Read NuWeld Manual-Edition_2-Rev_0.doc text version

NuWeld, Inc.

3327 Route 14 Highway Trout Run, Pennsylvania 17771

QUALITY CONTROL MANUAL NQA ­ 1, 1989

Edition #2, Revision 0 Dated 9-15-2006

Shop and/or Field fabrication of Power Boilers, Power Piping and Pressure Vessels in accordance with ASME Section I to be stamped "S" Or ASME Section VIII, Division 1 to be stamped "U" Also Metallic Repairs and/or Alterations in the shop and/or field sites in accordance with National Board Inspection Code including Jurisdictional requirements to be stamped "R" in addition fabricate parts and components, including hard surfacing, to military, government or other contract specifications

CONTROLLED # UNCONTROLLED UNCONTROLLED# ELECTRONIC

EDITION:

2 0 I-1 9/15/06

NUWELD, INC.

Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: INTRODUCTION AND SCOPE

INTRODUCTION AND SCOPE For NQA-1 work, this manual, including the specific NQA-1 paragraphs, sections and supporting procedures apply. If there is a conflict between the NQA-1 manual requirements and the base manual requirements, the NQA-1 requirements take precedence for NQA-1 work. GLOSSARY AI- AUTHORIZED INSPECTOR- An individual holding a certificate of competency, a valid National Board commission with the (A) endorsement and designed as such by an ASME accredited Authorized Inspection Agency. AIA- AUTHORIZED INSPECTION AGENCY- An inspection organization of states or municipality of the United States or a Canadian Province, or an insurance company authorized to write boiler and pressure vessel insurance. AIA's are accredited by the ASME to inspect boilers and pressure vessels (nuclear and non-nuclear) which are to be stamped with an ASME or National Board Code symbol. Alteration- Any change in the item described on the original Manufacturer's Data Report which affects the pressure containing capability of the pressure retaining item. Non-physical changes such as an increase in the maximum allowable working pressure (internal or external), increase in design temperature, or a reduction in minimum temperature of a pressure retaining item shall be considered an alteration. ASME Code- The American Society of Mechanical Engineers' Boiler and Pressure Vessel Code published by that Society, including addenda and Code Cases, approved by its council. Jurisdiction- A governmental entity with the power, right or authority to interpret and enforce law, rules or ordinances pertaining to boilers, pressure vessels or other pressure retaining items. It includes National Board member jurisdictions defined as "jurisdictional authorities. Jurisdictional Authority- A member of the National Board, as defined in the National Board Constitution. NBIC- The National Board Inspection Code published by The National Board of Boiler and Pressure Vessel Inspectors.

EDITION:

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Trout Run, Pennsylvania 17771

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QUALITY SYSTEM MANUAL

SUBJECT: INTRODUCTION AND SCOPE

NIAC- Nuclear Industry Assessment Committee NUPIC- Nuclear Procurement Issues Committee National Board- National Board of Boiler and Pressure Vessel Inspectors. National Board Commissioned Inspector- An individual who holds a valid and current National Board Commission. Original Code of Construction- Documents promulgated by recognized national standards writing bodies that contain technical requirements for construction of pressure retaining items or equivalent to which the pressure retaining item was certified by the original manufacturer. Pressure Retaining Items (PRI) - Any boiler, pressure vessel, piping, or material used for the containment of pressure, either internal or external. The pressure may be obtained from an external source, or by the application of heat from a direct source, or any combination thereof. Repair- The work necessary to restore pressure retaining items to a safe and satisfactory operating condition. Re-rating- See alteration.

EDITION:

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Trout Run, Pennsylvania 17771

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QUALITY SYSTEM MANUAL

SUBJECT: ORGANIZATION

1.0

ORGANIZATION 1.1 Organizational Chart

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SUBJECT: ORGANIZATION

1.2

Responsibilities 1.2.1 Staff Engineering ­ delegated by the President, the responsibility of all design requirements for fabrication, repair and alteration activities performed by NuWeld, Inc. This may be subcontracted to a qualified vendor. Quality Control Manager ­ has been delegated the responsibility of preparation, implementing and verifying the NuWeld, Inc. Quality System. 1.2.2.1 These responsibilities will be carried out by conducting inspections and monitoring repair/alteration activities in the shop or at field locations controlled by the shop. The QC Manager is responsible to perform an annual assessment of the Quality Program and report to the President.

1.2.2

1.2.2.2

1.2.3

President ­ assigns personnel and delegates the responsibilities as defined in this manual and NWS-026. Assess the effectiveness of the Quality Program. Resolves disputes, as required, within the organization.

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SUBJECT: ORGANIZATION

1.3

STATEMENT OF AUTHORITY AND RESPONSIBILITY 1.3.1 NuWeld Inc. will use and adhere to the QC program as documented in this Quality Control (QC) Manual when fabricating Power Boilers, Power Piping and Pressure Vessels in the shop and /or at field sites in accordance with ASME Section I to be stamped "S" and ASME Section VIII, Division 1 to be stamped "U", in addition Repairs and/or Alterations to Power Boilers, Power Piping and Pressure Vessels in the shop and/or at field sites in accordance with the National Board Inspection Code and any Jurisdictional requirements, hereafter referred to as the Code. Furthermore, the paragraphs or sections that specifically refer to NQA-1 apply only when NQA-1 is invoked by a customer for a specific order. The QC Manager has the full support of management and the authority and responsibility to initiate and execute this QC program with other members of our staff, with the understanding that his decision is binding in all Code related matters. The QC Manager will have the responsibility to define problem areas as related to quality, to provide input regarding the required solutions and implementing corrective action. The QC Manager is independent of cost and schedule considerations and has full authority to issue a stop-work order if the situation warrants. Should the QC Manager encounter problems in the execution of this QC program with various department heads, the President shall resolve the problem, without compromise, to the Code, Jurisdictional requirements and this QC Manual. This manual and any subsequent changes thereto must be approved by the QC Manager and accepted by the Authorized Inspector before implementation. Supplements may be added to this manual as necessary, to address additional customer or job specific requirements, The supplements may not replace or lessen any requirements in the basic manual, but only add to the basic manual requirements and/or add new requirements. These supplements must be approved by the QC Manager but do not require submittal to or acceptance by the A.I. prior to implementation. Supplements shall be made available for the AI to review.

1.3.2

1.3.3

1.3.4

1.3.5

EDITION:

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: QUALITY ASSURANCE PROGRAM

2.0

QUALITY ASSURANCE PROGRAM 2.1 Codes, Standards and Controls 2.1.1 This Quality System Manual addresses the requirements and provides the controls for the Codes and Standards as enumerated on the front cover page of this manual. The basic manual addresses the quality program requirements for ASME Section I, VIII, & NBIC work. For NQA-1 work, this manual, including the specific NQA-1 paragraphs, sections and supporting procedures apply. If there is a conflict between the NQA-1 manual requirements and the base manual requirements, the NQA-1 requirements take precedence for NQA-1 work.

2.1.2

2.2

Quality Indoctrination, Training & Planning 2.2.1 The QC Manager shall assure that all persons who perform functions described in this manual are properly indoctrinated and trained for those functions in accordance with NWS-029. Periodic review and discussion of the QC Manual requirements and related documents that are specific to assigned responsibilities is an integral part of the indoctrination and training program. Actual training may be by supervision or other personnel knowledgeable of the subject. The QC Manager shall maintain the training record form (Exhibit M) confirming indoctrination and training.

2.3

Management Assessment 2.3.1 The President will regularly assess the adequacy of the program using information from a number of sources including internal audits, customer audits, feedback / discussions with employees and daily observations.

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SUBJECT: QUALITY ASSURANCE PROGRAM

2.4

NDE Personnel 2.4.1 For work not specifically requiring NDE personnel training to SNT-TC1A, or equivalent, training may be in accordance with the basic requirements of this manual, Section 9.2. For NQA-1 orders or other orders requiring NDE personnel qualification and training to SNT-TC-1a (or equivalent) training and qualification will be in accordance with NuWeld standard NWS-006.

