QC MANUAL
COVER SHEET
EDITION Nº 10
SECTION 1
REVISION 0
PAGE 1 OF 1
Quality Control Manual
of
Berkes-BWE
for
Manufacture and assembly of power boilers and boiler external piping
at field sites in accordance with the
ASME Boiler and Pressure Vessel Code Section I and ASME B31.1.
Designator S
and
Manufacture of pressure vessels at field sites in accordance with the
ASME Boiler and Pressure Vessel Code Section VIII Division 1.
Designator U
Mailing and Administrative Office: Av. Rondeau 1950
Montevideo, 11800
Uruguay
TEL: (598) 29291064
www.berkes.com.uy
www.berkesenergy.com
__________________
DATE: 09/02/2024
QC Manager
__________________
DATE: ______
Authorized Inspector
QC MANUAL
TABLE OF CONTENTS
EDITION Nº 10
SECTION 2
REVISION 0
PAGE 1 OF 1
NUMBER SECTION
REV
DATE
(MM-DD-YYYY)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
COVER SHEET
TABLE OF CONTENTS
STATEMENT OF AUTHORITY AND
RESPONSIBILITY
GLOSSARY AND DEFINITIONS
MANUAL CONTROL
ORGANIZATION CHART
DRAWINGS, CALCULATIONS AND
SPECIFICATIONS CONTROL
MATERIAL CONTROL
EXAMINATION AND INSPECTION PROGRAM
CORRECTION OF NONCONFORMITIES
WELDING CONTROL
NONDESTRUCTIVE EXAMINATION
HEAT TREATMENT
CALIBRATION
RECORDS RETENTION
AUTHORIZED INSPECTOR
CERTIFICATIONS AND EXHIBITS INDEX
0
0
0
09-02-2024
09-02-2024
09-02-2024
0
0
0
0
09-02-2024
09-02-2024
09-02-2024
09-02-2024
0
0
0
0
0
0
0
0
0
0
09-02-2024
09-02-2024
09-02-2024
09-02-2024
09-02-2024
09-02-2024
09-02-2024
09-02-2024
09-02-2024
09-02-2024
QC MANUAL
STATEMENT OF AUTHORITY
AND RESPONSIBILITY
EDITION Nº 10
SECTION 3
REVISION 0
PAGE 1 OF 1
STATEMENT OF AUTHORITY AND RESPONSIBILITY
The General Manager and all personnel described in this Manual are totally committed to comply
with all requirements of the ASME Boiler and Pressure Vessel Code Section I, VIII Division 1 and
ASME B31.1 for power boilers, pressure vessels, boiler external piping and parts thereof as a
minimum.
All field, manufacture and assembly of power boilers, pressure vessels, boiler external piping and
parts thereof shall be done by this organization in accordance with the ASME Section I, ASME
B31.1 and VIII Division 1 as applicable and this Manual.
The Quality Control Manager possesses total authority and has the complete responsibility to
establish and implement this system in the field sites. He shall also put into action the procedures
which ensure the effective fulfillment of the system and maintain the records of all the
specifications, procedures, test and every document, in such a way that they can be put easily at
the disposition of the Authorized Inspector.
The Quality Control Manager has the authority, responsibility and organizational freedom to
identify Quality Control Problems and to initiate, recommend and provide solution also he is
authorized to stop the production at any phase and for any reason, related to the quality control
of the product.
In the event of any dispute between the Quality Control Manager and any other Department
Head, the final decision will be made by the General Manager. Compliance with the ASME Code
and this Manual shall always be fulfilled.
The Quality Control Manager is responsible for performing all examination and tests required by
this QC program and the applicable Section of ASME Boiler and Pressure Vessel Code. The QC
Manager shall have custody and control of the ASME Certification Mark and shall issue ASME
Certification Mark to the QC Inspector at the field site as needed and who will return it to the QC
Manager at the completion of the ASME Certification Mark.
Department heads, including the QC Manager, are responsible for their assigned activities. They
may delegate the performance of their assigned duties but they shall retain the responsibility for
their assigned activities.
______________
General Manager
09-02-2024
DATE: ______
QC MANUAL
GLOSSARY AND
DEFINITIONS
EDITION Nº 10
SECTION 4
REVISION 0
PAGE 1 OF 2
GLOSSARY AND DEFINITIONS
AI
Authorized Inspector as defined by the ASME Code.
AIA
ASME Accredited Authorized Inspection Agency
AIS
Authorized Inspector Supervisor
ASME
The American Society of Mechanical Engineers.
Certifying Engineer
An engineer or other technical professional duly accredited and qualified
to practice engineering activities as required by Section VIII-1.
Code
ASME Code. Section I, VIII Division 1, ASME B31.1, and referenced
Sections and standards.
Code Items
Power boilers, boiler external piping, pressure vessels and parts.
Company
Berkes-BWE
Designer
An individual who is qualified to design pressure vessels in accordance
with the rules of this Section VIII Division 1 by demonstrated
knowledge in Code requirements and proficiency in selecting correct
design formulas and appropriate values to be used when preparing
the design of a pressure vessel.
DI
Design Engineer
DMS
Document Management System
EM
Engineering Manager
Hold Point
An inspection point that shall not be bypassed and require the notification
to the AI by the QC Manager or QC Inspector.
HT
Heat Treatment.
Inspection Point
An inspection, test or examination that will be conducted by the QC
Inspector and the A.I.
ITP
Inspection and Testing Plan
Manual
Quality Control Manual
MDR
Manufacturer’s Data Report
MPDR
Manufacturer’s Partial Data Report
MT
Magnetic Particle Examination.
MTR
Material Test Report.
NCR
Nonconformity Report
NDE
Nondestructive Examination
PO
Purchase Order
PQR
Procedure Qualification Record.
PS
Purchase Specification
PT
Liquid Penetrant Examination.
PV
Pressure Vessel Section VIII Division 1.
Responsible Charge
The individual responsible for the design of pressure vessel shall be
actively engaged in performing the design work himself or have
QC MANUAL
GLOSSARY AND
DEFINITIONS
EDITION Nº 10
SECTION 4
REVISION 0
PAGE 2 OF 2
supervision and oversight responsibility other individuals performing
design work.
QC
Quality Control
QCC
Quality Control Chief
QCM
Quality Control Manager
RT
Radiography Examination.
UT
Ultrasonic Examination.
VT
Visual Examination
WOPQ
Welding Operator Performance Qualification
WPQ
Welder Performance Qualification
WPS
Welding Procedure Specification.
QC MANUAL
MANUAL CONTROL
EDITION Nº 10
SECTION 5
REVISION 0
PAGE 1 OF 1
5.1 GENERAL
5.1.1
The Manual and the implementation procedures shall be the full responsibility
of the QC Manager. This includes the preparation, approval, issue, control,
distribution, maintenance and revision and shall be current with the Code.
5.1.2
The only controlled copy of this Manual shall be available in the DMS to
Company employees and the AI. QC Manager shall assure that the last
revision of each section is available in the DMS. Printed copies shall be
considered as non-controlled, except as described in 5.1.6.
5.1.3
All editions or revisions to the Manual and procedures shall be prepared in
accordance with Section 17.
5.1.4
The Manual shall be revised on section-by-section basis and the Table of
Contents shall be revised accordingly, except for the Exhibit Index Section,
which will be revised by Exhibit. A summary of changes shall be shown at the
beginning of each revised section. New editions of this Manual may be issued
as required by the QC Manager. When a new edition is issued, the edition
number shall be increased by one, all sections shall be reverted to zero and
summary of changes shall be deleted.
