j.t. thorpe & son, inc. -...

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Quality Control Manual for NBIC Repairs

Sixth Edition

Revision 1 August 17, 2015

Revision 0 issued September 16, 2014

Scope:

Metallic repairs to pressure retaining items in accordance with the National Board Inspection Code (NBIC) and Jurisdiction rules at the above

location and field sites controlled by the above location

Quality Control Manual Number:

Quality Control Manual Issued to:

Quality Control Manager to designate “Controlled” or “Uncontrolled” Manuals

Controlled Copy Uncontrolled Copy

J.T. THORPE & SON, Inc. Established 1906

ENGINEERS and CONTRACTORS Corporate Headquarters

1060 Hensley St. Richmond, CA 94801-2196Phone (510) 233-2500 Fax (510) 233-2901

www.jtthorpe.com

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Uncontrolled Copy

Uncontrolled Copy

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J.T. THORPE & SON, Inc.Quality Control Manual for NBIC Repairs

Section: 3Revision: 0

Scope of Work and Definitions Date: 09/16/14

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The scope of J. T. Thorpe & Son, Inc. limits activities to those defined as metallic repairs at shop and field sites to Pressure Retaining Items constructed in accordance with, ASME Section I Power Boilers, ASME Section IV Heating Boilers, ASME Section VIII, Division 1 Pressure Vessels and ASME B31.1 Power Piping Systems as per the applicable edition the National Board Inspection Code (NBIC) and/or any local Jurisdictional requirement listed in Appendix 1 of this Quality Control Manual.

Repairs to pressure-retaining items shall conform, insofar as possible, to the section and edition of the ASME Code most applicable to the work planned. The Quality Control Manager will obtain access to and make available any and all required ASME Code books necessary to properly evaluate the repair procedure requirements.

Repair — The work necessary to restore pressure-retaining items to a safe and satisfactory operating condition.

Routine repairs — Routine repairs are repairs for which the requirements for in-process involvement by the Inspector and stamping by the “R” Certificate Holder may be waived as determined appropriate by the Jurisdiction and the Inspector. All other applicable requirements of this Code shall be met. Prior to performing routine repairs, the “R” Certificate Holder should determine that routine repairs are acceptable to the Jurisdiction where the pressure-retaining item is installed.

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Organization Chart Date: 09/16/14

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Line of communication Line of authority

*Shop/ Field activities

The responsibility of each department head is defined throughout the Quality Control Manual. The individual duties of each department head may be delegated to other competent employee; however the responsibility of the activities may not be delegated.

President

Regional Manager

*Project Manager

*Project Engineer *Superintendent

*Job Foreman

*Welders/welder Operators

*Purchasing Manager

Quality Control Manager

*Quality Control Inspector

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Quality Control Manual Date: 09/16/14

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6.1 SCOPE

6.1.1 This section describes the preparation, review and approval, the distribution and control of this Quality Control Manual and its revisions.

6.2 PREPARATION, REVIEW AND APPROVAL

6.2.1 Preparation, review, approval and implementation of this Quality Control Manual shall be the responsibility of the Quality Control Manager.

6.3 REVISION CONTROL

6.3.1 This Quality Control Manual and all its revisions shall be approved by the Quality Control Manager and presented to the Inspector for review and acceptance prior to issuance and implementation.

6.3.2 Revision to this Quality Control Manual shall be by complete sections, except for exhibits, which will be revised individually and documented on the Exhibits Index Page. Typographical error correction will not be considered as a revision to this Quality Control Manual.

6.3.3 The next revision level shall be recorded on the Table of Contents and each page of the revised section(s). Exhibits shall be revised individually.

6.3.4 The Quality Control Manager and the Inspector will indicate their respective approval, and acceptance of these revisions in the spaces provided on the Table of Contents page of this Quality Control Manual.

6.3.5 The latest revised paragraph(s) shall be shown in italics for easy identification of the revised requirement(s) except when the Quality Control Manual is advanced to the next edition level and the revision level of all sections and the exhibits are returned to "0".

6.3.6 At the option of the Quality Control Manager, the Quality Control Manual may be advanced to the next edition level, as indicated on the Title Page, and the revision level of all sections and the exhibits may be returned to "0" whenever there are substantial changes made to the overall content or structure of this Quality Control Manual.

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Quality Control Manual Date: 09/16/14

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6.4 DISTRIBUTION CONTROL

6.4.1 The Quality Control Manager shall issue copies of this Quality Control Manual andmaintain a Quality Control Manual Log (Exhibit #6-1) a record of the Quality Control Manual number, name of the recipient, and the date of issue of all Controlled Quality Control Manuals.

6.4.2 All Quality Control Manuals shall be identified on the Title Page as "CONTROLLED" or "UNCONTROLLED".

6.4.3 Controlled Quality Control Manuals shall be numbered for identification and control purposes. Only controlled copies shall be issued to J. T. Thorpe & Son, Inc. employees.

6.4.4 A controlled copy of the Quality Control Manual shall be made available to the Inspectorat all times.

6.4.5 All editions and revisions of this Quality Control Manual shall be distributed throughout this organization by hand carrying to the described individual. Superseded editions and revisions of this Quality Control Manual shall be retrieved and destroyed by the Quality Control Manager.

6.4.6 Uncontrolled copies are for issue to personnel outside this organization, such as current and potential customers. The Uncontrolled Quality Control Manuals shall be current at the time of issue, but will not be updated thereafter without a written request from the holder.

6.5 CODE EDITION

6.5.1 The Quality Control Manager shall review new NBIC editions, as well as any applicable Jurisdictional Rule or Regulation revisions, upon receipt. This review will be documented by memo to file. The Quality Control Manager shall determine what, if any impact it has on this Quality Control Manual. When necessary, revisions to this Quality Control Manualwill be made, and implemented prior to the effective date of the new requirement(s). For NBIC Codes this shall be within six months from the editions issue date.

6.6 CERTIFICATION OF DOCUMENTS

6.6.1 Certification of documents described in this Quality Control Manual shall be by written signature and date.

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Drawings, Designs and Specifications Date: 09/16/14

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7.1 SCOPE

7.1.1 This section describes the preparation or access to any required drawings, the Repair Plan (Exhibit #7-1A/B) or other specifications and the review, approval and distribution of these documents.

7.2 JOB NUMBER ASSIGNMENT

7.2.1 The Quality Control Manager shall assign a Job Number to each repair. This number is the next sequential number from the job list printout, and shall be used to identify documentation uniquely pertaining to that particular job. This Job Number will not be used to identify documentation like WPS, PQR, WPQ and other procedures which may be applicable to various jobs.

