and will ensure that all affected personnel are following the requirements of the Quality Manual and its controls.

3.3 The QAM is responsible for the conformity of the required exams, inspections, Non-Destructive Examination (NDE) and all other testing.

3.4 The QAM has the freedom to act, the authority and the responsibility to ensure that Quality Program is applied. The QAM is also responsible to identify any problems concerning the application of the program and to recommend, provide and initiate corrective actions to resolve these problems.

3.5 The QAM has the authority to stop work at any time if judged to be necessary.

3.6 To accomplish his functions the QAM has the full support of the president and the management team.

3.7 The Authorized Inspection Agency (AIA) will be advised if there is a change of the QAM.

3.8 Any differences in opinion between the QAM and management or site supervisors shall be brought to the attention of the undersigned for a resolution. The resolution must not compromise the requirements of the codes, acts, regulations and the project specifications.

3.9 Performance Qualification Testing of Pressure Welders and Machine Welding Operators

a. This Quality Management System Manual defines the organization and system employed by DCM Inc. to ensure that all Welders/Machine Welding Operators performance qualification tests, conducted field sites are in accordance with the Alberta Safety Codes Act, Pressure Welders Regulation, and ASME IX.

b. The Quality Control Manager is hereby appointed to administer the Welders/Machine Welding Operators performance qualification testing program. The Quality Control Manager and Welding Examiners assigned to conduct the performance qualification tests and issue performance qualification cards, pursuant to the Alberta Pressure Welders Regulation, have the organizational freedom, authority and responsibility to identify problems, and to initiate and provide solutions to problems concerning Welders/Machine Welding Operators performance qualification tests.

c. Any questions that arise concerning the implementation of the program for conducting Welders/Machine Welding Operators performance qualification tests that cannot be resolved through the Quality Control Manager shall be brought to my attention for resolution without compromising the ASME Code, the Alberta Safety Codes Act and Regulations and/or this Quality Management System.

d. This Quality Management System has my full support and shall be used for all Welders/Machine Welding Operators performance qualification tests conducted by DCM Inc.

President _____________________________ Serge Tousignant Date: _2012-03-12_

DCM Integrated Solutions Inc.


SECTION: 4.0 - CONTROL OF MANUAL & REVISIONSREVISION DATE: 2012-03-12


PAGE: 1 of 1

4.1 The objective of this section is to define how the Quality Management System Manual will be administered including the control of issues, reviews and revisions.

4.2 The QAM is responsible for the preparation, communication, distribution, and the updating of the controlled copies of the Manual as well as its’ revisions.

4.3 The QAM shall forward copies of the Manual according to the Manual Distribution List (form F4.1). The same control number as the one that appears on the distribution list of the Manual must appear on the first page of each Manual.

4.4 The new editions and addendums to the codes, the acts and regulations of the Jurisdiction are evaluated by the QAM in order to determine if revisions to the Manual are required. The evaluations are documented with the aid of the Control of Reviews, Revisions, and Addendums (form F4.3). When revisions are required they will be submitted to the Authorized Inspector (AI) for his approval prior to distribution to the holders of the Manual within a six (6) months delay of the publication of new edition and addendums.

4.5 All proposed revisions to the Quality Management System Manual shall first be approved by the QAM and submitted to the AI for review and acceptance prior to being issued and used. All revisions will be done by section of the Manual with the exception of the forms, specimens, procedures, and processes which are individually controlled (Section A – Forms; Section B – Procedures; Section C – Processes).

4.6 The revised sections of the Manual are distributed by the QAM to the holders of the Manual as outlined in the Manual Distribution List (form F4.1), with a revised table of contents page indicating the date and the number of the last revision of each section of the Manual as well as the date and signature of QAM and the AI.

4.7 All revisions to the Quality Management System Manual are done by the replacement of the outdated section or sections with the number of the revision indicated in the table of contents. A revision to a form will done by replacing it and indicating at the bottom the number of the revision as described in above article 4.5.

4.8 The revisions numbers shall be marked by a vertical line in the right margin beside the revised paragraph or paragraphs.

4.9 Should there be any discrepancies between the copies of the Manual; the AI copy will take precedence.

4.10 A controlled copy of the Quality Management System Manual will be available for review by the AI on each job site of an active project.

4.11 Non-controlled copies may be used outside the Company, however, they must be cleared marked “Non-controlled Copy” on the front page.

4.12 The Manual Revision Notice form (F4.2) will be used as a transmittal letter for the distribution of the Quality Management System Manual and its’ revisions to the outside holders of controlled copies. For internal controlled copies, the QAM will make the changes by hand in each copy.

Forms:F4.1 Manual Distribution ListF4.2 Manual Revision NoticeF4.3 Control of Reviews, Revisions, and Addendums


SECTION: 5.0 - ORGANIZATION & RESPONSIBILITYREVISION DATE: 2012-03-12


5.1 The organizational structure and lines of communication are shown on the attached Organizational Charts.

a. All personnel have the authority to perform their duties as described in this manual. Managers and Superintendents may delegate the performance of duties to those who report to them provided that they are qualified to perform the duties, however, the Manager or Superintendent shall retain the responsibility.

b. The Corporate QA/QC Manager has overall responsibility for the effective implementation of the Quality Control System in the Company, including field sites.

c. For a project scope to small to logistically justify full-time QC personnel, the Corporate QA/QC Manager shall provide oversight to the project and shall ensure the designated person is competent to perform the functions required.

5.2 Management Responsibilities

a. DCM Inc. management is committed to the development and implementation of a successful pressure piping and repair/alteration program and will endeavor to continually improve the effectiveness of the program.

b. The pressure piping construction program will be reviewed by management yearly to ensure the program is suitable and effective to the activities being performed.

c. Management will determine and provide adequate and competent resources, necessary facilities and equipment to effectively implement the pressure piping construction activities.

d. DCM Inc. is committed to creating an environment that encourages the involvement of personnel in the development of the quality processes.

e. DCM Inc. will ensure that responsibilities and authorities are defined and are communicated within the organization.




DCM INTEGRATED SOLUTIONS INC.QA/QC AUTHORITY STRUCTURE


SECTION: 6.0 - CONTROL OF SPECIFICATIONS, DESIGNCALCULATIONS, AND DRAWINGS


PAGE: 1 of 2

6.1 The objective of this section is to outline the responsibilities and procedures used for distribution control and revisions of drawings, calculations and specifications in order to ensure that the requirements of the codes, acts, regulations and the project specifications are met.

6.2 At the time of tender the CE is responsible for the verification of the specifications and drawings which must be approved by the client’s engineer confirming that the design conforms to the applicable codes, acts and regulations and project specifications.

6.3 In the case where the design is the responsibility of DCM Inc., the calculations and drawings will be subcontracted to a firm specializing and licensed in design engineering (DE). All the documents supplied by the DE shall be reviewed and approved by the PM or SS of DCM Inc.

6.4 During the annual review of the addendums or new issues of the codes, the client or the DE must incorporate any changes in design. After the issue of a new or revised code form (F4.3) will be up-dated and distributed to all of the holders of the manual form (F4.1).

The following information shall appear on the drawings and specifications: Applicable Code(s) with current edition and addendum The list of material including the material specification, type, grade or class, as required in the

applicable section of the Code. ASME B31.3 fluid category for process piping Weld designs and locations Bolted joint details Maximum and minimum Design pressures and temperatures. Operating pressures and temperatures when available. Hydrostatic or pneumatic testing, as required. Type and extent of NDE requirements Preheat and Post Weld Heat Treatment (PWHT) of welds if required. All other requirements of the Code. Project number. Drawing number and revision Each piping class shall refer to an Alberta Piping Registration Number (PRN) to ensure that

the design is registered with the Province.

6.5 If requested, the design calculations, drawings and specifications will be made available for review to the AI.

6.6 The Quality Control Supervisor (QCS) is responsible for the control of the distribution of the drawings and specifications as well as their revisions using the Drawing and Specification Control (form DCM-FO-AQ-101-A). Alternatively the distribution can be made using the clients’ forms (e.g. Specimen S6.1).

6.7 When a drawing or specification is revised, the distribution is controlled as per article 6.6. All out-dated documents must be identified as being void or must be destroyed by the QCS.

6.8 After completing a project one (1) copy of the last revision of the project documents will be maintained for reference. The latest revision of the execution drawings will be identified “as built” by the QCS.

6.9 Internal distribution of the drawings and specifications will be accomplished as follows: one copy to the CE (for tender only)one copy to the QCS


SECTION: 6.0 - CONTROL OF SPECIFICATIONS, DESIGNCALCULATIONS, AND DRAWINGS


PAGE: 2 of 2one copy to the PMone copy to the SSone copy to the Subcontractor (if required) three copies to the Jurisdiction (if required).

6.10 Any questions raised by the AI concerning the design calculations must be answered by the QAM.

6.11 Each project will be assigned a unique and sequential number which is identified in the contracts register by the AA.

6.12 If required, the project drawings, the design calculations and the specifications will be transmitted to the Jurisdiction for registration.

