QUALITY CONTROL MANUAL - Industrial Piping, Inc.

INDUSTRIAL PIPING, INC. 

2794 OLD RICHBURG ROAD 

RICHBURG, SC 29729 

QUALITY CONTROL MANUAL 

FOR 

ASME CODE CONSTRUCTION IN SHOP AND FIELD ASSEMBLY 

AND REPAIR OR ALTERATION 

OF PRESSURE VESSELS, 

BOILERS AND BOILER PARTS, 

PRESSURE PIPING, AND PROCESS PIPING 

IN ACCORDANCE WITH 

THE ASME BOILER & PRESSURE VESSEL CODE 

SECTION VIII, DIVISION 1 

SECTION I, B31.1, B31.3 

THE NATIONAL BOARD INSPECTION CODE 

AND JURISDICTIONAL AUTHORITY REQUIREMENTS 

ISSUE 2 REV. 1 

August 20, 2009 

ISSUED TO: 

MANUAL COPY NO. 

[ ] Controlled Copy 

[ X ] Uncontrolled Copy

Quality Control Manual 

Page ii 

Industrial Piping, Inc. Revision 1 

Issue 2 

TABLE OF CONTENTS 

SECTION TITLE PAGE REV. DATE 

Cover Sheet 1 8/20/09 

Table of Contents 1 of 3 1 

Statement of Authority and Content 1 of 1 1 

1 Quality Control Program 0 9/5/08 

1.1.0 General 1 of 4 0 

1.2.0 Quality Control Manual 1 of 4 0 

1.3.0 Custody and Control of Code Symbol 

Stamps 2 of 4 0 

1.4.0 Duties and Responsibilities of 

Personnel 2 of 4 0 

1.5.0 Organizational Chart 4 of 4 0 

2 Drawings, Design Calculations 

and Specifications 0 9/5/08 

2.1.0 General 1 of 2 0 

2.2.0 Control of Drawings, Design 

Calculations and Specifications 1 of 2 0 

2.3.0 Calculation Control 2 of 2 0 

3 Material Control 1 8/20/09 

3.1.0 General 1 of 4 1 

3.2.0 Control of Purchases 1 of 4 1 

3.3.0 Receiving Control 2 of 4 1 

3.4.0 Material Certifications and 

Partial Data Reports 2 of 4 1 

3.5.0 Identification 3 of 4 1 

3.6.0 Release of Material 3 of 4 1 

3.7.0 Field Material Control 4 of 4 1 

4 Examination, Inspection, and Testing 1 8/20/09 

4.1.0 General 1 of 5 1 

4.2.0 Travelers, Certified Drawings, and 

Inspection Points 1 of 5 1 

4.3.0 Release of Material for 

Fabrication 1 of 5 1 

4.4.0 Authorized Inspector Notification 1 of 5 1


Page iii 




4.5.0 In Process Inspections 2 of 5 1 8/20/09 

4.6.0 Final Inspection 3 of 5 1 

4.7.0 Hydrostatic Testing 3 of 5 1 

4.8.0 Pneumatic Testing 3 of 5 1 

4.9.0 Welded Repairs 4 of 5 1 

4.10.0 Data Reports and Stamping 4 of 5 1 

4.11.0 Distribution & Retention of Data 4 of 5 1 

Reports 

4.12.0 Field Site Program 5 of 5 1 

5 Correction of Nonconformities 1 8/20/09 

5.1.0 General 1 of 2 1 

5.2.0 Definition 1 of 2 1 

5.3.0 Affected Hardware Treatment 1 of 2 1 

5.4.0 Procedure 1 of 2 1 

5.5.0 Records 2 of 2 1 

6 Welding Control 0 9/5/08 

6.1.0 General 1 of 4 0 

6.2.0 Welding Procedure Specifications 1 of 4 0 

6.3.0 Welder/Welding Operator Qualifications 2 of 4 0 

6.4.0 Weld Filler Material Control 2 of 4 0 

6.5.0 Welder/Welding Operator Identification 

Number 3 of 4 0 

6.6.0 Tackwelds 4 of 4 0 

6.7.0 Assignment of Welders/Welding 

Operators for Welding 4 of 4 0 

7 Nondestructive Examination 1 8/20/09 

7.1.0 General 1 of 2 1 

7.2.0 Subcontracted NDE 1 of 2 1 

7.3.0 Liquid Penetrant, Magnetic Particle, 

and Visual Examinations 2 of 2 1 

7.4.0 Authorized Inspectors' Involvement 2 of 2 1


Page iv 




8 Heat Treatment 0 9/5/08 

8.1.0 General 1 of 1 0 

8.2.0 Procedure 1 of 1 0 

9 Calibration 0 9/5/08 

9.1.0 General 1 of 1 0 

9.2.0 Pressure Gages 1 of 1 0 

9.3.0 Micrometers 1 of 1 0 

10 Records Retention 0 9/5/08 

10.1.0 General 1 of 1 0 

10.2.0 Records Distribution and Retention 1 of 1 0 

11 Repairs and Alterations 0 9/5/08 

11.1.0 General 1 of 4 0 

11.2.0 Definitions 1 of 4 0 

11.3.0 Responsibility 2 of 4 0 

11.4.0 Procedures 2 of 4 0 

11.5.0 Records 2 of 4 0 

11.6.0 Stamping 3 of 4 0 

11.7.0 Distribution of NBIC Forms 4 of 4 0 

12 The Authorized Inspector 0 9/5/08 

12.1.0 General 1 of 2 0 

12.2.0 Definition 1 of 2 0 

12.3.0 Involvement with the Authorized 1 of 2 0 

Inspector 

13 Exhibits - Table of Contents 1 of 1 0 9/5/08 

APPROVED BY: 

QUALITY CONTROL MANAGER 

ACCEPTED BY: 

AUTHORIZED INSPECTOR 

DATE 

DATE

Quality Control Manual Page 1 of 1 


STATEMENT OF AUTHORITY AND CONTENT 

This Manual establishes the Quality Control System to be applied to the Construction, Repair or 

Alteration of Pressure Vessels, Boilers, Boiler Parts, Pressure Piping, and Related Parts, produced in 

compliance with the requirements of ASME Code, Sections VIII, Division 1 and Section I, B31.1, 

Jurisdiction and the National Board Inspection Code. This Manual has been reviewed and approved by 

the Quality Control Manager of Industrial Piping, Inc. Any subsequent proposed changes and/or 

revisions will also be reviewed and approved in the same manner. This manual may also be used for 

compliance to ASME B31.3 – Process Piping Code. 

It is recognized that this Quality Control System involves the team effort of all Departments, 

Supervisors, and Personnel in the Fabrication & Repair or Alteration of shop and field Code items. 

This program will be followed and enforced on all applicable work. Any problems or conflicts 

concerning this system which cannot be resolved by the Managers involved shall be presented to me 

for resolution, which shall not negate Code requirements or this Manual. 

The Quality Control Manager shall have the responsibility, the authority, and the organizational 

freedom to identify quality control problems and to initiate, recommend and provide solutions. 

Final responsibility for this Manual program and the authority to enforce it, has been assigned by the 

President to the Quality Control Manager. 

M. L. Jones Date 

President



1.1.0 GENERAL 

SECTION 1 

QUALITY CONTROL PROGRAM 

1.1.1 This section documents the measures undertaken by Industrial Piping, Inc. for the 

purpose of assuring compliance with the provisions of the ASME Code Section I, VIII, 

Division 1, B31.1, Jurisdiction, N.B.I.C., and B31.3. 

Note: All work performed in accordance with ASME B31.3 is exempt from any/all 

involvement of the A.I./C.I. where any/all reference to the other A.I./C.I., data reports 

and stamping is implied in this manual these shall be exclusive of ASME B31.3. 

