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Hardy Machine & Design, Inc. 5737 Windfern Houston, Texas 77041

QUALITY CONTROL MANUAL ASME “U” STAMP

FOR PRESSURE VESSELS

MASTER COPY February 23, 2004

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Quality Assurance Manual

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REVISION SHEET REV

DATE

DESCRIPTION

BY

CHECKED

Q.A.M

Approved By: ____________________

Date: ____________________

A.I.

Accepted By: ____________________

Date: ____________________

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Table of Contents 1.

GLOSSARY .................................................................................................................................. 3

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2.

STATEMENT OF POLICY AND AUTHORITY ..................................................................... 7

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3.

MANUAL CONTROL................................................................................................................. 8

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4.

DRAWING, DESIGN CALCULATIONS AND SPECIFICATION........................................ 9

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5.

MATERIALS CONTROL ........................................................................................................ 12

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6.

EXAMINATION AND INSPECTION PROGRAM ............................................................... 14

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7.

CORRECTION OF NONCONFORMITIES .......................................................................... 18

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8.

WELDING CONTROL ............................................................................................................. 20

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9.

NON DESTRUCTIVE EXAMINATION - NDE ..................................................................... 25

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10.

POSTWELD HEAT TREATMENT ........................................................................................ 27

11.

CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT .................................... 29

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12.

RECORDS RETENTION ......................................................................................................... 30

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13.

AUTHORIZED INSPECTOR .................................................................................................. 31

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14.

ANNUAL AUDIT ....................................................................................................................... 33

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15.

CONTROL OF CODE STAMP................................................................................................ 34

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ORGANIZATIONAL CHART ................................................................................................. 35

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0 0 0 0 17.

NATIONAL BOARD OF REGISTRATION........................................................................... 36

18.

EXHIBITS .................................................................................................................................. 37

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Q.A.M

Approved By: ____________________

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0

A.I.

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Accepted By: ____________________

Date: ____________________

1. GLOSSARY As used in the quality Control Manual, the following terms and abbreviations are defined:

AI Authorized Inspector from the ASME accredited Authorized Inspection Agency for Code items. Approve Signature/initials including date of acceptance as being in compliance with Code and Client Requirements. ASME American Society of Mechanical Engineers ASNT American Society for Nondestructive Testing Code The Applicable Codes and Standards to which work is being performed. This may be the ASME Boiler and Pressure Vessel Code, Sections I, V, VIII DIV. 1 and IX and associated ANSI Standards or Local Jurisdictional codes also National Board requirements. Client The contract requirements supplied by the Client to which Hardy Machine & Design is responsible for compliance. Client Requirements may include design specifications or drawings or applicable data from specifications as necessary for Hardy Machine & Design to perform fabrication and installation in compliance with the Code(s). Printed copies of this manual are Uncontrolled

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Customer/Client The organization that has instructed, by Contract, that Hardy Machine & Design furnishes fabrication services. Also applies to designees or representatives of the customer. Data Report Appropriate Code Form completed by the fabricator certifying Code compliance and certified by Authorized inspector. Department When department is specified, it shall be interpreted as being the manager of that department's responsibility or his designated representative. Design The basic owner document including specifications, drawings and calculations, which are required. Document A drawing, calculation, specification, procedure, instruction or other controlled printed information. Documentation Any form, record, or drawing that contributes to traceability or verification. Example Forms Attachments to this manual for "as-is" use or modification to project forms. Items Material, parts, sub-assemblies, components or services. Manual This Quality Control Manual. MT Magnetic Particle Examination (a form of NDE) Printed copies of this manual are Uncontrolled

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NBIC National Board Inspection Code NDE Nondestructive Examination - A method of indicating flaws in material or parts without altering effective use of the material or parts. Examples are: RT, UT, MT, PT, VT. PT Liquid Penetrant Examination (a form of NDE) Project Document A document prepared for a specific project either totally or by modification of a generic document. Q.A.M. Quality Assurance Manager Q.C. Quality Control QCSM Quality Control System Manual Repair Process of restoring a nonconforming characteristic to a condition so that the capability of an item to function reliably and safely is unimpaired, even though that item still may not conform to the original requirement. However, in all cases, it must conform to the Code as required. Rework Process by which a nonconforming item is made to conform to a prior specified requirements by completion, re-machining, reassembling, or other corrective means.

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RT Radiographic Examination (a form of NDE) SNT-TC-1A ASNT Recommended Practice SNT-TC-1A Code Accepted Condition UT Ultrasonic Examination (a form of NDE) Vendor A material manufacturer, material supplier, or subcontractor providing services. WPS Welding Procedure Specification

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2. STATEMENT OF POLICY AND AUTHORITY 2.1. This Quality Manual documents the quality system for manufacturing, fabricating and assembling of pressure vessels by Hardy Machine & Design which will meet all the requirements of the AMERICAN SOCIETY OF MECHANICAL ENGINEERS Boiler & Pressure Vessel Code Section VIII, Division 1. 2.2. Hardy Machine & Design management is totally committed to the execution of the procedures established in this Quality Assurance System and in complete compliance with A.S.M.E. Boiler & Pressure Vessel Code Section VIII, Division 1. 2.3. The Quality Assurance Manager of Hardy Machine & Design is delegated with authority and responsibility to establish, maintain, administer and audit this Quality Assurance System. It is his responsibility to formally report the findings, advise regarding corrective action and monitor that the proposed corrective action has been effectively implemented. 2.4. If during the implementation, conflicts arise regarding Code compliance between the Quality Assurance Manager and other departments, it will be resolved by the Manager and will not negate the Code rules. 2.5. The Quality Assurance Manager at Hardy Machine & Design is responsible for implementing this Quality Assurance System. 2.6. This Quality Manual will be printed and distributed only in the English language.