2.4.2

EDITION:

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Trout Run, Pennsylvania 17771

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QUALITY SYSTEM MANUAL

SUBJECT: DESIGN CONTROL

3.0

DESIGN CONTROL 3.1 Drawings, design calculations and specifications may be supplied by the customer, subcontractor and/or NuWeld, Inc. All drawings, design calculations and specifications shall be independently reviewed and approved by the Staff Engineer or his qualified designee, to assure Code(s) compliance. Drawings, design calculations and specifications are forwarded to the QC Manager for review for design adequacy and approval to assure Code(s) compliance. The Staff Engineer and QC Manager shall sign and date the Drawing and/or Process Traveler (Exhibit A) to document this approval. 3.1.1 When the standard governing the original construction is the ASME Code, NBIC Repairs and/or Alterations shall conform to the Section of the ASME Code most applicable to the work planned. When the standard governing the original construction is not the ASME Code, NBIC Repairs and/or Alterations shall conform to the "original code of construction" most applicable to the work. Where this is not possible or practicable, it is permissible to use other codes, standards or specifications, including the ASME Code, provided NuWeld, Inc. has concurrence of the Authorized Inspector and the Jurisdiction where the "pressure retaining item" is installed or located.

3.1.2

3.2

The Staff Engineer shall be responsible for assigning a Job Number to all drawings, calculations and specifications that will maintain traceability to the vessel or item being fabricated. Drawing(s) shall contain sufficient information for the proper fabrication of the vessel or item. This information shall include but is not limited to; material specifications (with SA, SB, or SFA designations), design specifications, Code Section (including Edition and Addenda), MAWP, MDMT, design temperature, nameplate information, dimensions and special process or inspections ( i.e., NDE, PWHT, etc.)

3.3

EDITION:

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NUWELD, INC.

Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: DESIGN CONTROL

3.3.1

Revisions to design documents shall be prepared and approved in the same manner as the originals. Substitution or alternate material(s), if not already provided for on the Drawing, shall only be used with approval of the Staff Engineer. All affected documents (i.e., calculations etc.) shall be revised accordingly. The Authorized Inspector shall be informed by the QC Manager for review/acceptance of all Code material substitutions.

3.3.2

3.4

When computer aided design calculations are prepared by the customer, subcontractor or NuWeld, Inc. the Staff Engineer shall validate each computer program output with a sample manual calculation. This validation shall reference the program identification name and revision level. The Staff Engineer shall review all computer validations with the Authorized Inspector upon request. The Staff Engineer shall be responsible for transmittal of all design documents and revisions to the Shop or Field Superintendent. A Letter of Transmittal (Exhibit H) shall be used for distribution of design documents to field sites. The Staff Engineer and Field Superintendent receiving the design documents shall sign and date the Letter of Transmittal. The Letter of Transmittal with the obsolete documents attached will be returned to the Staff Engineer. The Staff Engineer will destroy obsolete design documents with the exception of one file copy marked "VOID". The QC Manager shall maintain the letters of transmittal in the Job File. The Staff Engineer shall be responsible for review of Code Edition and/or Addenda at the time of issue to assure the compliance of all engineering controls. Revisions, when required, shall be completed within 6 months of Code Edition and/or Addenda issue date. The Staff Engineer shall document this review by signature and date on the Edition and/or Addenda Summary page. Prior to fabrication the Authorized Inspector shall be given the opportunity to review all design documents and specifications. This review shall be documented by signing the Pre-Job Review on the process traveler. All design documents shall be presented to the Authorized Inspector for review by the QC Manager.

3.5

3.6

3.7

EDITION:

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NUWELD, INC.

Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: PROCUREMENT DOCUMENT CONTROL

4.0

PROCUREMENT DOCUMENT CONTROL 4.1 All materials used in Code fabrication shall be purchased and accepted in accordance with the ASME Code Section II and any additional requirements of the applicable code of construction. The Staff Engineer is responsible for listing the material specifications to be used for fabrication on the approved Drawings. The Purchasing Manager is responsible for generating a Purchase Order (Exhibit #E) for materials as listed on the approved Drawing(s). The Purchase Order shall list the quantity, material specifications (using the SA, SB, and SFA designation) or other specifications permitted by the Code and supplementary requirements (i.e., impact testing) when required. The Purchase Order shall specify that the material is to be properly identified in accordance with the material specification. All plate and plate products shall be accompanied by the Material Test Report (MTR) or other Code acceptable certifications. When required by the customer contract or NuWeld, products shall be purchased with Material Test Reports or other acceptable certification. When ordering pressure boundary items of carbon and low-alloy steels, cold formed by subcontractors, the requirements of UG-79 (when applicable) shall be stipulated on the Purchase Order(s). The Purchase Order shall record the "Job Number" and/or "STOCK" notation. The Purchase Order shall be reviewed and approved by the Staff Engineer and reviewed by the QC Manager for Code compliance prior to issuance. For NQA-1 orders, the QC Manager shall. identify the quality program requirements (Exhibit L), which will be included as part of the Purchase Order. Any additional customer requirements that require "flow down" to the vendor will also be included in the Purchase Order prior to issuance. Purchasing will be in accordance with NWS-022. Copies of the Purchase Order shall be forwarded by the Purchasing Manager to the Vendor, Engineering Job File, QC and Receiving. For material that is to be shipped directly to the Field site, the "receiving" copy of the Purchase Order shall be directed to the Field Superintendent. This copy shall then be used to verify material upon receipt of the packing list by the Field Superintendent.

4.2

4.3

EDITION:

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NUWELD, INC.

Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: INSTRUCTIONS, PROCEDURES AND DRAWINGS

5.0

INSTRUCTIONS, PROCEDURES AND DRAWINGS 5.1 Procedures to detail & support the Quality System Manual. (NQA-1) Procedures have been developed, as required, using NWS-023,to provide detailed support for the activities in this manual. Reference to a supporting procedure will be found in the section or paragraph that it relates to. For NQA-1 orders, order entry will be in accordance with NWS-027. The fabrication, examination, assembly and testing of Code equipment or other equipment produced in accordance with this Quality Program shall be controlled by means of approved Drawing(s) and Process Traveler Form (Exhibit #A) prepared by the Staff Engineer or his designee. The Process Traveler Form (Traveler) lists the sequences of fabrication, examinations, process controls (i.e., WPS, NDE requirements etc.), and inspection operations for Code items. The Staff Engineer may consult with the QC Manager and Welding Engineer or others to verify the instructions on the Traveler are accurate, complete and Code compliant. When completed the Staff Engineer submits the approved Drawing and Traveler to the QC Manager for review / approval and to include quality control requirements for inspection, examination and testing. All quality control inspection operations on the Traveler shall be considered NuWeld Inc. mandatory "witness points" and require a sign-off by the QC Manager or his designee. The QC Manager shall review approved Drawings and Travelers with the Authorized Inspector and the customer (if required) for the designation of "Hold Points" prior to the start of any fabrication. The Authorized Inspector and the customer (if applicable) may designate "Hold Points" on the Traveler and/or approved Drawing by placing the letter "H" in the applicable operation block or at specific locations on the Drawing. The QC Manager, Authorized Inspector and customer (if applicable) will initial and date the Traveler to document this review and approval. Revisions to the approved Drawing(s) and Traveler shall be prepared, approved, accepted and distributed in the same manner as the originals. The QC Manager shall notify the Authorized Inspector and customer (when applicable) as to the nature of all revisions so that additional "Hold Point(s)" (when required) may be selected prior to the start of fabrication. The approved Drawing and Traveler shall remain with the item during

5.2 5.3

5.4

5.5

EDITION:

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NUWELD, INC.

Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: INSTRUCTIONS, PROCEDURES AND DRAWINGS

fabrication and be available to the Authorized Inspector and customer during any inspection(s). 5.6 The approved Drawing(s) and Traveler(s) are issued to the Shop and/or Field Superintendent, subsequent to the QC Manager and Authorized Inspector reviews, by the Staff Engineer. The Shop and/or Field Superintendent shall be responsible for supervising all work in accordance with the instructions on the Traveler and approved Drawing. The QC Manager or his designee shall perform any quality control inspection and examination for NuWeld Inc. noted on the Traveler and record acceptance by initialing and dating the Traveler. The QC Manager shall notify the Authorized Inspector and customer (as applicable) sufficiently in advance of the designated "Hold Point(s)". Work shall not progress beyond any "Hold Point(s)" until accepted and signed off or written approval is obtained by the QC Manager. The Authorized Inspector and customer (as applicable) may add additional "Hold Point(s)" as deemed necessary. 5.7.1 When Radiographic Examination (RT) is required by Code (i.e., ASME Section VIII, Div. 1) the QC Manager shall notify the Authorized Inspector so that RT locations can be selected by the Authorized Inspector prior to the RT examination being performed. The QC Manager may select the RT locations only with approval from the Authorized Inspector. This approval shall be noted on the Traveler by the QC Manager and signed off by the Authorized Inspector. When vessels and/or items are fabricated so that entry for final internal inspections would not be accessible an internal examination and inspection shall be made available to the Authorized Inspector before final closure. The QC Manager shall notify the Authorized Inspector when Code vessels and/or items are ready for final internal examination or inspection.