1.2.0 QUALITY CONTROL MANUAL 

1.2.1 Internal issue of the Q.C. Manual to Industrial Piping, Inc. personnel and to the 

Authorized Inspector shall be controlled. Such manuals shall be serialized, and the 

recipient assigned his/her own manual serial number, and the revision and date of issue 

shall be entered in a Master Issue Log-Controlled (Exhibit A) maintained by the 

Quality Control Manager. 

1.2.2 Uncontrolled copies of the Q. C. Manual will not be issued to company employees. 

When requested by an outside organization they will be issued an uncontrolled copy of 

the Q. C. Manual. This copy will be marked “Uncontrolled Copy” on the cover page. 

1.2.3 Responsibility for revisions to the Quality Control Manual shall be with the Quality 

Control Manager. A review of each ASME and NBIC Code Edition and Addenda will 

be made after its receipt to determine its effect on this program. Required revisions 

shall be implemented within 6 months of issue date and documented by initialing and 

dating the applicable document. 

Revisions will be drafted for those manual sections whose content is made inadequate 

by Code changes, or by development of new internal control systems. Revised text 

shall be italicized. Following approval of such drafts by QC Manager on Table of 

Contents, copies of the draft sections and of the existing sections it is intended to 

replace, shall be submitted to the Authorized Inspector with an approved copy of the 

Table of Contents. Upon acceptance of the draft by the Authorized Inspector and his 

signature on table of contents page, it shall be issued for printing and implementation. 

The QC Manager, at his discretion, may change the Issue level of the Manual. At 

which time, all revisions will revert to zero.



1.2.4 If customers specify changes which do not affect any rules or requirements of the 

ASME Code, project addenda are initiated which clearly indicate the 

customer and IPI job they cover. When the content of such addenda is mutually agreed 

to between IPI and the specific customer and submitted to the A.I. For the AIA of 

record for his review, the addenda is issued on colored pages to manual holders who are 

involved with the specific material being changed. This issue is by internal memo, 

requesting the addenda to be applied to the specific contract only, and a copy retained 

in the job file after completion. It shall be the Quality Control Manager's responsibility 

to retrieve the project addenda and restore the Quality Control Manual to its original 

content. 

1.2.5 A controlled copy of the latest revision of the Quality Control Manual will be made 

available to the Authorized Inspector, at the plant and at field sites. 

1.3.0 CUSTODY AND CONTROL OF CODE SYMBOL STAMPS 

1.3.1 The Quality Control Manager is responsible for custody and control of the Code 

Symbol Stamps. He shall maintain the Stamps in a secure place. The Quality Control 

Manager is responsible for the correct application of the Code Symbol Stamps. 

1.3.2 After the Authorized Inspector has made his final inspection, he will be presented with 

a completed Manufacturers' Data Report signed by the Quality Control Manager. Any 

records he may require will also be presented. When he is satisfied that all Code 

requirements have been met, he may sign and date the Manufacturer's Data Report. 

The A.I. will witness the application of the Code Symbol Stamp. 

1.4.0 DUTIES AND RESPONSIBILITIES OF PERSONNEL 

1.4.1 The Quality Control Manager shall be responsible for overall enforcement of the 

Quality Control Program. His responsibilities include QC Manual Control; distribution 

of Code Sections, Editions, Addenda, and Code Cases; final arbitration of conflicts 

through the President as may be necessary; Nonconformance Reports; assurance that all 

inspections, examinations, and tests are performed, found acceptable as required by the 

Code, and documented by signing and dating the Travelers; calibration of test 

equipment; notification of the Authorized Inspector; receiving inspection; custody of 

Code Symbol Stamps; and certification of Manufacturers' Data Reports or applicable 

NBIC Form.



1.4.2 The Fabrication Engineer is responsible for assuring that drawings, calculations, and 

various procedures are accurate and that all required tests, inspections, and 

examinations are clearly defined.



2.1.0 GENERAL 

SECTION 2 

DRAWINGS, DESIGN CALCULATIONS, AND SPECIFICATIONS 

2.1.1 The Industrial Piping, Inc. Quality Control System provides for procedures which 

ensure that the proper design information required by the ASME Code is used for 

construction, examination, and testing of fabricated Code items. (Fabrication as 

referenced throughout this QC Manual also pertains to Repairs and Alterations in the 

shop and in the field.) 

2.2.0 CONTROL OF DRAWINGS, DESIGN CALCULATIONS AND SPECIFICATIONS 

2.2.1 The Fabrication Engineer shall have the responsibility for review of the customer's 

calculations, specifications, and drawings to assure Code compliance can be attained. 

Preparation of design calculations and drawings, if not supplied by the customer, shall 

be made by the Fabrication Engineer using appropriate formulas required by the Code. 

All drawings and calculations are reviewed by the Quality Control Manager and 

submitted to the A.I prior to the start of fabrication so that he may designate his 

required Inspection Points on the IPI Traveler (Exhibit B). The Certified Drawing 

contains all essential information necessary to fabricate Code items as well as that 

information needed for examination, inspection and testing. 

2.2.2 Job order numbers are assigned by the Manager Administration. Each Division 

Manager is responsible for the drawings numbering system. These systems are in the 

form of running logs. 

2.2.3 The Fabrication Engineer is responsible for specifying materials to be used in ASME 

Code fabrication. The Fabrication Engineer prepares a Requisition (Exhibit C) listing 

all material and technical procurement requirements. 

2.2.4 The Fabrication Engineer releases the job by sending Certified Drawings and a job 

package (as described in Paragraph 4.3.1 of this Manual) to the Shop Superintendent 

for shop work or to the Field Superintendent for field work. A copy of the Certified 

Drawing is forwarded to the Quality Control Manager. In the event of a drawing 

change, the changes shall be redlined and the drawings shall be revised with revisions 

noted and delivered to the Shop or Field Superintendent and the Quality Control 

Manager. The Authorized Inspector shall be advised of the revisions by the Quality 

Control Manager. The superseded drawings shall be collected by the Fabrication 

Engineer and any copies not destroyed will be marked "VOID" and one copy retained 

in engineering job file.



2.2.5 The Fabrication Engineer will signify his approval of all drawings and revisions by his 

stamping and date in the area provided. The Drawing shall contain all essential 

information necessary to fabricate and test Code work, including dimensions, 

tolerances material specifications, welding procedures, weld symbols, NDE 

requirements, hydrostatic testing requirements, design information, Code Section 

Edition and Addenda and Code Case (if applicable). 

2.3.0 CALCULATION CONTROL 

2.3.1 When standard or computer aided design calculations are used for company designed 

Code items, the Fabrication Engineer is responsible for the input of correct design data 

and the verification that the correct output has been obtained. 

2.3.2 The Fabrication Engineer will review the applicable Code to determine if standard 

designs or computer software programs are affected, and that they meet the Section, 

Edition, and Addenda applicable for design and shall be documented on the design 

printout. 

2.3.3 All calculations as issued shall be reviewed and approved by the Quality Control 

Manager, and documented on the IPI Traveler. In the event revisions are made, the 

Quality Control Manager shall review and approve each affected document. The 

Fabrication Engineer is responsible for distribution of all revisions and collecting all 

void calculations and marking as such. 

2.3.4 Standard and computer aided calculations are available for review and acceptance by 

the Authorized Inspector. The Fabrication Engineer shall provide the Authorized 

Inspector with any alternative methods of calculations that the A.I. may request. 

2.3.5 The Fabrication Engineer is responsible to assure the security of the computer program 

to prevent tampering and its unauthorized use.



SECTION 3 

3.1.0 GENERAL 

MATERIAL CONTROL 

3.1.1 This section establishes the measures used to control materials used to fabricate Code 

items. 

3.1.2 The materials used in the fabrication of Code items shall conform to the specifications 

and stress tables in Section II, Part D and B31.1 of the Code, along with those 

requirements specific to B31.3 fabricated piping, and be acceptable in the applicable 

Code section. 