7.3 DETERMINATION OF REPAIR METHOD & EXTENT

7.3.1 Upon assignment of Job Number, the Quality Control Manager will obtain a copy of the original Manufacturer’s Data Report and/or drawing and any applicable specifications, whenever possible. The Quality Control Manager shall review these documents, and the applicable Original Code of construction requirements to determine the method and extent of the repair. When the original Manufacturer’s Data Report cannot be obtained, agreements on the method of establishing design basis for the repair shall be obtained from the Inspector and the Jurisdiction, when required.

7.3.2 For each repair performed, selection of units shall be based on the units used in the original code of construction and one system of unit shall be used consistently throughout all aspects of work required for repair.

7.3.3 Upon completion of the initial review, and if necessary based on the scope of the repair, the Quality Control Manager will prepare, or have prepared by a sub-contractor, any required drawings or specifications in accordance with the requirements of the original Code of construction.

7.3.4 All generated drawings will contain or reference as applicable a bill of material, the Original Code of construction, Code of construction to be used for repair, NBIC Edition, equipment pressure and temperature ratings, weld joint designs, Welding Procedure Specification (WPS) number(s), Non-Destructive Examination (NDE), Post Weld Heat Treatment (PWHT) and pressure test requirements.

7.3.5 At the discretion of the Quality Control Manger for some repairs, the extent of repair, description of method and the bill of material will be included or referenced on the Repair Plan itself without generating a drawing.

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Drawings, Designs and Specifications Date: 09/16/14

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7.3.6 The bill of material prepared shall be based on the existing material listed on the original Manufacturers Data Report, if available. If not available, the material shall conform insofar as possible to the applicable Code of construction. Carbon or alloy steel having a carbon content more than 0.35% shall not be welded unless permitted by the original Code of construction. If a copy of the original Data Report or drawings/ documentation from original manufacturer is not available, material may be identified by verification of material markings on the vessel or vessel nameplate or by taking a sample of the material and having it tested by a laboratory to establish the material properties. If the existing material cannot be verified (unknown), a chemical analysis and hardness testing of the unknown material shall performed as a minimum to verify its weldability and strength or may elect to qualify a weld procedure. If there is a question with regard to the weldability characteristics of the material, then competent technical advice should be obtained.

7.3.7 All completed drawings or other project specifications will be reviewed and approved by the Quality Control Manager for compliance to original Code of construction and NBIC requirements. These approvals will be shown by initial and date on each of the documents.

7.3.8 Sub-contracted drawings or specifications will be reviewed and approved by the Quality Control Manager in the same manner as those generated in house.

7.4 DOCUMENT CONTROL

7.4.1 The Quality Control Manager will maintain all original project documentation in the Job file. The Quality Control Manager will provide the necessary copies of this documentation to Job Foreman, Purchasing Manager and Q.C. Inspector(s) for reference and coordination of repair and inspection activities.

7.4.2 All project documents will be hand delivered and retrieved by the Quality Control Manager.

7.4.3 All repair project documentation will be presented to the Inspector for review and acceptance prior to the start of the repair, and will be made available at anytime during the project, when requested.

7.4.4 Revisions to all documents and specifications will be prepared, approved and distributed as the originals were, including re-submittal to the Inspector for acceptance. Superseded documents will be retrieved as specified in the preceding paragraph, and destroyed unless they contain information that warrants their retention. In such cases, they will be marked“FOR INFORMATION ONLY”, and retained in a separate file.

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Material Controls Date: 09/16/14

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8.1 SCOPE

8.1.1 This section covers the ordering, receiving, identification, storage and distribution of Code materials.

8.2 PURCHASE ORDERS

8.2.1 Purchase Orders (Exhibit #8-1), for Code material and parts shall be prepared by the Project Engineer or Purchasing Manager, from the bill of material listed in the approved drawing or Repair Plan without making any change. Sub contracted services, Stock material and welding material for Code work may be ordered from the instructions/ specifications issued by the Quality Control Manager.

8.2.2 All completed Purchase Orders for Code material shall be reviewed and approved by the Quality Control Manager, as denoted with initials and date. The Purchasing Managerforwards a copy of the Purchase Order to the Vendor, and a copy is placed in the Job file. The Job file copy shall be made available to Quality Control Inspector for use in receiving inspection.

8.2.3 All Code material procured shall be of Code accepted specification or equivalent and shall conform to all the ordering, material documentation, and marking requirements of the Original Code of Construction.

8.2.4 Material Substitution is not allowed without the approval of the Quality Control Manager and acceptance of the Inspector. The reconciliation of design documents are handled as per 7.4.4 of this Quality Control Manual.

8.3 RECEIVING INSPECTION

8.3.1 All Code material will be received at the shop, or field site, and shall be segregated pending receiving inspection by Quality Control Inspector. The Quality Control Inspector,using the Job File copy of the Purchase Order, shall examine all Code material for basic dimensions, Code or Standard required markings, physical condition, and quantity. The results of the receiving inspection are recorded on the Material Receiving Inspection Report (Exhibit #8-2). The completed Material Receiving Inspection Report, together with a copy of the Purchase Order and any applicable Material Test Reports (MTR), Certificates of Compliance or Manufacturer’s Partial Data Reports shall be forwarded to the Quality Control Manager for review, acceptance, and filing.

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8.4 MATERIAL TEST REPORTS

8.4.1 The Quality Control Manager shall review and initial the Material Test Reports to ensure they meet the requirements listed in the applicable Code edition/addenda of ASME Section II for the respective material specification, prior to use. Fabricated Code Parts shall be accompanied by their respective Manufactures Partial Data Reports and Stamping. The Manufacturers Partial Data Report and Stamping shall be verified by the Quality Control Manager. When deemed acceptable, the Quality Control Manager shall sign and date the Material Test Report section of the Repair Plan. The material is then released.

8.4.2 When directed by the Quality Control Manager, the Quality Control Inspector shall stamp, paint or tag all Code plate and pipe material with the job number. If the material is too small to be identified, then pieces of the same heat number, lot number or other identification shall be stored in boxes or containers which are identified with job number.Code material that does not meet all the Purchase Order requirements and/or Code requirements shall be marked or tagged "HOLD" or "REJECTED". This material shall be handled as described in Section 10 (Correction of Nonconformities) of this Quality Control Manual.

