Piping Quality Control Plan

PIPING GUIDE FOR DEVELOPING A QUALITY CONTROL PLAN

1.0

Scope The aim of this guide is to help to Contractor Quality Representative to develop a Quality Control Plan.

2.0

Responsibilities

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Contractor Pipe Supervisor is responsible of developing, implement, monitoring and a Quality Assurance and Quality Control Plan (QA/QC Plan) according to ASME B31.3, and FWI/DF specification, and local legislation. The QA/QC Plan shall include the following as a minimum:

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Written Quality Manual

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Organization chart and definition of responsibility

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Material Control

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Examination and Inspection Program

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Welding

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Non Conformance and corrective actions

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Document Control Procedure

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Heat treatment Procedure

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Measuring and Test equipment

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3.0

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Pressure Test

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Specific requirements on piping fabrication and erection to the local Codes and Regulations shall be included.

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Others (Painting, Supports, insulation procedures)

Contractor will submit Quality Assurance and Quality Control Plan to Construction Management for approval before starting fabrication activities.

Definitions •

Each shop drawing or isometric to be fabricated or revised on site will be accompanied by Piping Traveler.

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Piping Traveler will include information about welds, Welding Procedure, Welder, Material, Post Weld Heat Treatment and Non Destructive examination and test status. Traveler is an evergreen document during all fabrication process.

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Everyday Contractor Quality Representative shall inform Construction Management about the number of welds made during each shift and Nondestructive test and examinations. This information shall include isometric, Welding Procedure Specification (WPS) and Welder, and it shall marked on each Piping Travelers. The Construction Management shall have the right to designate the spools to be X-ray or other END examined on a random basis.

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4.0

Procedures •

Each shop drawing or isometric to be fabricated or revised on site will be accompanied by Piping Traveler. Everyday PC shall inform DF Quality about the number of welds made during each shift and Nondestructive test and examinations. This information shall include isometric, Welding Procedure Specification (WPS) and Welder, and it shall marked on each Piping Travelers.

The Construction Management shall have the right to designate the spools to be X-ray or other END examined on a random basis.

4.1

Material receiving

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The Contractor Quality Representative shall ensure that all materials and equipment furnished by the Construction Management are verified, stored, and maintained until incorporation into the work. Any such items that are damaged or otherwise unsuitable for use shall be recorded and reported to the Construction Management immediately. Proper notification to the Construction Management of receipt of any unusable materials or equipment must be made in order to ensure that the Construction Management retains the responsibility for providing useable materials or equipment.

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His duties include : o Checking all incoming material against the purchase order/Owners material list, and packing slip for:

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Visible damage

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Correct Dimensions

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Correct material markings, specification and grade, size, schedule.

o Checking MTRs (Materials Test Reports) against material markings, and verify that all material marks match those describe in MTRs; acceptance will be indicating by completing a Material Inspection Record, signed by Piping Contractor Control Respresentative. o Segregating and identifying acceptable material as a minimum.

Any material or item does not meet above requirements shall be considered a nonconformity.

4.2 Material Traceability Contractor Quality Representative is responsible for identification and traceability of all material at Site or Workshop: (i)

Ensure the correct colour code is provided

(ii)

Correct material, schedule, diameter are used.

(iii)

Heat number traceability involves the marking (with permanent marker) of the material specification, grade and/or the heat number on each section of pipe prior to marking the cut.

(iv)

Ensure the piping spools are identified with the line number, spool number and job number and spool list are supplied with each shipment to the site.

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Contractor Quality Representative shall establish and maintain procedures for identifying materials and equipment from applicable drawings, specifications, or other documents, during all stages of production, delivery, and installation. Where, and to the extent that, traceability is a specified requirement of the contract, individual products or product batches shall have a unique identification. This identification shall be recorded in the Job File and issued to the Construction Management with specified "As-Built" data. PC is responsible of developing and implementing a writing procedure for material traceability for all materials.

4.3 Examination and Inspection Program •

PC is responsible for the examination and inspection program for compliance with ASME B31.3, Project specification and local legislation: o Issue Quality Manual, Procedures, Travelers and Calibration Record to Construction Management prior to start the work. o Perform the Examination and Inspection Program. o Review all complete Examination and Inspection records for compliance with Code, Project Specification and Local Legislation. o Ensure that each individual assigned to Quality Control activities is competent and fully understands all requirements of Quality System Manual. o Maintain all inspection records. o Prior starting fabrication, notify Construction Management of the job and obtain the hold points.

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PIPING GUIDE FOR DEVELOPING A QUALITY CONTROL PLAN

o Inform about the examination to Construction Management. o Perform all examination required under Code, Project Specification and Local Legislation. o Sign Off inspections inspection program, when inspections points are reached. o Examine each system after completion and before pressure tests, to verify that all examinations have been done and the results are acceptable. o Verify that all “as-built” drawings have been revised and all approved changed incorporated. o Forward all job file including traveler to Construction Management

4.4. Welding •

Welding Procedures and Welder Qualifications shall be in accordance with ASME IX and project specifications.