3.2.0 CONTROL OF PURCHASES 

3.2.1 The Fabrication Engineer is responsible for listing materials for the job on the 

Requisition (Exhibit C). All materials for Code work shall be procured using a 

Purchase Order (Exhibit D) prepared from the Requisition issued by the Fabrication 

Engineer. Only the Fabrication Engineer, with approval of the Quality Control Manager 

and the concurrence of the A.I. shall have the authority to approve material 

substitutions. Material substitutions must meet applicable Code and design 

requirements. Revisions to design documents must be completed as specified in 

Section 2 of this Manual. 

3.2.2 The Purchase Orders shall contain all necessary information required by the applicable 

ASME Code material specification, job requirement and required Product Markings 

and Documents. The PO shall also contain any special testing required at receiving or 

during fabrication. 

3.2.3 All Purchase Orders for Code materials shall require that Material Certification be 

furnished on materials when required by the Code. In the case of materials from stock, 

it shall be the Quality Control Manager's responsibility to affirm that materials have 

traceability to Material Certifications that are on file and in compliance with the current 

Code and job design requirements. He shall note his approval of materials by initialing 

and dating the Requisition and the Material Certification. 

3.2.4 The Purchasing Agent and Fabrication Engineer are responsible for checking the 

Purchase Orders for correctness against the Requisitions prior to issue. A copy of the 

Purchase Order is forwarded to the Shipping/Receiving Clerk and one copy goes to a 

centralized job file.



3.2.5 All Purchase Orders for Code Fabrication, shall reference the Industrial Piping Inc. job 

number for which the material is being procured. 

3.2.6 Purchase Orders for cold formed carbon and low alloy steels shall contain a statement 

that they were properly formed to specified shapes (such as UG-79). 

3.3.0 RECEIVING CONTROL 

3.3.1 The Shipping/Receiving Clerk is responsible for the receipt, identification, and marking 

of material. Upon receipt, the IPI job number is marked on each item. Material is 

checked by the Shipping/Receiving Clerk against the appropriate Purchase Order for 

verification of item descriptions and quantities. 

3.3.2 Material is inspected by Quality Control Inspector upon receipt to ensure that it is 

properly stamped, stenciled, or otherwise marked with manufacturer's identification and 

Heat No./Code information and job number. The Quality Control Manager shall 

physically examine each item of material, making dimensional checks, and inspecting 

for damage and defects, comparing same with Purchase Orders, vendors shipping 

papers, and Material Certifications to affirm Code compliance and so indicate on the 

Receiving Inspection Report (Exhibit E). Material taken from inventory will be treated 

as described in this paragraph, including the completion of the Receiving Inspection 

Report. 

3.3.3 Materials found at receiving inspection to be nonconforming are documented and 

resolved as described in Section 5, Correction of Nonconformities. 

3.4.0 MATERIAL CERTIFICATIONS AND PARTIAL DATA REPORTS 

3.4.1 The Material Certifications will be reviewed by the Quality Control Manager for 

compliance to Section II of the ASME Code and he will note his review by initialing 

and dating the Receiving Inspection Report which references the job number and 

Purchase Order numbers. The Material Certifications will be included in the QC job 

file and available to the Authorized Inspector for review.



If the Material Certification is found to be nonconforming, the material will be marked 

as per Section 5, Control of Nonconformities. 

3.4.2 A Partial Data Report is required to accompany parts in which welding has been 

performed by someone other than Industrial Piping, Inc. The Partial Data Report will be 

reviewed by the Quality Control Manager and made available to the Authorized 

Inspector. A copy of this report will be attached to the Manufacturer's Data Report 

issued by IPI. 

3.5.0 IDENTIFICATION 

3.5.1 All plate and piping materials received that satisfy the Code, Purchase Order and 

Material Test Report requirements and have no defects or damage, shall be identified 

by assigning, in sequential order, an alpha-numeric code. This alpha-numeric code shall 

identify the material with the name or trademark of the manufacturer and any other 

markings as required by Code. This alpha-numeric code will be written on Material 

Test Reports for traceability. This identification number will then be applied to the 

material. All plate or pipe without such markings shall be utilized for Non-Code 

applications only. All coded material and associated documentation shall be reviewed 

and approved by the Quality Control Manager. Any coded marking system used must 

receive acceptance by the Authorized Inspector. 

3.5.2 Miscellaneous pressure parts will be marked with the name or trademark of the 

manufacturer and any other markings as are required by Code. 

3.5.3 Non pressure retaining parts welded to pressure retaining parts shall be marked in a 

manner that identifies the material to a specific ASME Section II material specification. 

3.6.0 RELEASE OF MATERIAL FOR FABRICATION 

3.6.1 The Certified Drawing contains Code designated materials required to construct the 

assembly. Prior to fabrication, the materials are compared to the Requisition to verify 

their acceptability for intended use. The Quality Control Manager shall indicate those 

materials released for fabrication by initialing on the shop copy of the Requisition.



3.7.0 FIELD MATERIAL CONTROL 

3.7.1 All materials are procured, inspected, and identified at the shop location in accordance 

with this section as Code items, and marked for the job. The accepted material will 

then be shipped to the field site with all appropriate documentation. The material will 

then be inspected at the field site for any damage that may have occurred during 

shipment and for maintenance of identification. 

3.7.2 The Field Superintendent is responsible for the storage, handling and the release of this 

material at the job site.



4.1.0 GENERAL 

SECTION 4 

EXAMINATION, INSPECTION, AND TESTING 

4.1.1 This section describes the Quality Controls exercised during fabrication operations. 

Provisions are included so that the Authorized Inspector and Quality Control can 

determine at what operations, Inspection Points are to be performed. 

4.2.0 TRAVELERS, CERTIFIED DRAWINGS, AND INSPECTION POINTS 

4.2.1 The IPI Traveler outlines the operations, inspections, tests and Nondestructive 

Examinations that are to be performed and provides for documentation and sign-offs for 

Quality Control Personnel and the Authorized Inspector. The Certified Drawing 

contains all essential information necessary to fabricate Code items as well as that 

information needed for examination, inspection, and testing. 

4.2.2 Review of the IPI Traveler, Certified Drawings, and calculations by the Authorized 

Inspector prior to fabrication, with the Quality Control Manager, serves as the 

opportunity to establish Inspection Points. These will be documented by initial and date 

on the IPI Traveler that accompanies the drawing through all phases of fabrication. 

4.3.0 RELEASE OF MATERIAL FOR FABRICATION 

4.3.1 Work shall begin on Code fabrication when the Quality Control Manager has given 

release of materials to the Shop/Field Superintendent by indicating such on the 

Requisition and the Fabrication Engineer has forwarded to the field/shop a Job Order 

Package. The Job Order Package includes but is not limited to a Certified Drawing, a 

copy of the Requisition, a description of the Code Item on the Job Release Memo 

(Exhibit F), and the IPI Traveler. 

4.4.0 AUTHORIZED INSPECTOR NOTIFICATION 

4.4.1 It shall be the responsibility of the Quality Control Manager to notify the Authorized 

Inspector of any pending inspection points that will require his inspection.



4.5.0 IN PROCESS INSPECTIONS 

4.5.1 It shall be the responsibility of the Quality Control Manager to question and "HOLD" 

any Code fabrication considered nonconforming with ASME Code. See Section 5, 

Control of Nonconformities. 

4.5.2 The Quality Control Manager shall assist in the layout of Code materials to be cut, 

sheared, or burned into two or more parts. He shall verify the transfer of material 

identifications to all parts prior to the cutting operation. The Quality Control Inspector 

shall be responsible for recording the Heat Numbers or alpha-numeric code on the 

Traveler or Certified Drawing at time of fit-up. He shall also make dimensional checks 

to assure proper location of materials to be joined. 