Forms:DCM-FO-AQ-101-A Drawing and Specification Control

Specimen:S6.1 Drawing and Specification Control - Specimen


SECTION: 7.0 - MATERIAL CONTROLREVISION DATE: 2012-03-12


7.1 The objective of this section is to ensure that only materials that conform to the requirements of the codes, acts, regulations and project specifications are used for the designated work.

7.2 The PM (or the SS) is responsible to complete the Material Requisitions form (DCM-FO-AP-03-A) in accordance with the material lists on the approved drawings and specifications. The PD is responsible to complete the Purchase Orders forms (e.g. Specimen S7.1) and to transmit the information to the suppliers. A copy of the purchase order will be forwarded to the supplier (when required).

7.3 The PM (or the SS) is responsible for the purchase of filler metals for welded joints. A material

requisition (form DCM-FO-AP-03-A) must be completed and transmitted to the PD who will then complete the purchase order and transmit the information to the suppliers. A copy of the purchase order will be forwarded to the supplier (when required).

7.4 The purchase order (Specimen S7.1) must include (or have annexed to) the following information: The project number The description and quantity of the materials to be ordered. The material specifications, grade, type or class if applicable and if required by all special

requirements. Requirements for obtaining the applicable material certification, such as mill test certificates,

letters of conformity, etc. Requirement that the fittings are registered with ABSA and have a CRN for installation in

Alberta.

7.5 A copy of the completed purchase order or the requisition (identifying the purchase order number and details) is distributed to the PM (or the SS) and the SRS.

7.6 Any alterations or revisions to a purchase order must be done in accordance with the original issuing and distribution procedures of this section of the manual.

7.7 All material will be held in a receiving area until it has been inspected and identified with the project number.

7.8 Using the purchase order or the requisition, along with Reception Inspection form (DCM-FO-AQ-07-A), the QCS will be responsible to verify that the material received conforms to the specifications, dimensions and quantities and has no visual defects. The QCS shall also ensure that material received is identified with the project number.

7.9 Material traceability is required. The QCS must verify that the mill test certificates conform to all applicable specifications. The QCS must also ensure that CRN numbers are provide when required.

7.10 Acceptance of the material is documented on the copies of the packing slips, Reception Inspection form (DCM-FO-AQ-07-A), as well as the mill test certificates. Once the QCS signs and dates the packing slips then the material is considered accepted. The documents must be placed in the project quality file and be at the disposal of the AI for review.

7.11 In the case where one or several pieces of material do not conform to the purchase specifications and are judged to be not acceptable to the purchasing specifications by the QCS then the material must be clearly marked “NC”. The QCS will complete a Non-Conformity Report, form (DCM-FO-AQ-01-A), and will send a copy to the PD who will then advise the supplier. The procedures to be followed for non-conformities are described in Section 16.0 of this manual.

7.12 When possible, non-conforming materials will be put in a quarantine area while awaiting a decision




on the corrective action. The procedures described in section 16.0 of this manual shall be followed.

7.13 After the material is received and approved, copies of the mill test certificates must be forwarded to the client or the DE to confirm their approval (if required).

7.14 The QCS (or the Administrative Assistant AA) is responsible for the filing of the mill test certificates in the quality dossier of each respective project.

7.15 Only materials that have been correctly identified and documented may be used for the designated work.

7.16 All documents referred to in this section of the Quality Management System Manual are to be made available for review and acceptance by the AI and/or the client if so required.

7.17 Any additional tests on materials that may be required upon receipt or during the installation shall be indicated on the Piping Data Report (PDR). For Alberta this is the latest revision of the AB-83 from ABSA.

7.18 Material taken from the warehouse inventory must be re-inspected by the QCS in order to verify that it meets the project specifications. The requirements of articles 7.8 to 7.11 must be repeated during the inspection.

7.19 Material Segregation:

a. The QCS is responsible for ensuring that all pipe material is either physically segregated, manually marked by stamp or paint stick, or is colour coded by a paint stripe over the full length, depending on the projects complexity and requirements.

b. The Colour Coded Markings Table (Exhibit 7.1) can be established for a project if so determined by the QCS or QAM.

c. The QCS is responsible to ensure that the correct colour code is provided to site personnel and that the Colour Coded Markings Table is made available to all project personnel and that it is posted where required.

d. If required by the owner’s specifications, an alternate colour code may be used or the material specification and grade shall be marked on each piece, prior to the cut.

7.20 Material Control for the Performance Qualification Testing of Pressure Welders and Machine Welding Operators

Para. 7.20 details the requirements for ordering, identification, receiving, storing, issuing and controlling traceability of materials used for Welder/Machine Welding Operator performance qualification testing.

a. The Welding Examiner is responsible for receiving and storing all the material used for performance qualification testing. The duties include:

Inspecting all received material for damage and correct material identification and thickness against purchase order.

Physical segregation, manually marking or colour coding, cutting, machining and storing the material in a manner that will maintain traceability.

Checking the material test report to ensure that it meets the requirements of ASME Section II.




Checking that all welding consumables received comply with the Purchase Order and are identified with the manufacturer’s name, SFA specifications, AWS classification and size. Unidentified spools, containers, or electrodes are unacceptable and are to be returned to the supplier or discarded.

Ensuring that all welding consumables are stored according to the manufacturer’s specification until they are used.

Forms:DCM-FO-AP-03-A Material RequisitionDCM-FO-AQ-01-A Non Conformity ReportDCM-FO-AQ-07-A Reception Inspection

ABSA Form:AB-83 Pressure Piping Construction and Test Data Report

Exhibits:Exhibit 7.1 Colour Coded Markings Table

Specimen:S7.1 DCM Purchase Order – Specimen




EXHIBIT 7.1 COLOUR CODED MARKINGS TABLE


SECTION: 8.0 - WORKING METHODSREVISION DATE: 2011-09-20


PAGE: 1 of 2

8.1 The objective of this section is to ensure that the designated work conforms to the codes, acts, regulations and project specifications.

8.2 The QAM is responsible for the implementation of the inspection program as well as the test procedures.

8.3 The PDR form (AB-83) is prepared by the QAM. The Piping Inspection Report (PIR) form (DCM-FO-AQ-102-A) is prepared by the QCS.

8.4 The QCS is responsible to ensure that the designated work is verified and inspected according to the requirements of PDR and the PIR. The QCS also has the authority to carry out any additional inspection as he may deem necessary during the project.

8.5 The PIR form (DCM-FO-AQ-102-A) shall identify where inspections and tests are required. The PDR form (AB-83) must always accompany the PIR. For designated work associated to boiler external piping in the Province of Alberta the Inspection and Test Plan (form DCM-GU-AQ-02-A) will be submitted to the AI for review and Hold Point identification prior to commencing the work.

8.6 The PDR form (AB-83) shall contain the following information:

DCM Inc. and the project number Client’s name Project address Type of work Pressure Piping characteristics Description of pressure vessels associated with the piping including CRN registration (when

required) Material description Accessories description Welding, NDE and heat treatment requirements Pressure test requirements

8.7 The PIR form (DCM-FO-AQ-102-A) shall contain the following information:

DCM Inc. and the project number Client’s name Service Line number References to specifications The description of required inspections and tests. Identification of the Hold Points (HP) The requirements for permanent line identification A column reserved for the signature and inspection dates carried out by the QCS and the

client (when required).

8.8 Following the work progress, each inspection point must be signed and dated on the PIR in order to indicate that the work has been accepted.

8.9 The Site Supervisor (SS) is responsible to advise the QCS prior to arriving at an HP.

8.10 All revisions to PDR and the PIR must be done in accordance with the original issuing procedures.

8.11 The QCS shall ensure that only accepted and specified material is used during the project.


SECTION: 8.0 - WORKING METHODSREVISION DATE: 2011-09-20


PAGE: 2 of 28.12 The weld traceability and the material traceability must be indicated or annexed to the isometric or

equipment drawings by the QCS. Alternatively, the weld traceability can be recorded on the Weld Report form (DCM-FO-AQ-104-A) depending on the type of project. The QCS shall ensure that all prefabricated pressure piping is supplied with a conformance certificate.

8.13 Non-conformities will be treated as per section 16.0 of this document.

8.14 The QCS is responsible to ensure and document the conformity of all tests and final inspections.

8.15 The QCS shall complete a daily log with a description of the work. Form (DCM-FO-AQ-103-A) must be completed containing the following information:

Client’s name Project Number RS number Description of the work Date of the work Installation approval

Depending on the type of project the daily log can also be recorded on Weld Report form (DCM-FO-AQ-104-A) or any client form containing the information.

8.16 The QCS shall make sure that all of the documentation certifying the conformity of the installation is made available to the AI for review.

Forms:DCM-FO-AP-102-A Piping Inspection ReportDCM-FO-AQ-103-A Daily Log RegisterDCM-FO-AQ-104-A Weld ReportDCM-GU-AQ-02-A Inspection and Test Plan



SECTION: 9.0 - REPAIRS AND ALTERATIONS TO BOILERSAND PRESSURE VESSELS


PAGE: 1 of 5

9.1 This section describes the system for controlling the repairs and alterations of existing boilers and pressure vessels. All other sections of this Quality Management System Manual shall apply for repairs and alterations, except as modified in this section.

9.2 All repairs and alterations shall be in accordance with the Alberta Safety Codes Act, and, insofar as possible, ASME Section I, ASME Section IV or ASME Section VIII Division 1, as applicable.