8.4.3 The Job Foreman and the Quality Control Manager shall be responsible to ensure that only Code material that has gone through the proper receiving inspection, and has been found acceptable is released for use.

8.5 MATERIAL IDENTIFICATION CONTROL

8.5.1 Before cutting or separating Code material into two or more pieces, the material specification and heat number shall be transferred by the individual laying it out and the transfer shall be verified by the Quality Control Manager.

8.5.2 Code material or parts sent to a sub contractor for heat treating or forming shall be inspected by the Quality Control Manager for identification and damage when returned from the sub contractor.

8.6 CUSTOMER SUPPLIED MATERIAL AND STOCK MATERIAL

8.6.1 Any Code material supplied by the customer and stock materials shall be inspected by the Quality Control Manager as described in paragraph 8.3, using the bill of material / drawing. The material shall be verified to meet the requirements of this section and Code requirements. J. T. Thorpe & Son, Inc. shall assume responsibility for the Code compliance of all materials supplied by the client.

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8.8 DOCUMENTATION CONTROL

8.8.1 Material Test Reports, Certificates of Compliance, and Manufacturer’s Partial Data Reports shall be submitted to the Inspector for review and acceptance, and then placed in the Job File.

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Method of Performing Work Date: 09/16/14

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9.1 SCOPE

9.1.1 This section describes the documentation, and procedures to be adhered to during the course of repair.

9.2 CONTROLS

9.2.1 The Quality Control Manager shall obtain authorization from the Inspector prior to starting the repairs. In case of verbal authorization the same shall be recorded on the Repair Plan.All repairs to Pressure Retaining Items including the method are subject to the acceptance of the Inspector.

9.2.2 All Code work shall be controlled using the Repair Plan. It shall be prepared by the Quality Control Manager from the information in the drawings, or any other available specifications. The Repair Plan shall list the sequence of examination and inspection operations and Inspector Hold Points. It shall document, as a minimum the applicable welding procedure(s), Welder's identification, NDE, PWHT and pressure test requirements. The Quality Control Manager shall record (if available) the original Manufacture's serial number and the National Board (National Board of Boiler and Pressure Vessel Inspectors) number on the Repair Plan.

9.2.3 The Quality Control Manager shall review the Repair Plan, the scope of work, and any drawings, calculations or sketches with the Inspector. At this time, the Inspector will assign a Hold Point in the appropriate space. The Quality Control Manager and the Inspector shall initial and date the Repair Plan in the spaces provided to document their initial review and to signify the authorization to release the job.

9.2.4 The Repair Plan provides for sign off by the Quality Control Manager and Inspector accepting the current activity before progressing onto the next step in the repair/alternation. Work shall not progress beyond an Inspector's designated hold point until they have been signed off.

9.2.5 Parts shall be examined for cleanliness and fit up prior to welding. Welds shall be examined for size, quality and Welder identification by the Job Foreman or Quality Control Manager.

9.3 FINAL INSPECTION PROCESS

9.3.1 Upon completion of the repair/alternation, the Quality Control Manager shall conduct a final inspection. The Quality Control Manager shall sign and date the Repair Plan when the item meets all requirements of the Code, Jurisdiction, and Customer specification requirements. The Inspector will make a final inspection upon work completion or immediately following final testing.

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9.4 HYDROSTATIC TESTS

9.4.1 The pressure test shall be applied as specified on the Repair Plan and witnessed by the Quality Control Manager and the Inspector.

9.4.2 The test pressure gage(s) used for hydrostatic testing shall be properly calibrated as described in Section 13 of this Quality Control Manual. The maximum range should be approximately double the intended test pressure, but in no case shall it be less than 1.5, nor more than 4 times the test pressure. Digital reading pressure gages having a wider range of pressure may be used provided the readings give the same or greater degree of accuracy as obtained with dial pressure gages. The pressure gauge serial number shall be recorded on the Repair Plan.

9.4.3 Repairs:

9.4.3.1 The pressure tests shall be of such a pressure to verify leak tightness but not greater than the original test pressure or 150% of the MAWP whichever is less, as adjusted for temperature, using water or other non explosive liquid medium. The pressure test temperature shall be in accordance with the Original Code of Construction but not less than 60° F metal temperature. For Boilers the water temperature shall be no less than 70°F. Lower temperatures may be used on acceptable notch toughness capability of thematerials. During the examination the metal temperature shall not exceed 120° F, unless a higher temperature is specified by the Owner, and is acceptable to the Inspector. The test pressure shall be held for ten minutes prior to examination by the Inspector.

9.4.3.2 Pneumatic testing may be conducted with the concurrence of the Owner, Inspector and Jurisdiction if permitted by the original Code of construction. Pneumatic test requirements and precautions shall be in accordance with the original Code of Construction and Jurisdictional requirements. The pneumatic test shall be performed as per a written procedure approved by the Quality Control Manager and accepted by the Inspector.

9.4.3.3 If the required test cannot be performed, or is impracticable, alternative NDE methods which prove the integrity of the repair may be used if acceptable to the Inspector and Jurisdiction.

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9.5 STAMPING

9.5.1 The Quality Control Manager shall stamp or attach a Nameplate (Exhibit #9-2), adjacent to the original stamping in accordance with the requirements of the NBIC, only when authorized by the Inspector. The Inspector shall verify the stamping or nameplate is correct and where applicable, the nameplate has been properly attached. The Quality Control Manager shall maintain custody and control of the “R” stamp.

9.5.2 If it becomes necessary to remove the original stamping, the Inspector shall, subject to the approval of the Jurisdiction, witness the making of a facsimile of the stamping, the obliteration of the old stamping, and transfer of the stamping to the new location. When stamping is on a nameplate, the Inspector shall witness the transfer of the nameplate to the new location. Any relocation shall be described on the applicable NBIC “R” Form. Reapplication of ASME Code symbol stamp or Certification Mark shall be as per the original ASME Code of construction.

9.6 ROUTINE REPAIRS 9.6.1 Prior to performing routine repairs this organization shall determine routine repairs are

acceptable to the Inspector and Jurisdiction where the work is to be performed. The Jurisdiction may mandate specific additional requirements not directly specified in the NBIC.