4.5.3 The Quality Control Inspector shall be responsible for making inspections of Code 

fabrication. He shall check fit-up and tack welding for compliance with the Code. No 

welding, except tack welding used for fit-up, shall be permitted until the QC Inspector 

releases the Code work for welding. The Quality Control Inspector shall document his 

inspection and release for welding by initialing and dating the IPI Traveler. This form 

will be available to the Authorized Inspector for his initials and date at time of 

inspection. 

4.5.4 Upon release for welding, the welding will be done in accordance with Weld Procedure 

Specifications listed on the Certified Drawing. Placement of WPS numbers on the 

Certified Drawing shall be the responsibility of the Fabrication Engineer. Welding 

Procedure Specifications shall be located in work areas for ready reference by all who 

need them. The Quality Control Manager shall randomly monitor the welding to assure 

it is performed in accordance with proper procedures by qualified personnel in 

accordance with the ASME Code. 

4.5.5 Nondestructive Examinations as required by the Code and delineated on the Certified 

Drawing by the Fabrication Engineer, shall be performed and accepted prior to the 

performance of final inspection and hydrostatic testing. The Quality Control Manager 

shall be responsible for the review of resulting NDE Reports for Code compliance. He 

shall document his review by initialing and dating the IPI Traveler.



4.6.0 FINAL INSPECTION 

4.6.1 Upon completion of welding, and all required NDE, the Superintendent will advise the 

Quality Control Manager and a final inspection shall be made by the QC Manager. As 

a minimum, the QC Manager shall perform a inspection of all welds and materials, 

check dimensions, and verify correctness of the nameplate data. He shall document his 

inspections by initialing and dating the IPI Traveler. This will release the work for 

hydrostatic testing. 

4.7.0 HYDROSTATIC TESTING 

4.7.1 After Code work has been completed it shall be subjected to a pressure test (see IPI-ES- 

10 for vessels and IPI-ES-22 for boilers), using water at ambient temperature, but at 

least 30 degrees F above the minimum design metal temperature for pressure vessels 

and 70 degrees F minimum for boilers. The Shop Superintendent will be responsible for 

tests performed in the shop, while the Field Superintendent will be responsible for those 

performed in the field. The test pressure shall be gradually raised to that specified on 

the Certified Drawing. The pressure shall be under proper control at all times so that 

the required test pressure is attained, but not overly exceeded. The pressure shall be 

held for at least 10 minutes at which time it may be reduced for inspection. The metal 

temperature shall not exceed 120 degrees F during the examination. 

4.7.2 The hydrostatic test will be witnessed and accepted by the Quality Control Manager 

and the Authorized Inspector. Verification that the test has been completed and 

accepted shall be made by initialing and dating the IPI Traveler. 

4.7.3 The calibrated hydrostatic test gages should have dials graduated over a range of about 

2 times the maximum test pressure, but in no case less than 1 and a half times nor more 

than 4 times that pressure. The spacing between graduations shall be such that the 

inspector and the operator controlling the test shall be able to determine when the 

required test pressure has been applied. 

4.8.0 PNEUMATIC TESTING 

4.8.1 In the event of Pneumatic Testing of pressure vessel, see IPI procedure IPI-ES-21, or 

IPI-ES-17 for B31.3.



4.9.0 WELDED REPAIRS 

4.9.1 Welded repairs to pressure retaining parts or materials are considered to be 

nonconformities, as described in Section 5 of the Manual. 

4.10.0 MANUFACTURER'S DATA REPORTS AND STAMPING 


a completed Manufacturers' Data Report signed by the Quality Control Manager. Any 



The A.I. will witness (Section I) the application of the Code Symbol Stamp. 

4.10.2 The Code Symbol Stamp will be kept by the QC Manager when not in use. When the 

Code Symbol Stamp is required in the shop or at a field site the QC Manager will issue 

it to the Shop/Field Superintendent or the QC Inspector will obtain the Code Symbol 

Stamp from the QC Manager. After usage the Code Symbol Stamp will be returned to 

the QC Manager. 

4.10.3 The Quality Control Manager is responsible for preparation, correctness, and 

certification of the Manufacturers' Data Report prior to presentation to the Authorized 

Inspector for this signature. The QC Manager is also responsible for checking the 

correctness of nameplate data or stamping on the vessel. 

4.11.0 DISTRIBUTION AND RETENTION OF MANUFACTURER'S DATA REPORTS 

4.11.1 The distribution of Manufacturers' Data Reports to the user or designated agent and 

Authorized Inspector upon request is the responsibility of the Quality Control Manager. 

4.11.2 Boilers and pressure vessels fabricated to the ASME Code may be registered with the 

National Board of Boiler and Pressure Vessel Inspectors. National Board numbers shall 

be controlled and issued in sequence, without skips or gaps of unused numbers or 

duplication, by the Quality Control Manager following the final pressure test. He shall 

maintain a record showing date issued, date mailed to National Board, and type of 

equipment manufactured, serial number and National Board Number.



The Quality Control Manager shall submit to the National Board the original copy of all 

Manufacturers' Data Reports required for Code stamped boilers and pressure vessels 

within 60 days of certification. 

4.12.0 FIELD SITE PROGRAM 

4.12.1 It shall be the responsibility of the Quality Control Manager to assure compliance with 

this Quality Control Manual for work performed at the field job site. 

4.12.2 All drawings, design calculations, and specifications are made available to the 

Authorized Inspector by the QC Manager, prior to the start of field work so that the A.I 

may designate on the IPI Traveler his required Inspection Points. The QC Manager 

shall notify the A.I. when any Inspection Points are ready for his inspection. 

4.12.3 The QC Manager shall, upon request, arrange for the A.I. to have access to those places 

where work under his jurisdiction is being performed. 

4.12.4 The QC Field Inspector is responsible to the Quality Control Manager for 

implementation and operation of the Quality Control System in the field. 

4.12.5 All welding performed in the field shall conform to the requirement of ASME Section 

IX with additional requirements of the applicable Code section. Reference Section 6 of 

this Manual. 

4.12.6 The Fabrication Engineer shall be responsible for determining the Nondestructive 

Examination required by the applicable Code Sections. These NDE requirements will 

be provided on the Certified Drawing. NDE will be accomplished as described in 

Section 7 of this Manual. 

4.12.7 The Field Superintendent will be responsible for conducting the final pressure test. 

Paragraphs 4.7.0 and 4.8.0 of this Manual delineate the procedure for performing final 

pressure tests. 

4.12.8 Nonconformities such as repairs to pressure retaining parts or materials will be referred 

to the Authorized Inspector prior to performing corrective action as described in 

Section 5 of this manual.



5.1.0 GENERAL 

SECTION 5 

CORRECTION OF NONCONFORMITIES 

5.1.1 Industrial Piping, Inc. maintains a system by which nonconforming items are identified, 

tagged, dispositioned, and corrective action taken in order to assure that nonconforming 

items are not inadvertently used in fabrication or shipped. 

5.2.0 DEFINITION 

5.2.1 A nonconformity is any condition which does not comply with the applicable rules of 

the ASME Code, Jurisdiction, NBIC or this QC Manual. 

5.2.2 Weld repairs to production welds (not including repairs to base material) are not 

covered by Nonconformance Reports. These shall be repaired using a Qualified WPS 

and a Qualified Welder and re-examined in accordance with the same method used to 

find the discontinuity. 

5.3.0 AFFECTED HARDWARE TREATMENT 

5.3.1 If a nonconformity is identified on an item prior to use (i.e. at receiving), the item shall 

be identified and not released for fabrication. 

5.3.2 If a nonconformity is identified on the item during the course of fabrication, activities 

which affect the resolution shall be stopped and not resumed until the resolution of the 

nonconformity has been completed. Activities which do not affect the resolution of the 

nonconformity may continue. The QC Manager shall be responsible for determining 

which activities may proceed with the AI's concurrence. 