5.7

5.7.2

EDITION:

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: DOCUMENT CONTROL

6.0

DOCUMENT CONTROL 6.1 MANUAL CONTROL 6.1.1 This manual shall be prepared / approved by the QC manager and submitted to the Authorized Inspector for review and acceptance prior to inclusion or implementation. The approval of the QC Manager and acceptance of the Authorized Inspector shall be indicated on the Manual Index page by their signature and date. The edition number and date shall be noted on the Title Page. The QC Manager shall designate the QC Manual copies as "controlled" or "uncontrolled" on the Title Page. Only "controlled" manuals shall be issued to company personnel and the AI. "Uncontrolled" manual copies will be current on the day of issue and will not receive further consideration. All "controlled" QC Manuals shall be numbered and entered on a QC Manual Control Log that will be kept in the "Master QC Manual" by the QC Manager. This Log shall indicate the holder, edition/revision level and date of each "controlled" QC Manual. Revisions to the QC Manual shall be prepared by the QC Manager and submitted to the Authorized Inspector for acceptance prior to inclusion or implementation. Revisions shall be performed by revising the entire applicable manual section with revised text identified by bold-type. The Edition / Revision level(s) and date shall be noted on the Title Page. Exhibits shall be revised individually with the revision level and date noted on the Exhibit Index Page. QC Manual sections and/or Exhibit revision levels and dates shall be noted on the Manual Index page. The approval of the QC Manager and acceptance of the AI shall be indicated on the Manual Index page by their signature and date. The QC Manager will review each Code Edition and/or Addenda at the time of issue, for changes that may require revisions to the QC Manual. Revisions, when required, shall be made as described above within 6 months of the Code Edition and/or Addenda issue date. The QC Manager shall document this review by signature and date on the Edition and/or Addenda Summary page.

6.1.2

6.1.3

6.1.4

6.1.5

EDITION:

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: DOCUMENT CONTROL

6.1.6

The QC Manager may at any time, preferably at the Code triannual Joint Review issue complete new editions of the QC Manual. New editions will be sequentially numbered and start at "Revision 0". New editions shall be approved, accepted, identified and revised as described for the original. The QC Manager shall forward all editions and/or revisions to those individuals noted on the QC Manual Control Log and retrieve/destroy the superseded document(s).

6.1.7

EDITION:

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REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: CONTROL OF PURCHASED ITEMS AND SERVICES

7.0

CONTROL OF PURCHASED ITEMS AND SERVICES (NQA-1 Orders only)

7.1

Selection of suppliers of critical materials and services will be made from an Approved Vendor List, created and maintained by the Quality department with input from Purchasing. Evaluation and selection methods shall be in accordance with NWS-024 and include one or more of the following methods: 7.2.1 Direct evaluation of facilities, personnel & QA Program implementation (Audit) 7.2.1.1 Audits will be performed by personnel trained and qualified in accordance with NuWeld, Inc. standard NWS020. 7.2.2 Evaluation of supplier's history of providing identical or similar product, or of Suppliers current quality records that can be objectively evaluated. 7.2.2.1 An evaluation by NuWeld at least once every three (3) years. The QC Manager will select an evaluation process that is appropriate for all material or services being supplied. The method may be an audit of the facility or confirmation testing of a sample of material. The QC Manager will maintain records of evaluation, results and schedules for the re-evaluation.

7.2

EDITION:

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: IDENTIFICATION AND CONTROL OF ITEMS

8.0

IDENTIFICATION AND CONTROL OF ITEMS For NQA-1 orders, the requirements of NuWeld, Inc. standard NWS-019 supplement or replace, as applicable, the requirements of this manual. 8.1 Materials received at NuWeld Inc. shall be segregated pending the QC Manager's acceptance of the MTR (and or other required documentation) in accordance with the Code and receiving inspection. The QC Manager, Receiver or other Designee, using the Purchase Order copy examines materials for marking, including heat number or other traceability to the MTR, forming, dimensions and condition. Upon material acceptance, the Receiver shall mark the materials with the Purchase Order and Job Numbers; initial and date the Purchase Order copy and forward the PO copy, Packing List and MTR (when applicable) to the QC Manager. 8.1.1 8.1.1 Materials received at NuWeld Inc. for field site fabrication shall be receipt inspected and identified as described above. The materials shall be identified with the Purchase Order and Job numbers. The QC Manager shall send the materials along with the Letter of Transmittal and copies of the applicable Purchase Order and MTR to the Field Superintendent. The Field Superintendent shall inspect the received materials. Verify the heat numbers with the MTR and document the "receipt inspection" by initialing and dating the Letter of Transmittal. Upon completion the Field Superintendent shall maintain the Letter of Transmittal in the Job File.

8.2

Material ordered at Field Sites shall be processed as required in paragraph 4.0. Materials received at Job Sites shall be segregated pending the Field Supervisor, Receiving Inspection. All documentation shall be forwarded to the QC Manager and processed as required by paragraph 8.1. Field Supervisor shall identify material with Job Number and Purchase Order. Field Supervisor shall be notified by the QC Manager that the material received is in compliance with ASME Section II. Field Supervisor will sign Traveler documenting Material Acceptance. Customer supplied materials shall be received and inspected as described above except that there will not be a NuWeld Purchase Order. The material shall only be acceptable for Code use if the materials have the original Material Manufacturer's product markings and the MTR as required by the applicable Code material specifications. Customer supplied materials that do not comply with the requirements of the Code

8.3

EDITION:

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REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: IDENTIFICATION AND CONTROL OF ITEMS

or this QC Manual shall be segregated and considered non-conforming and processed in accordance with the Non-conformance section of this QC Manual. 8.4 The Shop and/or Field Superintendent shall be responsible for ensuring the required identification markings are maintained on materials during all phases of fabrication. Materials shall be marked by methods that have been accepted by the AI. Stamping shall not be used on ferrous materials less than, 0.25" thick and on nonferrous materials less than 0.50". Prior to cutting materials into two or more pieces the material specification, heat/lot number and the Purchase Order and Job numbers shall be transferred to each piece or noted on the approved Drawing and verified by the Shop and/or Field Superintendent. Materials that have lost traceability shall NOT be used for Code fabrication unless re-certified by NuWeld, Inc.. The QC Manager shall be responsible for maintaining the "Receiving" Purchase Order copy and original MTR on file and shall submit all MTR's to the Authorized Inspector for review. Revisions to procurement documents shall be prepared, approved and distributed in the same manner as the originals. The QC Manager shall make all records referenced in this QC Manual section available for review to the Authorized Inspector. Government Representative (non-ASME Code) may request inspection at subcontractor or vendor facilities. The QC Manager will be notified of the hold or witness points who, in turn, will notify Purchasing to incorporate the requirements into the Purchase Orders. 8.6.1 The Government Representative will advise NuWeld Inc. which statements are applicable for each Purchase Order. 8.6.1.1 Government Inspection is required prior to shipment from your plant. Upon receipt of this order promptly notify the Government Representative who normally services your plant so that appropriate planning for government inspection can be accomplished. Upon receipt of this order, promptly furnish a copy to the Government Representative who normally services your plant so that appropriate planning for government inspection can be accomplished.

8.5

8.6

8.6.1.2

EDITION:

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SUBJECT: IDENTIFICATION AND CONTROL OF ITEMS

8.6.1.3

All purchasing documents and referenced documents applicable to government contracts are available to the Government Representative for review. The request for review or copies shall be directed to the QC Manager.

8.7

Inspection of Government-furnished (non ASME Code) materials shall be performed and documented. 8.7.1 8.7.2 8.7.3 Upon receipt verification of all items documented as shipped. Verification that no damage has occurred in transit. Verify identification of material type. Heat numbers and serial numbers if applicable. Material shall be stored to prevent any damage from handling or deterioration. Periodic inspections will be performed by the QC Manager. In the event that any discrepancies or damage is found it will be reported to the QC Manager at which time he will report the condition to the Government Representative.

