boiler parts qa

SECTION 4: QUALITY ASSURANCE, INSPECTION & TEST REQUIREMENTS BOILER

TABLE OF CONTENTS

SECTION TITLE PAGE

4.0 QUALITY ASSURANCE AND QUALITY CONTROL

4.1 Introduction............................................................................. 4.2

4.2 General Requirements............................................................ 4.2

4.3 Specific Requirements for ASME Pressure Parts ..................4.4

4.4 Final Documentation Package................................................. 4.7

APPENDICES

Appendix A Inspection Procedure for Boiler Sections

Table 1 Procedure Checklist

QA Pressure Parts 4.1 Rev. 1


4.0 QUALITY ASSURANCE AND QUALITY CONTROL

4.1 Introduction

This specification shall govern all quality activities from material receiving through shipping.

4.2 General Requirements

A. Seller shall submit, prior to or with the bid proposal, one copy of their current Quality Manual to Buyer for review. See Table 1. Seller shall be in current possession of the ASME ’s“S” stamp and shall submit a current copy of the ASME certificate of authorization with the bid.

This program shall contain the following elements of assurance and control, as a minimum:

1. Authority and Responsibility Statement2. Organizational Chart3. Drawings, design calculations and specification control4. Material control5. Examination and inspection program6. Correction of nonconformities7. Welding control8. Non-destructive examination procedures9. Heat treatment controls10. Calibration of measurement and test equipment11. Record retention system12. Sample forms13. Authorized Inspector involvement

B. Seller shall be responsible for assuring that his Suppliers’ quality control programs are approved for use by the Seller and are consistent with the specified requirements imposed on the Seller.

Seller shall submit with his bid proposal a list of all Sellers “approved suppliers” anticipated to work on this contract. Buyer reserves the right to reject any or all of these suppliers.

C. Based on Seller’s quality program, an Iinspection & Test Plan point program shall be established by the Seller covering all pertinent, sequential fabrication and inspection operations which will allow the Buyer to overview all aspects of Seller’s production, engineering and quality involvement and select critical witness points.

The Iinspection & Test Plan point program must contain all operations (material receiving through shipping) to assure compliance with Codes and Buyer requirements.

The following inspection points shall be considered typical and shall be incorporated into Seller’s inspection point program.



Review of certified material test reports Physical verification of actual materials Approval of inspection point program by BUYER Approval of applicable welding procedures by BUYER Verification of qualifications for welding operators Approval of fabrication, NDE, PWHT and hydro test procedures by BUYER Fit-up and root pass inspection Witness all non-destructive examinations Witness major weld repairs Verify heat treatment Witness all hydrostatic pressure tests Witness final visual and dimensional inspection and trial assembly of all field

joints Verify stamping and data reports. Inspect coating, packaging and preparation for shipment Review and submit final Q.A & ASME documentation package

After award of contract, Seller shall schedule each step in the Inspection & Test Plan in accordance with the overall fabrication schedule. This will allow Buyer to tentatively set dates of inspection prior to start of fabrication.

The Inspection Test Plan shall cover all components (purchase materials, parts or manufactured components) for all phases of the work. The ITP shall be submitted to the Buyer for acceptance, and shall be updated and resubmitted to Buyer to reflect revisions and comments.

D. After award of contract, but before fabrication begins, Seller shall submit for review and acceptance the quality procedures containing those design, manufacturing, testing, inspection, cleaning and packaging procedures necessary for the accomplishment of the work and to assure its proper quality.

Procedures shall be qualified as necessary to Code, Industry Standard, or Buyer requirements. These procedures shall detail such thing as equipment used, personnel qualifications, techniques employed, areas covered, acceptance criteria, and tolerances applicable. Table 1 shall be used as a guide for the required procedures, but procedures pertaining specifically to the Seller’s panel straightening and heating shall be submitted with Seller’s proposal. Copies of all documentation submitted should be properly referenced to Buyer’s contract number and purchase order number.

E. The Seller Quality Department shall contact the Buyer’s Quality Department after notification of award to discuss the salient or unresolved issues regarding quality matters.