9.3 The QAM or QCS will develop a written procedure for all repairs and alterations containing the following information:

Boiler or pressure vessel description Year built A number CRN Manufacturer Owners name and Owner's boiler or pressure vessel identification number when applicable Location of pressure vessel or boiler Detailed description of the repair and alteration methods Weld details Welding procedure specification number Material used by specification number, grade, and size NDE requirements PWHT requirements Pressure test requirements Any additional requirements

The repair or alteration report (AB-40) may be used to detail the repair or alteration procedure when suitable.

9.4 The information required for developing the procedure identified in 9.3 above may be found on the nameplate or the MDS which should be available from the owner.

9.5 The QAM or QCS shall obtain acceptance of the repair or alteration procedure from the ABSA Safety Codes Officer prior to the start of work. When required by the ABSA Safety Codes Officer, this procedure shall be submitted to the ABSA Design Survey Section for acceptance. The QAM or QCS shall ensure copies of all latest repair or alteration procedures, drawings and instructions are provided to the personnel responsible for the repair or alteration.

9.6 ABSA Authorized Pressure Equipment Integrity Quality Management Systems

a. When field or plant site repairs are performed for an organization with a valid Certificate of Authorization Permit issued by ABSA for an Owner-User Pressure Equipment Integrity Quality Management System, the QAM shall establish who will be responsible for the ASME Code inspections when the contract is initiated (whether ABSA Safety Codes Officer or Owner-User Inspector performs ASME Code required inspections). Owners that have an ABSA Owner-User Certificate of Authorization Permit may be authorized to perform the repair and ASME Code inspections that are otherwise performed by an ABSA Safety Codes Officer. The scope of permitted Owner-User inspections is defined in the organization’s Pressure Equipment Integrity Quality Management System Manual and this is limited to repairs done at their facilities only. An Owner-User may elect to have all repair ASME Code inspections conducted by ABSA.




PAGE: 2 of 5b. The ABSA Safety Codes Officer and the Owner-User Inspector shall be notified prior to the

start of work to accept repair methods and designate any hold and inspection points. The ABSA Safety Codes Officer may require that the repair procedure be submitted to the ABSA Design Survey Section for acceptance.

c. The ABSA Safety Codes Officer and/or the Owner-User Inspector shall be notified of all nonconformities.

d. The ABSA Safety Codes Officer or the Owner-User Inspector is required to inspect the repair and certify the repair or alteration report. DCM Inc. shall complete and certify this report for all repairs. Owner-User Certification of Compliance shall also be obtained when applicable.

9.7 If the boiler or pressure vessel is still under warranty, the QAM or the QCS will contact the Owner to obtain acceptance of the proposed work from the boiler or pressure vessel manufacturer.

9.8 For alterations, the DE will prepare detailed design calculations and drawings in accordance with the applicable referenced ASME Code section. The QAM shall submit the alteration procedure, design calculations, and drawings to ABSA Design Survey Section for acceptance prior to starting work.

9.9 The PD is responsible for ordering all material. The PD shall prepare a Purchase Order form (Specimen S7.1) from the repair or alteration drawing or procedure. The purchase order shall include:

Purchase Order numberMaterial ASME specification number, grade, schedule, dimensionsRequest for material test reports for shells, heads, repads and other pressure retaining material

and pipe material used for pressure vessel shells.Request for partial data reports for welded parts supplied by others.Request for certification to ASME Section VIII, Division 1 paragraph UCS 79 (or paragraph UHT

79, where applicable) for cold formed heads, shells and other pressure parts cold formed from carbon and low alloy steel plates for pressure vessel use.

Instructions that a welding procedure qualified to ASME Section IX must be used for all tack welds.

Heat treatment requirementsNDE requirementsStatement that all fitting designs must be registered with the ABSA or the applicable jurisdiction

as required.Other job specifications

Any proposed material substitutions must be approved in writing by the Owner, the Designer and ABSA Safety Codes Officer, when applicable.

9.10 The QCS is responsible for receiving of all material. His/her duties include:

a. Checking all material received against the purchase order and packing slip for visible damage, correct identification, markings, dimensions, thickness, ASME material specifications and grade.

b. Identifying all acceptable material with a job number and highlighting the material specification and grade stamping by circling with a waterproof marker.




PAGE: 3 of 5c. Verifying that the material is as specified on the drawings and conforms to ASME Code

requirements.

d. Confirming that the material identification markings conform to the material test reports and/or partial data reports.

9.11 The QCS is responsible for identification and traceability of all materials. His/her duties include:

a. Recording the material specification number, grade, thickness, etc. on the Repair or Alteration Examination and Inspection Sheet form (DCM-FO-AQ-105-A). In addition to this information heat and slab numbers shall be recorded for all shell, head and plate pressure retaining material, and any pipe used for pressure vessel shells.

b. Ensuring that material identification markings are transferred prior to dividing any material. This identification shall be die stamped for carbon steel material 1/4" and over. For other material, identification shall be by waterproof marker.

c. Checking, with templates, the dish and knuckle radii of replacement formed heads.d. Verifying that the material test reports include physical tests and chemical analysis and

conform to ASME Section II requirements. If the Material Test Reports (MTRs) conform to Section II, the QCS will sign and date the MTRs.

Note: Material Test Reports are required for all pressure retaining plate material and pipe shells.

e. Ensuring that all pipe material is identified by an approved means such as physical segregation, physical markings, or colour coded by a paint stripe over the full length as stipulated in the material control section of this Quality Management System Manual. To ensure identification to the specification and grade, for product forms such as couplings and nozzle pieces and attachments, each piece may be marked or stamped with the specification and grade or a coded marking acceptable to the ABSA Safety Codes Officer (or Owner-User Inspector when applicable) may be used per Exhibit 9.1.

f. Ensuring that fittings are identified by job number and stored by the job.

9.12 The QAM or the QCS is responsible for the examination and inspection program. His/her duties include:

a. Initiating a job file to include the Repair or Alteration Examination and Inspection Sheet, material reports, drawings, calculations, material test reports, non-destructive examination (NDE) reports, heat treatment (HT) reports, manufacturer’s data reports, and material receiving reports.

b. Initiating a Repair or Alteration Examination and Inspection Sheet form (DCM-FO-AQ-105-A) for each repair and alteration and presenting it to the ABSA Safety Codes Officer (and/or Owner- User Inspector when applicable) with drawings, specifications and calculations prior to the start of the job.

c. Notifying the ABSA Safety Codes Officer (and/or Owner-User Inspector when applicable) reasonably in advance of any hold points. Work shall not proceed beyond an established hold point until the ABSA Safety Codes Officer (and/or Owner-User Inspector when applicable) has released the hold by signing the Repair or Alteration Examination and Inspection Sheet.

d. Performing all examination functions specified on the Repair or Alteration Examination and Inspection Sheet and signing and dating each function when it is completed.

e. Verify that applicable material is identified with specifications and heat numbers and that these heat numbers are transferred and remain traceable throughout the repair or alteration.




PAGE: 4 of 5f. Verify that material contains no visible defects and is as specified on the drawings or repair

or alteration procedure. If material nonconformities are found, the ABSA Safety Codes Officer (and/or Owner-User Inspector when applicable) must accept all material repair procedures prior to commencement.

g. Ensure that material test reports are available for all pressure plate material and for all pipes used for pressure vessel shells and additional components as required by the customer.

h. Ensuring alignment tolerances are maintained during the repair or alteration.i. Weld details are correct.j. Non-destructive examination is performed in accordance with Section 11 of this Quality

Management System Manual and the referencing ASME Code Section.k. Heat treatment instructions are prepared in accordance with Section 12 of this Quality

Management System Manual and the referencing ASME Code Section, and heat treatment charts comply with instructions.

l. The correct hydrostatic test pressure, as indicated on the accepted repair or alteration procedure, is applied.

9.12 When required by the ABSA Safety Codes Officer (and/or Owner-User Inspector when applicable), an identification plate (Exhibit 9.2) will be attached to the pressure vessel or boiler adjacent to the pressure vessel or boiler manufacturer’s nameplate with the following information:

a. Repaired, Altered or Re-ratedb. Name of repair or alteration organizationc. Date of repair or alterationd. Maximum allowable working pressure and temperaturee. Minimum design metal temperature and pressure (when applicable)f. CRN

9.13 Upon satisfactory completion of the repair or alteration report, the QCS shall complete and certify the repair or alteration report (AB-40) and present it to the ABSA Safety Codes Officer (and/or Owner-User Inspector, when applicable) for acceptance. A copy of the Repair or Alteration Report shall be provided to the ABSA Safety Codes Officer and the Owner.