_____________________________ Ravi Goel President, Hardy Machine & Design

Date: ________________________

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3. MANUAL CONTROL 3.1. This Quality Manual has been prepared by Hardy Machine & Design. The Quality Assurance Manager is responsible for the Manual's compliance with the current A.S.M.E. Code. The Quality Assurance Manager is responsible for the initial issue of this Manual and any subsequent revisions. 3.2. Revisions are approved by the Quality Assurance Manager and submitted to the Authorized Inspector for review and acceptance, prior to inclusion into the Manual and subsequent implementation. The Quality Assurance Manager and the Authorized Inspector will document their approval and acceptance on the Table of Contents. This Manual shall not be revised to meet client requirements. Client specifications shall be addressed via an addendum outside the scope of this Manual. Whenever revisions are made, the part of the manual that is being revised will be identified by the symbol < > adjacent to the paragraph revised at the left-hand margin. 3.3. A controlled copy of the Quality Manual is available for the Authorized Inspector at the Shop. 3.4. The Quality Assurance Manager will issue controlled and uncontrolled copies of the Manual in accordance with the list of Manual holders maintained by him as per exhibit number 1 (QCSM DISTRIBUTION LOG). Each Manual will bear the same control number on its title page as is shown on the list. Only controlled copies shall be issued within the Hardy Machine & Design organization. 3.5. No part of this Manual may be reproduced or transmitted in any form or by any means including photocopying and recording without the written permission of Hardy Machine & Design.

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3.6. The Quality Assurance Manager will review Code addenda to determine if this Quality Manual is affected. Required revision will be made and implemented within six months of the addenda issue date and maintained in the QCSM Revision Log as per exhibit number 2.

4. DRAWING, DESIGN CALCULATIONS AND SPECIFICATION 4.1. Document Distribution (Pre-fabrication) 4.1.1. Upon being awarded the project, the Project Manager obtains a unique project job number. The Project manager will then notify the Design Engineer, and all others in operations the identity of the job number. 4.1.2. The Design Engineer is responsible for the distribution of all documents relative to the project as per exhibit number 3 (DRAWING TRANSMITTAL FORM). 4.1.2.1. Client data sheet(s), drawing(s), and specification(s) shall be distributed to the Design Engineer, QA/QC Department and Shop to begin job preparation. 4.1.2.2. The Design Engineer is responsible for issuing the latest revision(s), addendum (a) or change(s) of the specifications and drawings to all defined document holders. 4.2. Drawing & Design Calculation Approval 4.2.1. The Design Engineer is responsible for the approval process of all drawings and calculations as specified herein. 4.2.1.1. The Design Engineer upon receipt of the client documents, begins preparation of the Design Calculations and drawings material list. The drawings shall include all data, information’s and details required by the ASME Code as follows: 1) The applicable Code edition and addenda. 2) Identification Number 3) Bill of Materials as per exhibit number 4 with ASME material specification including nominal size, grade/type, classification number and special material requirements, if Printed copies of this manual are Uncontrolled

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any, NDE or impact test requirements. 4) Dimensions and Tolerances 5) Weld joint configurations and/or symbols. 6) Hydrostatic/Pneumatic Test Pressure. 7) Reference to applicable approved procedure (WPS). 8) Minimum Design Metal Temperature.

4.2.1.2. One (1) set of documents are transmitted by the Design Engineer to the Client and Authorized Inspector for review and comments. 4.2.1.2.1. The Design Engineer shall be responsible for pursuing a timely response to the documents from all parties. Any comments shall be evaluated prior to being incorporated into the design documents or drawings. 4.2.1.2.2. Upon incorporation of comments all documents shall be returned back to all parties with final revision. 4.2.2. The "original" documents are returned to the Design Engineer and shall be stamped or marked "Approved for Construction" on each drawing. A reproducible copy will be transmitted to the Project Manager for Official distribution and retention. 4.3. Distribution & Revision of Drawings & Design Calculations 4.3.1. The Design Engineer is responsible for the distribution of drawing and/or revisions. 4.3.1.1. If during fabrication, changes to the drawing(s) are required, the proposed revision shall be reviewed by the Design Engineer, who will submit for review to the client for approval. 4.3.1.1.1. After the client approval of the revised drawings, the drawing(s) shall reflect the changes and revision(s) and shall be noted in the revision blocks provided on drawing.