5.1.5
Distribution shall be carried out by the DMS in accordance with Section 17.
5.1.6
Non-controlled copies shall be issued by the QC Manager as required for
parties outside the Company. Non-controlled copies shall be current when
issued but will not be revised. If a controlled printed copy is required, shall be
registered in Exhibit 17.1. When a new revision is issued, all previous revisions
shall be retrieved and destroyed and the status shall be updated in Exhibit
17.1.
5.1.7
The QC Manager shall be responsible for reviewing Code Edition to determine
if any revision to this QC Manual and supporting procedures is required and
shall implement it within 6 months of the Code Edition issue date. The review of
changes shall be documented by signing a letter with a list of the Codes
reviewed.
5.1.8
The QC Manager shall be responsible for obtaining a Spanish version of this
Manual. In the case of conflict, the English version prevails. Distribution of the
both versions of the Manual shall be made in accordance with Section 17.
QC MANUAL
ORGANIZATION CHART
EDITION Nº 10
SECTION 6
REVISION 0
PAGE 1 OF 1
GENERAL
MANAGER
ENGINEERING
MANAGER
DESIGN
ENGINEER
QC MANAGER
QC CHIEF
DESIGNATED
WELDING
SUPERVISOR
OPERATIONS
MANAGER
FIELD MANAGER
ADMINISTRATIVE
AND FINANCIAL
MANAGER
WAREHOUSE
CHIEF
PURCHASING
MANAGER
NDE
SUBCONTRACTOR
DRAFTSMAN
FIELD CHIEF
WAREHOUSE
ATTENDANT
QC INSPECTOR
WELDERS AND
WELDING
OPERATORS
DRAWING, CALCULATIONS
AND SPECIFICATIONS
CONTROL
7.1
QC MANUAL
EDITION Nº 10
SECTION 7
REVISION 0
PAGE 1 OF 3
SCOPE
7.1.1
The purpose of this Section is to describe the procedure to assure that the Code
Items will be designed in accordance with the applicable construction Code,
and that the latest applicable drawings, design calculations and specifications
are used in the field, manufacturing and assembly of Code Items.
7.1.2
Each order for a Code Item to be completed by this organization shall be issued
a Job Number plus the Work Order by the Engineering Manager. The Job
Number plus the Work Order is used to identify the drawings and calculations as
a part of the document number and fabrication, examination, inspection and test
documents related to the Code Item.
7.1.3
Upon receipt of an order for a Code Item, the customer's specification is
reviewed for adequacy and for compliance to Code requirements by the EM. Any
deficiencies are reconciled with the customer prior to starting any design work.
7.1.4
The EM is responsible for selecting the units of measurement based on the
Company capabilities and the Customer requirements, if another units of
measurement system is required for reference, the values shall be converted
with four significant figures by the EM and the results shall be expressed to three
figures.
7.2
DESIGNS BY THE COMPANY
7.2.1
Upon acceptance of the customer's specification, the Design Engineer prepares
the calculations, inspection requirements material specification, and dimensions.
The mentioned documents shall be approved in the DMS by the EM. If the
customer does not issue an specification and/or the requirements from U-2 (a)
(2) are not complied, Appendix KK from ASME VIII-1 shall be issued.
7.2.2
Revisions to design documents (including Customer's Specifications) are
handled in the same manner as the originals.
7.2.3
For VIII-1 the EM or QCM shall designate a designer, engineer or Certifying
Engineer to be in responsible charge of the design of a pressure vessel.
7.2.3.1
Responsible charge, PVs Designers and individuals engaged in design activities
shall be qualified in compliance with Mandatory Appendix 47 of Section VIII
Div.1. Responsible Charge and Design personnel shall be designated by EM or
QCM using Exhibit 7.1.
7.2.3.2
QCM and/or EM are responsible to keep records updated and meet annual
frequency set in Table 5 of exhibit 7.1.
7.3
DESIGNS BY OTHERS
7.3.1
When design documents and drawings are provided to this organization by
others, the EM reviews them for compliance to the Code. Any discrepancies are
brought to the attention of the design concern for correction to meet Code
requirements.
DRAWING, CALCULATIONS
AND SPECIFICATIONS
CONTROL
QC MANUAL
EDITION Nº 10
SECTION 7
REVISION 0
PAGE 2 OF 3
7.3.2
When the design meets Code requirements shall be approved in the DMS by the
EM. Any disapproved document is returned to the design provider for correction
and re-submittal.
7.3.3
Revisions to design document are handled in the same manner as the originals.
7.3.4 For ASME VIII-1, personnel engaged in design activities shall be qualified in
compliance with Mandatory Appendix 47 of Section VIII Div.1. and this Manual.
7.4
RETENTION OF DESIGN DOCUMENTS
7.4.1
7.5
Approved design documents are transmitted by the DMS.
PREPARATION OF DRAWINGS
7.5.1
The Draftsman shall prepare the required drawings. The drawings shall at least
list the following information (as applicable):
7.5.1.1 Code Section, Division, Edition
7.5.1.2 The design conditions: Max. allowable working pressure (MAWP), Min.
design metal temperature (MDMT).
7.5.1.3 Test Pressure and minimum temperature (metal, water)
7.5.1.4 Charpy Impact Test or exceptions or other required tests
7.5.1.5 Nondestructive Examination
7.5.1.6 Dimensions and tolerances
7.5.1.7 Heat treatment (if any)
7.5.1.8 Welding joints and details,
7.5.1.9 Stamping information, and any additional information
7.5.1.10 Bill of material
7.5.1.11 Table of connections
7.5.1.12 Heating surface (Section I Code Items)
7.5.1.13 Maximum designed steaming capacity (Section I Code Items)
WPS’s numbers shall be indicated on the drawings or on the Welding List
(Exhibit 11.1) prepared by the QC Chief.
7.5.2
Revisions to drawings are handled in the same manner as the originals.
7.5.3
The units to be used in fabrication/construction as determined by the EM shall be
in accordance with calculations, stamping information and MDR.
7.6
DISTRIBUTION OF DOCUMENTS AND DRAWINGS
7.6.1
All documents described in this Section shall be distributed throughout this
organization by the EM using the DMS.
7.6.2
Original of all drawings are filed by the Design Engineer by DMS. The Design
Engineer maintains copies of all approved design documents by DMS.
7.6.3
The QC Chief is responsible for providing the AI access to all design documents
and drawings for his review prior to the start of work.
DRAWING, CALCULATIONS
AND SPECIFICATIONS
CONTROL
7.7
QC MANUAL
EDITION Nº 10
SECTION 7
REVISION 0
PAGE 3 OF 3
DESIGN & DOCUMENT CONTROL
7.7.1
Documents are transmitted to the QC Manager and Field Manager by the DMS.
7.7.2
Superseded documents are retrieved and destroyed by the receptor according
with Section 17.
7.8
COMPUTER AIDED DESIGN
7.8.1
When computer programs for design are used for Code Items, The EM is
responsible for all technical assumptions inherent in the programs, for the
application of these programs to their design and for the input of correct design
data and the verification that the correct output has been obtained, and verify that
the computer program has the capability of producing acceptable calculations.
This verification shall ensure that prepared calculations or analysis is verified as
follows:
(1) The computer program calculations or analysis shall be verified to show that it
produces correct solutions for the encoded mathematical model within defined
limits for each parameter employed.