9.14 The QAM shall assign a separate job number and file for each boiler or pressure vessel repaired or altered. The file will contain the following information:

a. Drawingsb. Calculationsc. Repair or alteration procedured. Purchase orderse. Material test reportsf. NDE reports, radiographic film and copies of Examiners’ certificationsg. Heat treatment instructions and chartsh. Weld identification records (when welds are not stamped) and copies of Welders/Machine

Welding Operators performance qualification cardsi. Nonconformity reportsj. Examination and inspection sheetk. Repair or alteration report with partial data reports when applicablel. Pressure gauge/recorder calibration records

9.15 The job file shall be retained for a minimum of 5 years.




PAGE: 5 of 5 Forms:

DCM-FO-AP-105-A Repair or Alteration Examination and Inspection Sheet

ABSA Form:AB-40 Boilers and Pressure Vessels Repair or Alteration Report

Exhibits:Exhibit 9.1 Coded MarkingsExhibit 9.2 Sample Nameplate for Repairs or Alterations

Specimen:S7.1 DCM Purchase Order

EXHIBIT 9.1 CODED MARKINGS Material Coded Marking (Nozzles, Couplings Welded attachments)

SA 105 (5)SA 350 LF2 (2)SA 106 B (6)SA 333 Gr 6 (3)SA 36 (4)

EXHIBIT 9.2 SAMPLE NAMEPLATE FOR REPAIRS AND ALTERATIONS

by DCM Integrated Solutions Inc.(Identify Here the “Repair”“Altered or “Rerated” as

Applicable)

MAWP at temp.IndicateUnits

MDMT at pressure

CRN

Date work completed.

Note: Markings shall be produced by casting, etching, embossing, debossing, stamping or engraving. Letters and numbers must be at least 5/32" high.


SECTION: 10.0 - WELDING MANAGEMENT SYSTEMREVISION DATE: 2012-03-12


PAGE: 1 of 5

10.1 The objective of this section is to establish control of the welding operations. These operations must conform to the requirements of Section IX of the ASME Code as well as any additional requirements in other applicable sections of the Code, depending on the types of work carried out and the requirements of the project specifications

10.2 The Welding Procedures Specifications (WPS) and their revisions are specified by the QAM before being used in contracts for the installation, alteration or repairs to pressure piping. These procedures numbers appear on the RS, the PIR (form DCM-FO-AQ-102-A) and/or Weld Report (form DCM-FO-AQ-104-A) and/or on the Non-Conformity Report (form DCM-FO-AQ-01-A) (if applicable).

10.3 The QAM is responsible to prepare and revise the WPS and to submit them to the Jurisdiction for review and acceptance.

10.4 After the WPS is reviewed by the Jurisdiction, the QAM is responsible to qualify the WPS by the welding of a test coupon as per the applicable code. The QAM is responsible to prepare the test coupons and to register the data utilised to weld the coupons. The QAM is responsible to advise the AI so that he may witness the welding of the weld coupons. The qualification tests are given to third party laboratory. The QAM shall complete the procedure qualification record (PQR) and he must certify that the test results meet the requirements of the Code.

10.5 For each WPS the description of the welding method must contain the essential variables, supplementary variables (when required) and non essential variables, as specifically outlined in Section IX of the ASME Code.

10.6 In order to adapt to the production requirements, changes to the description of the WPS can be made to the non essential variables without having to re-qualify the procedure. These changes must however be documented, either by a revision to WPS or by the issue of a new WPS.

10.7 The QAM shall certify that the WPS conforms to section IX of the ASME Code and must submit them to the Jurisdiction for registration. The WPS and the PQR shall be made available for review by the AI. The AI has the authority to request a re-qualification of a welding procedure. The PQR must identify all of the actual variables used during the welding of the test coupon.

10.8 Copies of the WPS are issued to the PM, SS and the QCS. The SS has the responsibility to train and supervise welders and to assign them to the appropriate work based on their certifications and competence. The QCS will ensure that the welders are using the specific WPS approved for the work. No welding can be undertaken on pressure piping until the WPS has been approved by the Jurisdiction and registered.

10.9 The QAM is responsible for specifying the WPS to be used. The WPS used for each stage of the work must be indicated on the PIR or on the Weld Report form including the revision number.

10.10 When a WPS requires a name or address change the WPS must be revised with the new information and revision number. The PQR will remain the same. The Welder Qualifications (WQ) must be revised to reflect the new changes and must be dated and signed.

10.11 The QAM is responsible organize the WQ tests as well as their renewal. The QAM and/or the AI will witness each WQ test. The QAM will register the data in a WQ test report. The test report must include the essential variables, the types of tests, the test results and the range of qualified thicknesses. The conformity of the reports to the Section IX of the ASME code must be certified by the QAM.




PAGE: 2 of 5

10.12 At his/her request, the AI can witness the WQ tests and he has the right to request the re-qualification of a welder.

10.13 The QAM will provide each welder with an identification symbol. Welders must stamp, or mark with paint marker, their identification number adjacent to the weld (not to exceed 3 feet). Stamping is forbidden on ferrous materials if the thickness is less than ¼” and ½’’. for non-ferrous materials. When stamping is not permitted the QCS must indicate the welder’s identification on the isometric drawings for each weld.

10.14 The QAM shall maintain a list of welders on the Welder Qualification Continuity Register form (DCM-FO-AQ-106-A).

10.15 Each month the QAM shall update the Welder Qualification Continuity Register with the project numbers for each welding procedure used by the welders.

10.16 All welding procedures are at to be made available to the welders for their information and review.

10.17 The validity of the welder’s qualifications is affected by the following conditions:

a. When a welder has not performed any welding on a specific WPS for a period of 6 months or more, his qualification for this procedure will expire.

b. Should there be a reason to doubt that a welder has the ability to meet the requirements of the WPS, his certification shall be revoked.

10.18 Tack welds used to maintain joint alignment shall be completely removed once they are no longer necessary. If the tack welds are to be incorporated into the final weld, then the start and stop areas shall be adequately prepared by grinding or other acceptable means.

10.19 Whether they are removed or not, all tack welds must be welded by qualified welders in accordance with an approved WPS. Tack welds that are not removed must be visually examined and any visible defects must be removed.

10.20 The PM or the SS shall specify on the Material Requisition form (DCM-FO-AP-03-A) the filler metals that are to be purchased. Only filler metals certified in accordance with ASME code, section II, part C can be purchased. The ASME designation for the filler metals must appear on the requisition form.

10.21 The purchased filler metals must conform to the type that is identified on the approved WPS.

10.22 Using the purchase order as a reference, the QCS shall verify all filler metals upon delivery to ensure that:

The quantity and description are as per the purchase order There is a reference to the applicable SFA The packaging seals are intact. They are not damaged

10.23 Once the filler metals have been accepted, the QCS shall stamp each container with “OK”. The packing slip shall be signed, dated and kept in the project quality file.

10.24 In the case that the filler metals do not conform to the requirements mentioned in article 10.22, they will be removed from the site and/or from the warehouse and given to the PD who will return them to the supplier. A non conformity report will be issued and processed as per section 16.0 of this manual.




PAGE: 3 of 5

10.25 The QCS is responsible for the control of the welding consumables. All filler metals must be stored at the manufacturer’s recommended temperature. Once the containers of filler metals have been opened, they shall be protected in a main oven order to prevent contamination from dirt, oil, grease, water, etc.

10.26 Filler metals removed from their containers to be used during the welding process shall be stored in portable ovens to maintain the recommended manufacturer’s temperature. At the end of the welding process only the filler metals that have been stored in functional portable ovens may be returned to the main ovens for re-use. Filler metals that are damaged or are wet must be discarded.

10.27 Special attention to the manufacturer’s recommendations shall be applied for filler metals with low hydrogen content.

10.28 All information described in this section of the manual shall be made available for review by the AI.

10.29 Named Affiliate Companies

For Welding Procedure Specifications and Welder Performance Qualifications Records qualified by a Named Affiliate Company (per QMS Manual Section 2.0, Para. 2.7) , the following Code operations control requirements shall be satisfied:

a. Welding Procedure Specifications that are properly qualified by a Named Affiliate Company may be used, as submitted without deviation, by DCM Inc. after review and acceptance by the QAM to ensure that they comply with the construction Code and ASME Section IX. Procedure Qualifications Records and all test documentation shall be part of the documents reviewed and accepted by the QAM. If changes to essential variables are required, the WPS shall be returned to the Named Affiliate Company for re-qualification. If DCM Inc. desires, they may re-qualify a new Welding Procedure Specification as specified in this Quality Manual.

i. DCM Inc. assumes all responsibility for Code compliance when using Welding Procedure Specifications qualified by the Named Affiliate Companies.

ii. Authority granted under ASME Code, Section IX, paragraph QW-201.b. Welders qualified by a Named Affiliate Company may be used by DCM Inc. if the following

conditions are satisfied:i. A copy of the Welder’s original performance qualification record is on file with

the Company.ii. The Named Affiliate will submit a copy of the welder’s continuity record to

DCM Inc.iii. Re-qualification can be required by the Named Affiliate Company or DCM Inc.iv. The QAM shall review and accept the qualification records for welders qualified

by the Named Affiliate Company before their use by the DCM Inc.v. DCM Inc. assumes all responsibility for Code compliance for Wilders qualified

by the named Affiliate Company that are used by DCM Inc.vi. Authority granted under ASME Code, Section IX, paragraph QW-300.2.