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4.3.1.1.2. Design calculations to support the revision (change or alteration of Design) may be required. The Design Engineer shall provide the calculations required. 4.3.2. Standard and Computer Aided Designs: 4.3.2.1. When standard or computer-aided design calculations and drawings are used, the Design Engineer is responsible for the input of correct design data and the verification that the correct output has been obtained. 4.3.2.2. The Design Engineer will review Code addenda to determine if standard designs or programs are affected. Required revisions will be made and implemented within six months of the addenda issue date. 4.3.2.3. All revisions are documented, signed by the Design Engineer and recorded on each affected document or in computer program documentation. 4.3.2.4. Standard and computer-aided drawings and calculations output is available for review and acceptance by the AI. The Design Engineer provides the AI with any manual calculations he requests to verify computer output. 4.3.3. Design Calculations shall be prepared and issued by the Design Engineer. 4.3.3.1. The design calculation shall be completed by the Design Engineer. 4.3.3.2. He shall also be responsible for the calculations and drawings, control of the changes and dated record of the changes. 4.3.3.3. Design calculations that require revisions shall be performed and/or verified by the Design Engineer. 4.3.4. The Design Engineer prepares a Bill Of Materials as per exhibit number 4 for the entire job based on the approved drawings. 4.3.4.1. The Bill Of Materials is distributed along with contract drawings and design calculations. Printed copies of this manual are Uncontrolled

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4.3.4.2. As contract drawings are revised, so shall the Bill Of Materials to reflect such changes. 4.3.4.3. The Bill Of Materials shall specify Code materials in accordance with ASME Section VIII Division 1 and ASME Section II specifications to the required edition and addendum or identical ASTM specifications per Appendix A in Section II.

5. MATERIALS CONTROL 5.1. The Project Manager is responsible for obtaining Code materials as specified on the Bill Of Materials as per exhibit number 4 and for all materials. Welding materials may be ordered verbal or by use of a Purchase Order Exhibit 5 5.2. The Project Manager will first source from stock inventory meeting ASME Code Specifications. 5.2.1. Code materials available in stock inventory shall be identified and their mill certificates retrieved. 5.2.2. Code materials determined acceptable and in conformance to Code requirements shall be identified with green mark. Materials not in conformance to Code requirements shall be identified with red mark. 5.3. Preparations of material Purchase Order as per exhibit number 5 based on the material lists are the responsibility of the Project Manager. 5.3.1. Completed Purchase Order is reviewed for Code compliance by and updated with any required corrections. It is then signed and dated. 5.3.2. The Project Manager will approve the Purchase Order. 5.4. The Project Manager is responsible for purchasing all materials, consumables and supplies in accordance with specifications. Any special ordering information must be noted on the Purchase order such as UCS-79(d), UG-80 on request for mill test reports. Printed copies of this manual are Uncontrolled

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5.4.1. A copy of the Purchase Order with supplier’s documentation shall be sent to the QC Department for review. 5.5. Free issue material or customer supplied material must meet all Code requirements of ASME Section II and Section VIII, Division 1. Received material shall be documented on the Material Examination Report as per exhibit number 6. 5.6. The QC Inspector is responsible for the inspection and verification of all materials including consumables received and/or issued to be in accordance with Code compliance. 5.6.1. All materials are inspected visually, dimensionally and readily traceable to the mill certificates. The QC Inspector shall inspect and verify for conformance to the requirements. Material received and inspected shall be transferred to shop with all original receiving and inspection reports. All original records of vessel material shall be kept by shop. Mill test report review and acceptance will be documented by initial and date of the QC Inspector on the mill test report. 5.6.2. A copy of all documentation is retained in a job file for reference fabrication. 5.6.3. Substitution of material shall only be made with the review and approval of the Client, Design Engineer and Authorized Inspector. 5.7. Material traceability shall be verified and recorded by the QC Inspector. 5.7.1. Prior to cutting Code material, the material traceability number shall be transferred to each pre-determined piece to maintain traceability to cutting. 5.7.2. All drop-off materials shall be positively identified.

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6. EXAMINATION AND INSPECTION PROGRAM 6.1. Vessel Fabrication Stage Inspection 6.1.1. The Examination and Inspection of ASME Code Pressure Vessels is the responsibility of the QC department. 6.1.2. Stage Inspection of pressure vessels is controlled by means of a Inspection Traveler Sheets as per exhibit number 7 prepared from the shop drawings by the QC Inspector who shall assign his QC Inspection points, Hold (H), Witness (W), Review (R) or Monitor (M) points and sign and date the quality plan. The QC Inspector shall submit the Inspection Traveler Sheet to the AI prior to fabrication for his designation of inspection points. AI inspection points shall be noted by *. 6.1.3. The Shop Foreman shall review the sequence of the activities provided on the Traveler Sheet. The sequence includes examination and inspection activities. 6.1.4. When fabrication is complete, the QC Inspector shall perform his final inspection. If acceptable, he shall signify his approval by initialing and dating the Inspection Traveler Sheet when he has ascertained that all Code requirements have been met and shall submit to the Authorized Inspector and Client for approval. When a pressure vessel is not provided with an opening or other means of access to inspect internal surfaces, an inspection point for the QC Inspector, client and AI will be shown to permit internal inspection before starting final closure weld or bolted joint. 6.2. Pressure Testing 6.2.1. Pneumatic tests as prescribed in this paragraph may be used in lieu of hydrostatic testing or when specified, except when the Code requires hydrostatic testing.