F. Non-Conformance Requirements

All non-conformances shall be documented. Major non-conformances or deviations shall be promptly submitted to the Purchaser’s QA Department for review, comment,



acceptance and resolution. This includes all non-conformances, except those agreed upon with the Purchaser as “standard routine repairs”.The Purchaser shall correct, rework or replace (at the Buyer’s option) work that is considered unacceptable to MTD-CA.

The Seller is responsible for maintaining written copies of all non-conformance events in his contract Quality records file complete with all associated correspondence.

The Seller shall provide copies of the non-conformance events in the Final Documentation Package, when required. The Seller is responsible for the correction of non-conforming items and for contacting the Purchaser with verification of compliance after performing any approved remedial action.

G. All quality control documentation shall be clear, legible and identified with the Buyer’s purchase order number and equipment or component number as required for full identification.

H. Shop trial assembly, dimensional checks, center and datum lines along with dot die steel match marking of all components shall be done to the mutually agreeable maximum feasible extent. All component identification markings, center of gravity, lifting points and lifting lugs are to be included to facilitate handling in transportation and at job site.

I. The Buyer and his designated representative shall have full access to Seller’s and Supplier’s facilities for reviewing conformance to the approved quality control program and for witnessing of inspection points.

J. The Purchaser’s Quality Assurance department shall be notified at least ten (10) working days (20 working days for Non-North American Vendors) prior to the designated witness points for tests and inspections identified by the Purchaser.

The vendor shall notify MTD-CA QA Dept. via the attached “Request for Inspection” form.

K. The Seller shall maintain full and adequate records that will be available to Buyer and Authorized Inspector (AI) for review and final submission of documentation.

L. No shipment shall be made without a prearranged final inspection by the Buyer that will include a final release authorized by Buyer’s quality representative.

4.3 Specific Requirements for ASME Pressure Parts

A. All welding processes, filler metal and welding operator qualifications shall be in accordance with American Society of Mechanical Engineers (ASME) Section IX for pressure parts welding.



B. All ferrous materials for pressure containing components shall be provided in accordance with ASME Section II, Part A, Applicable Addenda.

C. All non-pressure containing components shall be provided in accordance with ASME orASTM material specifications.

D. All welding, as a minimum, shall be demonstrated to be gas or airtight unless specified otherwise on the design drawings.

E. All pressure boundary components shall be listed on ASME manufacturer’s data reports and be Code stamped. An Authorized Inspector who holds a valid National Board Commission shall inspect all ASME Code components.

F. Seller shall review Table 1 and indicate which quality procedures shall be submitted for Buyer review and approval. Table 1 shall be submitted with the

proposal.G. Above and beyond ASME Code requirements, the following requirements apply:

1. A minimum of 10% of the tube to tube butt welds shall be radiographed. These radiographs shall be available for review and approval by the Buyer.

1.1 The sampling shall be a random selection made by the seller’s Quality Dept., if a MTD_CA Q.A. representative is not present. The radiographic technique shall be in general agreement with ASME Section V, Article 2 and ASME Section I. The acceptance criteria shall be per PW-51.3 for ASME Section I construction. If the radiographs are not acceptable, the defects shall be repaired, re-radiographed and an additional two more welds, made by the same welder, shall be selected for radiography. This program shall continue until all repairs are clear and the required additional radiographs are acceptable.

2. A visual inspection of at least 10% of the root passes on all tube to header

welds and a 100% visual inspection and dye penetrate (PT) of the final cap weld.

3. Visual inspection of the root passes and 10% magnetic particle examination of the final welds for all attachments to boiler elements.NOTE: that some of these attachments to boiler elements may be stainless

steel material. In those cases, do a final dye-penetrant examination in lieu of magnetic particle examination.

4. Visual examination of 100% of all refractory stud welds. The stud shall exhibit a full 360 flash around the base of the stud. There shall be no gaps or undercuts in the flash area. The flash may be irregular in height and can contain

shrinkage or fissure cracks. The flash is expelled metal, not deposited metal, and should not be subjected to the usual inspection criteria. Any stud not exhibiting a full 360 of flash shall be struck with a hammer to verify sufficient attachment to the

base metal surface. Torque testing of stud integrity is acceptable.