9.6.2 Acceptable routine repairs may be one or more of the following:

9.6.2.1 Welded repairs or replacements of valves, fittings, tubes, or pipes NPS 5 (DN 125) in diameter and smaller, or sections thereof, where neither PWHT nor NDE other than visual is required by the original code of construction. This includes their attachments such as clips, lugs, skirts, etc., but does not include nozzles to pressure-retaining items;

9.6.2.2 The addition or repair of nonload bearing attachments to pressure-retaining items where postweld heat treatment is not required;

9.6.2.3 Weld buildup of wasted areas in heads, shells, flanges and fittings not exceeding an area of 100 sq. inches or a thickness of 25% of nominal wall thickness or ½ inch, whichever is less;

9.6.2.4 Corrosion resistance weld overlay not exceeding 100 sq. in.

9.6.3 Routine repairs shall be performed per this Quality Control Program and the Inspector be notified prior to start of work however the requirement for in-process involvement of the

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Inspector and stamping may be waived as determined appropriate by the Jurisdiction and the Inspector.

9.6.4 In every circumstance Routine Repairs shall be documented on R1 Form with a statement in the remarks section, "Routine Repair" and presented to the Inspector for review and signature.

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Correction of Non-Conformities Date: 09/16/14

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10.1 SCOPE

10.1.1 This section describes the reporting, identification, disposition and correction of nonconformities.

10.2 DEFINITION AND IDENTIFICATION OF NONCONFORMITIES

10.2.1 Nonconformity is any condition or deficiency in a characteristic, documentation or procedure that does not comply with the applicable rules of Code requirements, or the requirements of this Quality Control Manual.

10.2.2 It is the duty of all employees finding or causing nonconformity to report it to their supervisor who will immediately notify the Quality Control Manager. Upon notification, the Quality Control Manager will determine if a nonconforming condition exists, will mark the item with the word "HOLD" in a conspicuous manner, and prepare a Nonconformance Report (NCR) (Exhibit #10-1). When practical, the nonconforming item, material or component is segregated from the on-going Code activities.

10.2.3 The Nonconformance Report, containing a suggested disposition for correction of the condition is prepared and serialized with the Job Number and a suffix starting at one (1), by the Quality Control Manager. The NCR is initialed and dated by the Quality Control Manager and forwarded to the Inspector for concurrence, and shall be documented on the Traveler for final sign off and acceptance.

10.3 OPTIONS FOR THE CORRECTION OF NONCONFORMITIES

10.3.1 USE-AS-IS:

When the disposition is use-as-is, the Quality Control Manager consults with and obtains the acceptance of the Project Manager, and Customer before denoting approval. Concurrence from the Inspector shall also be obtained. The disposition shall be technically justified. The Code requirements shall be met and affected design documents revised.

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Correction of Non-Conformities Date: 09/16/14

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10.3.2 REPAIR:

All dispositions requiring repair shall be carried out using approved procedures when they exist, or with procedures prepared and approved by the Quality Control Manager and accepted by the Inspector.

10.3.3 SCRAP/RETURN TO VENDOR:

This disposition requires the Quality Control Manager to verify and document on the Nonconformance Report that the item has been removed from the work area, and distinctly marked "REJECTED" to prevent its inadvertent use before disposal. The Inspector need not be advised.

10.4 VERIFICATION OF CORRECTIONS

10.4.1 The Quality Control Manager shall re-inspect the item, component or material after completion of disposition. When satisfied the item meets all specified requirements, including acceptance of additional hold points the Inspector may have designated, the Nonconformance Report is signed and the "HOLD" marking is removed, which releases the item to proceed to the next sequential operation listed on the Traveler.

10.5 DOCUMENTATION

10.5.1 Upon generating a Nonconformance Report, its number shall be posted in the space provided on the Traveler. All records of nonconformities are made available to the Inspector for review and acceptance.

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Welding Controls Date: 09/16/14

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11.1 SCOPE

11.1.1 This section covers the preparation, qualification and certification of welding procedure documents, qualification of Welders and Welding Operators, storage and distribution of welding materials, control of Welder qualifications, and the control of production welding.

11.2 GENERAL REQUIREMENTS

11.2.1 All Welding shall be performed in accordance with Welding Procedure Specifications (WPS) qualified in accordance with the original code of construction or the construction standard or code selected. When this is not possible or practicable, the WPS may be qualified in accordance with ASME Section IX.

11.2.2 The Inspector shall have the right at any time to call for and witness test of the welding procedure or the ability of any welder and welding operator.

11.3 WELDING PROCEDURE SPECIFICATIONS

11.3.1 The Quality Control Manager prepares Welding Procedure Specifications. The required test welds are made under the Quality Control Manager's direct supervision and the welding variables are recorded by the Quality Control Manager. The test specimens are then prepared in accordance with ASME Code Section IX requirements, and submitted to a testing facility. The Quality Control Manager reviews the test results, and if acceptable, prepares the Procedure Qualification Record (PQR) based on recorded welding variables and the test results and also certifies by signing and dating it. Copies of the qualified WPS are provided to the Job Foreman for use by the assigned Welders or Welding Operators.The originals are retained in the Quality Control Manager's file.

11.3.2 WPS' are revised whenever there is a change in a Nonessential Variable. A WPS is revised and re-qualified if an Essential Variable is changed.

11.3.3 The Standard Welding Procedures Specifications (SWPS) referenced in the NBIC may be used, without changing any variables, if they are determined to be appropriate for the job requirements, and the Quality Control Manager shall complete the certification portion on the SWPS form as required in the NBIC.

11.4 QUALIFICATION OF WELDERS AND WELDING OPERATORS

11.4.1 All Welders and Welding Operators are qualified to the requirements of the original Code of construction, the construction standard, Code selected or ASME Code Section IX, under the supervision of the Superintendent and the performance variables used for welding are recorded by the Superintendent. The testing of the specimens may be performed by an outside lab or done in-house. The records of the results are presented to the Quality Control Manager for review and acceptance. If the results of the test are

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satisfactory, the Quality Control Manager prepares the Welder/Welding Operator Performance Qualification form (WPQ/WOPQ) based on the performance variables recorded and the test results and also certifies by signing and dating it. Copies of the WPQ/WOPQ are provided to the Job Foreman for the qualified Welders or Welding Operators under their supervision and direction. The originals are retained in the Quality Control Manager's file.

11.5 RENEWAL OR RE-QUALIFICATIONS OF WELDERS

11.5.1 Welders' qualifications are renewed or requalified as required by the ASME Code Section IX, for any of the following reasons:

A. If the Welder or Welding Operator has not utilized a specific process for which he/sheis qualified for a period of six months or more shall require renewal of qualification.

B. If the Quality Control Manager or Inspector requests the individual to re-qualify.

C. A welder shall be re-qualified whenever a change is made in one or more of the performance essential variables listed for each welding process.