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6.2.1.1. The QC Inspector and Authorized inspector/Client shall witness the test. They shall affix their initials and date onto the test chart. 6.2.1.2. The test pressure for pneumatic testing shall be 1.25 times the Maximum Allowable Working Pressure (MAWP). 6.2.1.3. The pressure shall be gradually increased to not more than half of the test pressure (1.25 X MAWP). Thereafter, the pressure shall be increased in step one-tenth up to the test pressure. 6.2.1.4. Then the pressure shall be reduced to four-fifths of the test pressure and held for sufficient time to permit inspection. 6.2.1.5. When accepted, the QC Inspector/Client and Authorized Inspector shall sign and date the Pneumatic Test Record. 6.2.2. Hydrostatic tests will be conducted as per ASME Code Requirements. The gauge should be rated over a range twice the intended test pressure but in no case less than 1-1/2 the test pressure or more than 4 times the test pressure. 6.2.2.1. The temperature of the water shall be maintained as per Code requirements. 6.2.2.1.1. For Section VIII, Division 1 vessels, they shall be subjected to a hydrostatic test pressure which at every point in the vessel is at least equal to 1-1/2 times the maximum allowable working pressure to be marked on the vessel multiplied by the lowest ratio (for the materials of which the vessel is constructed) of the stress value S for the test temperature on the vessel to the stress value S for the design temperature. All loading that may exist during this test shall be given consideration. 6.2.2.1.2. It is recommended that the test pressure shall not be applied until the vessel and its contents are at about the same temperature. If the test temperature exceeds 120 degrees F, it is recommended that inspection of the vessel be delayed until the temperature is reduced to 120 degrees F or less. Printed copies of this manual are Uncontrolled

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6.2.2.2. The QC Inspector/Client shall affix his initials and date onto the test chart. 6.2.2.3. The test pressure for hydrostatic testing shall be at least equal to 1.5 times the Maximum Allowable Working Pressure (MAWP). 6.2.2.4. After successful application of the test pressure, it is reduced to two-thirds for a close examination of all welds. 6.2.2.5. When accepted, the QC Inspector and Authorized Inspector/Client shall sign and date the Inspection Traveler Sheet. 6.3. Data Reports 6.3.1. Upon completion of a vessel the applicable Manufacturer's Data Report shall be prepared as completed from the final records by the QA Manager. 6.3.2. The completed Manufacturer's Data Report, together with the final records, shall be presented to the Authorized Inspector for his review. When he is satisfied that all Code requirements have been met as per the Code, he will sign and date the Manufacturer's Data Report. 6.3.3. The Authorized Inspector shall verify the application of the Code Symbol U-Stamp to the nameplate. 6.3.4. The National Board serial numbers shall be controlled and issued by the Q.A.M. 6.3.4.1. A record of issuance shall be kept showing date issued, type of vessel to be used upon, and manufacturer's serial number and date sent to the National Board. 6.3.4.2. All pressure vessels meeting all Code requirements of the Code shall be stamped with the ASME Code Stamp. 6.3.4.3. The Project Manager shall submit to the National Board the original and one legible copy of all Manufacturer's Data Reports required for the stamped vessel (See Section 18). Printed copies of this manual are Uncontrolled

6.3.5.

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All documentation shall be retained on file.

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7. CORRECTION OF NONCONFORMITIES This section describes the methods used to control and resolve nonconforming conditions found in material, fabrication, documentation or construction. 7.1. Definition Nonconformance - is a deficiency in characteristic, documentation or procedure which renders the quality of an item unacceptable or indeterminate and not in compliance with the ASME Code and this Manual. 7.2. Responsibility All personnel have the responsibility to report any non-conforming conditions, which they have knowledge of. 7.2.1. It is the QC Inspector's responsibility to initiate and issue the Non-Conformance Report as per exhibit 8. 7.2.2. The QC Inspector shall prescribe a recommended corrective action. 7.3. Procedures Deviations will be handled by the QC Inspector. 7.3.1. When nonconformity is found, if it cannot be immediately resolved by the QC Inspector, it shall be identified. 7.3.2. A Non-Conformance Report shall be prepared for non conforming items by the QC Inspector 7.3.3. Copies of the Non-Conformance Report are issued to the Addressee, Authorized Inspector, Project Manager Client and Shop Foreman. The original shall be retained in the Job File. In case of repair to the base material, the Authorized Inspector/Client will be notified for his concurrence and designation of his 'hold' points. All use as is dispositions shall be notified to the AI prior to implementation. Printed copies of this manual are Uncontrolled

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7.3.4. The Project Manager shall be responsible for the final rectification of the nonconformance. When corrective action has been completed/accepted by the QC Inspector and AI, the QC Inspector and AI shall sign and date. 7.3.5. The QC inspector shall verify that the corrective action taken has satisfactorily restored the condition to within compliance of the Code. 7.3.5.1. Satisfactory results shall be documented by the Project Manager. Copies shall be distributed and the original retained in the file. 7.3.5.2. Unsatisfactory results that have been ineffective in correcting the non-conformance shall be re-addressed by issuing a revised Non-Conformance Report.

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8. WELDING CONTROL 8.1. General 8.1.1. All welding on Code vessels shall comply with a written Welding Procedure Specification (WPS) in accordance with ASME Section IX. All welding on Code vessels shall be performed by qualified welders and/or operators in accordance with ASME Section IX. 8.1.2. Welder(s) and Welding Operator(s) are qualified and certified to the essential variables by the Project Manager. 8.2. Project Planning (Pre-Fabrication) 8.2.1. When documents are received from the Design Engineer, the Project Manager reviews the drawings and specifications from which he prescribes appropriate Welding Procedure Specification (WPS) and Welder Qualifications for the Project. 8.2.2. Welding Procedure Specification(s) (WPS) shall be sourced from the Design Engineer files to meet project requirements. Should project requirements fall outside the limits of the variables expressed in the Welding Procedure Specification, a new Procedure will be required to meet these requirements. However, if only nonessential variables are changed, then the WPS can be revised to reflect that change. 8.2.3. Only qualified welders will be used for welding of Code items. 8.2.4. Copies of the applicable Welding Procedure Specification(s) (WPS), and Welder's certificate shall be submitted to client through Project Management. These documents will be available for review to the Authorized Inspector at all times. 8.3. Qualification of Welding Procedures Printed copies of this manual are Uncontrolled