PAGE: 4 of 5

10.30 Welder/Welding Operator Performance Qualification Testing

Para. 10.30 details the activities, procedures and requirements for performance qualification testing of Welders/Machine Welding Operators.

a. Responsibilities:i. The Quality Assurance Manager is responsible for implementing and maintaining

this procedure.ii. The Quality Assurance Manager is responsible for appointing the Welding

Examiner.iii. All parts of the performance qualification testing of Welders/Machine Welding

Operators shall be conducted and supervised only by those persons that have been appointed as a Welding Examiner. A Welding Examiner shall not issue a Performance Qualification Card to himself/herself.

b. Method:i. Prior to the performance qualification test, the Welding Examiner shall:

a. Review the candidate’s qualifications to ensure the candidate has an Alberta “A” or "B" Pressure Welder's Certificate of Competency, or Machine Welding Operator’s Certificate of Competency.

b. Make a photocopy of the candidate’s Certificate of Competency. c. Select the welding procedure to be used.d. Fill in the appropriate parts of the Welder/Welding Operator Qualification

Record (AB-76A or AB-76B).e. Issue a copy of the Performance Qualification Examination and Test

Procedure to the candidate (DCM-PR-AQ-06-A).f. Issue a copy of the Welding Procedure

Specification to the candidate.g. Assign a set of test coupons to the candidate.h. Assign a test area to the candidate.

ii. During the performance qualification test, the Welding Examiner shall:a. Verify the joint preparation including land and gapb. Check the position of the test couponsc. Verify welding machine set-up including voltage/amperage for specific

electrode size in accordance with the specified WPS.d. Assess the tack welds for length and featheringe. Complete the applicable section of the Welder/Welding Operator Qualification

Record (AB-76A or AB-76B).f. Monitor the root pass to ensure it is done in the correct position and

direction, and assess the root pass for quality (penetration, fusion, undercut, profile and spatter)

g. Monitor the hot pass, fill and cap to ensure welding is done in position and within the prescribed time frame.

iii. After the performance qualification test welding, the Welding Examiner must assess the weld quality by examining the completed weld for reinforcement, weld profile, arc strikes, weld width and undercut.

IF BEND TESTS ARE TO BE USED FOR TESTING:

The Welding Examiner shall:a. Identify the test specimens to be cut out and die stamp them for positive

identification of specimen number and candidate




PAGE: 5 of 5b. Monitor specimen preparation

c. Examine specimen acceptability for width and thicknessd. Verify the guided bend test jig for correct tolerancese. Complete the required bend testsf. Assess the acceptability of guided bend tests against acceptance criteriag. Complete the applicable portion of form Welder/Welding Operator

Qualification Record (AB-76A or AB-76B).

IF RADIOGRAPHIC TESTS ARE TO BE USED FOR VERIFICATION:

The Welding Examiner shall:a. Identify test coupons to be radiographed and die stamp them with the

candidate’s Identification.b. Ensure ASME Section IX requirements are met when radiography is used

to qualifyc. Review radiographic film and reports when radiography is used for

performance qualification testingd. Complete the Welder/Welding Operator Qualification Record (AB-76A or

AB-76B).e. Issue and sign a Welder Performance Qualification Card form (DCM-FO-

AQ-115-A) if the test is satisfactoryf. Identify all failed coupons and store them for a minimum of 90 days after

completion of the test.

iv. If a candidate is not satisfied with the performance qualification test, he/she may make a written complaint to the Administrator of ABSA.

v. If a Welder/Machine Welding Operator loses his/her performance qualification card issued by DCM Integrated Solutions Inc. and requires a duplicate, the Welding Examiner is responsible for a. Verifying that the Welder/Machine Welding Operator did perform a satisfactory

performance qualification test and b. Will issue a duplicate performance qualification card after the Request for

Duplicate Welder Performance Qualification Card form (DCM-FO-AQ-116-A) is completed.

c. The card must expire on the same date as the original card.

Procedures:DCM-PR-AQ-06-A Performance Qualification Examination and Test Procedure

Forms:DCM-FO-AP-03-A Material RequisitionDCM-FO-AQ-01-A Non Conformity ReportDCM-FO-AQ-102-A Piping Inspection ReportDCM-FO-AQ-104-A Weld ReportDCM-FO-AQ-106-A Welder Qualification Continuity RegisterDCM-FO-AQ-115-A Welder Performance Qualification CardDCM-FO-AQ-116-A Request for Duplicate Welder Performance Qualification Card

ABSA Forms:AB-76A Welder Qualification RecordAB-76B Welding Operator Qualification Record


SECTION: 11.0 - NON-DESTRUCTIVE EXAMINATIONSREVISION DATE: 2012-03-12


PAGE: 1 of 2

11.1 This section describes the requirements of non-destructive examination (NDE) in order to ensure that the activities conform to the requirements of the codes, acts, regulations and project specifications.

11.2 The QAM (or the QCS) shall determine the NDE requirements based on the project specifications. NDE requests are to be requested using the NDE Request Form (DCM-FO-AQ-111-A). The NDE levels and other requirements must be specified on the PDR (AB-83) with the procedure and revision number.

11.3 All NDE shall be performed by a specialized firm that shall supply qualified personnel, who are certified according to the requirements of CGSB or SNT-TC-1A standards. The NDE procedures shall be submitted and approved as required by the construction code article T-150, section V of the ASME Code. A copy of the registered procedures will be kept on file by the QCS.

11.4 The NDE examiner (level II/III CGSB or SNT-TC-1A) is responsible for the preparation and qualification of the following NDE procedures:

Ultrasonic (UT) Dye Penetrant (PT) Magnetic Particle (MT) Radiography (RT) Positive Material Identification (PMI) Eddy Current Ferrite Inspection

11.5 The NDE examiner (level II/III CGSB or SNT-TC-1A) is also responsible for the qualification and certification of NDE technicians.

11.6 The QAM will keep the following information on file for each specialized firm subcontracted to perform NDE activities.

The qualification of the NDE technicians A copy the NDE personnel’s eye exams results. (view and colour contrast) The NDE procedures which are used and approved by the subcontractor.

11.7 The specialized NDE firm shall supply a report, certified by a examiner (level II/III CGSB or SNT-TC-1A) for all NDE performed. The QCS must ensure that the NDE technicians possess an up-to-date qualification card or certificate. The QCS must also verify that the NDE report is dated and signed.

11.8 The AI may request the re-certification of NDE personnel and the re-qualification of the procedures.

11.9 Welder/Welding Operator Performance Qualification Testing

Para. 11.9 describes the radiographic examination that must be used to qualify Welders/Machine Welding Operators as an alternative to the guided bend test.

Interpretation of radiographic film must be performed to the standards specified in ASME Section IX.

a. The Quality Control Manager is responsible for appointing all NDE subcontractors and must specify that:


SECTION: 11.0 - NON-DESTRUCTIVE EXAMINATIONSREVISION DATE: 2012-03-12


PAGE: 2 of 2

i. All personnel performing NDE must be qualified and certified in accordance with SNT-TC-1A or CGSB.

ii. There be a level III examiner on staff to be responsible for NDE procedures and supervise examiner certification and training.

iii. That all examination is done under the supervision of a level II or level III examiner.iv. That all interpretation be done by a level II or level III examiner.

b. The Welding Examiner is responsible for liaison with the NDE subcontractor. His/her duties include:

i. Reviewing the qualifications of NDE examiners and their company’s written procedures and ensuring copies of qualifications and procedures are retained on file.

ii. Notifying the examiners of NDE requirements.iii. Identifying the welds to be examined.iv. Reviewing all NDE reports and radiographic film.v. Ensuring that the radiographs are traceable to the weld coupon.

Forms:DCM-FO-AQ-111-A NDE Request Form



SECTION: 12.0 - POST WELD HEAT TREATMENTREVISION DATE: 2012-03-12


PAGE: 1 of 2

12.1 The objective of this section is to specify the method and controls used in order to ensure that all preheating and post weld heat treatment work is performed in accordance with codes, acts, regulations and project specifications.

12.2 The preheating and post weld heat treatment activities will be subcontracted out to a firm specializing in this type of work. In some case the preheating will not be subcontracted and the work will be done by DCM Inc. personnel.

12.3 The QCS shall produce and supply specific written instructions to subcontractor describing the heating cycles and controls required by the project specifications. All instructions pertaining to the preheating (optional) and the post weld heat treatment requirements will be documented on the Heat Treatment Form (DCM-FO-AQ-110-A).

12.4 The written instructions shall include the following information:

The maximum cycle starting temperature. The rate of heating and cooling. The length of time maintained at the specified maximum temperature and allowable

tolerances. The location and method used to attach and remove the thermal couplings. The maximum cycle end temperature. The required documentation, such as the recording chart or band. The order number or the

relevant contract number must be identified on these documents and signed and dated by the technician or the subcontractor’s authorized personnel.

The preheating instructions shall include:

The heating method used (ex. induction, torch, heat pad, etc.) Temperature recording requirements. The minimum and maximum temperature requirements.

12.5 The QCS has the responsibility to ensure that:

All heat treatment equipment is calibrated and identified prior to use. The subcontractor has supplied documented proof of the conformity and calibration of the

equipment and instruments to be used. All documentation supplied by the subcontractor is approved.

12.6 The subcontractor shall supply a post weld heat treatment report in the form of a chart or band outlining the complete cycle of the heat treatment process. The report must contain the following information:

Client’s name Project number RS number Reference to written instructions Location of the work Date and subcontractor’s signature

12.7 The post weld heat treatment chart and other documentation shall be approved by the QCS and filed in the project quality file and also made available to the AI for verification.