8.7.4

8.7.5

EDITION:

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REVISION: SECTION: PAGE: DATE:

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SUBJECT: CONTROL OF PROCESSES

9.0

CONTROL OF PROCESSES 9.1 WELDING CONTROLS For NQA-1 orders, the requirements of the following NuWeld, Inc. standards supplement or replace, as applicable, the requirements of this manual. NWS-014: Welding Procedure & Welding Performance Qualification Testing NWS-016: Weld Performance Continuity NWS-017: General Welding and Hardfacing Specification NWS-018: Welding Instructions for Work Assignment and Filler Metal Control 9.1.1 All welding and documentation used for Code fabrication shall be in accordance with the ASME Code Section IX and any additional requirements of the applicable code of construction. The Welding Procedure Specification(s) to be used in the Code fabrication shall be noted on the process traveler by Welding Engineer or Staff Engineer. The assigned welder shall sign off on the process traveler the appropriate welding operation(s) that he completes. The Welding Engineer shall prepare the Welding Procedure Specification (WPS) and the supporting Procedure Qualification Record (PQR). The PQR welding test will be conducted under the supervision of the Welding Engineer. The test coupons are to be sent to a qualified test laboratory for preparation and testing specimens as required by ASME Section IX. The completed laboratory report is reviewed by the Welding Engineer and when ASME Code acceptable he will prepare and certify the PQR. The original PQR and WPS are kept on file by the Welding Engineer. These records are available for review by the Authorized Inspector or Government Representative. 9.1.2.1 When changes are made to non-essential variables, the WPS may be revised by the Welding Engineer. 9.1.2.2 When changes are made to essential and when applicable supplementary essential variables a new WPS will be prepared or new supporting PQR created, qualified and certified as stated above.

9.1.2

EDITION:

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REVISION: SECTION: PAGE: DATE:

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SUBJECT: CONTROL OF PROCESSES

9.1.3

The Welding Engineer will supervise the required welding test for Welder Performance Qualifications (WPQ). Performance tests may be terminated if it becomes apparent that the welder lacks the necessary skill to meet the specification. The test coupons are sent to a qualified test laboratory for preparation, and testing of coupons as required by ASME Section IX. The completed laboratory report is reviewed by the Welding Engineer and when ASME Code acceptable he will prepare and certify the WPQ. 9.1.3.1 WPQ shall be renewed or re-qualified whenever there is a change in a performance essential variable, or; 9.1.3.1.1 When the welder has not welded with a process during a period of 6 months (for Government contracts, 3 months shall apply) or more the welder qualification for that process shall expire, unless, within the 6 month period, prior to the welder expiration of qualification;

9.1.3.1.1.1 A welder has welded using a manual or semiautomatic welding process which will maintain the qualification for manual and semiautomatic welding with that process; 9.1.3.1.1.2 A welding operator has welded with machine or automatic welding process which will maintain the qualification for machine or automatic welding with that process; 9.1.3.1.2 Renewal of qualifications that expire may be made for any process by welding a single test coupon of either plate or pipe, of any material, thickness or diameter, in any position, and by testing that coupon as required by ASME Section IX (QW-301 and QW-302). A successful test renews the welder's previous qualifications for that process for those materials, thickness,

EDITION:

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diameters, positions and other variables for which he has previously qualified. 9.1.3.2 When there is specific reason to question the welders' ability to make welds that meet the WPS, the qualifications which support the welding he is doing shall be revoked. All other qualifications not questioned remain in effect. 9.1.3.2.1 Welders whose qualifications have been revoked as started above shall re-qualify. Qualification shall utilize a test coupon appropriate to the planned production work. The coupon shall be welded and tested as required by ASME Section IX (QW-301 and QW-302). Successful test restores the qualification.

9.1.4

All qualified welder's names and symbols, what process and last date welded in that process shall be maintained in a Welder Continuity Log (Exhibit # D). The Welder Continuity Log shall be updated quarterly by the Welding Engineer. The Welding Engineer is responsible for assigning each Code welder a welder identification symbol. Should the welder employment be terminated the welder's assigned symbol shall not be re-issued for a minimum of 3 years. 9.1.5.1 Each welder shall stamp his identifying symbol adjacent to and at intervals of not more than 3 feet to completed welds. To identify welders for ferrous material 0.25" or less and on non-ferrous material 0.50" and less suitable stencils or other surface markings shall be used by the welders as stated above. A record may be kept on the approved Drawing and/or traveler identifying the welder who welded each joint by the Shop and/or Field Superintendent.

9.1.5

9.1.5.2

9.1.6

The Shop and/or Field Superintendent are responsible for the selection and supervision of welders and shall instruct them as to the correct use of the WPS specified on the Traveler. Copies of

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WPS and WPQ shall be provided to Shop and/or Field Superintendent by the Welding Engineer. All WPS are made available to welders by the Shop and/or Field Superintendent. 9.1.6.1 Bars, jacks, clamps, tack welds, or other appropriate means may be used to hold the edges of parts in alignment. Tack welds used to secure alignment shall either be removed completely when they have served their purpose, or their stopping and starting ends shall be properly prepared by grinding or other suitable means so that they may be satisfactorily incorporated into the final weld. Tack welds, whether removed or left in place, shall be made using a fillet weld or butt weld procedure qualified in accordance with ASME Section IX. Tack welds to be left in place shall be made by qualified welders in accordance with ASME Section IX , and shall be examined visually for defects, and if found to be defective shall be totally removed.

9.1.6.2

9.1.6.3

9.1.6.4

9.1.7

Welding materials shall be ordered, either at NuWeld Inc. or at field sites, identified and received in accordance with ASME Code and as described in this QC Manual. Welding materials, at the shop or at field sites, shall be stored in their original containers in a dry storage area and shall be issued by the Shop and/or Field Superintendent. 9.1.7.1 Welding materials, in original hermetically sealed containers or opened spools and loose electrodes, shall have their identification (SFA#) and/or classification designators properly maintained. 9.1.7.1.1 Unused spools, coils or powder may remain on the welding feeder provided they are properly identified and

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covered to remain dry and maintain cleanliness. 9.1.7.2 When low-hydrogen electrode containers are open, the electrodes shall be placed in heated ovens or portable ovens at field sites, maintained at the temperature recommended by the electrode manufacturer or by ASME Section II, Part C and verified by the Shop and/or Field Superintendent. 9.1.7.2.1 Low-hydrogen electrodes shall be issued only in a quantity sufficient to complete the weld, or for a four-hour period, whichever is less. When issued from heated portable ovens the period may be extended to eighthours.

9.1.7.3

Unconsumed coated electrodes shall be examined by the Tool Room Attendant or Shop/Field Superintendent upon return for condition, cleanliness and identification and placed in a segregated area of the heated oven or in a separate portable heated oven, prior to reissue. Damaged, unidentified or partially consumed coated electrodes shall be scrapped.

9.1.8

In accordance with ASME Section I (PW-1.2) and Section VIII, Div.1 [UW-26(d)], NuWeld Inc. may utilize subcontracted welders (not directly employed by NuWeld Inc.) to fabricate boilers, power piping, pressure vessels

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and/or Parts. NuWeld Inc. shall maintain responsibility for all welding/fabrication, as required by the ASME Code and described in this QC Manual, supplied by any subcontracted welder(s). All subcontracted welders shall be qualified and identified in accordance with UW-26 (d) and ASME Section IX. 9.1.8.1 All subcontracted welding shall be performed only in accordance with NuWeld Inc. qualified/certified PQR and WPS. The PQR and WPS shall be reviewed by the Welding Engineer and QC Manager to ensure compatibility for Code fabrication prior to being issued to subcontracted welders. The WPS shall be listed on the Traveler by the Staff Engineer. Subcontracted welders shall weld at the NuWeld shop or at specific field locations only. Prior to any Code welding by the subcontractor, all individuals shall be qualified by NuWeld Inc. The welding of all test coupons shall be supervised by the Welding Engineer. Upon successful completion and test of coupon(s) the Welding Engineer shall prepare and certify the WPQ and issue a unique identification number. This unique identification number shall be listed on the NuWeld Inc. Welder Continuity Log and individual qualifications shall be maintained in accordance with the requirements as stated in the Code (ASME Section IX, QW-322) and this QC Manual. During any and all Code fabrication performed by the subcontracted welder(s), the Shop and/or Field Superintendent shall have the direct authority to assign and/or remove

9.1.8.2

9.1.8.3

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welders. The Shop and/or Field Superintendent shall supervise the actual welding and welder's identification during all Code fabrication. The assigned subcontracted welders shall identify all completed welds (including tack welds) by using their assigned identification numbers as described in this QC Manual. 9.1.8.4 All records noted above shall be made available to the Authorized Inspector and Government Representative by the Welding Engineer or QC Manager. The AI shall have the right to monitor/inspect all subcontracted welding being performed at the shop or at field sites. The Authorized Inspector's acceptance of this subcontracting system shall be documented by sign/dating the QC Manual Index Page.