Membrane welds shall undergo 100% visual examination, and be terminated in such a manner that the welds wrap around the end of the membrane bar located outside the heated zones. At those locations where membrane plate will be inserted into a field erected panel, the membrane weld provided by the Seller shall NOT be wrapped around the end of the membrane plate. In these cases, the field installed membrane plate shall be fully welded to the shop installed membrane by others.

6. When end to end butt welds are required in membrane bar materials these butt welds shall be full penetration welds and 100% visually inspected.

A. Hydrostatic pressure testing of all sections shall be done in the Seller’s shop at 150% of maximum allowable working pressure using water at a temperature not less than 70F.

Seller shall demonstrate and show that all dimensions of each fabricated component do not deviate from Buyer’s drawing by an amount greater than Seller’s approved shop tolerances.

K. Seller shall submit with this proposal an inspection point program that is representative of Buyer’s requirements but shall be considered preliminary.

L. When swaging is done by Rotary Hammer swaging machine, Dye Penetrant Examination shall be done on every swaged end.

M. All Seller’s fabrication drawings shall contain a welding and inspection table detailing:

1. Weld joint number2. Weld joint quantity3. WPS used4. Procedure Qualification Record used5. Percentage NDE and type NDEE. NDE procedure used

4.4 Final Documentation Package

The final documentation package shall include:

A. Two copies of all material test reports for all materials of construction and spare parts. One copy shall accompany shipping components, while the second copy is forwarded to Buyer at time of shipment.

B. Non-destructive examination reports for:1. Dye penetrant examination2. Magnetic particle examination3. Radiographic examination4. Ultrasonic examination



C. Final assembly and trial fitting documentation.

D. Post weld heat treatment charts with operator’s signature, equipment identification number, date of last calibration and date of treatment.

E. All nonconformance and deviation reports.

F. Hydrostatic pressure testing reports.

G. Rubbing or Photo of the ASME stamping for each component.

H. ASME Manufacture’s Data Reports.



1. .



APPENDIX A

INSPECTION PROCEDURE FOR BOILER SECTIONS

1. SCOPE

This procedure governs the inspection of superheater, reheater and economizer sections for Buyer’s Boilers.

2. PURPOSE

The purpose of this procedure is to provide inspection requirements that must be followed in order to assure product quality regardless of Seller’s specific requirements.

3. MATERIAL IDENTIFICATION INSPECTION

All material to be used in the section shall be verified as being correct in accordance with material certificate and manufacturing drawing.

4. BENDING INSPECTION

The first two (2) tubes fabricated during each production run and every tenth (10 th) tube made thereafter shall be checked for the following. Ovality:

A tube shall be rejected where the calculated ovality exceeds 10%Ovality (%)= Actual O.D Max-Actual O.D. Min. x 100

Nominal O.D.The raised metal resulting from the die forming shall not exceed 1/16” above the surface of the tube.

Wrinkles:

One wrinkle 1/8” or greater in depth and multiple wrinkles 1/16”or greater in depth shall be cause for rejection.

Reduction at outside diameter or “necking” may occur on the straight leg near the bend.If this distortion exceeds 10% of the tube O.D. as determined by the formula, the necked down area shall be rejected.

Distortion (%) = (Original tube O.D.-Smallest O.D. at bend) x 100Original Tube O.D.

Temperature for hot bending shall be verified through the use of temperature indicating crayons, optical pyrometers, or heat sensing devices.

5. FIT-UP INSPECTION



Verify identification marking.Inspect fit-up for tube butt-welding.Inspect attachment location and material type.Inspect overall length, dimensions and terminal points.

6. WELDING INSPECTION

Verify that a qualified welder has performed all welding.R.T. of all welding joints per the Contract requirements.NDE of attachment welds per the Contract requirements.

7. HYDRO TESTING (When Applicable)

Procedure:

Each section shall be tested in an area having suitable lighting for visual examination of the surfaces of the section while under pressure.