11.5.2 Evidence of Welder and Welding Operator continuity shall be recorded on the Welder's Continuity Record (Exhibit #11-1) and shall be updated by the Quality Control Manager from the actual job information and maintained for at least three years. The entries shall identify the process (es) each Welder or Welding Operator is qualified in, and the process (es) utilized.

11.6 CODE FABRICATION WELDING

11.6.1 The Job Foreman shall verify that all Welders and Welding Operators are qualified for the applicable WPS variables that will apply to the job to be completed. He shall be responsible for supervising and assignment of the Welders and Welding Operators for Code work, and for instructing the Welder in the correct use and variables of the respective WPS(s).

11.7 WELDERS AND WELDING OPERATORS IDENTIFICATION

11.7.1 Each qualified Welder and Welding Operator is assigned a unique symbol / number, by the Quality Control Manager. The symbol / number shall be stamped adjacent to the weldto identify each weld completed or shall be recorded on the Traveler by the Quality Control Manager. If an individual leaves our employ, the symbol or number shall not be reassigned for at least six months.

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11.8 TACK WELDS

11.8.1 Tack welds, whether left in place or removed, shall be made using a weld procedure qualified in accordance with ASME Code Section IX. Tack welds to be left in place shall be made by Welders qualified in accordance with ASME Code Section IX. If left in place, the ends of each tack weld shall be properly prepared to ensure satisfactory inclusion into the finished weld. After preparation, each tack weld is examined visually for defects by welder, and if defective, it shall be completely removed.

11.8.2 Tack welds made by a Subcontractor shall be performed using a qualified WPS approved by the Quality Control Manager. These tack welds shall be removed and not be incorporated into the final weld.

11.9 WELDING MATERIAL CONTROL

11.9.1 All welding material is purchased and received as described in Section 8.0. Welding material shall be stored in their original sealed containers in a dry storage space designated for that purpose. Material is issued to Welders by the Job Foreman. Low hydrogen type weld electrodes, when used, shall be placed in heated ovens immediately after opening the original container or consumed within 4 hours. The temperature in these ovens shall be maintained as per the electrode manufacturers’ recommendations. Low hydrogen electrodes removed out of heated storage shall be consumed within 4 hours or discarded.

11.10 DOCUMENTATION

11.10.1The Quality Control Manager maintains the master WPS, PQR, and the WPQ/WOPQ file. All records referenced in this section are available for review by the Inspector prior to use on a Code job and at anytime thereafter when requested.

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Non Destructive Examination and Heat Treatment Controls

Date: 09/16/14

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12.1 SCOPE

12.1.1 This section describes the requirements for Nondestructive Examination procedures, personnel qualification and documentation, should it fall within the scope of our repair activities.

12.1.1 In general NDE or PWHT are not anticipated as a regular operation for current repair activities.

12.2 GENERAL

12.2.1 The nondestructive examination (NDE) requirements, including technique, extent of coverage, procedures, personnel qualification, and acceptance criteria, shall be in accordance with the original Code of construction for the pressure-retaining item.

12.2.2 Weld repairs shall be subjected to the same nondestructive examination requirements as the original welds. Where this is not possible or practicable, alternative NDE methods acceptable to the Inspector and the Jurisdiction where the pressure-retaining item is installed, where required, may be used.

12.2.3 All Nondestructive Examination (NDE) requirements are described on the drawings or

Repair Plan.

12.2.4 In general, all Nondestructive Examinations are performed by a subcontracted NDE firm, whose written practice, procedures, personnel qualifications and certifications andequipment calibration records have been reviewed and accepted by the Quality Control Manager. Visual (VT) or Liquid Penetrant (PT) Examinations may be performed in-house and it shall be conducted utilizing a procedure generated by the Quality Control Manager, in accordance with the requirements of the applicable original Code of construction.

12.2.5 In case radiography (RT) and ultrasonic (UT) examinations are required by the Code of construction then the Quality Control Manager, after review and acceptance of the Level III’s qualifications and certifications, shall appoint a Level III Examiner by letter to act in that capacity on behalf of J. T. Thorpe & Son, Inc.. The Level III shall acknowledge this appointment in writing.

12.3 NONDESTRUCTIVE EXAMINATION PROCEDURES

12.3.1 NDE procedures of Subcontractor shall be approved by the appointed Level III Examiner qualified in that method. It shall be the responsibility of the Quality Control Manager to establish that all NDE are performed in accordance with a written procedure meeting the requirements of T-150 of ASME Section V.

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Date: 09/16/14

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12.3.2 Radiography, Ultrasonic, Liquid Penetrant, Magnetic Particle and Visual Examination procedures shall be submitted to the Inspector for review. Prior to its use, all procedures shall be demonstrated as capable of providing satisfactory results to the Inspector's satisfaction.

12.4 NONDESTRUCTIVE EXAMINATION PERSONNEL

12.4.1 NDE personnel shall be qualified and certified in accordance with the requirements of the original Code of construction. When this is not possible or practicable, NDE personnel may be qualified and certified in accordance with their employer’s written practice in accordance with their Employer's Written Practice, which shall be based on the requirements of the latest Code accepted edition of SNT-TC-1A or CP-189.

12.4.2 The Quality Control Manager shall have verified, prior to the start of NDE activities, that the NDE Examiner, including the Level III Examiner, has current qualifications and certifications.

12.4.2 In-house Visual (VT) and Liquid Penetrant (PT) Examiners shall be qualified and certified utilizing the procedures generated by the Quality Control Manager, in accordance with the requirements of the applicable ASME Codes.

12.5 NONDESTRUCTIVE EXAMINATION REPORTS

12.5.1 All reports of NDE including RT film are reviewed and accepted by the Quality Control Manager before submittal to the Inspector for review and acceptance. Adequate film viewing equipment including a film density comparator strip or a densitometer will be provided for the Inspector to review film. All NDE reports including RT film are filed by the Quality Control Manager for retention as described in Section 14 of this Quality Control Manual.

12.6 HEAT TREATMENT GENERAL

12.6.1 In general heat treatment is not performed as a regular operation. If required, heat treatment activities will be subcontracted, and approved procedures or approved detailed heat treatment instructions will be furnished to the subcontractor. Postweld heattreatment shall be performed as required by the original Code of construction, the construction standard or Code selected. Under certain conditions, postweld heat treatment, in accordance with the original Code of construction, may be inadvisable or impractical. In such instances, the alternative methods as per NBIC may be used provided it is acceptable to the Inspector and, when required by the Jurisdiction.