Contractor Quality Representative responsibilities : •

Submit Welding Procedure list and Welding Procedure Specifications (WPS and PQR) to Construction Management before the start of the work, for revision and approval.

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Submit Welders Qualifications list and Welders Qualifications to Construction Management before the start of the work to Construction Management before the start of the work for revision and approval.

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If it is required to develop new procedures, develop Welding Procedures Specifications (WPS and Procedure Qualification Records (PQR) and conduct physical test. Construction Management would witness the welding of the test coupons for the procedure qualification, if not an independent third inspector shall be available.

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Ensure that WPS and PQR cover all works, and ensuring copies of the registered welding procedures available at each work site.

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Ensure that Welder Qualifications cover all works, and they have not expired.

Qualify new welders as needed. Construction Management would witness the new welder qualification, if not an independent third inspector shall be available during the process of welding coupons and tests.

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Issuing symbol stamps to each Welder.

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Instructing each welder prior to start of work to ensure that he understand the welding procedure requirements, the job specifications, the system of controlling electrodes etc.

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Ensuring that all welding procedures are followed and visually examining each preparation and complete weld.

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Verify that all welds are identified with the welder symbol by stamping and recording on travelers.

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Examine welding consumables prior to start the work to verify that they are identified and correct.

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Verify to start of work that all low hydrogen electrodes are package in airtight containers and that there are no open boxes in portable rigs.

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Ensure that low hydrogen electrodes are placed in heated storage at temperatures according to electrode manufacturer´s specifications, upon removal from hermetically sealed containers.

4.5 Non Conformities Contractor Quality Representative responsibilities : •

All Non Conformities related to piping shall be corrected or eliminated before the completed component can be considered comply with the code, work specification and/or local legislation.

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Inform to Construction Management about any new Non Conformity open, about corrective actions and when it is closed.

4.6 Non Destructive Examination •

Non Destructive Examination (NDE) shall be performance for a company independent of the Contractor Quality Representative.

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All personnel performing and evaluating NDE shall be certified level II or III.

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All NDE shall be done following written NDE procedures, available, for each method.

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Maintain records indicating welds examined on travelers.

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To maintain records showing inspection percentage (10%) per WPS, Welder and Shift.

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Forward inspection reports to Construction Management.

4.6 Heat Treatment •

Develop Heat Treatment Procedure, including location of Thermocouples, and Calibration Records for measurement instruments.

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Submit Heat Treatment Procedure and Calibration Records to Construction Management for revision and approval.

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Verify Heat Treatment procedure implementation and follow up Heat treatment.

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Verify hardness after Heat treatment. 10% for Welds and HAZ for welds treated in an Oven and 100% for local treatments.

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Mark welds as heat treated on travelers and attach heat treatment charts.

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Verify that heat treatment was acceptable and sign travelers.

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Submit travelers with heat treatment to Construction Management for approval.

4.7 Measuring and Test Equipment •

Submit calibration gauges and recorders procedures to Construction Management for revision and approval.

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Submit calibration records to Construction Management for revision and approval.

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Calibrate pressure gages at intervals not exceeding 12 months.

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Keep records of gage calibrations

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Verify the equipment, prior to test, for visible damage and calibration status.

4.8 Pressure Test •

Submit written test procedure with meets code, project, specification, and local legislation requirements to Contractor Management for revision and approval.

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Define test system for pressure test and use two calibrated gages per test.

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Notify Contractor Management in advance of any pressure test.

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Examining the system before and after the test following a check list.

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Witnessing all pressure tests and verifying that all test were performed in accordance with approval procedures and job specifications.

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if test is acceptable, sign off pressure test report and traveler.

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4.9

Documentation •

Documentation will be kept in accordance with this procedure and applicable supporting procedures.

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The Contractor Quality Representative shall forward all documentation to the Construction Management for inclusion in the Project or Work Order File.

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The Contractor Quality Representative will ensure that the following records are maintained in the job file, identified by job number: a)Design Specifications b)Drawing c) Pressure piping data reports d)Material test reports e)Non Destructive Test Reports f) Radiographic film and reports g)Heat treatment reports h)Non Conformity reports i) Travelers j) Welding Procedures k)Welder qualification records l) Pressure test procedure, reports and pressure gauge /recorder calibrations records. m)

Material List, Spool lists

n)Copies of NDE Examiner´s Certificates

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o)As built drawings

4.10

Management Construction Review\Audit •

5.0

The established Contractor QA/QC policies and procedures shall be reviewed at appropriate intervals by Construction Management to ensure continuing suitability and effectiveness. These reviews will include assessment of the results of internal audits and shall assess overall conformance to Construction Management’s requirements and expectations. Records of such reviews and audits shall be maintained.