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8.3.1. The Project Manager is responsible for conducting the qualification of procedures and certifying the procedure qualification record. 8.3.2. Materials and Consumables required are sourced as per engineering requirement. 8.3.3. Qualification and documentation of the welding procedure shall be in accordance with ASME IX. 8.3.4. WPS shall be submitted to the A.I. upon request. The AI may require re-qualification of welders or procedures for just cause. 8.4. Welder and Welding Operator Renewal 8.4.1. The Project Manager will have ultimate responsibility for the maintenance of welders and welding operator's qualification. Qualified welders and operators continuity is documented on the Welders Performance Record Exhibit #9. 8.4.2. The performance qualification of a welder or welding operator shall be affected when one of the following condition occur: 8.4.2.1. When he has not welded during a period of 6 months or more using a specific process. 8.4.2.2. When there is a specific reason to question his ability to make welds that meet the specification, the qualifications which support the welding he is doing shall be revoked. All other qualifications not questioned remain in effect. 8.4.3. Adequate proof of documentation that supports the effective use of a welding process by the welder shall renew that welder’s qualification for another period. 8.4.3.1. Welders that have inadequate proof of documentation or have exceeded the limits shall require requalification. 8.5. Qualification of Welders and Welding Operators 8.5.1. The Qualification of welders shall be the responsibility of the Project Manager. Printed copies of this manual are Uncontrolled

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8.5.2. Welders and welding operators are qualified by any of the two methods listed below: 

test coupon



or Production test (If not GMAW Short circuiting)

8.5.3. Qualification of Welders and Welding Operators shall be in accordance with ASME IX. 8.6. Production Welding 8.6.1. The QA Manager is responsible for verifying that all production welders are qualified, and the Shop Foreman is responsible for instructing each welder in the appropriate WPS he shall use. 8.6.2. Each welder and welding operator shall stamp or stencil the identifying number, letter, or symbol, assigned by the QA Manager, adjacent to and at intervals of not more than 3 ft. along the welds which he makes in steel plates 1/4 in. and over in thickness and in nonferrous plates 1/2 in. and over in thickness; or a record shall be kept by the QA Manager of welders and welding operators employed on each joint which shall be available to the Inspector. For identifying welds on vessels in which the wall thickness is less than 1/4 in. (6mm) for steel material and less than 1/2 in. (13mm) for nonferrous material, suitable stencil or other surface markings shall be used; or a record shall be kept of the welders and welding operators employed on each joint by the QA Manager which shall be available to the Authorized Inspector/Client. 8.6.3. The appropriate Welding Procedure Specification (WPS) use shall be determined by the QA Manager after consultation with the Shop Foreman. The procedures will be noted on the "Approved for Construction" drawings (AFC).

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8.6.4. Tack welds shall be made in accordance with qualified procedures and welders; all tack welds, which are not, removed, shall be feather ground and visually inspected for defects by the Shop Foreman. Tack welds made by subcontractors shall be removed. However, they shall be made in accordance with a qualified procedure approved by the Q.A.M. 8.6.5. Welder and Welding Operators I.D. numbers are recorded onto the Welders Performance Record. This record is retained on file. 8.6.6. The QC Inspector shall audit the welding in compliance to the WPS. 8.7. Welding Material 8.7.1. All welding filler metals and fluxes are purchased as per requirements either verbally or by use of a Purchase Order. 8.7.2. All welding materials are received as per requirements. 8.7.3. Welding materials are to be stored in accordance with the Code and Filler Metal Manufacturing Recommendations. 8.7.4. It is the Shop Foremans responsibility to ensure correct Welding Consumables are used in accordance with the applicable Welding Procedure Specification (WPS). Sufficient quantity is issued to the welders to complete the welding job by the Shop Foreman who then instructs the welders of the correct WPS to be used. WPS are made available to all welders/welding operators. 8.8. Equipment Maintenance 8.8.1. All welding leads, cutting torches and other apparatus shall be kept clean and free of unnecessary dirt, grease, moisture or any other foreign matter. 8.8.2. Welding machines shall be blown free of dust. 8.8.3. Electrode Holding and Storage Ovens shall utilize thermostats to ensure proper temperature control. Printed copies of this manual are Uncontrolled

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8.9. Authorized Inspector 8.9.1. The WPS and the Welder/Welding Operator shall be requalified when required by the AI.