(2) The encoded mathematical model shall be verified to show that it produces
correct solutions to the physical problem associated with the particular
application.
NOTE: For (1) and (2), verification against examples found in ASME PTB-4,
ASME Section VIII, Division 1 Example Problem Manual may be sufficient to
show that verification is met.
Verification results shall be available to the AI for review.
7.8.2
The EM shall review the Code Edition to determine if the computer programs are
affected. The Code Section, Division, Edition used shall be included on the
design documents. The review process shall be documented by the EM by
signing a letter with a list of the Codes reviewed. When changes are required,
these changes shall be implemented within 6 months of the Code Edition date of
issuance or prior to use any new program or revision.
QC MANUAL
MATERIAL CONTROL
EDITION Nº 10
SECTION 8
REVISION 0
PAGE 1 OF 4
8.1
PURPOSE
8.1.1
The purpose of this Section is describing the procedure to assure that all
materials used in the construction of Code Items meet the requirements of the
applicable construction Code.
8.1.2
All intended materials for Code Items shall be in compliance with the Code, only
materials accepted by the applicable construction Code, shall be used in the
fabrication of Code Items.
8.2
BILL OF MATERIALS AND PURCHASING SPECIFICATIONS
8.2.1
The Bill of Materials as given in fabrication drawings shall indicate the item, the
SA, SB or other Code acceptable specification, dimensions and the Purchasing
Specification (Exhibit 8.1) applicable for the item.
8.2.2
The Purchasing Specification shall include all the material requirements per
Section II of the Code, any construction Code requirement, heat treatment, the
requirements for MTR, the requirements for marking, any supplementary
requirement, Charpy impact Test or further material testing. For purchase of
certified parts as U-parts requirements set in U-2(j) will be considered and a PS
shall be issued.
8.2.3
Design Engineer, QC Manager or Designated Welding Supervisor can elaborate
the Purchasing Specification. The Purchasing Specification shall be approved by
the EM using the DMS.
8.2.4
The Bill of Materials and the Purchasing Specifications are reviewed against the
stock by the Warehouse Chief. If the material is not in the stock, the Warehouse
Chief or Field Manager creates a purchase request in the Management Software
indicating job number, item, Purchasing Specification and quantity. If the material
is in stock, the QC Inspector shall examine the material against the requirements
of the Code Edition of the applicable construction Code for the job, the job
requirements, bill of material and Purchasing Specification.
8.3
PURCHASE ORDERS
8.3.1
The Purchasing Manager creates the Purchase Order (Exhibit 8.2) from the
purchase request, which is sent to the selected vendor with the Purchasing
Specification attached. Electronic Authorization of PO in the Management
Software shall be by the Purchasing Manager.
8.3.2
Copies of the PO are filed by the QC Chief in the Job file.
8.3.3
The QC Chief forwards his copy to the QC Inspector at the field site.
8.3.4
Changes to PO's are handled in the same manner as the originals.
8.4
RECEIVING INSPECTION
8.4.1
All Code material received at the field site is placed into a "HOLD" area pending
the QC Inspector receiving inspection.
QC MANUAL
MATERIAL CONTROL
EDITION Nº 10
SECTION 8
REVISION 0
PAGE 2 OF 4
8.4.2
The Warehouse Chief verifies the material for type and quantity in accordance
with the PO. The QC Inspector using the Quality Control copy of the PO and the
Company Material Receiving Procedure JBPG-8.2 examines all Code material for
dimensions, marking and condition.
8.4.3
For material which requires Material Test Reports, the QC Chief reviews the MTR
against the requirements listed in Section II and the construction Code, and the
QC Inspector verifies the original marking identification found on the item at the
receiving inspection matches the one on the MTR.
8.4.4
The QC Inspector, if acceptable, marks the material with the Company coded
marking, which shall be traceable to the original marking, and acceptable to the AI
according to Material Traceability Procedure JBPG-8.3. Findings of material
condition are recorded on the Material Receiving Report (Exhibit No. 8.3, 8.4, 8.5,
8.6), signs and dates the Receiving Inspection Report and forward it to the QCC
for review and filing in the job file (welding gases are excepted). These files are
available for the AI.
When material is acceptable, the QC Chief signs and dates the MTR. The QC
Chief is responsible for filing the MTR in the job file.
8.4.5
If the material is received as ASTM material, the QCC shall review and assure
that the material has been certified as one of the acceptable editions of ASTM
showed on ASME Code Section II Part A or B. If the material is certified to
another ASTM/ASME edition, the QCC shall compare the specification shown on
the MTR with the required specification and if the material meets the Code
requirements, he stamps, sign and date the MTR or the Receiving Inspection
Report, certifying with evidence acceptable to the AI that the corresponding ASME
specification requirements have been met.
8.4.6
Material that does not meet all PO and Code requirements is marked HOLD on
the item and retained in a segregated area and controlled as described in Section
10 of this Manual.
8.4.7
Small parts and items will be placed in bags, boxes, or bins marked with the Job
number or PO number, and the required material identification.
8.5
RECEIVING INSPECTION OF CODE STAMPED PARTS OR MATERIALS
8.5.1
Code stamped parts are unloaded in the assigned lay-down area, and inspected
by the QC Inspector for damage, Code stamping and identification marking to
provide traceability to the Manufacturer’s Partial Data Reports, Data Reports,
Purchase Specifications and drawings.
8.5.2
The Manufacturer’s Partial Data Report must be received and verified against the
part stamping to the requirements of paragraph 8.3 before the QC Inspector can
release the item for further processing. Approval of the received part is recorded
by the ITP.
8.5.3
Parts that do not meet all Code and customer requirements are considered to be
nonconforming and are handled per Section 10 of this Manual.
8.5.4
The Manufacturer’s Partial Data Report shall be made available to the AI for review.
QC MANUAL
MATERIAL CONTROL
EDITION Nº 10
SECTION 8
REVISION 0
PAGE 3 OF 4
8.6
CUSTOMER SUPPLIED MATERIAL
8.6.1
All Code material supplied by the customer or his designee is received and
inspected as described above. The drawing and the Purchasing Specification
prepared per this Section is used during receiving inspection to assure Code
compliance.
8.6.2
Nonconforming material is handled per Section 10 of this Manual.
8.7
STOCK
8.7.1
Material in stock shall be re-examined by the QC Inspector in accordance with
paragraph 8.4; the Code Section Edition used for the job and the job requirements
showed on the Purchasing Specification, shall be considered for the acceptance
of the material
8.7.2
Nonconforming material is handled per Section 10 of this Manual.
8.8
MATERIAL SUBSTITUTIONS
8.8.1
8.9
MATERIAL IDENTIFICATION
8.9.1
The material identification shall be documented by the QC Inspector on the
Materials Traceability Record (Exhibit 8.7). The marking system and method of
marking must be acceptable to the AI.
8.9.2
Prior to cutting any Code material into two or more pieces, the Company coded
marking shall be transferred to each piece by the operator.
8.9.3
Prior to cutting or splitting containers or bundles of Code material in storage, the
required material identification is recorded by the QC Inspector on the Materials
Traceability Record to maintain the traceability. The remaining material shall be
identified in storage showing the Company traceability code.
8.10
8.11
Material substitutions are allowed after approval by the EM and QC Manager with
the concurrence of the AI. The applicable documents shall be revised in
accordance with the requirements of this Manual.