The sections being tested and the test water shall be maintained at a minimum temperature of 70 F for the duration of the test.

The test pressure shall be 1-1/2 times the maximum allowable working pressure (+6, -0 percent), and shall be specified on the manufacturing drawing or work instruction.

The pressure shall be maintained not less than 5 minutes prior to a complete examination for leaks.

Inspection:

While the hydrostatic test pressure is being maintained, the surfaces of the section, particularly the welds, shall be visually examined for evidence of leakage.If leakage is observed the section or module shall be rejected until the leak has been repaired and the section or module is successfully retested.

QA inspector shall verify that correct test pressures are maintained and that pressure gages are within their calibration period.

8. FINAL INSPECTION

The final inspection shall verify that the following are done:1. The tube ends are machined for field weld and are protected with deoxaluminate or are

buffed and prepared for expanding or socket welding.2. The sections are cleaned and free of debris.3. All sections shall be thoroughly drained of test fluid and dried prior to shipment.



APPENDIX E

INSPECTION OF LOOSE TUBES AND PIPE 3-1/2 NPS UP TO AND AND INCLUDING 8” NPS

1. SCOPE

This procedure governs inspection of all loose tubes and pipe 3-1/2” NPS up to andincluding 8” NPS for pressure part application.

2. GENERAL REQUIREMENTS

Ten percent (10 %) of tube or pipe material, diameter and thickness shall be checked prior to the start of fabrication and recorded if not per specifications.Temperatures for hot forming shall be verified through the use of temperature indicating crayons, optical pyrometers, or other approved heat sensing devices.Welding shall be in accordance with applicable qualified and BUYER approved welding procedure specification (WPS).

Local heating shall be uniform around the circumference of the tube or pipe that is to be formed. It shall not be permissible to heat and quench only one side of a tube or pipe.

When thermal cutting of a tube or pipe is required, the shop will assure there is sufficient excess material for grinding or machining the torch cut end. If the material can not be machined because of excessive hardness after torch cutting, a local stress relief at 1300 to 1350F may be applied for at least ten (10) minutes followed by cooling in still air.

Tube and pipe material shall, prior to assembly:

Be cleaned inside after manufacturing operation & prior to capping. Be visually inspected for general appearance and condition of O.D. & I.D. surfaces,

including unacceptable pitting. Post forming heat treatment shall be in accordance with applicable procedure and/or

instructions (if required).

3. OVALITY

Each tube or pipe bend inspected shall also be dimensionally inspected for ovality.

Unless specified otherwise on the applicable instruction or in attachments.Formula for calculating ovality is as follows:

Ovality (%) = (Actual O.D. Max-Actual O.D. Min.) x 100Actual O.D. before Bending

The maximum ovality tolerance is 10 percent. If ovality exceeds 10 percent, the bend shall be rejected.



4. TOLERANCES AND ATTACHMENTS

Tubes or pipe requiring attachments shall be dimensionally inspected to assure that the correct attachments are properly located within applicable tolerances.

TUBING TYPE TOLERANCE ON LENGTH

BOILER BANK TUBES minus 0.0 & plus 0.25 inches3 inch Dia. tubes minus 0.0 & plus 0.25 inches4 inch Dia. tubes minus 0.0 & plus 0.25 inches

5. WELDING

Welds including circumferential or repair welds, shall be made in accordance with the applicable welding procedure specification (WPS).

For tubes or pipe that are to be hot bent, all circumferential welds shall be kept a minimum distance of one (1) tube diameter from the tangent of the proposed bend.

For tubes or pipe to be cold bent, all circumferential welds shall be kept a minimum distance of one (1) tube diameter plus one inch from the tangent of the proposed bend.

All NDE required for a particular weld shall be in accordance with the applicable NDE procedure(s).

All welding shall be visually inspected, and applicable NDE performed per the drawings.

6. MARKING AND IDENTIFYING

All tubes and pipe shall be clearly identified and marked in accordance with the applicable drawings and/or instruction.