5.3.3 A nonconforming item may be moved to different locations to facilitate storage and 

inspection, or it may be stored in place. Nonconformities will be clearly identified. 

5.4.0 PROCEDURE 

5.4.1 A Nonconformance Report (NCR - Exhibit G), and a Hold Tag (Exhibit H) or Hold 

marking, shall be utilized for all nonconformities. The NCR will be filled out by the 

Quality Control Manager stating the nonconforming characteristics of the item, and 

other appropriate information required to identify the item. If the nonconformity is 

found prior to use, a copy of the NCR shall be attached to the Requisition. If found 

during the course of fabrication a copy of the NCR shall be attached to the IPI Traveler. 

The Hold Tag shall be attached to the



nonconforming hardware. This will be the responsibility of the QC Manager. 

5.4.2 Responsibility for disposition of nonconformities shall lie with the Quality Control 

Manager or Fabrication Engineer. The item may be reworked, repaired, scrapped, 

returned to the vendor, or used as is (may only be used when those items meeting all 

Code requirements and then only with design justification). The Authorized Inspector 

shall be consulted on disposition of in-process nonconformities involving weld repairs. 

The Quality Control Manager is responsible for assigning the Welding Procedure 

Specification for welded repairs. The disposition shall be documented on the 

Nonconformance Report. 

5.4.3 The Nonconformance Report shall be submitted to the Authorized Inspector for his 

review of the disposition and assignment of Inspection Points prior to commencement 

of corrective action. These will be documented on the Nonconformance Report. 

5.4.4 Corrective action shall be performed in accordance with the assigned disposition unless 

it is discovered that the disposition is not adequate to properly resolve the 

nonconformity, in which case the Quality Control Manager shall provide a revised 

disposition. The Quality Control Manager shall be responsible for coordination of the 

Authorized Inspector's Inspection Points with performance of the corrective action. 

5.4.5 Upon completion of corrective action, the Quality Control Manager shall perform a 

final inspection. If final A.I. concurrence is required, the Quality Control Manager 

shall obtain this prior to releasing the nonconformity. Acceptance of this corrective 

action shall be documented by the Quality Control Manager and the Authorized 

Inspector on the Nonconformance Report. The Hold Tag or marking shall then be 

removed from the hardware by the Quality Control Manager and the item returned to 

fabrication. 

5.5.0 RECORDS 

5.5.1 A Nonconformity Log (Exhibit I) shall be maintained by the Quality Control Manager. 

Copies of the Nonconformance Reports shall be maintained by the Quality Control 

Manager. The Nonconformity Log shall be available to the A.I.



6.1.0 GENERAL 

SECTION 6 

WELDING CONTROL 

6.1.1 This section outlines the basic elements of welding control within Industrial Piping, 

Inc. 

6.1.2 All welding performed on Code fabrication shall conform to the requirements of ASME 

Section IX with additional requirements of the applicable Section to which work is 

performed. 

6.2.0 WELDING PROCEDURE SPECIFICATIONS 

6.2.1 The Quality Control Manager has the responsibility for preparing the Welding 

Procedure Specifications. The essential, supplemental (if required), and non-essential 

variables are documented. A Welding Procedure Specification (WPS) will be revised 

whenever there is a change in any nonessential variable. The revision will be noted on 

the WPS and dated. A change in any essential variable or supplementary essential 

variable shall require requalification to be by another Procedure Qualification Record 

(PQR). 

6.2.2 The Quality Control Manager is responsible for conducting the qualification tests for 

the WPS and documenting the Procedure Qualification Record. Preparation and testing 

of the required specimens is performed to Section IX requirements by a testing 

laboratory. The Laboratory Test Results are reviewed by the Quality Control Manager, 

and if acceptable, he records the test results on the Procedure Qualification Record 

which he will date and certify. The Laboratory Test Reports will be maintained on file 

by the Quality Control Manager. 

6.2.3 The Fabrication Engineer is responsible for assigning the WPS for welding of new 

fabrication to the ASME Code and for repair or alteration welding to the National 

Board Inspection Code. The applicable WPS number shall be included on the Certified 

Drawing. In the case of dispositioning of in-process nonconformities involving welded 

repairs, the Quality Control Manager shall be responsible for assigning WPS's on the 

Nonconformance Report. (See 4.9.1 and 5.4.2).



6.3.0 WELDER/WELDING OPERATOR QUALIFICATIONS 

6.3.1 The Quality Control Manager is responsible for the qualification of all 

welders and welding operators (welders) to an applicable Welding Procedure 

Specification. Qualification may be by radiography if permitted by the Code or by 

guided bend tests performed in-house. The Quality Control Manager shall maintain on 

file and certify the welder/welding operator performance qualifications (WPQ). 

6.3.2 Requalification of a welder/welding operator is required when he has not welded with a 

process during a period of 6 months or more. Requalification is required when there is 

reason to question a welder/welding operator's ability to make a sound weld that meets 

the Welding Procedure Specification to which he is certified, or when welder essential 

variables change. 

6.3.3 A record of welders'/welding operators' qualifications in various processes is 

maintained by the Shop/Field Quality Control Inspector. The Welders continuity 

record shall be updated quarterly by the Shop/Field Quality Control Inspector. The 

ASME Welders Qualifications (Exhibit J) shall be updated monthly by the Shop/Field 

Quality Control Inspector. Updated copies of the log of qualified welders will be 

returned to the Shop/Field Superintendent who is responsible for assignment of 

welders/welding operators to a particular job. 

6.3.4 A copy of all applicable Welding Procedure Specifications is maintained on file in the 

shop and at the field job site. These are available for use by all who require them. 

6.3.5 The Welding Procedure Specifications, Procedure Qualification Records, and Records 

of Welder/Welding Operator Performance Qualification are made available to the 

Authorized Inspector for his review. The Authorized Inspector shall have the right to 

require re-qualifications of the Welder and/or WPS for cause. 

6.4.0 WELD FILLER MATERIAL CONTROL 

6.4.1 The Quality Control Manager is responsible for instructing the Purchasing Agents 

regarding the welding filler materials to be purchased. All Code weld filler materials 

shall be ordered to the proper SFA/AWS specification number.



6.4.2 Weld filler material and flux is inspected by the Quality Control Manager to ensure that 

it is properly identified with Heat Code information, meets the requirements of the 

Purchase Order and applicable material specifications, and is free from damage and 

defects. Materials which do not comply with the Purchase Order or material 

specifications, are not properly identified, or are damaged or defective are considered 

nonconformities and shall be returned to the vendor or processed as described in 

Section 5, Control of Nonconformities. 

6.4.3 All received and accepted weld filler materials and flux are placed in a designated 

storage area under the control of the Shop/Field Superintendent. All flux coated 

electrodes requiring temperature control by the manufacturer or Code are placed in 

holding ovens after opening of their containers. The electrodes are segregated in the 

ovens relative to their size and classification. Welding electrodes of different 

classifications or sizes are not intermingled in the oven. The ovens are maintained at 

temperatures in accordance with the manufacturer’s requirements or ASME Section II 

Part C. 

6.4.4 The Shop/Field Superintendent is responsible for the issuance of low hydrogen filler 

materials. These electrodes are issued for the duration of the welder’s shift and are to be 

stored in portable rod ovens issued with the low Hydrogen electrodes. 

6.4.5 The welder/welding operator shall return unused materials at the end of his shift. All 

material is examined for identification and condition, and low Hydrogen electrodes 

placed in the oven. Materials that are damaged or otherwise unfit for use are not used 

for Code work. 