FURTHER MATERIAL TESTING
8.10.1
If the material requires any further material testing, it will be done in accordance
with the requirements of the Code. The QC Chief shall prepare NCR or an
Inspection and Testing Plan (Exhibit 9.1) for this purpose.
8.10.2
Test results shall be reviewed and accepted by the QC Manager and shall be
made available to the AI for review.
STORAGE
QC MANUAL
MATERIAL CONTROL
EDITION Nº 10
SECTION 8
REVISION 0
PAGE 4 OF 4
8.11.1
The Warehouse Chief is responsible to store Code material in the proper zone
with the proper identification.
8.11.2
The QC Chief shall verify proper storage of the material.
8.11.3
Material transfer between sites are not acceptable.
8.12
RECORDS
8.12.1
All records described in this Section are filed in the job file and are made available
for review by the AI.
8.12.2
The QC Inspector shall prepare and maintain in the job file the Materials
Traceability Record.
QC MANUAL
EXAMINATION AND
INSPECTION PROGRAM
EDITION Nº 10
SECTION 9
REVISION 0
PAGE 1 OF 2
9.1
FIELD ASSEMBLY
9.1.1
Field, manufacturing and assembly of Code items is controlled by the use of
drawings, the ITP and the Welding List.
9.1.2
The ITP is prepared by the Field QC Chief.
9.1.3
The QC Chief presents the ITP, welding list and drawings to the AI for review,
acceptance and designation of Inspection Points prior to start the manufacturing
or field assembly. The QC Chief / QC Manager and the AI will initial and date the
ITP to document their review and acceptance.
9.1.4
All inspections during manufacturing or assembly shall be performed in
accordance with the activities listed in the ITP and the Welding List. The ITP and
the Welding List contains space for the initials and date of the QC Inspector and
the AI for those operations they accept. Hold points designated by H on the ITP
are inspection points that shall not be bypassed and require the notification to the
AI by the QC Manager or QC Inspector.
For Section I the visual examination in process shall be according to PG-75.
9.1.5
In case an ITP revision is issued, old revisions shall be maintained attached to the
new revision.
9.2
FINAL INSPECTION
9.2.1
When the fabrication or assembly of a Code item is completed, the QC Chief and
the AI will make their final inspection and initial and date the ITP when the item
meets Code requirements.
9.2.2
When a pressure vessel is not provided with an inspection opening permitting
access to inspect internal surfaces a Hold Point for the QC Chief or QC Inspector
and the AI will be shown to permit internal inspection before making the final
closure weld.
9.3
PRESSURE TEST
9.3.1
EM has defined that pressure test made in the field, shall be hydrostatic only.
9.3.2
The final pressure test in accordance with the Company Procedure will be
witnessed by the QC Inspector and the AI and will be applied by the Field Chief
after the completion all fabrication and assembly as specified on the ITP.
9.3.3
When the pressure test is completed satisfactorily the QC Inspector and the AI will
initial and date the Pressure Test Report (Exhibit 9.2) and the ITP.
9.3.4
At least one directly connected pressure gage visible to the operator controlling
the pressure test and having a range of about double the intended maximum test
pressure but not less than one and one half (1-1/2) nor more than four (4) times
the test pressure shall be used for the test. Hydrostatic head on the gage shall be
considered depending on the location of the gage.
QC MANUAL
EXAMINATION AND
INSPECTION PROGRAM
EDITION Nº 10
SECTION 9
REVISION 0
PAGE 2 OF 2
9.3.5
9.4
An additional pressure gage may be necessary to allow the test pressure to be
visible to the operator at all times during the test to prevent excessive pressure
being applied.
MANUFACTURER’S DATA REPORTS AND STAMPING
9.4.1
Upon completion of manufactured or field assembled Code item the
Manufacturer's Data Report (MDR) is completed from final records by the EM
and certified by the QC Manager.
9.4.2
The completed Manufacturer's Data Report (MDR) and final records will be
presented to the AI for his review. When he has satisfied himself that all Code
requirements have been met he sign the Manufacturer's Data Report (MDR),
authorize and witness the application of the ASME Certification Mark on the item
or on a nameplate attached to the item in accordance with the construction Code
requirements.
9.4.3
The ASME Certification Mark and required Boiler Stamping Information or Pressure
Vessel Stamping Information shall be stamped on the Code Item or on a
nameplate as applicable, attached to the Code Item as permitted by the Code.
The QC Inspector shall verify the correct stamping on the nameplate in
accordance with Code and attachment to the correct item. Alternative methods for
applying the ASME Certification Mark are not allowed.
9.4.4
All records described in this Section are collected at the completion of the Job by
the QC Chief for retention in the Job file. Copies of the Manufacturer's Data
Report (MDR) shall be furnished by QC Manager to the user (and Jurisdiction
and AI when request) of the Code Items or his designated agent.
9.5
NONCONFORMITIES
9.5.1
All non-conformities found during fabrication, installation, or assemblies are handled
as described in Section 10 of this Manual.
QC MANUAL
CORRECTION OF
NONCONFORMITIES
EDITION Nº 10
SECTION 10
REVISION 0
PAGE 1 OF 2
10.1
IDENTIFICATION OF NONCONFORMITIES
10.1.1
A nonconformity is any condition which does not comply with the applicable rules
of the Code, this Manual or other specified requirements. Nonconformities must
be corrected before the completed component can be considered to comply with
the Code.
10.1.2
It is the duty of all Company employees to report non-conformities to their
supervisor who shall notify the QC Inspector. The QC Inspector shall verify the
nonconforming condition and mark the material or fabrication with “Hold”,
complete a Nonconformity Report (Exhibit 10.1) and include the number of the
Nonconformity Report on the Inspection and Testing Plan. If practicable the
nonconforming item or material shall be moved to a segregated area.
10.1.3
The Nonconformity Report together with his suggested disposition signed by the
QC Inspector is forwarded to the QC Manager, and the EM for review and
approval.
10.2
CORRECTION OF NONCONFORMITIES
10.2.1
USE-AS-IS: When the disposition is use-as-is the QC Manager will consult with
and obtain the approval of the EM. Any required revisions to drawings,
calculations, specifications, and procurement documents will be done as
described in this Manual. All such dispositions must meet the Code requirements
and have AI concurrence.
10.2.2
REPAIR AND REINSPECT: When the disposition requires repair, it shall be
made using procedures and Inspection and Testing Plan approved by the QC
Chief, and accepted by the AI. Repair proposed disposition shall be submitted to
the AI for acceptance of the method and extent of repair, and designation of
required inspection points on the NCR or Inspection and Testing Plan prepared
prior to making the repair.
10.2.3
SCRAP OR RETURN TO VENDOR: When the disposition taken by QC Manager
is to scrap or return to vendor the QC Inspector shall verify that the item or
material has been removed from the work area and is clearly marked “Reject” to
prevent its inadvertent use prior to disposal.
10.2.4
OTHER: When the disposition is “OTHER”, is applicable to changes on drawings,
specifications, procedures, implementation of this Manual, etc. The QC Manager
will consult with the document originator for changes required. All such
dispositions must meet the Code requirements and have AI concurrence.
10.2.5
The QC Inspector shall re-inspect the item or material after the disposition as
described above and when he has satisfied himself that they meet Code
requirements and AI's inspection points have been accepted, QCI and AI will sign
the Nonconformity Report, remove the "Hold" marking, and permit the item or
material to return to its proper sequence of fabrication.