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Date: 09/16/14

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12.7 POST WELD HEAT TREATMENT PROCEDURES

12.7.1 The Quality Control Manager will review and approve the sub-contractor’s PWHT procedures for compliance to Code requirements. If the PWHT procedure is not sub-contractor supplied, the Quality Control Manager shall generate a PWHT procedure, approve it and present it to the Inspector for review.

12.7.2 The Quality Control Manager will verify the calibration status of temperature recording

instruments, number and placement of thermocouple’s and time at temperature recording. The completed records will be presented to the Inspector for review and acceptance.

12.7.3 Items sent to a sub-contractor for heat treating shall be inspected for identification and damage upon return from the heat treater by the Quality Control Manager.

12.8 POST WELD HEAT TREATMENT RECORDS

12.8.1 Records submitted by the PWHT sub-contractor shall be representative of actual conditions regarding duration and time exposure relative to temperature. PWHT records will be reviewed by the Quality Control Manager and signed and dated to denote his acceptance before submittal to the Inspector for review.

12.9 DOCUMENTATION

12.9.1 All NDE and PWHT documentation, including records of equipment calibration, will be presented to the Inspector prior to or during a final review of documentation for verificationof Code compliance. The Inspector may request re- qualification of NDE Examiners or procedures if there is reason to question the procedure or the ability of the examiner to perform the examinations with acceptable results.

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Calibration Controls Date: 09/16/14

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13.1 SCOPE

13.1.1 This section describes the procedures, duration between calibrations or verifications, and the documentation used to control the calibration status of all test pressure gauges and measurement Instruments used for Code acceptance.

13.1.2 The calibration of pressure gages, measurement, examination, and test equipment, and documentation of calibration shall be performed, as required, by the applicable standard used for construction. In the absence of any specific requirements by the original Code of construction the requirements mentioned in this section shall be followed.

13.2 CALIBRATION CONTROL AND IDENTIFICATION

13.2.1 All pressure gauges and instruments shall be assigned a serial number for identification purposes. The identification number shall be affixed directly to the gauges and instruments.

13.2.2 It is the Quality Control Manager's responsibility to ensure the calibration status of each pressure gauge/instrument prior to use. Defective pressure gauge’s/instruments shall be distinctly marked or otherwise positively identified to be out of service and not available for use.

13.3 PRESSURE GAUGES

13.3.1 Each calibrated pressure gauge shall have a sticker attached to it or the case from which it comes, which shall indicate as a minimum the calibration date. Gauges shall not be used when the calibration date is more than a year old until the gauge has been recalibrated.

13.3.2 Calibration of pressure gauges using a standard deadweight tester or calibrated master gauge shall be performed by a facility capable of providing reports of calibration results and use suitable calibration methods whose accuracy is traceable to known standards. Gauges shall also be calibrated at anytime error is suspected.

13.4 MEASURING INSTRUMENTS

13.4.1 Measuring instruments (Micrometers, Calipers), if used, shall be compared against a standard certified test block prior to use, by the Quality Control Manager. The test block shall be re-certified at anytime it appears to have been damaged or if corrosion is evident.

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Calibration Controls Date: 09/16/14

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13.4 SUB-CONTRACTED VENDOR CALIBRATIONS

13.4.1 The Quality Control Manager shall require sub-contracted vendors to provide records of calibration for their equipment. This shall include but not be limited to NDE vendors and vendors providing PWHT services. The Quality Control Manager shall review these records and ensure they comply with vendor's requirements, and the applicable Code requirements.

13.5 DOCUMENTATION

13.5.1 Reports of calibration from vendors are maintained on file by the Quality Control Manager. All documentation pertaining to this Section shall be made available to the Inspector upon request.

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The Inspector Date: 09/16/14

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14.1 SCOPE

14.1.1 This section describes the responsibilities of the J. T. Thorpe & Son, Inc. personnel coordination of Inspector’s services.

14.2 GENERAL

14.2.1 The Inspector shall be a current National Board commissioned Inspector with “IS” In- Service Commission or New Construction Commission with “AR” endorsement holding a valid certificate of competency (commission) for the Jurisdiction where the work is to take place and employed by an Authorized Inspection Agency.

14.2.2 The Regional Manager is responsible to ensure that a service agreement exists and is current with a National Board accredited Authorized Inspection Agency. National Board shall be notified by the Regional Manager if this agreement is canceled or changed to another Authorized Inspection Agency.

14.2.3 If it becomes necessary to use an Inspection Agency, other than the Authorized Inspection Agency of Record, the Quality Control Manager shall notify the National Board and the Authorized Inspection Agency of Record of the change.

14.3 LIAISON

14.3.1 The Inspector shall be provided free access to all areas where repair are being performed and all documents pertaining to the repair. This access shall also be provided to the Inspector Supervisor during required audits or as requested.

14.3.2 The Inspector shall have access to a controlled Quality Control Manual at all times.

14.3.3 The Inspector shall be contacted prior to making any repair for authorization and for selecting Hold/ Verification points.

14.3.4 The Inspector shall be notified of non-conformities and his concurrence shall be obtained prior to any correction.

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Records Completion and Retention Date: 09/16/14

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15.1 SCOPE

15.1.1 This section describes the requirements for control and distribution of the completed job documentation and the NBIC “R” Forms.

15.2 DOCUMENTATION

15.2.1 Upon completion of a repair activity, the Quality Control Manager shall review all documentation for compliance to this Quality Control Manual, the NBIC and Jurisdictional requirements. If acceptable, the Quality Control Manager shall prepare and certify the applicable NBIC “R” Form from final records.

15.2.2 When satisfied that the repairs meet Code, Jurisdiction and NBIC requirements the Quality Control Manager shall present the NBIC “R” Form and the final records to the Inspector for review and signature. The Quality Control Manager shall distribute legible copies of the NBIC “R” Form together with attachments as follows:

15.2.3 REPAIRSThe owner or user, Authorized Inspection Agency responsible for in service inspection of the Pressure Retaining Item, the Inspector, Jurisdiction (if required), and an original to theNational Board when required.

15.2.4 The Quality Control Manager shall also maintain documents as per the record retention schedule specified in figure 1.6.5.1 of NBIC Part 3.

15.3 NATIONAL BOARD REGISTRATION

15.3.1 The Quality Control Manager shall maintain a sequential log for repairs registered with the National Board. The R Form shall be submitted to the National Board within 60 days of Certification. R Forms not registered with the National Board shall be maintained on file for a minimum of 5 years.

