National Board Training Department Quality Control Manual

Small Vessel Works, Inc.

123 Main Street
Columbus, OH 43229-1183

QUALITY CONTROL
MANUAL
SHOP CONSTRUCTION AND SHOP AND FIELD
REPAIRS/ALTERATIONS
OF PRESSURE VESSELS & POWER BOILERS
TO ASME CODE SECTIONS I “S” and VIII, DIV. 1 “U”, “UM”
NBIC "R"
AND
JURISDICTION REQUIREMENTS
Edition 2
Revision 0
Date 09/01/XX
QCM No.:

Assigned to:

Controlled
Uncontrolled

Note: For reference use only.

This document is the property of The National Board of Boiler and Pressure Vessel
Inspectors and is provided upon the condition it will neither be reproduced, copied, nor issued
to a third party.
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6. Material Control

6.1. General

6.1.1. The Project Manager shall 'be responsible for the procurement of all materials (except weld
materials) and for identifying those materials that require a Material Test Report. Materials
shall be ordered to SA, SB or SFA material specifications, or other materials as permitted by the
applicable Construction Code.

6.2. Purchase Orders

6.2.1. Using the information contained in the list of materials on the approved drawings the Project
Manager shall order materials by preparing a "Purchase Order" (Exhibit 2). The Purchase Order
shall contain the material specification and type or grade, quantity, special requirements
marking requirements, certification requirements and the "Ordering Information" specified in
the applicable material specification listed in ASME Code Section II (SA, SB or SFA). For the
purchase of welding materials, the purchase order shall be based on the materials permitted by
the WPS assigned to the Job.

6.2.2. The Quality Control Manager shall review completed Purchase Orders for correctness and Code
compliance; his dated initials on the Purchase Order show approval. The approved Purchase
Orders shall be then returned to the Project Manager for placement with the vendor, with a copy
maintained to the Project Manager. The Project Manager shall be responsible for maintaining
Purchase ꞏOrders in the project file with a specific job number.

6.2.3. Any substitution of materials from those materials required in the original approved design shall
require the approval of the Engineer .and the Quality Control Manager, and concurrence of the
authorized inspector.

6.3. Receiving Inspection

6.3.1. Materia1 received at the shop shall be placed in a designated "Receiving Hold Area", pending
the Quality Control Inspector's receiving inspection.

6.3.2. The Quality Control Inspector, using the Quality Control copy of the Purchase Order, applicable
ASME Section II Materia1 Specification and the "Receiving Report" (Exhibit 3), examines
material for marking, forming, dimensions, condition and quantity.

6.3.3. The Quality Control Inspector shall review any required Material Test Reports for compliance
to the requirements of the applicable material specifications in Section II. He also verifies the
heat/lot number marked on the material is identical with that listed on the Material Test Report.
His approval is shown by his dated initials on the Material Test Report.

6.3.4. The Quality Control Inspector documents his inspection on the Receiving Report; signs and
dates the Receiving Report. The original Inspection Report, Receiving Purchase Order Copy
and the original Material Test Report are maintained on file by the Quality Control Inspector
and will be available to the Authorized Inspector. A copy of the receiving report and the
Material Test Report is forwarded to the Project Manager to be kept in the job file.
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6.4. Customer Supplied Material

6.4.1. Prior to the use of customer supplied materials, and in accordance with the above requirements,
the Project Manager shall place a Purchase Order (without price listings) with the customer.

6.4.2. Materials supplied by the Customer shall be received and inspected as described above and shall
only be acceptable for use if the materials have the original material manufacturer's product
markings as required by the applicable materia1 specification. Customer supplied material that
does not comply with the requirements of the Code or this Manual shall be considered
nonconforming and handled in accordance with Section 8 of this Manual.

6.5. Material Identification

6.5.1. Upon satisfactory completion of receiving inspection and review of any applicable Material
Test Reports, the Quality Control Inspector shall record the heat/lot/code number/ for each
material in the Material Trace Log. The date received, Supplier and Purchase order 'number will
also be recorded. The Quality Control Inspector shall maintain a Material Trace Log (Exhibit 4)
for the traceably and identification of materials used in fabrication. Unique alpha numerical
designator placed on the code material, the trace code log and material certifications as
applicable. When material is cut and the number is removed on the piece being used the
operator must write the number on the remaining material that is not being used.

6.5.2. Weld materials or for pressure parts manufactured in accordance with ASME Product Standards
(e.g. ASME B 16.9), which require the permanent marking of each item will not be recorded
unless original markings will be removed by subsequent fabrication activities.