QC MANUAL
CORRECTION OF
NONCONFORMITIES
EDITION Nº 10
SECTION 10
REVISION 0
PAGE 2 OF 2
10.2.6
Completed Nonconformity Reports are returned to the QCC for review and when
he has satisfied himself that they have been completed as required he shall file
them in the Job file.
10.2.7
All records of non-conformities are made available to the AI for review and
acceptance.
10.3
REPAIR OF DEFECTS IN MATERIALS: Defects in materials may be repaired
provided acceptance by the AI is first obtained for the method and extent of
repairs. Defective material that cannot be satisfactorily repaired shall be rejected.
QC MANUAL
WELDING CONTROL
EDITION Nº 10
SECTION 11
REVISION 0
PAGE 1 OF 4
11.1
GENERAL
11.1.1
All welding on Code Items shall be performed using Welding Procedure
Specifications (WPS) and welders or welding operators qualified in accordance
with the applicable Code of Construction and Section IX of the Code.
11.1.2
For the supervision, control, evaluation, and acceptance of qualification testing
(PQRs, WPQs, WOPQs), the personnel involved shall be designated as
Designated Welding Supervisor/s by the QCM as required by QG-106 (exhibit
11.5 and 11.6 or 11.7). The QCM is responsible to keep updated records with
objective evidence of the qualification, training or experience.
Personnel shall be qualified based on experience (at least six months) in
manufacture of pressure vessels, boilers or welding inspection and have formal
training in the following areas:
_ Section IX for the qualification of procedures and/or joining personnel and the
scope, complexity, or special nature of the activities to which oversight is to be
provided.
_ Company՚s Quality Program
11.2
WELDING PROCEDURE SPECIFICATION (WPS)
11.2.1
WPSs are written by the Designated Welding Supervisor. The Designated
Welding Supervisor shall monitor and record all actual essential and
supplementary essential (if applicable) variables during the welding of test
coupons. QC Inspector shall provide full supervision and control of Welders
during production of these test coupons. The Designated Welding Supervisor
reviews the test report submitted by the laboratory and if acceptable he prepares
and certifies the Procedure Qualification Record (PQR).
11.2.2
Originals of qualified WPS and PQR and laboratory test reports are maintained
by the QC Manager. Copies of the WPS are provided to the Field Manager for
use by the Welders and Welding Operators. Copies of the WPS and PQR shall
be maintained in the job file by the QC Chief.
11.2.3
WPSs are revised when there is a change in a nonessential variable and a new
WPS shall be qualified when there is a change in an essential or supplementary
essential variable.
11.2.4
WPSs and PQRs are made available to the AI for review. The AI may witness
welding of a WPS for cause.
11.3
QUALIFICATION OF WELDERS AND WELDING OPERATORS
11.3.1
All Welders and Welding Operators to be used for Code welding are qualified to
Section IX and the Construction Code under the full supervision and control of
the Designated Welding Supervisor who is responsible for monitoring and
recording the actual variables. The Designated Welding Supervisor shall assure
that the required specimen preparation and its testing by Company or a
laboratory meets the Code requirements. The report of test is reviewed by the
Designated Welding Supervisor. and if acceptable he prepares and certifies the
QC MANUAL
WELDING CONTROL
EDITION Nº 10
SECTION 11
REVISION 0
PAGE 2 OF 4
Welder or Welding Operator Performance Qualification Test Report (WPQ /
WOPQ).
11.3.2
The QC Chief issues each qualified Welder and Welding Operator an identifying
letter, number or symbol with which they identify each weld, continuous weld or
series of similar joints they make at intervals of no more than 1 m.
11.3.3
Copies of the WPQ / WOPQ are received and maintained by the Field QC
Inspector. The original records and reports of test are maintained by the QC
Manager. The QC Chief is responsible for maintaining copies of the WPQ/WOPQ
in the Job file
11.3.4 WPQ / WOPQ are available for review by the AI who may request re-qualification
and witnessing at any time of Welder or Welding Operator tests whenever there
is a specific reason to do so.
11.4
REQUALIFICATION OF WELDERS AND WELDING OPERATORS
11.4.1 Welders and welding operators are re-qualified when:
a)
A change in one or more of the Essential Variable occurs for each
welding process.
b)
They have not welded with a process and method for a period of six (6)
months or more their qualifications for that process shall expire; unless,
within the six month period, prior to his expiration of qualification,
(1) a welder has welded under direct supervision of the QC Inspector
with that process using manual or semiautomatic welding, that will
extend his qualification for an additional 6 months;
(2) a welding operator has welded under direct supervision of the QC
Inspector with that process using machine or automatic welding, that
will extend his qualification for an additional 6 months (machine
process extends machine and automatic; automatic extends only
automatic).
c)
Where there is reason to question their ability to make welds that meet
the specification, the qualifications that support the welding they are
doing shall be revoked. All other qualifications not questioned remain in
effect.
11.4.2 Renewal of qualifications shall be in accordance with QW-322.3.
11.5
MAINTENANCE OF WELDER QUALIFICATIONS
11.5.1
Each welder and welding operator is listed on the Welder Log (Exhibit 11.2)
maintained by the QC Chief from every six-month data provided by QC
Inspectors using the welding list. The Welder Log indicates if the welder or
welding operator has welded in each process and type this period. The QC Chief
determines from the Welder Log, when a welder or welding operators
qualifications are about to expire. The QC Chief notifies the Field Chief so they
QC MANUAL
WELDING CONTROL
EDITION Nº 10
SECTION 11
REVISION 0
PAGE 3 OF 4
can assure that the welder or welding operator welds in the required process or
processes or is properly re-qualified in accordance with 11.4.1.
11.6
PRODUCTION WELDING
11.6.1
The Field Chief and the QC Chief are responsible for assigning all production
welders by using the Qualified Welders List (Exhibit 11.3). The QC Inspector
instructs them in the WPS they are to use as listed on the drawings for each
weld.
11.6.2
Tack welds whether left in place or removed are made by qualified welders using
qualified procedures.
11.6.3
Welders making tack welds shall be recorded by the QC Inspector for each weld
that they make by entering their stamps on the Welding List.
11.6.4
Tack welds left in place shall be properly prepared for inclusion into the weld,
visually examined by QC Inspector, and if found defective, shall be removed.
This examination shall be documented on the Inspection and Testing Plan.
11.6.5
Tack welding performed by others, shall be made using a qualified company
procedure, provided by the QC Chief and shall be removed before the welding.
11.6.6
Welder identification shall be recorded by QC Inspector for each weld that they
made (including tack weld) by entering their identifications on the welding list
(Exhibit 11.1).
11.6.7
Company does not subcontract welding activities.
11.6.8
Preheating, interpass temperatures and thermal cutting operations shall be
accordance with PW-38. It shall be controlled by QC Inspector or welders using
calibrated instruments.
11.7
WELDING MATERIAL
11.7.1
The welding material is requested by the Field Manager based on the information
of the WPS. The Purchasing Specification shall be reviewed and approved by the
QC Chief. Welding material is purchased and received as described in Section 8.
11.7.2
Welding materials are stored in a controlled storage area. Welding materials
issued to welders and welding operators shall be authorized by the Field Chief by
using the Welding Material Voucher (Exhibit 11.4).
11.7.3
Low hydrogen coated electrodes will be received and stored in sealed
containers. When the containers are opened the electrodes are placed in heated
ovens maintained at the temperature recommended by their manufacturer or
ASME Code Section II Part C prior to issuance to welders.
11.7.4
Welding Material is issued by the Warehouse Attendant only in a quantity
sufficient to complete the weld or for an eight hours period whichever is less. Low
Hydrogen electrodes shall be stored in heated portable ovens.