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Exhibits Index Page Date: 09/16/14

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Exhibits Description Revision Date

6-1 Quality Control Manual Log 0 09/16/14

7-1A Repair Plan 0 09/16/14

7-1B Repair Plan- Supplementary 0 09/16/14

8-1 Purchase Order 0 09/16/14

8-2 Material Receiving Inspection Report 0 09/16/14

9-1 Name Plates 0 09/16/14

10-1 Nonconformance Report 0 09/16/14

11-1 Welders Continuity Record 0 09/16/14

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Exhibit Number: 6-1Revision: 0

Quality Control Manual Log Date: 09/16/14

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Edition Number:

ASSIGNED MANUAL NUMBER

MANUAL EDITION REVISION RECIPIENT

DATE MANUAL SENT TO

RECIPIENT

REMARKS (CONTROLLED

OR UNCONTROLLED)

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Exhibit Number: 7-1ARevision: 0

Repair Plan Date: 09/16/14

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Form R-1 No. JTT Job No.: Date:

Original manufacture: Item Description:

Identification No.: NB No.: Jurisdiction No.: Year Built

Location of Installation:

Original Code ASME Section I IV VIII-1 B31.1 Edition Addenda

Code Used ASME Section I IV VIII-1 B31.1 Edition Addenda

NBIC Edition Addenda Original Code is non ASME specify

Jurisdictional Approval Required Yes No Verified by

QCM Date Inspector Date

Verbal Authorization Yes No Name Date & TimeSketch- Weld Detail:

Inspection and Examination Operations QC Date H / V I DateReview Drawing No. Rev.Review PWHT ProcedureReview Material Receiving Inspection ReportsReview MTR, Material Identification/ CertificationReview WPS PQRVerify, WPQ, Welder Continuity & Welder IDInternal Weld InspectionExternal Weld InspectionNDE Radiography Ultrasonic VisualNDE Liquid Penetrant Magnetic ParticleReview Heat Treatment Chart Hydro test @ Gauge IDStamping/ Name PlateReview & Certification of R formReview Non- Conformance Report No.

H - Hold Point V - Verification Point QC – Quality Control I - Inspector

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Exhibit Number 7-1BRevision: 0

Repair Plan - Supplementary Date: 09/16/14

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Form R-1 No. JTT Job No.: Date:Original manufacture: Item Description:Identification No.: NB No.: Jurisdiction No.: Year Built

Weld/ Joint No.

WPS No.

Welder ID

Fit Up Final

QC Date H/V I Date QC Date H/V I Date

H - Hold Point QC – Quality Control I - Inspector

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Purchase Order Date: 09/16/14

of 41 Th

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Material Receiving Inspection Report Date: 09/16/14

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JTT Job Number:Purchase Order Number: Date:

Receiving Inspection by: Date:

Condition of Packing- Damages in Shipping: Yes No

Explain Damages: (If any)

Material Received as Ordered: Yes No

Material Traceable to Material Test Report: Yes No

Material Test Report comply with Code Requirements: Yes No

Dimensional Check Acceptable: Yes No

Quality Control Inspector: Date:

Quantity Description and Size

Material Specification

Heat / Slab / Lot Number

Actual Marking on Material

LAYDOWN AREA:

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Name Plate Date: 09/16/14

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Figure 1a. Repair Nameplate

REPAIRED BY J.T. THORPE & SON, Inc.

R-5452

NATIONAL BOARD DATE REPAIRED “R” CERTIFICATE NUMBER

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Exhibit Number 10-1Revision: 0

Nonconformance Report Date: 09/16/14

of 41

Job Number: NCR Number:DESCRIPTION OF NONCONFORMANCE:

Reported By: Date:

PROPOSED DISPOSITION:

Quality Control Manager: Date:

Authorized Inspector: Date:

CORRECTIVE ACTION/ REINSPECTION:

Quality Control Manager: Date:

Authorized Inspector: Date:

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Welder Continuity Record Date: 09/16/14

of 41

WELDER CONTINUITY RECORD YEAR

Previous continuity has been verified and current for each process Certified by Date

WELDER NAME STAMP PROCESS JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

When updating this record, the Job Number is entered in the box for the month welding was performed in a specific process. The welder's qualifications for that process shall expire if no welding is performed in a 6-month period. (QW322)

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Appendix: 1 Section: 17Requirements of California Division of

Occupational Safety and Health (DOSH)Revision: 0

Date: 09/16/14

of 41

17.1 GENERAL

17.1.1 Repairs when performed to Pressure Retaining Items installed in California shall meet the California Jurisdictional requirements as listed in the California Code of Regulations Title 8 Division 1, Chapter 4:

(1) Unfired PV Safety Orders, Subchapter 1,(2) Boiler and Fired PV Safety Orders, Subchapter 2,(3) Petroleum Safety Orders subchapters 14 and 15.(4) Circular Letters issued by the Division (PV-2001-1, PV-2006-2, & PV-2006-3)

17.1.2 The California Division of Occupational Safety and Health(DOSH) shall be provided free access to conduct audits of the Quality System and Code activities upon a valid request from an Owner, User, Inspection Agency, or the National Board.

17.2 ROUTINE REPAIRS

Routine repairs are NOT allowed on Pressure Retaining Items installed in California.

17.3 JURISDICTIONAL ACCEPTANCE

17.3.1 A written procedure submitted to and accepted by the Jurisdiction and the Inspector, is required prior to the following activities:

17.3.1.1 PWHT not in accordance with the original Code of Construction. This includes use of the alternative weld procedures and localized PWHT procedures.

17.3.1.2 NDE not in accordance with the original Code of Construction.

17.3.1.3 Repairs: Pneumatic test in lieu or hydro, NDE in lieu of hydro.

17.3.2 Written prior acceptance from the Jurisdiction is required on a case by case basis for the following activities:

17.3.2.1 Using MT or PT to examine welds when RT was required by the original Code of construction. This applies to alternative weld procedures in lieu of PWHT.

17.3.2.2 The repairs involving unstayed boiler furnace cracks in knuckles or turns of flanges of boiler openings, mechanical repairs of bulged plates, seal welding of riveted joints.

17.3.2.3 Rerates

17.3.2.4 Minimum wall thickness calculations using higher material stress values allowed on later editions of the ASME Code.