SECTION: 12.0 - POST WELD HEAT TREATMENTREVISION DATE: 2012-03-12


PAGE: 2 of 212.8 Welder/Welding Operator Performance Qualification Testing

DCM Inc. does not normally require heat treatment of Welder/Machine Welding Operator performance qualification test coupons since this is not an ASME Code requirement. If heat treatment of test coupons is required by DCM Inc. client, then it must be in accordance of this section of the DCM QMS Manual.

Forms:DCM-FO-AQ-110-A Heat Treatment Form


SECTION: 13.0 - CALIBRATION OF MEASURING ANDTESTING EQUIPMENTREVISION DATE: 2011-09-20


PAGE: 1 of 1

13.1 The objective of this section is to ensure that calibrated equipment is used for all dimensional inspections and testing.

13.2 The QCS is responsible to ensure that all measuring and testing equipment, including pressure test gauges are calibrated. He shall maintain calibration records at all times using DCM Inc.’s Instrument Management database located on DCM Inc’s intranet server “Eliot”. If Eliot is unavailable on a project then the Calibration of Measuring and Testing Equipment form (DCM-FO-AQ-112-A) shall be used in its place. The QCS will also ensure that all sub contactors are also using calibrated measuring and testing equipment.

13.3 The calibration of the measuring and testing equipment must be subcontracted to a specialized firm who will supply the following information for all calibrated equipment.

An identification tag for the equipment with the date of the calibration The expiry date of the calibration The calibration results and traceability to the National Institute of Standards and Technology

(NIST)

13.4 All pressure gauges used for pressure testing must be calibrated to “master” instrument. Whenever there is a doubt concerning the calibration expiry date and/or the precision of a pressure gauge it shall be recalibrated prior to use.

13.5 The QCS or the SRS shall identify all measuring and testing equipment with a distinct number using a sticker, stamp or other adequate means.

13.6 The calibration interval for all measuring and testing equipment is one (1) year. If necessary the calibration interval may be less in order to ensure precise and constant readings of calibrated equipment.

13.7 The QCS must inform the QAM if there is reason to believe that any measuring or testing equipment is not exact. The QCS must issue a non-conformity report in order to evaluate the impact on any designated work that may have been already accepted or that are in the process of being accepted. The Non-conformity Report shall be processed as per section 16.0 of this manual.

13.8 The QCS is responsible to ensure that the storage, handling and application methods safeguard the equipment from unauthorized adjustments.

Forms:DCM-FO-AQ-112-A Calibration of Measuring and Testing Equipment

DCM Intranet Eliot:Business Unit-Warehouse Instrument Management


SECTION: 14.0 - PRESSURE TESTREVISION DATE: 2012-03-12


PAGE: 1 of 6

14.1 The objective of this section is to ensure that hydrostatic and pneumatic pressure tests are performed under safe conditions for the general public and for the personnel performing the tests. All pressure testing must conform to the codes, acts, regulations and project specifications.

14.2 The QCS has the responsibility to ensure that the pressure tests are performed in accordance with project specifications. The QCS must sign and date the Pressure Test Report form (DCM-FO-AQ-107-A), or site specific equivalent.

14.3 The gauges used for the hydrostatic and pneumatic tests must be calibrated in accordance with section 13.0 of this manual.

14.4 A minimum of 2 gauges shall be installed on the system being tested. Dial indicating pressure gauges used in testing shall be graduated over a range of about double the intended maximum test pressure, but in no case shall the range be less than 1.5 nor more than 4 times that pressure. (See Table below for specific codes).

ASME CODE Preferred Gauge Face Range WitnessB31.3 1.5 to 4 times test pressure Owner Inspector (OI)

SECTION VIII 1.5 to 4 times test pressure OI and/or Authorized Inspector (AI)B31.1 NBEP 1.5 to 2 times test pressure Owner Inspector (OI)

B31.1 BEP 1.5 to 2 times test pressure OI and/or AISECTION I 1.5 to 2 times test pressure OI and/or AI

SECTION IV 1.5 to 2 times test pressure OI and/or AI

14.5 The QCS is responsible to advise the AI sufficiently in advance of pressure testing activities when he is required to witness a test. (ASME Section I, B31.1 BEP).

14.6 The Pressure Test Report form (DCM-FO-AQ-107-A) must include as a minimum the following information:

Client’s name Code references Date of the test Description of the material to be tested Type of test fluid used Test pressure Name of the test supervisor Name of the visual test inspector Approval of the test results by the QCS The number(s) of the measuring and testing equipment

14.7 If repairs, additions or alterations have been performed on an existing pressure pipe system a new pressure test must be performed in accordance with the applicable project specifications.

14.8 In the case where pressure tests are required but they are not possible or are impractical, different alternative test methods may be considered such as:

A complete x-ray of the pressure welds, Partial pressure tests of prefabricated components prior to installation. Closure welds procedure.

Any deviations to the required testing methods must be approved by the AI.




PAGE: 2 of 6

14.9 PREPARATION FOR PRESSURE TESTING OF PIPING

a. All welded and mechanical joints shall be left un-covered for visual inspection during pressure testing. No protective or paint coatings shall be applied prior to hydrostatic testing. Prior approval from the AI must be obtained when pressure testing of painted pipe is being considered.

b. When a hydrostatic test is performed on a piping system that has been designed for steam or gas application consideration should be made for adding of temporary supports to support the weight of the test fluid.

c. The following requirements must be followed during all pressure tests activities:

Expansion joints shall be temporarily re-enforced if they are to be included in the pressure test. If not, they are to be removed or isolated from the test circuit.

Any piping elements that cannot be subject to pressure testing shall be removed or isolated from the test circuit with the use of blind flanges or other similar methods.

When a bolted connection has been used as a pressure test isolation point with a blind flange this connection will not be subject to a new pressure test once the blind flange has been removed. However, the bolted joint will be subject to a visual inspection during system start up to detect for any possible leaks.

If the test pressure is maintained for a period long enough to affect the thermal dynamics of the tests medium, precautions shall be made in order to avoid any over pressurization of the test circuit. It is recommended to use a pressure relief valve set at 1.3 times the pressure test rating.

14.10 HYDROSTATIC TESTING

a. Air vents

An air vent must be installed at each high point of the piping system in order to allow air to escape during filling of system. Captive air can also be evacuated from the system at any bolted joint having more than four (4) bolts.

b. Testing Fluids

Unless otherwise specified by the manufacturer, the fluid used for hydrostatic tests must be clean, treated water, in order to minimize corrosion of the pipes.

The water temperature used for hydrostatic tests must be approximately the same as that of the piping which is being tested.

When the temperature of the test fluid is lower than -5 degrees Celsius, the QCS must ensure that the piping material composition can resist to the test fluid temperature.

c. Pre-Test Verification

Prior to pressurizing the piping system, the pressure test apparatus shall be inspected to ensure that all of the connections are watertight. Low pressure piping or any elements not to be tested must be disconnected or isolated from the piping system with an isolating valve or other adequate methods.




PAGE: 3 of 6

d. Test Pressure

Each section of pipe system shall be subjected to a minimum pressure equal to 1.5 times the maximum operating pressure, unless client specifications differ.

e. Pressure Test Duration

The pressure test must be maintained for a minimum 10 minutes and for a sufficient length of time to determine if there are any leaks.

f. Verification of piping for leaks

Each joint or connection must be verified by a visual inspection which must show no signs of leaks.

14.11 PNEUMATIC PRESSURE TESTS In accordance with AB 522 - Standard Pneumatic Test Procedure Requirements

a. Use of Pneumatic Tests

A pneumatic pressure test can be used in the place of another test method in the following situations:

When the design of the piping system will not allow for the use of water or other types of liquid as test fluids.

When no traces of fluid in the piping system are permitted.




PAGE: 4 of 6

All pneumatic testing of process piping shall be carried out following the requirements of the construction code as applicable. References should be made to ASME Section VIII Div. 1 UG-100, B31.3-2008, para. 345.5, PCC 2 Article 5 and any other relevant safety regulation such as those issued by Workplace Health and Safety. ABSA AB-522 Standard Pneumatic Test Procedure Requirements (AB-522), can be used as a resource document as well.

For pressure piping systems exceeding 0.5 m³ in aggregate volume or 2172 kPa design pressure, all proposed pneumatic test procedures shall be submitted to the ABSA Design Survey Section for acceptance prior to the test.

For pressure piping systems constructed of P-1 or P-8 materials with a flange class of 150 or greater and below 0.5 m³ in aggregate volume or 2172 kPa design pressure, the following procedure must be followed.

b. Testing Design Basis

The test pressure shall be 110% of design pressure.

A pressure relief device (PRD) shall be provided, having a set pressure not higher than 110% of the test pressure. The pressure relief device shall be sized to relieve the maximum output of the pressure source to prevent excessive testing pressure.

Set point of the PRD shall not be > Test Pressure + lesser of 345 kPa (50 psi) or 10% of the test pressure.

Test manifold(s) and temporary test piping shall have been designed for a pressure not less than the pressure relief device set pressure and shall have been hydrostatically tested in accordance with ASME B31.3.