QC MANUAL
WELDING CONTROL
EDITION Nº 10
SECTION 11
REVISION 0
PAGE 4 OF 4
11.7.5
11.8
Unconsumed electrodes are returned to the Warehouse Attendant and are
inspected for damage, and identification before returning to a storage oven. Any
electrode-received cold and/or damaged shall not be used for Code work.
Unacceptable electrodes are scrapped. Rebake of the electrode are not allowed.
WELDING RECORDS
11.8.1 All records referenced in this section are available for review by the AI.
11.9
PREVIOUS WORKS FROM JULIO BERKES S.A.
11.9.1 Berkes-BWE assumed responsibility of documents issued by Julio Berkes S.A, in
accordance with requirements from QW-107.
QC MANUAL
NONDESTRUCTIVE
EXAMINATION
EDITION Nº 10
SECTION 12
REVISION 0
PAGE 1 OF 2
12.1
SCOPE
12.1.1
12.2
All NDE required by the Code (as stipulated on design documents) will be
performed by the Company’s personnel or subcontractors. In both cases written
practice, personnel qualifications, records, procedures and equipment calibration
shall be reviewed and approved by the QC Manager.
The NDE procedures shall be in accordance with ASME Code Section V and the
applicable construction Code.
NDE PROCEDURES
12.2.1
PT, MT, RT is performed using written procedures approved by a Level III
Examiner qualified in the specific method and certified as the Company Level III
(or subcontracted Level III), and reviewed and approved by the QC Manager.
12.2.2
All procedures are detailed enough to provide the technique to meet the Code
Section used for Construction requirements and they are reviewed and approved
by the QC Manager in accordance with Table 17.1 of this Manual.
12.2.3 All NDE procedures / written practice will be submitted for review by the AI. The
AI can require demonstration of and NDE procedure by NDE personnel for cause.
12.2.4 NDE procedures from sub-contracted companies shall be reviewed and approved
by the QC Manager.
12.2.5
RT, PT and MT and procedures shall be demonstrated to the satisfaction of the
AI and shall be certified by the QC Manager as meeting the requirements of
Section V Paragraph T-150.
12.2.6 VT is performed using a written procedure prepared by Level III and reviewed and
approved by the QC Manager.
12.2.7
12.3
QC Chief is responsible for ensuring that the procedures are available to
NDE personnel, at the work area.
NDE PERSONNEL
12.3.1
The Company’s NDE personnel shall be qualified and certified in accordance
with the Company’s written practice which shall be based on SNT-TC-1A as
modified by Section V, Article 1. QC Manager shall review level III’s qualifications
based on his written practice and upon satisfactory results, QC Manager shall
appoint him by letter as Company’s level III.
12.3.2
Subcontracted NDE personnel shall be qualified and certified in accordance with
the Subcontractor’s written practice which shall be based on SNT-TC-1A as
modified by Section V, Article. This written practice and their NDE personnel
qualification records shall be reviewed and approved by the Company’s Level III
and the QC Manager. These records shall be maintained on file by the QC
Manager.
QC MANUAL
NONDESTRUCTIVE
EXAMINATION
EDITION Nº 10
SECTION 12
REVISION 0
PAGE 2 OF 2
12.3.3
NDE personnel qualification records are available to the AI for review and
acceptance. The AI may request re-qualification if he has reason to question their
ability to perform the examination.
12.3.4
VT Examiners shall be qualified and certified in accordance with the Company´s
Written Practice, based in ASME B 31.1 requirements.
12.4
NDE REPORTS
12.4.1
All reports of NDE, including RT film, are reviewed and approved by the QC
Chief prior to submittal to the AI for his review. For NDE performed at a field site
the Field QC Inspector performs the review prior to submittal to the AI.
12.4.2
All NDE reports, including RT film, are filed by the QC Chief in accordance with
the Section 15 of this Manual
12.5
CALIBRATION OF NDE EQUIPMENT
12.5.1
NDE subcontractors shall be responsible for calibration of NDE equipment.
Verification shall be done by the QC Chief.
12.5.2
NDE equipment shall be calibrated. Densitometer shall be calibrated at least
every three months and record of calibration shall be available for review.
Calibration shall be carried in accordance with ASME Section V, Article 2, T-262.
12.5.3
The calibration records (including for subcontractor) shall be maintained on file
by the QC Chief and made available to the AI for review.
QC MANUAL
HEAT TREATMENT
EDITION Nº 10
SECTION 13
REVISION 0
PAGE 1 OF 1
13.1
GENERAL
13.1.1 Heat treatment, required by the Code, (as stipulated on the drawings) is
performed by the Company’s personnel or by a subcontractor using calibrated
equipment in accordance with the HT procedure (JBPG-13.1 Heat Treatment
and exhibit 13.1 Heat Treatment Record), which is prepared and approved by
the Design Engineer.
13.1.2 The QC Inspector will review and approve the controls, equipment and
calibration records prior to initiating any Heat Treatment required by the Code.
13.2
HEAT TREATMENT INSTRUCTION
13.2.1 All Code Heat Treatment is performed as specified in written instruction
approved by the Design Engineer, which describes the placement and the
method of attachment and removal of thermocouples, heating and cooling
rates, time at temperature and the required records as a minimum.
13.3
RECEIVING INSPECTION
13.3.1 The QC Inspector is responsible for the item identification prior to HT and he
shall examine all items for damage and identification during the receiving
inspection. Nonconformities will be handled as described in Section 10 of this
Manual.
13.4
HEAT TREATMENT RECORDS
13.4.1 Heat Treatment records shall be actual furnace charts which record the
conditions; identification of thermocouples, items treated, and shall be signed
and dated by the furnace or equipment operator including the instruction used.
13.4.2 Heat treatment records are reviewed and approved by the field QC Inspector.
13.4.3 Heat treatment records, including procedures and calibration records, are
submitted to the AI for review and acceptance by the QC Chief.
13.4.4 After review and approval, the QC Inspector and the acceptance by the AI, heat
treatment records are filed by the QC Inspector in the Job file.
QC MANUAL
CALIBRATION
EDITION Nº 10
SECTION 14
REVISION 0
PAGE 1 OF 2
14.1
GENERAL
14.1.1
14.2
All measurement, test, and examination equipment used in fulfillment of
requirements of the Code shall be calibrated in accordance with this Section.
CALIBRATION PROCEDURE
14.2.1
Each item of measurement, test and examination equipment which requires
calibration is identified by a unique number on the item and which is recorded on
the applicable Instrument List.
14.2.2
The QC Chief is responsible for maintaining all equipment in calibration, unless
out of service and clearly marked "NOT USE". Out of calibration equipment shall
also be marked in the same manner.
14.2.3
Calibration shall be performed by a testing laboratory or by the QC Inspector
using national recognized standards and providing certified records of calibration.
Calibration certificates supplied by the subcontractors and QC Inspector
calibration results shall be reviewed and approved including accuracy by the QC
Chief and recorded on the Calibration Control Record (Exhibit 14.1).
14.2.4
Pressure gauges used for final pressure tests are calibrated against a calibrated
dead weight tester or compared to a calibrated master gauge every year.
14.2.5
The frequency of calibration for other equipment is as indicated by recognized
standards, the Code or recommended by the equipment manufacturer, or from
experience with the equipment. The frequencies of calibration are indicated in the
calibration control system of instruments see Procedure JBPG-14.1 (Instruments
Calibration).