References

5.1 Code ASME B31.3 ASME IX Job Specification Local Legislation

6.0

Attachments

6.1

Piping Fabrication Traveler ATTACHEMENT Nº 6.1

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ATTACHMENT 6.1 PIPING TRAVELER

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ATTACHMENT 6.2 PIPING FABRICATION INSPECTION RECORD Project/WO

Area/Building

Piece No(s)

Shop Fabrication

P-Code

Paint

ANSI B31.3 Class

Yes

No

Paint Specification

NDE Req.'s.

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Isometric Drawing No.

Test Pressure

Yes

No

Field Fabrication

Special Cleaning

Insulate

Yes

No

Hydrostatic

Yes

Yes

No

No

Insulation Specification

Yes

No

Pneumatic

Yes

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No

PIPING GUIDE FOR DEVELOPING A QUALITY CONTROL PLAN

When nonconformances are found, record them and the corrective action taken in the remark section below.

Attributes

Accept

Reject

NA

Date Closed

Inspect

Exam

Material ID Marked Material PMI Verified Material PSM Critical Tagged Heat Numbers Recorded Schedule Flange Rating Flange Face Finish + Protected Lining Welding Procedures Welder Qualifications Filler Metal ID Marked/Flagged Filler Metal PMI Verified Filler Metal PSM Critical Tagged Fit-up Root Pass Weld VT Inspection NDE (other) Pre/Post Weld Heat Treatment Brinnel Hardness

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Welder’s Stamp Dimensions and Configuration Pipe Marked with Dwg. and Pc. Nos. Coating

Remarks:

Contractor Quality Representative

Date

Construction Management

Date

Representative

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ATTACHMENT 6.3: PRESSURE TEST EXAMINATION GUIDE PRESSURE TEST EXAMINATION GUIDE

Q.C INSP

Q.C INSP

JOB Nยบ:

Contractor

CM

PRESSURE TEST PREPARATION 1.

All Punch list items corrected

2.

Test blinds correct thickness

3.

All items which could be damaged by test isolated or removed (control valves, safety valves, instruments, expansion joints etc)

4.

Equipment with internals (i.e. filters) that could be damaged, isolated as required.

5.

Vents and drains correctly installed.

6.

Open and Close position of all valves verified.

7.

Shipping bars in place-bellows

8.

Hanger Stops in place.

PRESSURE TEST COMPLETION

1.

All temporary blinds (blanks) removed

2.

Temporary gaskets changed for correct gaskets

3.

Temporary supports removed from bellows

4.

Shipping bars removed from bellows

5.

Spring Hangers stops removed-cold settings checked

6.

Pressure relief valves-correct ASME code symbol and correct set pressure and capacity installed.

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7.

Pressure relief valve vents are correct size-adequately supported-drains hole and or weather hoods installed.

8.

Screens for pumps and compressors installed 8inital startup and permanent screens)

Q.C. Contractor Representative Signature :

Date:

QC Insp (Construction Management) Signature:

Date:

Comments:

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ATTACHMENT 6.4: NON CONFORMITY REPORT NON CONFORMITY REPORT JOB NUMBER:

NON CONFORMITY REPORT Nº:

LINE NUMBER: IDENTIFICATION DETAILS: DESCRIPTION OF NON CONFORMITY:

QCI/QCM SIGNATURES:

DATE:

PROPOSED DISPOSITION OR REPAIRS:

QC MANAGER APPROVAL:

DATE:

CLIENT/OWNER´S DESIGN APPROVAL:

DATE:

NONCONFORMITY RECTIFIED: QC MANAGER APPROVAL:

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QC CM APPROVAL: :

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ATTACHMENT 6.5: HEAT TREATMENT FORM HEAT TREATMENT FORM JOB Nº:

CUSTOMER:

DESCRIPTION: DATE: COMPONENTE DESCRIPTION ISO Nº AND LINE Nº

DIAMETER

THICKNESS

MATERIAL

LENGTH

WEIGHT

TYPE OF HEAT TREATMENT: INSTRUCTION: STRESS RELIEVE 1.-Temperature to be raised from_____ºC to______ºC at a maximum rate of________________ºC per hour.

Note: MUST NOT EXCEED 222ºCPER HOUR (Calculated rate=400ºF/h divided by governing metal thickness) 2.-Temperature to held_______plus or minus________________________ for_______________minutes

3.-Temperature to be lowered from_____ºC to______ºC at a maximum rate of________________ºC per hour. Note: MUST NOT EXCEED 278ºCPER HOUR (Calculated rate=500ºF/h divided by governing metal thickness) 4.-Additional Requirements: Job number and description required on heat treatment chart

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5.-Furnace Heat number 6.-Furnace Operator Signature QC Contractor Representative Signature

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