6.5.3. The Foreman shall be responsible for ensuring the required identification markings are
maintained on materials during all phases of fabrication. * Materials shall be marked by
methods that have been accepted by the Authorized Inspector. Stamping shall not be used on
ferrous materials less than ¼” thick or on nonferrous materials less than ½” thick. Prior to
cutting material into two or more pieces, the material trace code number shall be transferred to
each piece and verified by the Quality Control Inspector or recorded as described above. *
Alternatively material code required markings may be recorded on the drawing.

6.6. Material Release

6.6.1. Upon satisfactory completion of receiving inspection and documentation review the Quality
Control Inspector shall release accepted materials from the Receiving Hold Area and have them
moved to the designated Code material storage areas.

6.7. Material Storage

6.7.1. The storage of accepted Code materials and their subsequent release for fabrication activities
shall be the responsibility of the Foreman. Segregated storage areas shall be established by the
Foreman and sign posted "Accepted Code Material".
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6.8. Nonconformities

6.8.1. Any material that does not meet Purchase Order or Code requirements shall be considered
nonconforming and handled in accordance with Section 8 of this Manual.

6.9. Procurement Records

6.9.1. The Project Manager shall be responsible for maintaining the Receiving Reports & Material
Test Reports on file and shall submit all Material Test Reports and Manufacturer’s Data Reports
to the Authorized Inspector for review and acceptance.

6.9.2. Revisions to procurement documents shall be prepared, approved and distributed in the same
manner as the originals.

6.9.3. The Quality Control Manager shall make all records referenced in this Section available for
review by the Authorized Inspector.
 Section 18
Small Vessel QUALITY Exhibit 2
Works CONTROL MANUAL Rev. 0
Date 09-01-20XX

Purchase Order
Small Vessel Works, Inc. Date:
P.O. No.:
Customer ID:
Supplier: Ship to:
Small Vessel Works, Inc.
123 Main Street
Columbus, Oh 43229
555-555-5555

Shipping Method Shipping Terms Delivery Date

Truck Net 30

Item Qty Description Job Unit Price Line Price

Notes: Subtotal
1 Please send two copies of your invoice. Sales Tax
2 Enter this order in accordance with the prices, terms, delivery method, and Total
specifications listed above.
3 Please notify us immediately if you are unable to ship as specified.
4 Material Test Reports must be sent with shipment. Heat Numbers must be
marked all material; Heads, sheet, plate, pipe, tube,& fittings
5 Material Must conform to the requirements of ASME Section II and be
Silicone and Mercury free.
6 Send all correspondence to: Prepared by: Date
Purchasing Manager
Mr. Bob O. Link
123 Main Street Approved by Date
Columbus, Oh 43229 Quality Control Manager
555-555-5555
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Small Vessel QUALITY Exhibit 3
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Receiving Report
Job No.: PO No.: Date:

Plate Quantity 1 .
Coded Marking AAAB‐1 _
Spec. No.: Grade/Type: Heat / Slab #:
T-1: T-2: T-3: T-4:
W: L: MTR Received: Yes No
Original Identification Markings:
Accepted: Rejected:

Heads: Quantity . Coded Marking _

Spec. No.: Grade/Type: Heat / Slab #:
Stamping:
O.D.: I.D.: D: L:
SL: T-1: T-2: MTR Received: Yes No
Original Identification Markings:
Accepted: Rejected:

Pipe: Quantity . Coded Marking _

Spec. No.: Grade/Type: Heat#:
I.D.: O.D.: T-1: T-2:
L: MTR Received: Yes No
Original Identification Markings:
Accepted: Rejected:

Fittings: Quantity . Coded Marking _

Spec. No.: Grade/Type: Heat#:
Original Stamping: MTR Received: Yes No

Accepted: Rejected:

Other: Quantity . Coded Marking _

Spec. No.: Grade/Type: Heat#:
Description:
Stamping: MTR Received: Yes No
List Inspection Points:
Original Identification Markings:
Accepted: Rejected:

Material Accepted: Date:

Quality Control Inspector
 Section 18
Small Vessel QUALITY Exhibit 4
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Date 09-01-20XX

Material Trace Log

Date Trace
Original Material Identification Markings
Received Code
 Section 18
Small Vessel QUALITY Exhibit 9
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Date 09-01-20XX

Rejected Tag

Rejected
Job No. _______