9.1.9

All records referenced in this Section shall be made available to the Authorized Inspector by the QC Manager upon request.

9.2

NONDESTRUCTIVE EXAMINATION For NQA-1 orders, the requirements of NuWeld, Inc. standard NWS-006 supplement or replace, as applicable, the requirements of this manual. 9.2.1 Required NDE shall be performed using written procedures, qualified personnel and adhering to the acceptance standards in accordance with ASME Section V and any additional requirements of the applicable code of construction used for Code fabrication. The Staff Engineer shall be responsible for determining the Code requirements, acceptance standards to be used and the extent of NDE to be utilized during Code fabrication. The Staff Engineer

9.2.2

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shall specify the Code required NDE on the approved Drawing and Traveler. 9.2.2.1 The Inspector performing the NDE examination shall record the results and initial and date the NDE operation on the Traveler.

9.2.3

Code required NDE may be performed in the shop or at field sites by NuWeld Inc. qualified and certified Inspectors using NuWeld Inc. or subcontractor's NDE procedures which have been reviewed and accepted by the NuWeld Inc. QC Manager. Alternatively, NDE may be subcontracted to a subcontractor whose current written practice, NDE procedures and Personnel Qualifications have been reviewed and accepted by the QC Manager in accordance with ASME Code and SNT-TC-1A (latest ASME Code accepted edition/addenda). 9.2.3.1 NuWeld Inc. NDE procedures shall be prepared or approved by the Level III in accordance with ASME Section V and the ASME Code section most applicable to the fabrication being performed.

9.2.4

The QC Manager shall have verified, prior to the start of Code required NDE activities, that, the personnel (NuWeld, Inc. Inspectors, or subcontracted NDE Level I, II, and III Inspectors) engaged in these activities, have current qualifications and annual eye examines. Subcontracted NDE Inspectors shall be qualified and certified in accordance with their employer's Written Practice which must comply with the requirements of SNT-TC-1A as a guide. For Government work (non-ASME Code), other specifications such as MIL-STD-271F may apply. 9.2.4.1 The QC Manager shall appoint by letter the subcontractor's NDE Level III Examiner, by name, to act in that capacity on behalf of NuWeld Inc. The letter shall state the specific NDE method(s) he is qualified for, and be maintained on file by the QC Manager to the Authorized Inspector for review. The AI has the right to request re-qualification of an NDE Inspector for just cause.

9.2.4.2

EDITION:

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9.2.5

Code required NDE shall be performed using written procedures that have been prepared and/or approved by the NuWeld Inc., appointed NDE Level III Examiner qualified in the specific NDE method or in-house by the QC Manager. NuWeld Inc. NDE procedures, when be prepared by the Level III Examiner, shall be reviewed and accepted by the QC Manager. All NDE procedures shall provide enough detail as to the technique to be used, to assure that ASME Code Section V and the code of construction requirements are met. All NDE procedures shall be reviewed and accepted (sign/dated) by the QC Manager, prior to use and maintained on file. 9.2.5.1 All NDE procedures used in Code fabrication shall be submitted to the Authorized Inspector for review and shall be proved by actual demonstration to the satisfaction of the AI. This demonstration shall be documented and sign/dated by the QC Manager and AI. The Authorized Inspector has the right to request re-qualification of any NDE procedure when the Authorized Inspector has reason to question its capability of producing meaningful results. NDE procedures shall be made readily available to NDE personnel and Authorized Inspector for their reference and use by the QC Manager. Revisions to NDE procedures shall be prepared, approved and accepted in the same manner as the originals.

9.2.5.2

9.2.5.3

9.2.6

Code required NDE shall be evaluated, interpreted and accepted by a qualified NDE Level II or III Inspector in accordance with ASME Section V and the code of construction. NDE Reports shall be supplied by the subcontracted NDE Level II or III Inspector and shall be reviewed and accepted by the QC Manager prior to submittal to the Authorized Inspector for review. All NDE Reports shall be maintained in the Job File by the QC Manager. 9.2.6.1 ASME Section I power boilers and/or parts and ASME B31.1 power piping, all Radiographic (RT) films shall be maintained by the QC Manager for a minimum of 5 years.

EDITION:

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9.2.6.2

ASME Section VIII, Div. 1 pressure vessels and/or parts, RT film(s) may be discarded after the Authorized Inspector signs the Manufacturer's Data Report.

9.2.7

NuWeld Inc. may choose to have in-house NDE Inspectors perform Liquid Penetrant (PT), Magnetic Particle (MT), and Visual (VT) Examinations to the requirements of ASME Section V and the code of construction. 9.2.7.1 Instructions will be given in the fundamentals of the specific NDE method by the Level III Examiner. Onthe-job training will be provided to familiarize the Inspectors, with the appearance and interpretation of indications of weld(s) and material defects. The extent of such training shall be as required by NuWeld Inc. written practice, Standard NWS-006. A visual acuity examination shall be performed annually to determine optical capability of the Inspector to perform the required NDE examination. The following requirements shall be met;

9.2.7.2

9.2.7.2.1

The Inspector has vision, with correction if necessary to enable him to read a Jaeger Type #1 (or better) Standard Chart at a distance of not less than 12 inches, and is capable of distinguishing contrast between colors used.

9.2.7.3

Certification of each Inspector shall be recorded on a NDE Personnel Certification Record (Exhibit K) sign/dated by the QC Manager and maintained on file. 9.2.7.3.1 Personnel who have not performed a specific NDE method for a period of one year shall be re-certified by successfully completing the written examination and visual acuity examination as described above.

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9.2.7.3.2

Substantial changes in procedures or equipment, as determined by the QC Manager shall require re-certification of NuWeld, Inc. Inspectors.

9.2.7.4

The QC Manager shall make all records referenced in this QC Manual Section available to the Authorized Inspector for review.

EDITION:

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9.3

HEAT TREATMENT 9.3.1 Code required Heat Treatment is limited to Post Weld Heat Treatment (PWHT). PWHT, when required by Code, shall be performed by a qualified subcontractor and/or NuWeld Inc. in the shop or at the field site. PWHT shall be noted on the approved Drawings and Traveler by the Staff Engineer or his designee. All PWHT shall be performed in accordance with a written procedure in accordance with the code of construction. PWHT procedures shall be prepared by the Weld Engineer and reviewed/accepted by the QC Manager. All PWHT procedures shall be made available to the Authorized Inspector for review. 9.3.2.1 As a minimum the procedures shall detail the heating and cooling rates, time at temperature, placement of thermocouples and the required records.

9.3.2

9.3.3

PWHT records submitted by the subcontractor and/or NuWeld Inc. shall be actual furnace charts that record the identification of the item(s), conditions, identification of thermocouples and shall be sign/dated by the subcontractor. Copies of the Calibration Certification(s) for the recorder shall be supplied by the subcontractor. 9.3.3.1 PWHT records shall be reviewed and accepted (sign/dated) by the QC Manager prior to submittal to the Authorized Inspector for review. PWHT records shall be maintained in the Job File by the QC Manager.

9.3.4

Prior to shipping materials, parts and/or vessels to a subcontractor's facility, items shall be stamped or etched with a trace code number to ensure their identification. When PWHT items are returned from the subcontractor, the QC Manager shall perform an inspection and examine each item for damage and possible loss of identification. The QC Manager shall make all records referenced in this QC Manual section available to the Authorized Inspector for review.

9.3.5

EDITION:

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10.0

INSPECTION 10.1 General Inspection Requirements 10.1.1 Inspection Personnel 10.1.1.1 Inspection personnel shall not report directly to the immediate supervisors who are responsible for performing the work being inspected. 10.1.1.2 Personnel who verify conformance of work activities for purposes of acceptance shall be qualified to perform the assigned inspection task. 10.1.1.3 Inspections by persons during on-the-job training shall be performed under the direct supervision of a qualified person. Verification of performance shall be by the qualified person until certification of the trainee is achieved. 10.1.1.4 Mandatory inspection hold points, if required, shall be indicated on the traveler. Work shall not proceed beyond a hold point with out specific consent of the designated representative who placed the hold point. 10.1.1.5 Inspection activities shall be planned and documented. Specific procedures will be developed prior to any inspections which will identify characteristics, methods and acceptance criteria. The procedures shall also provide for recording objective evidence of inspection results. 10.1.1.6 Inspection records shall, as a minimum, identify; item inspected date of inspection inspector type of observation results or acceptability references to information taken in connection with non-conformances.