6.5.0 WELDER/WELDING OPERATOR IDENTIFICATION SYMBOL 

6.5.1 Qualified welders/welding operators shall be assigned an identification number or 

symbol by the Quality Control Manager. The welder/welding operator shall record his 

identification symbol adjacent to all welds made by him, at intervals not exceeding 3 

feet. For ferrous materials ¼” and over in thickness and nonferrous materials ½” and 

over in thickness, he shall utilize a low stress stencil or vibroetcher issued by the 

Quality Control Manager. For identifying welds on materials in which the thickness is 

less than stated above the welder/welding operator shall mark his identifying symbol by 

vibroetching or another marking method acceptable to the Authorized Inspector.



6.5.2 In lieu of stamping, stenciling, or vibroetching a welder/welding operator's identifying 

symbol onto the hardware, Industrial Piping, Inc. may elect to maintain a record of 

personnel utilized on each joint. This record shall be made available to and found 

acceptable by the Authorized Inspector. 

6.5.3 When a welder/welding operator leaves the employment of Industrial Piping, 

Inc. the identifying number assigned to him should not be reissued for 3 months. 

6.6.0 TACKWELDS 

6.6.1 Tackwelds 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 maybe satisfactorily incorporated into 

the final weld. 

6.6.2 Tackwelds, whether removed or left in place, shall be made using a buttweld procedure 

qualified in accordance with Section IX. Tackwelds to be left in place shall be made by 

welders qualified in accordance with an IPI Welding Procedure. They shall be 

examined visually for defects by the QC Inspector, and if found to be defective shall be 

removed. 

6.7.0 ASSIGNMENT OF WELDERS/WELDER OPERATORS FOR WELDING 

6.7.1 The Shop Superintendent for shop work and the Field Superintendent for fieldwork 

shall be responsible for instructing, supervising, and assigning welders and welding 

operators for Code Welding. It is their responsibility to assure that the welders/welding 

operators are properly qualified and skilled to perform welding to which they are 

assigned.



7.1.0 GENERAL 

SECTION 7 

NONDESTRUCTIVE EXAMINATION 

7.1.1 The purpose of this section is to describe the methods and procedures used by Industrial 

Piping, Inc. to accomplish Nondestructive Testing and to assure these tests are 

performed by qualified personnel. 

7.1.2 The Fabrication Engineer shall be responsible for determining the NDE required by the 

applicable Code Sections, which shall be performed by qualified personnel. These 

requirements will be provided on the Certified Drawing. 

7.1.3 Each NDE Examiner shall have visual acuity to enable him/her to read Jaeger J-2 

letters at not less than 12". Eye exam to be administered annually. 

7.1.4 Radiography, UT and Magnetic Particle will be conducted by a qualified subcontractor. 

Liquid Penetrant, and Visual Examinations shall be performed by a qualified Industrial 

Piping, Inc. employee or by a qualified subcontractor who will be certified by IPI. 

7.2.0 SUBCONTRACTED NDE 

7.2.1 Industrial Piping, Inc.'s subcontracted Level III Examiners are appointed in writing by 

the President after review and acceptance of their written procedures, practices, 

calibration and personnel qualification and certification records by Quality Control 

Manager. It shall be the responsibility of the Level III Examiner to approve all 

subcontracted procedures and requalification of procedures when ever the essential 

variables change. Personnel qualification records for examiners used shall be retained 

on file by the Quality Control Manager. 

7.2.2 Radiography shall be performed in accordance with a standard written procedure which 

meets the requirements of ASME Section V and the other applicable Sections of the 

Code. All phases of film exposure, development, and interpretation shall come under 

the supervision of a Level II or Level III Examiner qualified per employers' written 

practice under the guidelines of SNT-TC-1A latest code accepted edition. The results 

will be recorded on a Radiograph Inspection Report. Verification that tests have been 

completed and accepted is also recorded on the IPI Traveler.



7.3.0 LIQUID PENETRANT, MAGNETIC PARTICLE, AND VISUAL EXAMINATIONS 

7.3.1 Examiners in Liquid Penetrant, and Visual Examinations shall be certified as competent 

in performing examinations and interpreting results by IPI. Qualification shall be 

accomplished as described in IPI's written practice, which meets the requirements of the 

ASME Code. This will be the responsibility of the QC Manager. 

7.3.2 Liquid Penetrant, and Visual Exams, when required, shall be performed in accordance 

with a standard written procedure which meets the requirements of ASME Section V 

and the other applicable Sections of the Code. Verification that the tests have been 

completed and accepted is made on the IPI Traveler. This will be the responsibility of 

the QC Manager. 

7.4.0 AUTHORIZED INSPECTORS' INVOLVEMENT 

7.4.1 Results of all Nondestructive Examinations (including film and interpretations for 

Radiography) shall be available to the Authorized Inspector for his review and 

concurrence. 

7.4.2 The Authorized Inspector has the prerogative of requiring requalification of NDE 

procedures and examiners if he has reason to doubt effectiveness of results. 

7.4.3 Nondestructive Examination procedures shall be demonstrated capable of producing 

meaningful results to the satisfaction of the Authorized Inspector, and all NDE 

procedures shall be certified by Quality Control Manager or Level III Examiner.



8.1.0 GENERAL 

SECTION 8 

HEAT TREATMENT 

(PWHT) 

8.1.1 The heat treatment as described in this section shall be adhered to for all shop and field 

Code work including all Code repair work. 

8.2.0 PROCEDURE 

8.2.1 Heat treatment, when required by the Code will be done in accordance with a written 

procedure. This written procedure will be approved by the Fabrication Engineer with 

the acceptance of the Quality Control Manager and shall be in compliance with the 

Code. As a minimum, this procedure will specify heating and cooling rates, time and 

temperature, thermocouple method of attachment, location, record, and equipment 

calibration requirements. 

8.2.2 The QC Mgr will oversee all PWHT operations both internally and externally. This 

includes but is not limited to the equipment and controls, procedures and calibration 

records. 

8.2.3 Records of heat treatment such as strip or dial charts shall reference the Industrial 

Piping, Inc. Purchase Order, and job order numbers. The job record and/or charts shall 

be signed and dated by the operator or other supervision personnel. The 

time/temperature charts and any other applicable records will be reviewed, approved 

and retained by the Quality Control Manager and made available to the Authorized 

Inspector for his review. 

8.2.4 A metal identification tag will be attached to the item to be heat treated to identify 

materials and parts sent to the subcontractor's facilities. The Quality Control Manager 

shall perform a receiving inspection of the heat treated item upon receipt of the item 

from the subcontractor. 

8.2.5 Any tests required by an applicable Code Section, shall be performed either by 

Industrial Piping, Inc., or the subcontractor. Where performed by the subcontractor, the 

requirements shall be specified in the written procedure.



9.1.0 GENERAL 

SECTION 9 

CALIBRATION 

9.1.1 This section establishes the measures used to assure that gages and instruments used for 

quality acceptance inspections are properly controlled, calibrated and adjusted (see IPI 

procedure IPI-ES-14). 

9.1.2 The Quality Control Manager is responsible for the control of the calibration of 

measuring and test equipment. 

9.2.0 PRESSURE GAGES 

9.2.1 Each Pressure Gage shall be identified with a unique serial number. All records and 

certifications shall reference this serial number. 

9.2.2 Master Pressure Gages shall be calibrated against a standard dead-weight tester or 

master gage, every 12 months or whenever an error is suspected in accordance with a 

written procedure maintained by the Quality Control Manager. Industrial Piping, Inc. 

contracts the services of an independent instrument company for calibration of master 

gages. The calibration results shall be reviewed and accepted prior to being listed in 

the Calibration Log for Pressure Gages (Exhibit L) by the Quality Control Manager. 

Pressure gauges shall be checked against the master gauge prior to each use. 

9.3.0 MEASURING INSTRUMENT 

9.3.1 Each Measuring Instrument (micrometer, dial caliper and ultrasonic thickness tester) 

shall be marked with a unique serial number. All records and certifications shall 

reference this serial number. 

