Number: JVICQC-14.0 03/07/2016 Revision: 5 Page: Page 1 of 6 Approvals Author Director of Quality Assurance Name: Gary Corley Doyle Cassity Signature: Date: 03/07/2016 03/07/2016 Electronic versions of this procedure are considered the latest revision and a Controlled Copy when viewed from the JVIC Corporate site. When printed, this procedure is considered an uncontrolled copy unless signed by the Director of Quality Assurance or his Designee. Doyle Cassity Director of Quality Assurance TABLE OF CONTENTS 1.0 SCOPE/FIELD OF APPLICATION 2.0 REFERENCES 3.0 PURPOSE 4.0 RESPONSIBILITY 5.0 CODE PACKAGE 6.0 JOB PACKAGE 7.0 HYDRO GAUGES 8.0 FORMS 9.0 RECORD OF REVISION
Number: JVICQC-14.0 03/07/2016 Revision: 5 Page: Page 2 of 6 1.0 SCOPE/FIELD OF APPLICATION Unless the client has a specified requirement for quality assurance, and quality control documentation, gathering, recording and organization, the following instructions must be followed by all JV Industrial Companies, Ltd. projects. Regardless of size or duration, the following information must be submitted to the client and the JVIC Corporate Quality System Department, upon completion. 2.0 REFERENCES Procedure JVICQC-2.0 Field Document Control JVIC Quality Control Manual (Code Work) JVIC Quality Manual 3.0 PURPOSE To ensure all Quality documentation is gathered, recorded, and organized in a standardized format to be included in the permanent project file. 4.0 RESPONSIBILITY The following files must be assembled, maintained and updated throughout the duration of any project. If work is performed in different units, separate files must be kept for each unit. If a QC Inspector is onsite, he/she is responsible for insuring this is done. If there is no QC Inspector present, the person responsible for insuring this is done is per Section 1.5 in the JVIC Quality Manual. If there is no Site QC inspector the Project Manager or most senior JVIC employee is responsible for compiling the completed Project Quality System Package and forwarding it to the Area QC Manager 5.0 CODE PACKAGE Code packages will be set-up and maintained as per the JVIC Quality Control Manual and will be accessible to the client, Lead Inspector, Project Manager and/or Authorized Inspector as required.
Number: JVICQC-14.0 03/07/2016 Revision: 5 Page: Page 3 of 6 Completed packages must be submitted to the client and the Regional QC Manager. 6.0 JOB PACKAGE The following, as a minimum, is required for job packages: 6.1 Weld Procedure Specifications (WPS) and Procedure Qualification Records (PQR) should be kept together in a file. 6.2 Welder Performance Qualifications (WPQ) should be kept in a separate file. 6.3 Weld logs must be kept in the same file as the corresponding weld map file even if only one weld is made. Weld numbers shall not be duplicated even if there are several areas where welding is performed. Weld numbers should be consecutive for the entire project. 6.3.1 Weld Maps must be accompanied by a client P&ID or Isometric drawing and shall be kept in the same file as the corresponding weld log, even if only one weld is made. If no P&ID or Isometric drawing is available then a fabrication drawing or a hand sketch shall be used. The weld number and welder who made the weld shall be marked on the drawing or P&ID using a circle, square, etc. divided into two sections. The weld number shall be logged on the top half and the welders stencil in the bottom half. 6.4 Flange logs must be kept in the same file as the corresponding flange map file even if only one flange is assembled. Flange numbers shall not be duplicated even if there are several areas where mechanical joints are assembled. Flange numbers should be consecutive for the entire project. 6.4.1 Flange Maps must be accompanied by a client P&ID or Isometric drawing and kept in the same file as the corresponding flange log even if only one flange is assembled. If no P&ID or Isometric drawing is available then a fabrication drawing or a hand sketch shall be used. The flange number shall be marked on the drawing or P&ID using a circle, square, etc. The flange number shall be logged in the circle, square, etc. 6.4.2 Flange Map Log Wall Chart. Refer to JVICQC-21.0 JVIC Flange Management System procedure for procedures and instructions. 6.5 All Non Destructive Examination (NDE) reports (PT, RT, PMI, PWHT, etc.) shall be kept with the corresponding weld map and log and kept in each package. Note: For all code applications, follow the procedures found in the JVIC Quality Control
Number: JVICQC-14.0 03/07/2016 Revision: 5 Page: Page 4 of 6 Manual. 6.6 Material Test Reports (MTR) will be kept in a separate file and identified for traceability. Reference JVICQC-3.0 Customer Supplied Material and JVICQC-16.0 Material Receiving for procedures and instructions. Note: For all code applications, follow the procedures found in the JVIC Quality Control Manual. 6.7 Punch Lists (pre and post-hydro) will be kept in the appropriate test package. 6.8 Pressure Test forms and charts will be kept in the appropriate test package. 6.9 Completion/Closure forms will be kept in the appropriate test package. 6.10 All Flange Map Wall Charts will be kept with the corresponding flange map and log for the corresponding job package. 7.0 HYDRO GAUGES 6.10.1 The job documentation should be as follows: Book 1 - WPS/PQR Book 2 WPQ Book 3 MTR Book 4 Weld Map/Weld Log with NDE and MTR Reports Book 5 Flange Map/Log with corresponding Pressure test and Closure forms Test Packages 7.1 Pressure test gauges can be checked out by contacting the Area Quality System Manager, or his/her designee, and requesting the gauges needed for the applications. To calculate the gauges needed for your project, find the required hydrotest pressure and ensure the gauge requested has a pressure rating of 1 ½ to 4 times the test pressure. Example: Test Pressure=322 psig Gauges that could be used=600 psig or 1000 psig
Number: JVICQC-14.0 03/07/2016 Revision: 5 Page: Page 5 of 6 7.2 Attention to detail will eliminate the need for having too many gauges onsite. Calibration certification papers can be obtained from the Director of Quality Assurance or his/her designee. 7.3 When the gauges are onsite, one method to prevent gauge loss is to have the gauges checked out through the tool room. Lead inspectors can keep possession of the gauges and monitor their use, but the tool room method has a better gauge return rate. 7.4 Gauges must be installed downstream from all block valves to prevent over pressuring the gauge by dead heading. Ensure gauges are not screwed-in by the housing, turn with a wrench. To avoid damaging the gauge, remove the gauge when the hydrotest is complete before disassembling the tree, and return the gauge to the tool trailer. Any gauges lost or badly damaged will be charged to the job. Please return all gauges to the Regional QC Manager ASAP. 7.5 If a gauge runs out of certification during a project, a notice (verbal or written) will be sent from the Area QC Manager or his/her designee, to the Site QC Lead Inspector requesting the gauge be returned for re-calibration. The gauge should then be tagged and removed from service. When possible return the gauges to the Area QC office. 8.0 FORMS QC Forms can be found on the JVIC Internet Site in the file named 2.7 JVICQC Forms. http://intranet.jvic.com/groups/qaqc/sitepages/home.aspx
Number: JVICQC-14.0 03/07/2016 Revision: 5 Page: Page 6 of 6 9.0 RECORD OF REVISION Revision Date Description 0 Initial Issue 1 01/11/2008 Second Issue 2 04/03/2008 Added MTR s, corrected spacing, changed caps 3 01/27/2009 Changed Format 4 07/14/2010 Changed Format 5 03/07/2016 Removed references to La Porte for gauges. Changed Logo. Updated title from Corporate Quality System Manager to Director of Quality Assurance. Corrected section numbering.