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9. NON DESTRUCTIVE EXAMINATION - NDE 9.1. General 9.1.1. All NDE shall be performed by a qualified examiner or outside company, under the direction of a written procedure, using calibrated equipment in accordance with ASME Section V and VIII, Division 1. 9.2. Project Planning (Pre-Fabrication) 9.2.1. When documents are received from the Design Engineer, the Project Manager reviews the drawings and specifications from which he prescribes the appropriate NDE Procedures. 9.3. The NDE requirements of pressure vessels are noted on the fabrication drawings by the Engineering Manager. 9.4. Non Destructive Examination (NDE) performed on the Code Vessels shall be conducted in accordance with a written procedure certified by the Level III personnel, who shall be qualified in accordance with written practice. SNT-TC-1A 9.4.1. All NDE reports including radiographic film shall be reviewed for Code compliance by the QA Manager. 9.4.2. Should the examiner have any doubt, he shall consult with the QC Inspector. 9.5. Documentation & Reporting 9.5.1. The NDE As-built drawings of the Code vessels shall be maintained by the QC Inspector for documentation purposes. 9.5.2. Any or all NDE Documentation shall be made available for review to the Authorized Inspector/Client. Printed copies of this manual are Uncontrolled

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9.5.3. All NDE Documentation shall be retained on file. 9.6. Subcontracting 9.6.1. The subcontractor is to perform all NDE testing. The QA Manager shall appoint by letter a Level III to act on behalf of Kamgage for all NDE. The Level III shall accept this appointment by letter. 9.6.2. The subcontractor shall submit the calibration of his equipment and procedures for QA Manager's approval. All NDE personal shall be qualified in accordance with SNT-TC-1A Code accepted edition. 9.6.3. Materials sent to the subcontractor's facility shall be properly identified/marked and inspected upon return from the vendor for proper identification and damage. 9.6.4. As a minimum, a calibrated density strip and a film viewer will be available. 9.6.5. The A.I. may call for requalification of procedures or personnel for just cause.

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February 23, 2004

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10. POSTWELD HEAT TREATMENT 10.1. General 10.1.1. Postweld heat treatment shall be performed in accordance with a procedure approved by the QC Inspector. The requirements of the applicable sections of ASME Section VIII Division 1 shall be met. 10.2. Project Planning (Pre-Fabrication) 10.2.1. Before preparing the vessel for stress relieve the final visual and dimensional checks should be carried out. When it is found to be satisfactory, the QC Inspector shall sign the final inspection reports and the release for stress relieve. 10.2.2. The QA Manager shall review the Postweld Heat Treatment Procedure and the Approved for Construction (AFC) drawings to establish the vessel thermocouple assignment. 10.2.3. The QA Inspector and Shop Foreman shall review the thermocouple arrangement drawings and mark the location on the vessel. 10.2.4. After the clamps have been welded in place in accordance with a qualified welding procedure, the QC Inspector shall inspect the location of the clamps prior to furnace start up to assure correct thermocouple location. Clamps shall be welded by Kamgage and shall be of appropriate material. 10.3. Subcontracting 10.3.1. The subcontractor is to perform a postweld heat treatment operation. The QC Inspector or the Project Manager will review the procedure with the subcontracting company representative. 10.3.2. The subcontractor shall submit the calibration certificate of the recorder to the QA Manager for the approval. Printed copies of this manual are Uncontrolled

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February 23, 2004

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10.3.3. Materials sent to the subcontractor's facilities shall be properly identified/marked and inspected upon return from the vendor for proper identification and damage. 10.4. Documentation & Records 10.4.1. All postweld heat treatment documentation shall be signed and dated by the subcontractor. 10.4.2. Visual inspection of the internals after PWHT shall be carried out by the QC Inspector. 10.4.3. The documentation shall be presented to the Authorized Inspector/Client for his review. 10.4.4. All documentation shall be retained on file.

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February 23, 2004

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11. CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT 11.1. All test equipment, including subcontractors used for verifying Code items shall be calibrated in accordance with this section and Gauge Calibration Log maintained as per exhibit 10. 11.2. Each item of measurement, test and examination equipment which requires calibration shall be identified by marking with a serial number and calibration date. 11.3. The QC Inspector is responsible for ensuring that all equipment is maintained in current calibrated condition. 11.4. Calibration may be performed by a qualified testing laboratory, having adequate standards traceable to the National Standards or similar, and able to provide certificates of calibration. 11.5. Mechanical Test Equipment (Laboratory) shall be calibrated in accordance with ASME SA 370. 11.6. Each calibrated item shall have a Calibration Record maintained by the QA Manager or his designee in the calibration file. 11.7. Calibration record shall be available for review. 11.8. When instruments are found out of calibration, the QC Inspector or his designee will remove it from the work area and arrange for its calibration or replacement. 11.9. Calibration of all measurements and test instruments are controlled. There will be calibrations on an annual basis. 11.10. Micrometers and/or calipers shall be checked for accuracy before and after each use to a test block of a known thickness. These verifications will not be recorded.

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February 23, 2004

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12. RECORDS RETENTION 12.1. All documentation described in this manual is collated at the completion of the job, and reviewed for completeness, prior to preparation of the Manufacturer's Data Report. 12.2. Manufacturer's Data Reports, upon certification by the QAM and AI, shall be furnished to the user or his agent, and to the Authorized Inspector if required. 12.3. All documentation for the job shall be assembled into a Job Data Book. The original data book will be retained by the company and copies of which will be distributed to the client. 12.4. Manufacturer Data Reports shall be retained for a minimum of five (5) years if not registered with the National Board. 12.5. The National Board serial numbers shall be controlled and issued by the Project Manager. All pressure vessels will be stamped with the A.S.M.E. Code Symbol Stamp upon satisfactory completion.