Particular care must be taken to minimize the chance of brittle failure during a pneumatic leak test. The metal temperature shall be maintained at a minimum of 17 degrees C (60 degrees F) above the minimum design metal temperature for the piping. (See ASME B31.3 paragraph 345.5.1 and figure 323.2.2A).

c. Testing Procedure

Prior to the test, a pneumatic test procedure, and pressure test report will be prepared by the QCS.

Precautions:




PAGE: 5 of 6

The medium for all pneumatic testing will be air or nitrogen. When testing with nitrogen in an enclosed area, care should be taken that adequate ventilation is provided in the event there are leaks. Caution should also be exercised when leak testing nitrogen filled systems.

Pneumatic testing involves the hazard of released energy stored in compressed gas.

Care must be taken to minimize the chance of brittle failure during the pneumatic leak test. Test temperature is important in this regard and must be considered when the designer chooses the material for construction.

i. All personnel not directly involved with the pneumatic test shall be evacuated from the area. No unauthorized personnel shall be allowed within 15 metres (50 feet) of the test area. Rope or ribbon barriers shall be used to keep personnel from entering the area. No personnel shall be allowed within the barriers during pressurization.

ii. Wrap all flanged connections with masking tape. Make a small hole for leak testing.

iii. Carefully pressurize the system until the pressure is the lesser of 172 kPa (25 psig) or ½ of the Test Pressure and hold for at least 10 minutes, so that the system can stabilize.

iv. Soap test all welds, flanges, threads and other possible leak sources. Mark all leaks for repair.

v. Depressurize carefully and repair all leaks found. Repeat the leak test (steps iii. to v.) until the system is gas tight at the lesser of 172 kPa (25 psig) or ½ of the Test Pressure.

vi. Increase the pressure to 345 kPa (50 psig) and thereafter in increments of 345 kPa (50 psig) until the test pressure is reached. The pressure shall be increased gradually in steps, providing enough time for the pressurized piping system to equalize strains.

vii. The minimum hold time at each increment shall be 10 minutes. During each hold period, check for leakage by monitoring the ability of the system pressure to remain constant during the hold time. The pneumatic test report shall be completed, denoting all hold pressures and the time shall be logged at each step.

viii. A minimum of two calibrated pressure gauges shall be used to monitor the pressure. The pressure gauge ranges shall be not less that 1.5 times nor more than 4 times the final test pressure.

ix. If a leak is detected at any time; the leak is to be marked, the system safely depressurized, the leak repaired and the test begun again (step iii.).

x. Once the required test pressure is reached, the pressure is to be held for a minimum of 10 minutes.

xi. The pressure shall be slowly reduced to design pressure and the system tested for leaks (step iv.). If no leaks are detected the test is successfully completed.




PAGE: 6 of 6

xii. The system will be slowly and safely depressurized. Depressurization must take place in a controlled manner to avoid sub-cooling due to the refrigeration effect, equalizing pipe strains, and being cautious about the effluent.

o The procedure must address the dangers of confined space and the possibility of asphyxiation from the test medium such as nitrogen. This danger is especially high should a leak occur or at the time of depressurization.

Note: The safe distance must be observed from after the preliminary test until the system pressure is reduced to design pressure after successful attainment of test pressure.

After Testing, The QCS and the Owner’s Inspector will sign the test report stating that they have witnessed and accepted the test.

Forms:DCM-FO-AQ-107-A Hydrostatic Pressure Test ReportDCM-FO-AQ-118-A Pneumatic Pressure Test ReportDCM-FO-AQ-119-A Boiler and Boiler External Hydrostatic Pressure Test Report


SECTION: 15.0 - DOCUMENTATIONREVISION DATE: 2012-03-12


PAGE: 1 of 2

15.1 The objective of this section is to describe how the documentation will be recorded and controlled.

a. For each project the QCS shall complete the Completion of Construction Declaration form (AB-40), or job specific equivalent.

b. The QAM shall sign and date this declaration.c. The document shall carry a unique and sequential identification number obtained from the

Register of Completion of Construction Declarations form (DCM-FO-AQ-108-A).d. The QCS shall distribute the report in the following manner :

a copy for the clientcopy for project quality filea copy for the AI a copy for the QAM

15.2 Identification

a. The pressure piping systems are to be identified as per the project specifications. The PIR shall include the identification requirements (see article 8.7 of this manual).

15.3 Documentation History and Conservation Duration

a. The QAM shall ensure that for each completed project, the following documentation is kept in a clean, dry area for a period of five (5) years.

Design calculations and drawings, if applicablePurchase ordersDeclaration of constructor conformity duly completed and certified if the fabrication work

was done in a shop by another companyCompletion of Construction Declaration formsDaily log reportsPDR and PIRMill Test ReportsPWHT ChartsNDE Reports and Radiographic FilmNon-conformity reports, if applicableWelder/Machine Welding Operator Qualification RecordsCopies of candidates Certificates of CompetencyCalibration RecordsRequest for Duplicate Welder Performance Qualification CardsHeat treatment instructions and charts, if applicableCopies of Welder/Machine Welding Operator performance qualification cards

b. All of these documents shall make reference to the project number for which they apply.c. All documents will be made available to the AI both during and after the project.

15.4 Documentation Control

DCM Inc.’s Quality Management Process, which includes the Document Control Process (pg.10), is part of DCM Inc.’s ISO 9001:2008 Quality Management System and is referenced in process PS-CH-03-A.


SECTION: 15.0 - DOCUMENTATIONREVISION DATE: 2012-03-12


PAGE: 2 of 2 Forms:

DCM-FO-AQ-108-A Register of Completion of Construction Declarations

ABSA Form:AB-81 Completion of Construction Declaration

Processes:DCM-PS-CH-03-A Quality Management Process


SECTION: 16.0 - NON-CONFORMITY MANAGEMENTREVISION DATE: 2011-09-20


PAGE: 1 of 1

16.1 The objective of this section is to describe the procedures used to control non-conformities detected upon receiving inspection, pressure tests and installation inspections and to ensure that the corrective actions conform to the codes, acts, regulations and project specifications.

16.2 The QAM is responsible for the resolution and approval of the non-conformity treatment.

16.3 A non-conformity is defined as being a deviation or a condition that does not conform to the codes, acts, regulations, project specifications and the Quality Management System Manual.

16.4 The QCS shall prepare the Non-conformity Reports form (DCM-FO-AQ-01-A) on which the on-conforming items must be identified.

16.5 The QAM, together with the QCS shall establish the appropriate corrective action for the non-conformity. The corrective action will be identified on the non-conformity report and approved by the QAM and/or the client and/or ABSA (if required).

16.6 After approval of the corrective action of the non-conformity by the QAM and/or the client and/or ABSA (if required) the QCS shall:

Follow-up on the corrective action plan. Advise the QAM sufficiently in advance if there are any mandatory hold points requested by

the AI and /or the client. Sign and date the non-conformity report to indicate that repair work has been completed and

accepted.

16.7 All non-conformity reports shall have a unique and sequential number which is controlled by DCM Inc.’s Non Conformity database located on DCM Inc’s intranet server “Eliot”, if Eliot is unavailable on a project then the Register of Non-conformity Reports (form DCM-FO-AQ-113-A) shall be used in its place. The unique NC number must appear on the routing sheet. The QCS must keep non-conformity reports in the appropriate project quality file and they must be available to the AI for his review.

Forms:DCM-FO-AQ-01-A Non Conformity ReportDCM-FO-AQ-113-A Register of Non Conformity Reports

DCM Intranet Eliot:Business Unit: Quality-Non Conformity Database


SECTION: 17.0 - EMPLOYEE TRAININGREVISION DATE: 2012-03-12


PAGE: 1 of 1

17.1 All employees directly involved in the implementation of this quality program shall receive specific training for each section of the Quality Management System Manual which applies to their applicable tasks.

17.2 The training will be documented, showing which sections of the Quality Management System Manual were covered, the date of the training and the names of the employees present.

17.3 All employees who will use DCM Inc’s intranet server Eliot, shall receive training on the specific areas that they will utilize from the Corporate QA Manager, QAM or a qualified individual.

17.4 DCM Inc.’s Training Management Process is part of DCM Inc.’s ISO 9001:2008 Quality Management System and is referenced in process PR-RH-02-A.

Process:DCM-PR-RH-02-A Training Management Process


SECTION: 18.0 – CONTRACT REVIEWREVISION DATE: 2012-03-12


PAGE: 1 of 1

18.1 The objective of this section is to describe the process to ensure that contract requirements are defined and agreed upon prior to the start of work.

18.2 The Project Manager shall review the contract/purchase order prior to acceptance, to ensure that requirements are adequately defined. When requirements are inadequately defined or there is no written contract/order the Project Manager shall contact the client to ensure requirements are stated and agreed upon, and shall record the information in the job file.

a. The Project Manager, or assigned designate, shall ensure that:

The scope of work is defined, including the applicable code of construction and service (e.g. ASME B31.3 service category).

Drawings are approved for construction, assembly, repair or alteration, and the responsible party for design and design submission for registration by ABSA is/are identified.