9.3.2 Before use, the above mentioned measuring instruments shall be checked with standard 

gage blocks and pins. Gage blocks and pins shall be calibrated (see IPI Procedure IPI- 

ES-14). 

9.3.3 A defective Measuring Instrument or one which cannot be properly calibrated shall be 

removed from usage. If not repairable, the serial number shall not be reused on another 

Measuring Instrument. 

9.3.4 Items inspected with defective measuring instruments will be handled by Section 5.



10.1.0 GENERAL 

SECTION 10 

RECORDS RETENTION 

10.1.1 Records shall be maintained to demonstrate conformance to specified requirements and 

effective implementation of the ASME Code and this manual. 

10.2.0 RECORDS DISTRIBUTION AND RETENTION 

10.2.1 Industrial Piping, Inc. will maintain manufacturers’ data reports and partial data reports 

on file for 5 years. RT film for Section I work shall be maintained on file for 5 years. 

This will be the responsibility of the QC Manager. 


a completed Manufacturers' Data Report certified by the Quality Control Manager. Any 



10.2.3 The Manufacturer's Data Reports for the boiler or pressure vessel shall be distributed to: 

the user or designated agent, the Authorized Inspector upon request, Jurisdictional 

Authorities, and the original to the National Board. Distribution is the responsibility of 

the Quality Control Manager. 

The Manufacturer or Assembler shall maintain the documents outlined below for a 

period of at least 3 years; 

(1) Manufacturer’s Partial Data Reports 

(2) Certified drawings 

(3) Design calculations 

(4) Material Test Reports and/or material certifications 

(5) Welding Procedure Specifications and Procedure Qualification Records 

(6) Welders Qualification Records 

(7) RT and UT reports 

(8) IPI Travelers 

(9) Postweld heat treatment records 

(10) Nonconformances and dispositions 

(11) Hydrostatic test records




SECTION 11 

REPAIRS AND ALTERATIONS 

11.1.1 Shop or field repairs and alterations to pressure retaining items (PRI) are made in 

accordance with the applicable requirements of the National Board Inspection Code 

(NBIC), ASME Code, Jurisdictional/Requirements and this Quality Control Manual. 

11.2.0 DEFINITIONS 

11.2.1 Repair - defined as the work necessary to restore a pressure retaining item (PRI) to a 

safe and satisfactory operating condition. 

11.2.1(a) Routing Repairs – Routine Repairs are limited to those listed in NBIC. Routine 

Repairs shall be controlled as required in this Quality Manual, except the CI may waive 

in process inspections and stamping. Routine Repairs shall be documented on the R-1 

form with “Routine Repair” in the Remarks section. 

11.2.2 Alteration - any change in the item described on the original Manufacturer’s Data 

Report that affects the pressure containing capability of the PRI. Nonphysical changes 

such as an increase in the maximum allowable working pressure (internal or external) 

or design temperature of a boiler or pressure vessel shall be considered an alteration. A 

change in minimum temperature shall also be considered an alteration. 

11.2.3 National Board Commissioned Inspector (CI) - An individual who holds a valid and 

current National Board Commission. The AI can perform any functions that the CI can 

perform. 

11.2.4 Jurisdiction - A Governmental entity which administers and enforces one or more 

sections of the ASME Code. 

11.2.5 Pressure Retaining Item (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.



11.3.0 RESPONSIBILITY 

11.3.1 The Quality Control Manager is responsible for compliance with the Quality 

Control Manual for shop and field repairs and alterations to Code items. 

11.4.0 PROCEDURES 

11.4.1 Inspection and certification of repairs and alterations shall be made by a 

Commissioned Inspector (CI). 

11.4.2 The Quality Control Manager, prior to the start of work, provides the CI with 

drawings, calculations, procedures, IPI Travelers, copy of the original 

Manufacturer's Data Report for the item, and any other documents necessary for the 

CI to accept the method of repair or alteration, and to designate his required 

inspection points. 

11.4.3 The Quality Control Manager, if requested by the CI, arranges for his access to 

make such inspections of the PRI he deems necessary in order to accept the method 

of repair or alteration. 

11.4.4 The Quality Control Manager or Field Quality Control Inspector keeps the CI 

informed of the progress and completion of the work so he may make his 

designated inspections, and accept the repair or alteration after his final inspection 

of the completed work. 

11.4.5 All NDE and PWHT required by the Code for the original construction of the PRI 

are required for the repair or alteration, except when not possible or practical, 

alternative methods may be used provided concurrence with the CI and Jurisdiction 

(if required) is obtained. The final pressure test shall be as required in Part 3 of the 

NBIC for repairs and for alterations. 

11.5.0 RECORDS 

11.5.1 The repair or alteration is to be documented on the current R-1 Report of Repair or 

R-2 Report of Alteration as applicable. 

The Form R-4 Report Supplementary Sheet shall be used for additional information 

not included on the forms R-1 or R-2.



11.5.2 When the work is complete, the applicable NBIC Form is prepared and certified in 

ink by the Quality Control Manager, and distributed as described in 11.7.0 below. 

11.5.3 The final records, together with the completed NBIC Forms and attachments are 

presented to the CI for his review. When he has satisfied himself that all NBIC, 

Jurisdiction, Code and Manual requirements have been met, he may authorize 

application of the "R" Symbol to the appropriate nameplate stamping and then 

certify the applicable NBIC Forms. All records referenced in this section are 

available for review by the CI. 

11.6.0 STAMPING 

11.6.1 If, during the repair or alteration of a pressure retaining item, it is necessary to 

remove the original Manufacturer's ASME Code Stamping or nameplate; the CI 

will, subject to the approval of the Jurisdiction: 

(a) Witness the making of a facsimile or rubbing of the old and new stamping; 

(b) Witness obliteration or removal of the old stamping, and transfer of the 

stamping to the new part or location on the item, less the original Code 

Symbol. The Code Symbol is NOT restamped. 

11.6.2 When the stamping is on a nameplate, the CI witnesses the transfer of the 

nameplate to its new location. 

11.6.3 The stamping or attachment of a National Board nameplate (Exhibit K) shall be 

adjacent to the original Manufacturer's stamping or nameplate. The stamping or 

nameplate shall comply with the NBIC. In the event a PRI is repaired repetitively 

by IPI, the original repair tag can be stamped with the new date of repair in lieu of 

adding an additional tag.



11.6.4 The Quality Control Manager retains custody and control of the "R" stamp. This 

symbol stamp is the property of the National Board. 

11.7.0 DISTRIBUTION OF NBIC FORMS 

11.7.1 One copy of Form R-1, Report of Repair, with attachments, is filed with the 

owner/user and when required by the AIA responsible for inservice inspection and 

jurisdiction at the location of installation and CI. 

11.7.2 One copy of Form R-2, Report of Alteration, with attachments, is provided to the 

CI, the owner/user, the Jurisdiction and AIA responsible for inservice inspection 

when required. A copy is retained in the job file. 

11.7.3 R-1 and R-2 for non registered PRI may be registered with The National Board. R- 

2 for registered PRI shall be registered with the National Board. 

11.7.4 The QC Manager shall maintain a single, sequential log of all Forms R-1 and R-2 

registered with the National Board. Those reports not registered with the National 

Board shall be retained for a minimum of 5 years. 

11.7.5 The CI’s authorization to perform a repair or alteration shall be obtained and 

documented on the IPI Traveler, prior to initiation of a repair or alteration to a PRI. 

The CI making the acceptance inspection should be same CI who authorized the 

repair or alteration, but, in all cases, shall be an employee of the same organization 

as that of the Inspector that authorized the repair or alteration.




SECTION 12 

THE AUTHORIZED INSPECTOR 

12.1.1 The purpose of this section is to define Industrial Piping, Inc.'s involvement with 

the Authorized Inspector. 