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10.1.1.7 If a sampling method is used to verify acceptability of a group of items, the sampling plan shall be based on recognized standard practices. 10.1.1.8 Inspection of items in-process or under construction shall be performed for work activities where necessary to verify quality. 10.1.1.9 If inspection of processed items is impossible or disadvantageous, indirect control by monitoring of processing methods, equipment and personnel shall be provided. 10.1.1.10 Completed items presented for final acceptance shall be inspected for, as a minimum,: completeness dimensions/tolerances markings calibration adjustments protection from damage other characteristics required to verify the quality and conformance to specified requirements 10.1.1.11 Acceptance of an item shall be documented and approved by authorized personnel

EDITION:

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11.0

TEST CONTROL 11.1 The Shop and/or Field Superintendent are responsible for the actual final pressure testing in accordance with the applicable Code. The QC Manager will coordinate with the Authorized Inspector in advance to make any required visual inspections of the vessel and/or item and witness the final pressure test. 11.1.1 The Staff Engineer shall determine the code required pressure(s) and temperature(s) to be applied to vessels and/or items during final pressure testing. The Staff Engineer shall list the final test pressure(s) and temperature(s) on the approved Drawing and Traveler. 11.1.1.1 When final hydrostatic testing is performed for ASME Section I power boilers, items and power piping. The water temperature shall be at no less than ambient temperature, but in no case lower than 70 degrees F. The metal temperature shall not exceed 120 degrees F during the examination. At no time during the hydrostatic testing shall any part of the boiler be subjected to a general primary membrane stress of greater than 90% of its yield strength (0.2% offset) at test temperature. The test pressure shall be under proper control at all times so that the required test pressure is never exceeded by more than 6%. When pneumatic testing is utilized for final pressure testing of ASME Section VIII, Div. 1 vessels and/or items. The Staff Engineer shall write a testing procedure in accordance with ASME Section VIII, Div. 1, UG-100. The Staff Engineer shall list the pneumatic testing procedure and Liquid Penetrant (PT) Procedure numbers along with the pneumatic test pressure(s) and temperature(s) on the approved Drawing and Traveler. The PT examination required by Code (re: ASME Section VIII, Div.1, UW-50) and PT personnel performing the examination shall be documented on the Traveler by the person accepting the PT and reviewed by the Authorized Inspector.

11.1.1.2

11.1.2 At least two pressure gauges shall be utilized during final hydrostatic pressure testing. One gauge shall be connected at

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the highest point and directly to the vessel and/or item being tested. The other gauge shall be visible to the operator controlling the pressure being applied. The gauges shall have a range of about double the maximum test pressure, but not less than one half or more than four times the test pressure. The pressure gauge serial numbers used for final pressure testing shall be noted on the traveler by the QC Manager. Pressure gauges shall be calibrated and/or checked in accordance with the Calibration section of this QC Manual. 11.1.3 When the final pressure test meets Code requirements and is accepted the QC Manager and Authorized Inspector will sign and date the Traveler in the spaces provided. 11.2 The QC Manager shall have control and custody of the ASME and National Board Code(s) symbol stamps. The applicable Code symbol stamp ("S" "U" or "R") shall be stamped on the vessel or applied to the nameplate (Exhibit J) with approval of the Authorized Inspector and be attached to the correct vessel by the QC Manager after final pressure testing is completed and accepted. The QC Manager and Authorized Inspector shall verify that the correct Code nameplate has been applied to the vessel and/or item. 11.2.1 The QC Manager may pre-stamp the applicable Code symbol stamp(s) with approval of the Authorized Inspector, on the nameplate(s) for vessels and/or items fabricated at field sites. These pre-stamped nameplates shall be forwarded to the Field Superintendent along with a Transmittal Letter by the QC Manager for application to the Code Vessel and/or item. The Field Superintendent and Authorized Inspector at the field site shall verify that the correct Code nameplate has been received and applied to the vessel and/or item. 11.3 When working to MIL-I-45208A (non-ASME Code) or other standards requiring objective evidence of quantitative and qualitative results the QC Manager will document the number inspected and record actual values of critical dimensions on the Process Traveler or drawing(s) traceable to the Process Traveler. 11.3.1 Customers and Government Representatives (non-ASME Code) are granted free access to witness or perform inspections or other verification activities.

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11.3.2 Measuring and Testing Equipment shall be made available for their use to determine conformance of product with contract requirements. 11.3.2.1 When conditions warrant, personnel shall be made available for operation of these devices during inspection of our product, for verification of their accuracy and condition 11.4 National Board "Repairs and/or Alterations" shall be performed as described in this QC Manual with the following additional requirements. 11.4.1 If during the Repair and/or Alteration of a pressure retaining item it becomes necessary to remove the original manufacturer's stamping or nameplate, the AI, subject to the approval of the Jurisdiction if applicable, will witness the making of a facsimile or rubbing of the stamping to the new part without restamping the ASME Code symbol stamp. When the stamping is on a nameplate, the AI shall witness the transfer of the nameplate to the new part. Any relocation of the stamping or nameplate shall be described on the NBIC R-Form. The ASME Code symbol stamp is NOT to be re-stamped. 11.4.2 ROUTINE REPAIRS; prior to performing Routine Repairs, the QC Manager shall determine that these types of repairs are acceptable to the Jurisdiction at the vessel and/or item location. The following categories shall constitute Routine Repairs: 11.4.2.1 Welded repairs or replacement of tubes or pipes NPS 5 and smaller, or sections thereof, where neither postweld heat treatment nor NDE other than visual examination is required by the original code of construction. Addition or repair of non-load bearing attachments to pressure retaining items where Post Weld Heat Treatment is not required. Weld build-up of wasted areas in shells and/or heads etc., not exceeding 100 square inches or 25% of the nominal wall thickness or 0.50", whichever is less.

11.4.2.2

11.4.2.3

EDITION:

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11.4.2.4

Corrosion resistance weld overlay not exceeding 100 square inches.

11.4.3 Routine Repairs shall be performed in accordance with the requirements of the NBIC, acceptance of the Authorized Inspector and this QC Manual; however the in-process involvement of the Authorized Inspector may be waived. The QC Manager, prior to beginning any Routine Repair, shall notify the AI. The QC Manager shall note this notification on the Traveler. 11.4.4 Routine Repairs shall be documented on the NBIC R-1 Form with a statement in the "Remarks": "Routine Repair". The R-1 Form and all associated documents shall be completed and certified by the QC Manager and presented to the Authorized Inspector for review and signature.

EDITION:

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12.0

CONTROL OF MEASURING AND TEST EQUIPMENT For NQA-1 orders, the requirements of NuWeld, Inc. standard NWS-028 supplement or replace, as applicable, the requirements of this manual. 12.1 The QC Manager is responsible for calibration of all measuring and test equipment (M&TE) used for receiving, in process or final inspections. For Government work (non-ASME Code) calibration will be in accordance with MIL-STD-45662. All M&TE subject to calibration shall have a unique serial number assigned for traceability. Personal M&TE shall not be used for final inspections or testing during Code fabrication unless it is included in the NuWeld calibration system. A record of each calibration for all M&TE will be recorded on the Calibration Log (Exhibit G). This Log will contain the M&TE serial number, description, range, calibration date and next calibration due date. The Calibration Log shall be maintained by the QC Manager. 12.3.1 After calibration is complete, a Calibration Sticker (Exhibit F) showing the next calibration due date will be attached to the M&TE or its container. 12.4 All pressure test gauges used for final testing in shop or field shall be calibrated annually and checked against another calibrated gage prior to use. Calibration is also required at any time that there is reason to believe that they are in error. Calipers or Micrometers thickness measuring devices used in receiving, during in-process or final inspections will be calibrated against Gage Blocks with calibration certification traceable to a National Standard. This assures at least a 4:1 ratio of accuracy. 12.5.1 Measuring devices shall be calibrated annually or at any time that there is reason to believe that they are in error. 12.5.2 Gage Blocks shall be calibrated by subcontractor who shall supply certification of calibration traceable to a National Standard. Gage Blocks shall be calibrated every 15 years. Earlier recalibration is required if there is evidence of damage or corrosion.