The material list including ASME material specification numbers (or other specification allowed by the code of construction), grades, material thickness, schedules, classes and sizes (as applicable), is provided.

The welding procedures are specified and qualified for the job. The degree and type of NDE and the determination of “Lot Sizes” shall be agreed

upon. The type of pressure test is defined, and responsibility for these requirements is

assigned. The responsibility for material procurement is defined. The responsibility for Post Weld Heat Treatment is defined. The requirements of a Turnover Package and contents thereof are agreed upon The certification of construction using an AB-83 or AB-83 Partial or AB-83F as the

case may be is agreed upon between the contracting parties. The responsibility for certifying the installation and readiness for operation using an

AB-81 is identified.

18.3 The Project Manager shall obtain written verification defining responsibility for the above activities from the owner or Owners Agent using the Contract Review Form (form DCM-FO-AQ-117-A).

Forms:DCM-FO-AQ-117-A Contract Review Form


SECTION: 19.0 – INTERNAL AUDITSREVISION DATE: 2012-03-12


PAGE: 1 of 1

19.1 The objective of this section is to describe how the Internal Audit procedure is conducted at DCM Inc.

19.2 DCM Inc.’s Internal Audit Procedure is part of DCM Inc.’s ISO 9001:2008 Quality Management System and is referenced in procedure PR-AQ-03-A.

Procedure:DCM-PR-AQ-03-A Internal Audit Procedure


SECTION: A - FORMSREVISION DATE: 2012-03-12


PAGE: 1 of 1

NUMBER TITLE REVISION DATEF4.1 MANUAL DISTRIBUTION LIST 3.0 2012-03-12F4.2 MANUAL REVISION NOTICE 2.0 2011-09-20F4.3 CONTROL OF REVIEWS, REVISIONS AND

ADDENDUMS2.0 2011-09-20

DCM-FO-AP-03-A MATERIAL REQUISITION 1.0 2011-09-20DCM-FO-AQ-01-A NON CONFORMITY REPORT 1.0 2011-09-20DCM-FO-AQ-17-A RECEPTION INSPECTION 1.0 2011-09-20DCM-FO-AQ-101-A DRAWINGS AND SPECIFICATION CONTOL 2.0 2011-09-20DCM-FO-AQ-102-A PIPING INSPECTION REPORT 2.0 2011-09-20DCM-FO-AQ-103-A DAILY LOG REGISTER 2.0 2011-09-20DCM-FO-AQ-104-A WELD REPORT 2.0 2011-09-20DCM-FO-AQ-105-A REPAIR OR ALTERATION EXAMINATION AND

INSPECTION SHEET2.0 2011-09-20

DCM-FO-AQ-106-A WELDER QUALIFICATION CONTINUITY REGISTER

2.0 2011-09-20

DCM-FO-AQ-107-A HYDROSTATIC PRESSURE TEST REPORT 3.0 2012-03-12DCM-FO-AQ-108-A REGISTER OF COMPLETION OF

CONSTRUCTION DECLARATIONS2.0 2011-09-20

DCM-FO-AQ-110-A HEAT TREATMENT FORM 1.0 2011-09-20DCM-FO-AQ-111-A NDE REQUEST FORM 1.0 2011-09-20DCM-FO-AQ-112-A CALIBRATION OF MEASURING AND TESTING

EQUIPMENT2.0 2011-09-20

DCM-FO-AQ-113-A REGISTER OF NON CONFORMITY REPORTS 2.0 2011-09-20DCM-FO-AQ-115-A WELDER PERFORMANCE QUALIFICATION

CARD1.0 2012-03-12

DCM-FO-AQ-116-A REQUEST FOR DUPLICATE WELDER PERFORMANCE QUALIFICATION CARD

1.0 2012-03-12

DCM-FO-AQ-117-A CONTRACT REVIEW FORM 1.0 2012-03-12DCM-FO-AQ-118-A PNEUMATIC PRESSURE TEST REPORT 1.0 2012-03-12DCM-FO-AQ-119-A BOILER AND BOILER EXTERNAL

HYDROSTATIC PRESSURE TEST REPORT1.0 2012-03-12

DCM-GU-AQ-02-A INSPECTION AND TEST PLAN 3.0 2011-09-20

ABSA FORMS TITLEAB-40 BOILERS AND PRESSURE VESSELS REPAIR

OR ALTERATION REPORT2007-07

AB-81 COMPLETION OF CONSTRUCTION DECLARATION

2005-03

AB-83 PRESSURE PIPING CONSTRUCTION AND TEST DATA REPORT

2011-01

AB-76A WELDER QUALIFICATION RECORD 2010-09AB-76B WELDING OPERATOR QUALIFICATION

RECORD2010-09

SPECIMEN TITLES6.1 DRAWING AND SPECIFICATION CONTROL -

SPECIMEN1.0 2011-09-20

S7.1 PURCHASE ORDER – SPECIMEN 1.0 2011-09-20


SECTION: A - FORMSREVISION DATE: 2012-03-12


PAGE: 2 of 1


SECTION: B - PROCEDURESREVISION DATE: 2012-03-12


PAGE: 1 of 1

NUMBER TITLE REVISION DATEDCM-PR-AQ-03-A INTERNAL AUDIT PROCEDURE 5.0 2012-03-12DCM-PR-AQ-06-A PERFORMANCE QUALIFICATION

EXAMINATION AND TEST PROCEDURE0.0 2012-03-12


SECTION: C - PROCESSESREVISION DATE: 2012-03-12


PAGE: 1 of 1

NUMBER TITLE REVISION DATEDCM-PS-CH-03-A QUALITY MANAGEMENT PROCESS 1.0 2012-03-12DCM-PR-RH-02-A TRAINING MANAGEMENT PROCES 1.0 2012-03-12


MANUAL DISTRUBUTION LISTREVISION DATE: 2012-03-12

THE CONTROLLED COPIES OF THE MANUAL ARE ASSIGNED TO THE FOLLOWING HOLDERS AND CORRESPONDING COPY NUMBER

COPY NAME TITLE / DEPARTMENT ISSUE / REVISION DATE01 Rob Dowler QAM 3.0 2012-03-1202 ABSA Alberta Boiler Safety

Association 3.0 2012-03-12

03 DCM Inc.- Head Office #184, 2693 Broadmoor Blvd, Sherwood Park, AB

3.0 2012-03-12

04 Eliot DCM Intranet Server 3.0 2012-03-1205060708091011121314 TSASK Technical Safety Authority of

Saskatchewan02 2011-09-20

151617181920

F4.1 Rev.3.0

MANUAL REVISION NOTICEREVISION DATE: 2011-09-20

THIS FORM IS USED FOR EXTERNAL USE ONLY

A: CONTROLLED COPY NO: ______________

HOLDER: _______________________

DATE: _____________________________

REVISION NO: ______________________ EDITION: __________________

Please replace and destroy the revised pages of your Quality Management System Manual as listed hereafter:

Please insert the attached revised pages in your Quality Management System Manual

SIGNATURE: __________________________________ DATE: _______________ QUALITY ASSURANCE MANGER

THE BOTTOM SECTION OF THIS FORM MUST BE COMPLTED AND RETURNED TO THE ATTENTION OF THE QUALITY ASSURANCE MANAGER

PLEASE NOTE: IF THIS FORM IS NOT RETURNED WITHIN 30 DAYS YOUR MANUAL WILL AUTOMATICALLY BECOME A NON-CONTROLLED COPY.

RETURN TO: DATE:

WE ACKNOWLDEGE RECEIPT OF REVISED PAGES AND HAVE INSERTED THE COPIES IN THE MANUAL.

SIGNED: DATE:

F4.2 Rev.2.0

CONTROL OF REVIEWS, REVISIONS, AND ADDENUMSREVISION DATE: 2011-09-20

DOCUMENTATION EDITION ADDENDA CHECK Pressure Equipment Safety Regulation AR49/2006 Section 12

1 April 2006 RD

Administrative Items Regulation AR16/2004

1 April 2004 RD

Power Engineers Regulation AR85/2003

1 May 2003 RD

Pressure Welders Regulation AR169/2002

1 October 2002 RD

Pressure Equipment Exemption Order 56/2006

1 April 2006 RD

CSA B51-09Boiler, Pressure Vessel, and Pressure Piping Code

2009 RD

CSA W47.1-03Certification of Companies for Fusion Welding of Steel

2008 RD

CSA W59-03Welded Steel Construction(Metal Arc Welding)

2008 RD

B31.1Power Piping ASME

ASME B31.1-2007 B-31.1a-2008 RD

B31.3 Process Piping ASME

ASME B31.3-2008 RD

ASME Section IRules of Construction of Power Boilers

July 2007 July 1, 2008aJuly 1, 2009b

RD

ASME Section II Parts A & D

July 2007 RD

ASME Section IVRules for Construction of Heating Boilers

July 2007 RD

ASME Section VNon-destructive Examination

July 2007 July 1, 2009b RD

ASME Section VIIIDivision 1Rules for Construction of Pressure Vessels

July 2007 RD

ASME Section IXWelding and Brazing Qualification

July 2007 July 1, 2008aJuly 1, 2009b

RD

DCM Inc. ___________________

DATE : September 20, 2011

F4.3 Rev.2.0

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