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February 23, 2004

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13. AUTHORIZED INSPECTOR 13.1. The Authorized Inspector is the Inspector required by Code, who is employed by an ASME, accredited Authorized Inspection Agency. 13.2. When requested by the Authorized inspector, hold witness and review points shall be identified on the checklist for those activities he wishes to witness and verify. 13.3. The QC Inspector is the liaison with the Authorized Inspector, and is responsible for keeping him advised of the progress of the work. 13.4. The Authorized Inspector shall have access to and be furnished with all drawings, calculations, specifications, procedures, repair procedures, records, test results and any other documents as required performing his duties. 13.5. All non-conformance and corrective actions shall be submitted to the Authorized Inspector for his review. 13.6. The QA Manager shall notify the Authorized Inspector sufficiently in advance of pressure tests so that he may be present to witness them. 13.7. The final records, together with the completed Manufacturer's Data Report shall be submitted to the Authorized Inspector for his review and signature. The Authorized Inspector shall sign the Manufacturer's Data Report when he has satisfied himself that all Code requirements have been met. 13.8. The QC Inspector shall provide a controlled copy of the Quality Manual for the Authorized Inspector at all times. 13.9. The Authorized Inspector will review and accept all changes to the Quality manual prior to distribution to manual holders.

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13.10. The Authorized Inspector and/or the AI's Supervisor shall have free access to all parts of the Shops, suppliers or material manufacturers where work is being performed. 13.11. The Authorized Inspector shall be responsible for his inspection requirements as ASME Section VIII Specifies. 13.12. The QC Inspector will provide necessary assistance to the Authorized Inspector during the Annual Audit required by the National Board rules and regulations and ASME QAI-1.

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February 23, 2004

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14. ANNUAL AUDIT 14.1. An Annual Audit of the Quality Control System may be made by an independent person within Hardy Machine & Design, Inc., if deemed necessary by the QAM. 14.2. The Audit shall verify implementation of the entire Quality Control System and report findings. 14.3. Audit Reports are submitted to the Quality Assurance Manager for review and copies shall be forwarded to the affected department.

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February 23, 2004

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15. CONTROL OF CODE STAMP 15.1. The Hardy Machine & Design policy is to maintain control over the Code Symbol Stamp and to assure its proper use. 15.2. Procedures 15.2.1. The Code Symbol Stamp is controlled by the Quality Assurance Manager. All requests for the use of the Code symbol stamp shall be made directly to the Quality Assurance Manager. 15.2.2. The Project Manager, prior to start of work, shall obtain from the client, and prepare from drawings and/or specifications, a list of the items or systems that will be required to be stamped and stamping to be witnessed by the Authorized Inspector.

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February 23, 2004

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16. ORGANIZATIONAL CHART

Kamgage Fabrication

President

Operating Officer Company Secretary

Technical/Sales Design Engineers & CAD Drafting

Estimating

QA Manager

Project Managers

QC Inspector

Procurement

Subcontractors Manager NDE

Postweld Heat-treating

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X-Rays

Shop Foreman

Shop Welders

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17. NATIONAL BOARD OF REGISTRATION Items that require National Board numbers shall be issued in numerical order without skips or gaps by the QA Manager. The QA Manager shall maintain a record, which includes date of issue, type of item and manufacturer’s serial number, and date sent to National Board, which will be transmitted within 90 days of issuance.

The QA Manager shall submit to the National Board the original and one legible copy of all Manufacturer’s Data Reports required for Code items. The arrangement of nameplate marking is indicated on Exhibit #11.

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18. EXHIBITS EXHIBIT NO. 1:

Q.C.S.M DISTRIBUTION LOG

EXHIBIT NO. 2:

Q.C.S.M. REVISION LOG

EXHIBIT NO. 3:

DRAWING TRANSMITTAL FORM

EXHIBIT NO. 4:

BILL OF MATERIAL

EXHIBIT NO. 5:

PURCHASE ORDER

EXHIBIT NO. 6:

MATERIAL EXAMINATION REPORT

EXHIBIT NO. 7:

INSPECTION TRAVELER SHEET

EXHIBIT NO. 8:

NON-CONFORMANCE REPORT

EXHIBIT NO. 9:

WELDERS PERFORMANCE RECORD

EXHIBIT NO. 10:

GAUGE CALIBRATION LOG

EXHIBIT NO. 11:

STAMPING ARRANGEMENT

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EXHIBIT NO. 1 Q.C.S.M DISTRIBUTION LOG NUMBER

ISSUED TO

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SIGNATURE

TITLE

DATE

EXHIBIT NO. 2 Q.C.S.M. REVISION LOG REVISON SUMMARY

Q.C.M SIGNATURE

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&

DATE

A.I. SIGNATURE &

DATE

EXHIBIT NO. 3 DRAWING TRANSMITTAL

TO: _________________________________ WORK ORDER NO: ____________________

ATTACHED ARE THE FOLLOWING:

THESE ARE TRANSMITTED FOR:

BY: _______________________________________________ DATE: __________________

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EXHIBIT NO. 4 BILL OF MATERIALS Hardy Machine & Design 5737 Windfern St. Houston, TX 77041

DATE BILL OF MATERIALS NO.

TO:

QTY.

DESCRIPTION

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UNIT WEIGHT

TOTAL WEIGHT

UNIT PRICE

TOTAL PRICE

EXHIBIT NO. 5 PURCHASE ORDER

ISSUE DATE

5733 Windfern Rd. Houston, TX 77041 SUPPLIER:

SHIP TO:

Contact

Phone : Fax :

REQ’D DELIVERY DATE

SHIPPING METHOD

Contact

TAXABLE YES

ITEM NO.

PURCHASE ORDER NO.