14.3
RECORDS
14.3.1
Calibrated equipment shall be identified through the an unique number and the
use of a Calibration Sticker (Exhibit 14.2) attached to the equipment or the
equipment container if too small for the sticker to be attached. The Calibration
Sticker shall list the date calibrated, expiration date and the person who made or
approved the calibration.
14.3.2
Calibration records including those of subcontractors that perform NDE, HT and
mechanical testing are kept in QC file by the QCC and shall be available to the AI
for review.
14.4
DISCREPANT EQUIPMENT
14.4.1
When equipment requiring calibration is found to be out of calibration it shall be
tagged "NOT USE" by the QCI, removed from the work area, repaired, recalibrated, or replaced.
14.4.2
Damaged equipment or the equipment that generates doubt (when the error is
suspected) shall not be used until be re-calibrated. It shall be tagged “Not Use”.
QC MANUAL
CALIBRATION
EDITION Nº 10
SECTION 14
REVISION 0
PAGE 2 OF 2
14.4.3
If any inspection were performed using equipment without calibration in
manufacturing or assembly of Code items, a NCR shall be issued in accordance
with Section 10.
QC MANUAL
RECORDS RETENTION
EDITION Nº 10
SECTION 15
REVISION 0
PAGE 1 OF 2
15.1
GENERAL
15.1.1
The QC Manager collects all records described in this manual at completion of
the job, and reviews them for completeness, correctness and Code compliance
before he prepares the Manufacturer’s Data Report. He is responsible to
maintain all records in a manner that prevents damage, deterioration and loss.
15.1.2
Manufacturer’s Data Reports, after certification by the QC Manager, are
presented to the AI with the job file for his signature. The QC Manager shall
distribute the MDR to the user, the AIA, and the Jurisdiction, if applicable.
15.1.3
Manufacturer’s Data Reports shall be kept for a minimum of 3 years for Section
VIII Division , and 5 year for Section I.
15.1.4
For Section VIII, Division 1 vessels the following records shall be kept for three
years:
 Manufacturer’s Partial Data Reports
 Manufacturing drawings
 Design Calculations including any applicable Proof Test Reports
 Material Test Reports and/or material certifications
 Pressure Parts documentation and certifications
 WPSs and PQRs
 Welder / Welding Operator Performance Qualification Records for each
welder who welded on the vessel and continuity records for each one of
them.
 NDE interpretation reports
 Repair procedures and records
 Process Control Sheets (ITP, Welding List)
 Heat treatment records and Test Results Records
 Post Weld Heat Treatment records
 Non-conformances and dispositions
 Hydrostatic test records
 Transfer Forms
15.1.5
For Section I items, the following records shall be kept for five years.
 Manufacturer’s Partial Data Reports
 A complete set of RT reports.
 UT reports.
 Welder / Welding Operator Performance Qualification and continuity
records for each Welder employed in the item construction / assembly.
 Welding procedures and qualifications
15.1.6
For Section VIII Division 1 and Section I a complete set of Radiography films,
for each Code Item shall be retained, until the Manufacturer´s Data Report has
been signed by the AI.
QC MANUAL
AUTHORIZED INSPECTOR
EDITION Nº 9
SECTION 16
REVISION 0
PAGE 1 OF 2
16.1
GENERAL
16.1.1
Company shall have a Contract for Inspection Services with an ASME
accredited AIA who employs AI's. The AI is the third party inspector required by
the ASME Code, and holds a current NB “AI” Commission.
16.1.2
Work shall not proceed beyond the AI's Hold Points until he has witnessed or
verified the operation and initialed and dated the Inspection and Testing Plan
per Section 9 of this Manual.
16.1.3
The QC Manager is the company's liaison with the Authorized Inspection Agency
(AIA) and the AI. At field sites the QC Chief is the company's liaison. They are
responsible for keeping the AI advised of the progress of the work so that he may
be present to make his designated Hold Points, including any scheduled
pressure tests.
16.1.4
The AI shall have access to all drawings, calculations, specifications, procedures,
process sheets, repair procedures, proof test reports, records, tests results, and
any other documents as necessary for the inspector perform his duties.
16.1.5
All Nonconformity Reports are submitted by the QC Manager to the AI (per
Section 10) for his acceptance.
16.1.6
A controlled copy of the Manual is available by the QC Manager for use by the AI
in the field sites.
16.1.7
The AI and Authorized Inspector Supervisor (AIS) shall be provided with free
access to the field sites where Code work is performed and to such parts of all
plants and facilities that are concerned with the manufacture and supply of Code
material as requested.
16.1.8
The QC Manager will provide any assistance requested by the AI during his
monitoring of the Quality Control System and to the AIS during the Audits.
16.1.9
The Authorized Inspector shall review and accept all changes to the Manual,
prior to implementation.
16.1.10 When requested by the Purchaser, or whenever the AIA of record cannot provide
coverage for inspection at a specific field site, the ASME required inspections of
the Code items may be conducted by an secondary AIA selected by the
purchaser provided the following details are met.
1)
The Company liaison with the AIA of Record shall inform the AI of the AIA of
Record of this request and provide objective evidence indicating this request by
the purchaser or objective evidence of the lack of coverage at the specific field
site.
2)
The QC Manager shall make a copy of the company’s QC Manual available for
use by the secondary AIA performing the inspections.
QC MANUAL
AUTHORIZED INSPECTOR
EDITION Nº 9
SECTION 16
REVISION 0
PAGE 2 OF 2
3)
The Company shall enter into a written agreement with the secondary AIA
performing the Code inspections.
4)
If the secondary AIA request modifications to this Manual or associated
procedures, these modifications shall be presented to the AI of the AIA of record.
5) The item will be supplied to a second party, who is a valid ASME Certificate
Holder, and the contract requires the use of the second party’s AIA of Record.
16.1.11 QC Manager is responsible to inform ASME if the AIA is changed or cancelled.
16.1.12
The AIA identified on the ASME application for a new issuance, renewal of
Certificate of Authorization, current inspection contract, or agreement with an AIA
is known as, and hereafter referred to as, the Authorized Inspection Agency of
Record. The AIA of Records is responsible for all inspection services under the
scope of the Certificate of Authorization.
QC MANUAL
EDITION Nº 10
CERTIFICATIONS AND EXHIBITS INDEX
SECTION 17
REVISION 0
PAGE 1 OF 6
17.1 QUALITY DOCUMENTS MANAGEMENT SYSTEM AND CERTIFICATION METHOD
17.1 Provisions for approvals, acceptance, issuance, distribution and revisions are listed in Table 17.1
17.2 In case of documents managed by the DMS, authorization to access the system is managed by password and levels of
authorization are provided in the DMS system.
17.3 Revisions are uploaded to the DMS and approvals are done by DMS software. In some cases (as listed in Table 17.1)
acceptance or approval can be done by signature for some authorized individuals and final approval is done by DMS by
the QC Manager.
17.4 When a revision is approved, the DMS will send an email to the distribution list with the required information. DMS systems
includes a log to check that authorized individuals have accessed to the new revision. The person who approved the
revision is responsible to check that all the authorized individuals in the distribution list have accessed to the document.
17.5 Approvals and acceptance are identified by the DMS system log.
17.6 The AI will have access to the DMS system for revisions and acceptance.
17.7 Paper copies in field shall be controlled by the Field Manager and shall be registered in Exhibit 17.1. When a new revision is
issued, all previous revisions shall be retrieved and destroyed and the status shall be updated in Exhibit 17.1.