17.3.2.5 When the original Manufacturer’s Data Report cannot be obtained for design basis.

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Date: 07/9/15

Page 1 of 3

18.1 PRE-APPROVED REPAIR PLAN FOR PT/MT or VT IN LIEU OF HYDROSTATIC TESTING

18.1.1 J. T. Thorpe & Son, Inc. plans to use Solvent Removable Visible Dye Penetrant (PT), Dry Power Magnetic Particle (MT) or Visual Examination (VT) in lieu of hydrostatic testing, that have been accepted by California Division of Occupational Safety and Health.

18.1.2 The use of this procedure satisfies J. T. Thorpe & Son, Inc. the need to notify the California Division of Occupational Safety and Health of the repair, requesting PT/MT or VT in lieu of hydrostatic testing.

18.1.3 J. T. Thorpe & Son, Inc. is still responsible for notification and approval of this repair plan, by the Inspector. The Inspector may require changes in the repair plan, and if so, J. T. Thorpe & Son, Inc. will be responsible for proper notification and approval by California Division of Occupational Safety and Health. The description of the repair will be noted on the R-1 form.

18.2 J. T. THORPE & SON, INC. REPAIR PROCEDURES

18.2.1 Repair Plan 1 – WELD BUILD UP OF WALL THICKNESS (P1 – P11 Material)

This repair plan is applicable for the following:o weld build-up of area not exceeding 100 square incheso weld build-up of up to 25% of nominal wall thickness or ½” whichever is lessUT map the area to identify limits of wall thinning or shell damageMT or PT thin area for cracking prior to weldingWeld build up area using stringer beadsBlend grind weld build up to flush with existing shell with no sharp risersMT or PT final weld in lieu of hydrostatic test

18.2.2 Repair Plan 2 – FILLET WELD ATTACHMENT (P1 – P11 Material)

Remove existing fillet weld by grinding or scarfingRemove attachmentVisually inspect existing steel for cracking or corrosionFit attachment for fillet weldReplace fillet weldPT final weld in lieu of hydrostatic test

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Date: 07/9/15

Page 2 of 3

18.3 Repair Plan 3 - PRE-APPROVED PLAN FOR VISUAL EXAMINATION (VT) OF REPAIRS WHEN HYDROSTATIC TESTING, MAGNETIC PARTICLE AND LIQUID DYE PENETRANT EXAMINATION IS DEEMED AS NOT PRACTICABLE

18.3.1 This procedure is applicable for repairs that meet all of the following conditions:

18.3.1.1 This Repair Plan only applies to ASME Section I Power Boilers and ASME Section VIII Div. 1 Pressure Vessels.

18.3.1.2 Hydrotesting, magnetic particle and liquid dye penetrant examination after repairs isdeemed as not practicable.

18.3.1.3 Exclusive use of Visual Examination (VT) is only permitted with the following conditions:

18.3.1.3.1 When a pressure test or alternative NDE methods other than Visual Examination (VT), are not practicable the exclusive use of direct VT as an NDE method shall be limited to nonload bearing attachments to pressure-retaining items such as refractory anchors, hexsteel, insulation pins or clips where postweld heat treatment is not required.

18.3.1.3.2 As a minimum, direct VT shall be performed after the root weld layer or first-pass is deposited, and the final weld surface. Other weld layers shall be examined as identified by the Inspector and, where required, the Jurisdiction.

18.3.1.3.3 Personnel completing direct VT shall be qualified and certified in accordance with AWS QC-1, or the employer's written practice based on ASNT SNT-TC-1 or ASNT CP-189. Visual acuity shall be demonstrated using as a minimum, standard J-2letters on standard Jaeger test type charts for near vision.

18.3.1.3.4 Direct VT shall be performed in accordance with a written procedure meeting the procedure and reporting requirements listed in the original code of construction or ASME Section V, Article 9.

18.3.2 The use of this procedure satisfies the need for JTT to notify the California Division of Occupational Safety and Health.

18.3.3 JTT is responsible for notifying and obtaining approval by the Inspector to use this procedure. The Inspector may require changes to this procedure, and if so, JTT will be responsible for proper notification and approval by California Division of Occupational Safety and Health. The description of this procedure will be noted on the Form R-1.

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Appendix: 3 Section: 19

Repair plan for stud welded attachments Revision: 0Date: 7/9/15

Page 1 of 2

19.1 PRE-APPROVED REPAIR PLAN FOR STUD WELDED ATTACHMENTS WHEN HYDROSTATIC TESTING IS DEEMED AS NOT PRACTICABLE

19.1.1 This procedure is applicable for repairs that meet all of the following conditions:

19.1.1.1 Repairs are nonload bearing stud welded attachments such as refractory anchors, studs, insulation pins, clips or other similar metallic items where post weld heat treatment is not required.

19.1.1.2 This procedure only applies to ASME Section I Power Boilers and ASME Section VIII Div. 1 Pressure Vessels. Stud weld size restrictions and other requirements of stud welded attachments in ASME Section I and ASME Section VIII Div. 1 current edition shall be followed.

19.1.1.3 Pressure-testing and other forms of NDE such as MT and PT after repairs aredeemed as not practicable.

19.1.1.4 Personnel completing direct VT shall be qualified and certified in accordance with paragraph 2015 NBIC Part 3, 4.2- b), American Welding Society QC-1, or the employer's written practice based on ASNT SNT-TC-1 or ASNT CP-189. Visual acuity shall be demonstrated using as a minimum, standard J-2 letters on standard Jaeger test type charts for near vision.

19.1.1.5 Direct VT shall be performed in accordance with a written procedure meeting the procedure and reporting requirements listed in the original code of construction or ASME Section V, Article 9.

19.1.2 The use of this procedure satisfies the need for J. T. Thorpe & Son, Inc. to notify the California Division of Occupational Safety and Health.

19.1.3 J. T. Thorpe & Son, Inc. is responsible for notifying and obtaining approval by the Inspector to use this procedure.

19.2 J. T. THORPE & SON, INC. REPAIR PROCEDURE

19.2.1 At the start of each work shift, each stud welding operator shall be qualified for the remainder of the work shift as follows:

19.2.1.1 Each stud welding operator shall weld five studs on a separate test plate or tube. The stud welds will be performed using the same equipment and welding parameters (position, stud size, ferrule, gun model, etc.) as production welding.

19.2.1.2 Each stud (five joints) shall be tested by hammering over until at least one-fourth of its length is flat on the test piece. An alternate test is to bend each stud to an angle of at least 15 degrees and returning it to its original position using a test jig and an adapter location dimension that are in accordance with ASME Section IX, Figure QW-466.4.

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