12.2

12.3

12.5

EDITION:

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12.6

When M&TE are found to be out of calibration or damaged, the QC Manager shall remove it from the work area and arrange for the recalibration or replacement. All Code items checked with discrepant M&TE are non-conforming until the QC Manager has verified that they meet Code requirements or they are re-tested with accurate, calibrated instruments. The non-conforming condition will be documented on an NCR in accordance with Section 13. M&TE used in the shop and/or field shall be issued by the QC Manager to the Shop and/or Field Superintendent. Upon completion, all M&TE issued shall be returned to the QC Manager and examined for damage. All records referenced in this QC Manual section shall be made available to the Authorized Inspector for review.

12.7

12.8

EDITION:

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SUBJECT: HANDLING, STORAGE AND SHIPPING

13.0

HANDLING, STORAGE & SHIPPING 13.1 Handling, storage and shipping will be performed and controlled in accordance with NuWeld standard NWS-013. Instructions relative to any special handling, storage and shipping requirements will be listed on the Process Traveler. When necessary, special coverings, special equipment and special protective environments will be specified. The Shop Superintendent or his assigned individual is responsible for insuring that all special handling, storage, packaging and shipping requirements are met. He will insure that the marking and labeling on both the product and the package correctly reflects the information provided by the Traveler Package. Final shipping documentation and packaging shall be verified by the QC Manager or his assigned Inspector and/or Quality Engineer.

EDITION:

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SUBJECT: INSPECTION, TEST STATUS

14.0

INSPECTION, TEST STATUS 14.1 To insure that the required inspections and tests are performed and that items which have not passed the required inspections and tests are not inadvertently used, a system of Process Travelers and non-conformance reports is used. The use of Process Travelers, including material release, inspection and test operations, and NuWeld and/or customer hold points is documented in Sections 10 and 11 of this manual. The Non-Conformance Report system, including tagging to prevent use until disposition of the NCR, is documented is Section 15 of this manual.

14.2

14.3

EDITION:

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SUBJECT: CONTROL OF NON-CONFORMING ITEMS

15.0

CONTROL OF NON-CONFORMING ITEMS 15.1 Non-conformity is any condition that does not meet all requirements of the Code, manufacturing and control documents, or the requirements of this QC Manual. 15.1.1 It is the duty of all employees to report non-conformities to the Shop and/ or Field Superintendent, who shall notify the QC Manager. 15.1.2 The QC Manager shall verify the non-conforming condition, prepare a "Non-Conformance Report" (Exhibit C), list the Nonconformance Report (NCR) number on the Traveler and identity the item as non-conforming by attaching a "Non-Conformance Tag" (Exhibit B) 15.1.3 When deemed practical by the QC Manager, the non-conforming item shall be moved to a segregated "Hold" area. The QC Manager shall control the item until the non-conformity is acceptably corrected. 15.2 The QC Manager shall forward the NCR form to the Staff Engineer who shall be responsible for providing the disposition for the non-conforming condition. The disposition shall be reviewed by the QC Manager for compliance with Code and contract requirements. Approval will be documented on the NCR by the QC Manager. 15.2.1 USE-AS-IS: When the disposition is use-as-is the Staff Engineer shall provide a technical justification for acceptance. Any revisions to approved Drawings, calculations and procurement documents shall be controlled as described in this QC Manual, including submittal to the Authorized Inspector and/or Government Representative (non-ASME Code work) for review and acceptance. 15.2.2 REWORK: Rework will be performed when a non-conforming item is made to conform to a prior, specified requirement by completion, re-machining, re-assembly or other means. Dispositions requiring rework shall be made using standard approved procedures, or special procedures approved by the QC Manager and accepted by the customer (if required), Authorized Inspector or Government Representative (non-ASME Code

EDITION:

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SUBJECT: CONTROL OF NON-CONFORMING ITEMS

work). For reworks to completed welded joints and base metals by welding, the proposed disposition and Travelers shall be submitted to the customer (if required), Authorized Inspector or Government Representative (non-ASME Code work) for review and acceptance of the method and extent of the rework, and designation of required "Hold Points" prior to the performance of any rework. The disposition shall include re-inspection in accordance with applicable procedures to the original acceptance criteria unless the disposition has established an alternate criteria. 15.2.3 SCRAP/RETURN TO VENDOR: This disposition requires the QC Manager to verify and document on the NCR that the item has been removed from the work area, and clearly marked "REJECTED" to prevent the item inadvertent use prior to disposal. All dispositions of non-conforming conditions by SCRAP/RETURN shall be approved by the QC Manager. SCRAP/RETURN to vendor shall not require Authorized Inspector acceptance. 15.2.4 REPAIR: Repair will be performed when a non-conforming item is restored to a condition such that the capability of the item to function reliably and safely is unimpaired, even though the item still does not conform to the original requirements. Dispositions requiring repair shall be made using standard approved procedures, or special procedures approved by the QC Manager and accepted by the customer (if required), Authorized Inspector or Government Representative (non-ASME Code work). For repairs to completed welded joints and base metals by welding, the proposed disposition and Travelers shall be submitted to the customer (if required), Authorized Inspector or Government Representative (non-ASME Code work) for review and acceptance of the method and extent of the repair, and designation of required "Hold Points" prior to the performance of any repair. The disposition shall include re-inspection in accordance with applicable procedures to the original acceptance criteria unless the disposition has established an alternate criteria. 15.2.5 When required by contract, the customer will be notified on all repair or use-as-is dispositions.

EDITION:

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15.3

The QC Manager along with the Authorized Inspector and/or Government Representative (non-ASME Code work) shall inspect all non-conforming items after completion of the approved disposition. When assured that the non-conforming condition has been corrected including the Authorized Inspector's and/or Government Representative (non-ASME Code work) acceptance of any designated "Hold Points", they shall sign-off the NCR. The QC Manager and Authorized Inspector and/or Government Representative (non-ASME Code work) shall review the NCR together with any associated documents and if acceptable shall sign-off the NCR, indicating closeout of the non conforming condition. The QC Manager or Field Supervisor shall then remove the Hold Tag. 15.3.1 The QC Manager will review all NCR to determine if they have an assignable cause. These NCR will be investigated further and a correction action will be determined, implemented and documented on the NCR. 15.3.2 The QC Manager shall maintain a Log of all NCR by year issued. This Log shall be available for review by the Authorized Inspector and/or Government Representative. The QC Manager shall maintain a copy of the NCR in the Job File.

15.4

Revisions to NCR shall be prepared, approved and distributed in the same manner as the originals. The QC Manager shall make all NCR available to the Authorized Inspector and/or Government Representative.

EDITION:

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

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SUBJECT: CORRECTIVE ACTION

16.0

CORRECTIVE ACTION (NQA-1 Orders Only) 16.1 Conditions adverse to quality shall be identified promptly and corrected as soon as practical. Significant conditions adverse to quality shall be further evaluated to determine the cause and corrective action required to prevent recurrence. These conditions may be found during routine verification and monitoring by Quality personnel, audit findings, or may be the result of a trending review of NCR's required by NuWeld standard NWS-021. Regardless of the detection method, a Corrective Action Request (CAR) will be issued and processed in accordance with NuWeld standard NWS021.

16.2

EDITION:

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

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SUBJECT: QUALITY ASSURANCE RECORDS

17.0 17.1

QUALITY ASSURANCE RECORDS The QC Manager shall collect all job records to complete the NuWeld Inc., Job File. This Job File shall contain, as a minimum, approved Drawings, ASME Part Manufacturer Data Reports (when applicable) design calculations, PO copies w/ MTR, Travelers, NDE films, and/or PWHT records, NCR records, Code nameplate facsimile(s) and ASME Manufacturer Data Reports and/or National Board R-Forms as applicable. The QC Manager shall collect all records described in this QC Manual at the completion of Code fabrication and final testing and review them for completeness, correctness and Code compliance prior to preparing the ASME Manufacturer Data Report (MDR) and/or NBIC Report Forms (i.e., R-1, R-2 etc.). The QC Manager shall certify the MDR and/or Report Form(s) together with all Job Records submit them to the Authorized Inspector for his review and signature. 17.2.1 A Certificate of Conformance, when required by the customer specifications, will be issued by the Quality Manager after review and acceptance of all relevant job records. 17.3 The MDR, after certification by the QC Manager and Authorized Inspector, shall be filed by the QC Manager with the Jurisdiction, Authorized Inspection Agency, Authorized Inspector (when requested), and the National Board when applicable, and as required by the applicable Code. An original MDR together with attachments shall be forwarded to the National Board for registration by the QC Manager within 60-days following MDR certification. 17.4.1 National Board numbers, when applicable, shall be controlled and issued by the QC Manager. The QC Manager shall maintain a record of insurance showing: the National Board number, date issued, date registered, type of vessel (w/ASME Code symbol), name and location of purchaser, and the NuWeld Inc. Job Number. 17.4.2 National Board numbers shall be issued after successful completion of final pressure tests. The National Board number series shall start with #001, without suffixes or prefixes and progress upward without skips or gaps.