12.2.0 DEFINITION 

12.2.1 Authorized Inspector - An individual, designated as such by an ASME and National 

Board accredited Authorized Inspection Agency, who holds a valid Certificate of 

Competency and National Board Commission with an "A" endorsement, and is 

employed by the Authorized Inspection Agency with whom IPI has a valid 

inspection agreement. Industrial Piping, Inc. does not use a secondary ASME 

Accredited Authorized Inspection Agency (A.I.A.). If in the future a secondary AIA 

is required this section shall be revised. 

12.3.0 INVOLVEMENT WITH THE AUTHORIZED INSPECTOR 

12.3.1 The Quality Control Manager will be the primary point of contact for the 

Authorized Inspector. He is responsible for assuring notification of the Authorized 

Inspector in all cases where his direct involvement has been specified. 

12.3.2 The Authorized Inspector shall be granted free access to those places where work 

under his jurisdiction is being performed. The Authorized Inspector shall have free 

access to documents, records, drawings, procedures, instructions, Purchase Orders, 

in all plants that are concerned with the supply or manufacture of materials for the 

vessel, or other documents which he may request to assist his determination of 

product compliance to Code requirements. 

12.3.3 A current controlled copy of the Quality Control Manual will be made available to 

the Authorized Inspector at the plant or in the field. 

12.3.4 The Authorized Inspector will have direct involvement with those materials, partial 

assemblies or assemblies found to deviate from the Code requirements for any 

reason. This involvement shall include notifying him of the nature of the deviation 

and notification of Industrial Piping, Inc.'s proposed disposition. This involvement 

shall be in the depth he may direct such as establishing Inspection Points, to assure 

him that the final disposition fulfills Code compliance.



12.3.5 The Authorized Inspector shall be consulted on repairs to any pressure retaining 

materials prior to the repairs being performed. 

12.3.6 Free access as described in Paragraph 12.3.2 shall so apply to the Authorized 

Inspector's Supervisor in order to perform periodic audits of Industrial Piping, Inc.'s 

system and performance of the Authorized Inspector as required.


Revision 0 

Industrial Piping, Inc. 

SECTION 13 

EXHIBITS - TABLE OF CONTENTS 

EXHIBIT TITLE REV. DATE 

A Master Issue Log - Controlled 0 9/5/08 

B IPI Traveler 0 9/5/08 

C Requisition 0 9/5/08 

D Purchase Order 0 9/5/08 

E Receiving Inspection Report 0 9/5/08 

F Job Release Memo 0 9/5/08 

G Nonconformance Report 0 9/5/08 

H Hold Tag 0 9/5/08 

I Nonconformity Log 0 9/5/08 

J ASME Welders Qualifications 0 9/5/08 

K National Board Nameplate Facsimile 0 9/5/08 

L Calibration Log for Pressure Gages 0 9/5/08


Revision 0 

EXHIBIT A 

INDUSTRIAL PIPING, INC. 

MASTER ISSUE LOG 

"CONTROLLED" 

Serial No. Revision Assigned Date Issued


EXHIBIT B Revision 0 

IPI TRAVELER 

PRESSURE VESSEL CHECK LIST 

CUSTOMER CHEMICAL DESIGN, INC. JOB NO. W-2599C 

STAMP REQ U DWG. NO. D062599C 

NDE REQ 

RT 

EQUIP. REGENERATION HEATER CASE 

NO SEQUENCE WPS IPI DATE AI DATE 

01 DRAWINGS AND CALCULATIONS CHECKED 

02 MILL TEST REPORTS ON FILE 

03 MATERIAL MARKINGS TRANSFERRED 

04 MATERIAL RECEIPT INSPECTION 

05 

06 LAYOUT NOZZLE B ON BOTTOM HEAD 

07 FIT & TACK NOZZLE B IN BOTTOM HEAD 

08 WELD NOZZLE B IN BOTTOM HEAD 

09 

10 FIT & TACK GUSSET TO NOZZLE B & BOTTOM HEAD 

11 WELD GUSSET TO NOZZLE B & BOTTOM HEAD 

12 

13 LAYOUT NOZZLE A ON SHELL 

14 FIT & TACK NOZZLE A IN SHELL 

15 WELD NOZZLE A IN SHELL 

16 

17 FIT & TACK GUSSET TO NOZZLE A & SHELL 

18 WELD GUSSET TO NOZZLE A & SHELL 

19 

20 FIT & TACK TOP FLANGE TO SHELL 

21 WELD TOP FLANGE TO SHELL 

22 

23 LAYOUT LUGS & NAMEPLATE BRACKET ON SHELL 

24 FIT & TACK LUGS & NAMEPLATE BRACKET ON SHELL 

25 WELD LUGS & NAMEPLATE BRACKET ON SHELL 

26


EXHIBIT B Revision 0 

IPI TRAVELER 

PRESSURE VESSEL CHECK LIST 

27 WELDERS STAMP & QUALIFICATIONS 

28 

29 INTERNAL INSPECTION 

30 REVIEW RT 

31 DIMENSIONAL 

32 VISUAL & MATERIAL ID 

33 HYDROSTATIC TEST @ 488___ PSIG 

34 

35 CODE NAMEPLATE ATTACHED 

36 

37 QC DATA PACKAGE SIGN OFF 

38 

39 

40 

41 

42 

43 

44 

45 

46 

47 

IPI JOB NO___W-2599C_____________ 

NOTES: 1. AUTHORIZED INSPECTOR’S REQUIRED INSPECTION HOLD POINT INDICATED BY MARK BESIDE 

SEQUENCE DESCRIPTION. 

INSPECTION ESTABLISHED BY: ________________________________ DATE:_______________ 

2. QCM REVIEW OF HOLD POINTS WITH FABRICATION FOREMAN. 

PREPARED BY: _______ ___________________ DATE: _____________ 

Q.C. MANAGER


EXHIBIT C Revision 0 


EXHIBIT D Revision 0


EXHIBIT E Revision 0 

RECEIVING INSPECTION REPORT


EXHIBIT F Revision 0 

FABRICATION DIVISION 

2794 Old Richburg Road 

Richburg, SC 29729 

TELEPHONE 

704/588-1100 

FAX 800/789-3537 

Website: www.goipi.com 

JOB RELEASE MEMO 

JOB NO.: W-2631 C&D 

Customer: Wittemann Date: September 25, 2006 

Location: Taiwan Scope: (2) 12” Code Vessels 

Customer Contact: John Day Estimated Man-Hours: T & M 

Scope: 

Fabricate (2) pressure vessels per ASME Code Section VIII, Division I 2004 Edition A05 

Addenda. Fabricate per the attached drawings. 

Schedule Required: 

All fabrication to be complete no later than October 31, 2006. 

Materials: 

Material for the vessels has been ordered and the majority is here now. Use only materials which 

have been marked for use on this job. 

Quality Requirements: 

See drawings for paint and quality requirements. NO RT is required on vessel per UW-11. All 

material must have Mill Test Reports with matching Heat numbers. 

Direct questions to Travis Ramsey 

File No. W-2631


EXHIBIT H Revision 0 

HOLD TAG 

RED


EXHIBIT I Revision 0 

NONCONFORMITY LOG 

NCR 

NO 

DESCRIPTION 

DATE 

DISCOVERED 

DATE 

CLOSED


EXHIBIT J Revision 0 

Bold X – Qualfied by Testing. 

X indicates qualification by QW-423 QW-433 allowance 

E indicates continuity Expired.


EXHIBIT K Revision 0 

NATIONAL BOARD NAMEPLATE FACSIMILE


EXHIBIT L Revision 0 

Calibration Log for Pressure Gages 

SERIAL 

NUMBER 

DESCRIPTION 

RANGE 

DATE 

CALIBRATED 

CALIBRATED 

BY 

CALIBRATIO 

N 

DUE DATE

QUALITY CONTROL MANUAL - Industrial Piping, Inc.

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