7. FINAL INSPECTION

After completion of fabrication and preparation for shipment Quality Control shall visually inspect tubes or pipe in their final configuration as follows:

All tubes or pipe shall be visually inspected to assure that they have been cleaned and dried.A minimum of 10% of all tubes shall be verified to a layout or a jig. Any row where the 10% sample reveals nonconformity shall be 100% checked. The Buyer suggests the Seller photo this verification (layout) and sends one set of prints the Buyer.Verify that the NDE examination as stated in paragraph 5 has been performed if necessary.

After cleaning and drying, the tubes or pipe shall be visually inspected for cracking or other flaws, particularly in areas where bending has taken place.



Questionable areas shall be examined by the magnetic particle method.The examination will be made on the extrados (bend exterior) 45 degrees radially from the center of the extrados and from tangent to tangent.

Any MT indication found in the bend areas shall be removed by grinding. If minimum wall thickness is not maintained, bend should be replaced.

After surface preparation, the repaired area shall be examined by the magnetic particle method to assure that the required area is free of surface indications.

Ultrasonic wall thickness measurements shall be made to assure that the minimum wall thickness has been restored.

All tubes or pipe with field weld prep ends shall be inspected for burrs, roundness andproper dimension. Verify that tube or pipe ends have been polished when required by the applicable drawings.

Verify that the tubes or pipe have been properly identified, preserved, capped, andsealed in accordance with the applicable procedures and/or instruction.

Swaged Tubes: Ten (10%) percent of all swaged tubes shall tubes shall be check and results recorded after annealing for hardness, misalignment, swag length and swag tube thickness.

Swaged tube end Material Hardness (Brinell- standard ball)

SA-178 A or SA-192 135SA-210 A 145SA-178 C or SA-210 C 179SA-213 163

Materials shall be annealed at temperatures below the lower critical temperature of that material.



Table 1

PROCEDURE CHECKLIST

Seller shall indicate which of the following applicable procedures shall be submitted to Buyer for review and approval. Seller shall include procedure or specification numbers for all items on this table except those noted as N/A. Seller shall include a current copy of their normal check list (dimensional check list for instance) that is part of any procedure listed below. Copies of those items noted with * shall be provided to the Buyer with the proposal if available, or immediately after project specific items have been developed. Seller shall provide the current version of all documents.Procedures (as applicable) Applicable Seller

Procedure No.Quality Manual *_______________Welding Procedure Specifications *_______________Procedure Qualification Records _______________Repair Welding Procedure *_______________Radiographic Examination Procedures _______________Magnetic Particle Testing Procedures _______________Liquid Penetrant Test Procedure _______________Ultrasonic Testing Procedure _______________Visual Inspection Procedure _______________Hydrostatic Pressure Testing Procedure _______________Post Weld Heat Treatment Procedure _______________Localized Stress Relieving Procedure _______________Control of Welding Materials Procedure _______________Minimum Wall Thickness Inspection Procedure _______________ Cleaning Procedures _______________Packaging and Preservation Procedures _______________Shipping and Handling for Loading Procedure _______________

Production Procedures for Panel Fabrication (with Check List) _______________Production Procedures for Panel Straightening *______________Production Procedures for Panel Bending _______________Production Procedures for Tube Bending _______________Production Procedures for fin to fin butt welding ( end to end) _______________Dimensional Inspection Procedures (with Check List) ______________Refractory Studding Testing Procedure _______________Shop Trial Procedures *______________


MTD_CA CANADA LTD.

REQUEST FOR INSPECTION10 Working Days Notice Required (North American Vendors)

21 Working Day Notice Required (Non-North American Vendors)

TO: MTD-CA.

FAX:

Phone:

Date:

MTD-CA PO No

MTD-CA Contract No

Vendor: Vendor’s Reference No

Address:

* (*Address where inspection will occur)

Telephone Contact:

Name:

Phone:Email:

Fax:

List / Describe material to be inspected:

Date of Requested Inspection

Type of Requested Inspection

MTD-CA’s Inspection is Scheduled as follows (confirmation)

Inspector's Name: Date:

Form – QA638 rev.0

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