17.2

17.4

EDITION:

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SUBJECT: QUALITY ASSURANCE RECORDS

17.4.3 MDR and/or NBIC R-Forms not registered with the National Board shall be kept on file by the QC Manager for a minimum of 5 years. 17.5 The QC Manager shall maintain a separate R-Form Log (Exhibit I) for National Board R-Forms registered, when applicable, with the National Board. The QC Manager shall maintain a single, sequential log of RForm numbers assigned for NBIC Report Forms (i.e., R-1, R-2, etc.) that are registered with the National Board. 17.5.1 For "Repairs", legible copies of the completed certified R-1 Form, Report of Repair, together with attachments, shall be distributed by the QC Manager to the Owner or User, the Authorized Inspector, the Jurisdiction if required and the Authorized Inspection Agency for in-service inspection. 17.5.1.1 National Board R-1 Forms may be registered with the National Board if required by the Jurisdiction or the Owner/User. 17.5.1.1.1 When required an original R-1 Form, together with attachments, shall be forwarded to the National Board within 60days of certification by the QC Manager for registration. 17.5.2 For "Alterations", legible copies of the completed certified R-2 Form, Report of Alteration, together with attachments, shall be distributed by the QC Manager to the Authorized Inspector, Authorized Inspection Agency responsible for the in-service inspection of the pressure retaining item, the Owner and/or User and the Jurisdiction, if required. 17.5.2.1 If the item is registered with the National Board, an original R-2 Form together with attachments shall be registered with the National Board within 60-days of certification by the QC. Manager. If the item is not registered with the National Board, an original R-2 Form together with attachments may be registered with the National Board as described

17.5.2.2

EDITION:

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SUBJECT: QUALITY ASSURANCE RECORDS

above, when required by the Jurisdiction or the Owner and/or User. 17.6 All records identified for retention in accordance with this section shall be legible and identifiable to the Shop Order. Records will be collected by the QC Manager at the completion of the order and after final review and acceptance by the A.I. and customer (if applicable). The records will be maintained for five years, or as specified by the Code and contract requirements. The files will be maintained in controlled access filing cabinets in the QC Manager's office to minimize damage, deterioration or loss. After the end of the required maintenance period and prior to disposition of the records by NuWeld, the customer will be notified and given the opportunity to acquire the records if they desire. For NQA-1 orders only, record retention shall be as described in NuWeld standard NWS-015

17.7

EDITION:

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

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SUBJECT: AUDITS

18.0 18.1

AUDITS (NQA-1 Orders only) Internal audits will be planned, scheduled and conducted in accordance with NuWeld Inc. standard NWS-012 to verify compliance with the Quality program. Audits will be performed by personnel who do not have direct responsibility for the area being audited, using the appropriate checklist from NSW-012. Audits results will be documented as described in NWS-012 and reported to responsible management for review and required follow-up activities. NuWeld Inc. management, after review of audit results, will arrange for any follow-up activities that are deemed necessary and assign personnel to re-audit that area for implementation. Follow up activities must be verified as closed out by the QC Manager. Audits will be performed by personnel trained and qualified in accordance with NuWeld, Inc. standard NWS-020.

18.2

18.3

18.4

18.5

EDITION:

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Trout Run, Pennsylvania 17771

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SUBJECT: AUTHORIZED INSPECTOR

19.0

AUTHORIZED INSPECTOR 19.1 The Authorized Inspector is the independent third-party inspector required by Code and a person holding a valid certificate of competency issue by a state of the United States of America or Province of Canada, a valid National Board Commission card with an "A" endorsement and designated as such by an ASME accredited Authorized Inspection Agency. When requested by the AI, "Hold Points" shall be inserted on the Travelers for those operations wished to be witnessed or verify before fabrication proceeds. Work shall not proceed beyond the AI "Hold Points" until it has been inspected and signed off by the AI. The QC Manager shall be NuWeld, Inc. liaison with the AI, and shall be responsible for keeping the AI advised of the progress of work so that the AI may make any designated inspections. The AI shall have access to and be furnished with all approved Drawings, calculations, procedures, specifications, process sheets, rework procedures, records, test results and other documents as are required to perform the AI duties. This access shall be extended to the Authorized Inspector Supervisor (AIS) when performing required audits or visits to the shop and/or field sites. The QC Manager shall notify the AI sufficiently in advance of all "Hold Points" and pressure tests and any other inspection points the AI has designated that he may be present to witness them. The final records, together with the completed MDR and/or NBIC RForms certified by the QC Manager shall be submitted to the AI for review and signature. When the AI is satisfied that all Code requirements have been met, the AI signs the MDR and/or NBIC R-Form and authorizes application of applicable Code symbol stamp. A current "controlled" copy of the QC Manual shall be made available for use by the AI at the shop and/or field sites. The AI shall review and accept all changes to the QC Manual prior to implementation and distribution. The AI and AIS shall be provided free access to the shop and/or field sites when Code work is performed, subcontractor's facilities and to such

19.2

19.3

19.4

19.5

19.6

19.7

19.8

19.9

EDITION:

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Trout Run, Pennsylvania 17771

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SUBJECT: AUTHORIZED INSPECTOR

parts of all plants that are concerned with the manufacturing or supply of Code materials. 19.10 The QC Manager shall provide any assistance to the AI during his required monitoring of the QC system, and to the AIS during his National Board required audit.

EDITION:

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

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SUBJECT: EXHIBITS

20.0

EXHIBITS

20.1 20.2 20.3 20.4 20.5 20.6 20.7 20.8 20.9

Exhibit A Exhibit B Exhibit C Exhibit D Exhibit E Exhibit F Exhibit G Exhibit H Exhibit I

Process Traveler Non-Conformance Tag Non-Conformance Report Welder Continuity Log Purchase Order Calibration Sticker Calibration Log Letter of Transmittal R-Form Log "R" Stamp NDE Personnel Certification Record Quality Requirements Checklist Training Record Form

20.10 Exhibit J 20.11 Exhibit K 20.12 Exhibit L 20.13 Exhibit M

EDITION:

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

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SUBJECT: EXHIBITS

EXHIBIT A

EDITION:

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

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SUBJECT: EXHIBITS

EXHIBIT A

EDITION:

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: EXHIBITS

NON-CONFORMANCE TAG

EXHIBIT B

EDITION:

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

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SUBJECT: EXHIBITS

EXHIBIT C

EDITION:

2 0 20.0 20-6 9/15/06

NUWELD, INC.

Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: EXHIBITS

WELDER CONTINUITY LOG

EXHIBIT D

EDITION:

2 0 20.0 20-7 9/15/06

NUWELD, INC.

Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: EXHIBITS

EXHIBIT E

EDITION:

2 0 20.0 20-8 9/15/06

NUWELD, INC.

Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: EXHIBITS

CALIBRATION STICKER

EXHIBIT F

EDITION:

2 0 20.0 20-9 9/15/06

NUWELD, INC.

Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: EXHIBITS

CALIBRATION LOG

EXHIBIT G

EDITION:

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NUWELD, INC.

Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: EXHIBITS

EXHIBIT H

EDITION:

2 0 20.0 20-11 9/15/06

NUWELD, INC.

Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: EXHIBITS

R-FORM LOG

R-NO. R-FORM JOB NO. DATE ISSUED DATE REGISTERED

EXHIBIT I

EDITION:

2 0 20.0 20-12 9/15/06

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

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SUBJECT: EXHIBITS

EXHIBIT I

EDITION:

2 0 20.0 20-13 9/15/06

NUWELD, INC.

Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

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SUBJECT: EXHIBITS

EXHIBIT J

EDITION:

2 0 20.0 20-14 9/15/06

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

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SUBJECT: EXHIBITS

EXHIBIT K

EDITION:

2 0 20.0 20-15 9/15/06

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Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

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SUBJECT: EXHIBITS

EXHIBIT L

EDITION:

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NUWELD, INC.

Trout Run, Pennsylvania 17771

REVISION: SECTION: PAGE: DATE:

QUALITY SYSTEM MANUAL

SUBJECT: EXHIBITS

EXHIBIT M

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