All work should be performed per the requirements of the latest version of ASME Section VIII Div. 1, API-510 and any/all applicable “your client” standards/specifications.
Note: all Section VIII
Div. 2 Vessels should be considered on an individual basis.
Prior to start of fabrication and/or mobilization a complete set of detailed construction drawings should be provided to, reviewed by and accepted by at a minimum:
·
A client engineer or
client designated engineer who specializes in pressure retaining equipment.
AND
·
A person who is
currently certified through the API organization as a 510 inspector in good
standing.
A qualified inspector
CWI and/or 510 is required to follow all the requirements below. If one is not
provided by the contractor, a qualified third party inspector will be provided
by the project owner.
Documents to be submitted to Client for approval prior to
mobilization/fabrication:
·
Quality Control Manual
·
Copy of policies and
procedures for ASME code work
·
Copy of all
applicable Code stamps, licensure, certification or qualifications
·
WPS’s, PQR’s, WPQ’s
for all weld processes to be used
·
QA/QC personnel
resumes and certification
·
Qualification
records/visual acuity for NDE/QC personnel
·
Continuity logs for
all welders to be utilized (if applicable)
Quality Control
Package – Should be job specific and maintained onsite and updated daily by
contractor QC. The package should be in a location accessible to Client
inspection. The following documentation is required:
·
Scope of work
·
An Inspection Test
Plan (ITP) prepared by the contractor and approved by the client prior to
construction is required for each job. It must be maintained through out
construction. This documentation to be submitted in package format for
review and approval prior to any construction shop or field. The ITP should
include all required visual and NDE inspection requirements and inspection hold
points.
·
WPS’s, PQR’s, for all
weld processes to be used
·
WPQ’s for all welders
·
MTRs with heat number
for all plate, pipe, and welding consumables used
·
NDE test reports
·
Weld maps with heat
number’s for material
·
Drawings and
calculations for nozzle and manways installed or revised.
·
As built drawings for
new bottoms, roofs, and shell replacements
·
Daily inspection
reports for visual inspections and non destructive testing
·
Non conformance
reports with documentation of corrections.
·
Facsimile of the
repair name plate if applicable.
Repair Activities:
·
Any deviations from
Client Standards or governing codes must be reviewed and approved.
·
Welding consumables.
·
Contractor QC should
coordinate and review all required NDE. Reports will be maintained in the QC
package.
·
Heat numbers must be
transferred to each fabricated component.
After completion of
the repairs and prior to acceptance, the QC package should be reviewed. Once
approved, the QC package should be turned over to Client Inspection within 3
business days.
For New Construction
All design,
fabrication, erection, and documentation should be per Client Standards and
ASME Section VIII Div. 1.
Prior to Construction - Design review/approval of
document packages to include:
·
Manufacturer’s design
calculations.
·
General arrangement
drawings with complete material specifications.
·
Detailed fabrication
drawings.
·
Welding procedure
specifications, procedure qualification records, and welder performance
qualifications (current).
·
Heat treatment
procedures if applicable.
·
Nondestructive
examination procedures and testing procedures.(Inspection Test Plan).
·
Description of
proposed test gaskets including material properties, dimensions, and design
characteristics.
·
An Inspection Test
Plan (ITP) prepared by the contractor and approved by the client prior to
construction is required for each job. It must be maintained through out
construction. This documentation to be submitted in package format for
review and approval prior to any construction shop or field The ITP should
include all required visual and NDE inspection requirements and inspection hold
points.
During Construction - Interim documentation during
construction
·
Rod control-
Electrodes should be stored in accordance with industry standard or client’
specification (care of welding consumables).
·
Documentation- Receiving
inspection and reports will be performed and maintained in “real time” up to
date on site.
·
MTR’s for materials
and electrodes maintained on sight with job package.
·
Heat number’s for
materials should be indicated on the project weld mapping to correspond with
the MTR’s maintained. Heat number’s must be transferred to each fabricated
component.
·
Daily inspection
reports for visual inspections and testing maintained daily.
·
Non conformance
reports with documentation of corrections.
Post Construction
After completion of
the repairs and prior to acceptance, the QC package should be reviewed,
approved and turned over to Client Inspection within 3 working days.
Package to consist of
the following as per API 650 appendix W:
·
Manufacturer’s Data
Report (Code form)
·
Final General
Arrangement and detail fabrication drawings, marked “as built” by the
manufacturer, complete with dimensions and data, with complete material
specification and parts list.
·
Design calculations
·
Copies of material
test reports on all components requiring documentation
·
Nameplate
rubbing/facsimile, including Code stamping
·
Completed copy Company
Pressure Vessel Specification/Data Sheet
·
Completed copy of
Company Tower Tray Specification/Data Sheet (if applicable)
·
Reports of results of
all tests to include:
o
Welded vessel test
plates (if applicable)
o
Hydro test pressure
chart(s)
o
RT performed w/film,
maps, weld ID and film interpretations
o
Heat treatment records
which show complete cycle
o
UT/MT and/or PT if
applicable
o
Hardness testing
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