17.8 All documents sent to persons outside the Organization Chart shall be considered Non-Controlled.
17.9 Printed copies except for those registered in Exhibit 17.1 are considered Non-Controlled.
17.10 Superseded documents in DMS are retrieved by the software.
17.11 When electronic signature is used, approbation of the document by Quality Manager in DMS is required. Quality Manager
shall ensure the integrity of the certification, authorization or approval.
QC MANUAL
EDITION Nº 10
CERTIFICATIONS AND EXHIBITS INDEX
SECTION 17
REVISION 0
PAGE 2 OF 6
Table 17.1
Type
Owner / Preparation
Authorization / Approval
/ Certification
Acceptance
Certification method
Responsible for distribution and noncontrolled copies management
Quality Manual
pdf
QC Manager
General manager
(signature) / QC Manager
AI (signature)
Signature / DMS
At field: QC Chief. Otherwise: QC
Manager.
Procedures (not mentioned in this
table)
pdf
QC Manager
QC Manager
AI (signature)
Signature / DMS
At field: QC Chief. Otherwise: QC
Manager.
Exhibits (not mentioned in this
table) - FORMAT
pdf
QC Manager
QC Manager
Authorised Inspector if
requiered by the
procedure
Signature / DMS
At field: QC Chief. Otherwise: QC
Manager.
Exhibits (not mentioned in this
table) - ACTUAL LOG
paper
QC Inspector
QC Chief
Authorised Inspector if
requiered by the
procedure
Signature
QC Chief
Engineering Record
pdf
Engineering Manager
QC Manager
-
Signature / DMS
Design Engineer / QC Manager / QC
Senior Assistant
User design specification
pdf
Design Engineer
Engineering Manager
-
DMS
Design Engineer
Calculations
pdf
Design Engineer
Engineering Manager
-
DMS
Design Engineer
Drawings
pdf
Design Engineer
Engineering Manager
-
DMS
Design Engineer
Customer specifications
pdf
Design Engineer
Engineering Manager
-
DMS
Design Engineer
Bill of materials (if not included in
drawings)
pdf
Design Engineer
Engineering Manager
-
DMS
Design Engineer
Purchase specification
pdf
Design Engineer / QC
Manager / QC Senior
Assistant
Engineering Manager
-
DMS
Design Engineer / QC Manager / QC
Senior Assistant
Purchase orders
pdf
Purchasing Manager
-
-
Nodum
QC Chief
Material receiving reports
paper
Quality Inspector
QC Chief
-
Signature
QC Chief
Document
General
Chapter 7
Chapter 8
QC MANUAL
EDITION Nº 10
CERTIFICATIONS AND EXHIBITS INDEX
SECTION 17
REVISION 0
PAGE 3 OF 6
Materials traceability records
paper
Quality Inspector
Quality Inspector
AI
Signature
QC Chief
Chapter 9
ITP (Instruction)
excel
QC Chief
QC Manager
-
DMS
QC Manager / QC Chief
ITP (Actual Log)
paper
QC Chief
According to ITP
AI (signature)
Signature
QC Chief
Pressure test report
paper
Quality Inspector
Quality Inspector
AI
Signature
QC Chief
MDR
paper
Design Engineer
QC Manager
AI
Signature
QC Manager
Boiler stamping information
pdf
Design Engineer
Engineering Manager
-
DMS
Design Engineer
Pressure vessel stamping
information
pdf
Design Engineer
Engineering Manager
-
DMS
Design Engineer
paper
QC Inspector
QC Manager / Engineering
Manager
AI
Signature
QC Inspector
Welding list
paper
QC Chief
QC Manager
Authorised Inspector
Signature
QC Chief
Welder log
paper
QC Chief
QC Chief
-
Signature
QC Chief
Qualified welders list
pdf
QC Chief
-
-
-
QC Chief
Welding material voucher
paper
Field Chief
Field Chief
-
Signature
NA
Designation for Welding Inspectors
pdf
QC Manager
QC Manager
-
DMS
QC Manager
Certification to supervise welding
for WPS and PQR
pdf
QC Manager
QC Manager
-
DMS
QC Manager
Certification to supervise welding
for WPQ
pdf
QC Manager
QC Manager
-
DMS
QC Manager
PQR
pdf
QC Chief
QC Manager (if necessary
Designated Welding
Supervisor signature)
-
DMS
QC Chief
Chapter 10
Non conformity report
Chapter 11
QC MANUAL
EDITION Nº 10
CERTIFICATIONS AND EXHIBITS INDEX
SECTION 17
REVISION 0
PAGE 4 OF 6
WPS
pdf
QC Chief
QC Manager (if necessary
Designated Welding
Supervisor signature)
-
DMS
QC Chief
WPQ
paper
QC Chief
Designated Welding
Supervisor
-
Signature
QC Chief
NDE personnel written practice
pdf
Subcontractor NDE level
III
Company’s Level III
(signature) and QC
Manager
Authorised Inspector
(Signature)
Signature / DMS
QC Chief
NDE personnel qualifications
pdf
QC Manager
Company’s Level III
(signature) and QC
Manager
-
Signature / DMS
QC Manager
NDE procedures
pdf
Subcontractor NDE level
III
QC Manager
Authorised Inspector
(Signature)
Signature / DMS
QC Chief
Heat Treatment Records
(Instruction)
pdf
Design Engineer
Engineering Manager
Authorised Inspector
DMS
Design Engineer
Heat Treatment Records (Actual
log)
paper
Heat treatment operator
QC Inspector
Authorised Inspector
Signature
QC Chief
Calibration control record
pdf
QC Chief /QC Inspector
QC Chief /QC Inspector
-
DMS
QC Chief /QC Inspector
Calibration stickers
paper
QC Chief /QC Inspector
QC Chief /QC Inspector
-
Signature
QC Chief /QC Inspector
paper
Field Manager / QC Chief
/ QC Manager / QC
Inspector
-
-
Signature
Field Manager / QC Chief / QC
Manager / QC Inspector
Chapter 12
Chapter 13
Chapter 14
Chapter 17
Non-controlled copies
management
QC MANUAL
EDITION Nº 10
CERTIFICATIONS AND EXHIBITS INDEX
SECTION 17
REVISION 0
PAGE 5 OF 6
17.2 EXHIBITS INDEX
EXHIBIT
No.
7.1
TITLE
Engineering Record
8.1
Purchasing Specification
8.2
Purchase Order
8.3
Receiving Inspection Report (Plates)
8.4
Receiving Inspection Report (Pipe And Tubes)
8.5
Receiving Inspection Report (Heads)
8.6
Receiving Inspection Report (Miscellaneous)
8.7
Materials Traceability Record
9.1
Inspection and Testing Plan
9.2
Pressure Test Report
10.1
Nonconformity Report
11.1
Welding List
11.2
Welder Log
11.3
Qualified Welders List
11.4
Welding Material Voucher
11.5
Company Letter Designation for welding inspectors
11.6
Form for Certification to Supervise Welding for Procedure and Performance Qualification Test Coupons
11.7
Form for Certification to Supervise Welding for Performance Qualification Test Coupons
13.1
Heat Treatment Record
QC MANUAL
EDITION Nº 10
CERTIFICATIONS AND EXHIBITS INDEX
SECTION 17
REVISION 0
PAGE 6 OF 6
14.1
Calibration Control Record
14.2
Calibration Sticker
17.1
Printed copies and non-controlled copies management