DESCRIPTION

Phone : Fax :

PAYMENT TERMS

SIGNATURE & DATE

NO

QTY

UNIT WEIGHT

UNIT PRICE

TAX TOTAL Printed copies of this manual are Uncontrolled

TOTAL PRICE

EXHIBIT NO. 6 MATERIAL EXAMINATION REPORT P.O.________________________________ SHOP ORDER____________________________ ITEM NO.___________________________ DESCRIPTION___________________________

CHECK LIST

1.

APPEARANCE:

______________________________________________________

2.

THICKNESS:

______________________________________________________

3.

DEFECTS:

______________________________________________________

4.

TRACEABILITY: ______________________________________________________

5.

HEAT NUMBERS: ______________________________________________________

6.

MATERIAL ID:

______________________________________________________

7.

DIMENSIONS:

______________________________________________________

8.

MISCELLANEOUS:_____________________________________________________

MATERIAL RECEIVED BY: ________________________________ DATE: ___________

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EXHIBIT NO. 7-1 Job Number:__________ SECTION:

INSPECTION TRAVELERS SHEET O.D. ________________ I.D. _______________ VESSEL ____________ PIPE ______________

CUSTOMER/INSPECTO R

Q.C.

A.I.

REMARKS *A.I. HOLD POINTS

CALCULATIONS SERIAL NUMBER DRAWING NUMBER NATIONAL BOARD NUMBER DATA REPORT MILL TEST REPORTS SHELL THICKNESS HEAD THICKNESS FORMED SECTIONS HEAT NUMBER, SHELL HEAT NUMBER, HEAD GRADE OF MATERIAL, SHELL GRADE OF MATERIAL, HEAD CUT EDGES PIPE SURFACE PLATE SURFACE INSPECTION FITTINGS ALIGNMENT WELDING PROCEDURE WELDER QUALIFICATION WELDER SYMBOLS PREHEAT WELDING APPEARANCE POST WELD HEAT TREATMENT X-RAY, R-1, R-2, R-3, R-4 MAGNA FLUX-DYE PENETRANT HYDRO TEST NAME PLATE, STAMPED OR ATTACHED TEST GAUGE NUMBER INTERIOR OR EXTERIOR COATING CUSTOMER ______________________________________ P.O. # __________ ITEM # _______ SHIP TO: ______________________________________________________________________________ Printed copies of this manual are Uncontrolled

EXHIBIT NO. 7-2 JOB #

CUSTOMER:

DESCRIPTION:

MATERIAL IDENTIFICATION ITEM

HEAT NO.

MNFR

SLAB

MIKE

HHRG-1 RG-2 RG-3 RG-4 RG-5

MK

MFG

FLANGES AND COUPLINGS MK MATL. MK MFG

SPECIAL NOTES:

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MK

MATL.

EXHIBIT NO. 7-3 JOB # PART & ITEM

CUSTOMER:

DESCRIPTION:

FUNCTIONS IN PROCESS FABRICATION & INSP. L.O. QC AI

PREP QC AI

FORM FIT QC AI QC AI

SPECIAL NOTES:

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WELD QC AI

X-RAY QC AI

NDE QC AI

EXHIBIT NO. 8

NONCONFORMANCE REPORTS WORK ORDER NO:

REPORT NO.

CUSTOMER: DESCRIPTION OF NONCONFORMITY:

SIGNED: ___________________ QC INSPECTOR

RECOMMENDED DISPOSITION USE-AS-IS

REPAIR/REWORK

SCRAP/RETURN TO VENDOR

SIGNATURE & TITLE: DATE: DISPOSITION APPROVAL: DESIGN ENGINEER:

DATE:

Q.C. MANAGER:

DATE:

AUTHORIZED INSPECTOR:

DATE:

DISPOSITION VERIFIED: INSPECTED BY:

DATE:

AUTHORIZED INSPECTOR REVIEW: ACCEPTED REJECTED SIGNED:

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DATE:

EXHIBIT NO. 9 WELDERS PERFORMANCE RECORD DATE: ______________ NAME: _______________________ STAMP NO.: ________________ YEAR: ___________

CHECK THE MONTHS DURING WHICH THE WELDER WELDED UNDER THE FOLLOWING PROCEDURE: WPS _____________________________________ PROCESS ________________________________ JANUARY ______________

FEBRUAURY ___________

MARCH

____________

APRIL

______________

MAY

___________

JUNE

____________

JULY

______________

AUGUST

____________

SEPTEMBER ____________

NOVEMBER

___________

DECEMBER

OCTOBER ______________

___________

_____________________________ PRODUCTION MANAGER

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EXHIBIT NO. 10

GAUGE CALIBRATION LOG NAME OF EQUIPMENT______

MODEL NO. _______________

SERIAL NO. ________

SIZE AND TYPE ____________ MANUFACTURER __________ ACCURACY ________ DATE ACQUIRED __________

CALIBRATION FREQUENCY ______________________

STATUS CALIBRATED

RESULTS

DATE

CHECKED BY

MAINTENANCE HISTORY

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DATE

DUE DATE

EXHIBIT NO. 11 Stamping Requirements

* NAT’L BD.

(National Board Serial Number)

Stamping in this area shall comply with the requirements of the applicable construction code

Facsimile of Required Stamping for National Board Registration 

Acceptable forms of National Board marking: NAT’L BD. NATL BD NATIONAL BD NATIONAL BOARD

The size of the National Board stamping shall not be less than that required by the applicable code of construction for the item being stamped. National Board markings shall appear only on pressure retaining items registered with the National Board.

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