ASME Welding Contractor

QA/QC Plan Sample

Selected pages (not a complete plan)

Part 1: Project‐Specific Quality Plan

Part 2: Quality Manual
Part 3: Submittal Forms

Contact:
FirstTimeQuality
410‐451‐8006

Pat

[Pick the date]

PROJECT-SPECIFIC WELDING QUALITY PLAN
TABLE OF CONTENTS
Background Information .......................................................................................................................... 7

Customer .................................................................................................................................................... 7
Project Name .............................................................................................................................................. 7
Project Number .......................................................................................................................................... 7
Project Location .......................................................................................................................................... 7
Overall Project Description ......................................................................................................................... 7
[CompanyName] Scope of Work ................................................................................................................ 7

A. [CompanyName] Quality Policy ........................................................................................................... 8

B. Key Elements of the Weld Quality Plan ................................................................................................ 9

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Project Quality Assurance/Quality Control Plan Overview ...................................................................... 12

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C. Project Quality Coordination and Communication ............................................................................. 13
D. Project QC Personnel ......................................................................................................................... 17
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Project QC Job Position Assignments ....................................................................................................... 17
Project QC Organization Chart ................................................................................................................. 18

E. Duties, Responsibilities, and Authority of QC Personnel .................................................................... 19

F. Personnel Qualifications and Technical Certifications ........................................................................ 25
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Personnel Certification and Qualification Requirements ......................................................................... 26

G. Qualification of Third Party Inspection/Testing Companies and Subcontractors and Suppliers ......... 31
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Third Party Weld Inspection Qualification Requirements ........................................................................ 31

Qualification ............................................................................................................................................. 31
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Purchase Order Approval ......................................................................................................................... 32

H. Quality Training ................................................................................................................................. 34

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I. Weld Project Quality Specifications .................................................................................................... 37

Compliance with Industry Welding Standards ......................................................................................... 37

Project - Specific Welding Procedure Standards ...................................................................................... 37
Local fabrication Codes............................................................................................................................. 38

J. Material Inspection Traceability and Quality Controls ........................................................................ 42

Identification of Lot Controlled Materials ................................................................................................ 42

Heat Traceability of Metals ...................................................................................................................... 42
Customer Supplied Materials ................................................................................................................... 43
Material Receiving and Inspection ........................................................................................................... 43
Preservation of Materials and Completed Work ...................................................................................... 43

K. Weld Equipment ................................................................................................................................ 48

L. Weld Inspection and Test Plan ........................................................................................................... 50

Welding Inspection and Testing Standards .............................................................................................. 51

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 Calibration of Inspection, Measuring, and Test Equipment ..................................................................... 52

M. Work Task Quality Inspections.......................................................................................................... 55

Identification of Quality Inspected Work Tasks ........................................................................................ 55

Required Inspections For Each Work Task ............................................................................................... 55
Daily Quality Control Report..................................................................................................................... 56

N. Control of Corrections and Nonconformances ................................................................................... 63

Marking of Nonconformances and Observations ..................................................................................... 63

Control the Continuation of Work ............................................................................................................ 63
Recording of Nonconformances ............................................................................................................... 63
Quality Manager Disposition of Nonconformance Reports ..................................................................... 64
Corrective Actions .................................................................................................................................... 64
Nonconformance Preventive Actions ....................................................................................................... 65

O. Project Completion Inspections ......................................................................................................... 67

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Punch-Out QC Inspection ......................................................................................................................... 67

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Pre-Final Customer Inspection ................................................................................................................. 67
Final Acceptance Customer Inspection .................................................................................................... 68
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P. Project Quality Records and Documents ............................................................................................ 71
Q. Quality Assurance Surveillance.......................................................................................................... 74

Project Quality Performance Surveillance ................................................................................................ 74

Project Quality Audits ............................................................................................................................... 74
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Project Audit Plan ..................................................................................................................................... 75

Project Audit Requirements ..................................................................................................................... 75

R. Additional Quality Control Requirements .......................................................................................... 77

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 I. WELD PROJECT QUALITY SPECIFICATIONS
Fulfilling customer contract expectations is a primary objective of the [CompanyName] Quality System. To
ensure that customer expectations will be fulfilled, [CompanyName] clearly defines the requirements for
each contract before it is approved.

The Project Manager ensures that the information in customer contracts clearly defines customer
expectations and that the necessary details are provided to set requirements for fabrication.

[CompanyName] personnel and subcontractors and suppliers are accountable for compliance to
standards-based written specifications.

To achieve expectations reliably and consistently, specifications are clearly spelled out, not only for results
but also for processes. Specifications apply to materials, work steps, qualified personnel and
subcontractors and suppliers, safe work rules, and environmental work conditions.

Standards ensure that results are specified rather than left to discretionary practices.

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All [CompanyName] fabrication activities comply with generally accepted good workmanship practices

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and industry standards.

COMPLIANCE WITH INDUSTRY WELDING STANDARDS Pa

Codes that may apply to this project include those listed below.
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Regulatory Codes and Industry Standards

Reference
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Division Description Reference Standard Title

Standard No.
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5 Minimum spacings and edge AISI SG02-KIT North American Specification for the Design of Cold-Formed Steel
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distances for screws Structural Members

5 Installation of bracing and CFSEI Field Installation Guide for Cold-Formed Steel Roof Trusses
permanent bracing and bridging
5 Installation of chimneys, vents, and NFPA 211 Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances
smokestacks
5 Framing and reinforcing openings SDI DDP Deck Damage and Penetrations
through a steel deck
5 Install high-strength bolts RCSC's "Specification for Structural Joints Using ASTM A 325 or A 490 Bolts"

5 Beveling, alignment, heat treatment, ASME B31.1 Power Piping

and inspection of weld
5 Requirements for piping of fluids ASME B31.3 Process Piping

PROJECT - SPECIFIC WELDING PROCEDURE STANDARDS

The Quality Manager approves welding procedures before they can be used to fabricate metal.

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Form QW-483 Welding Procedure Qualification Record

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 [CompanyName]
Metals Material Receiving Inspection Report
Version 20140615

Project ID Project Name P.O.# Supplier Receipt Date

[ProjectNumber] [ProjectName]

Type of Material Material Description Heat Number/ Condition / Damage Color Code Marking

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(i.e., steel plate) (nominal dimensions) Serial Number/Markings

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Receiving Inspector Approval Signature / Date
c te Government Representative
Name/Approval Date
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 Material Receiving
Inspection Passed
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 [CompanyName]
Quality Inspection and Test Plan

Project ID Project Name CONTRACTOR

[ProjectNumber] [ProjectName] [CompanyName]

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SPECIFICATION
SECTION ACCREDITED/ LOCATION DATE
AND APPROVED OF TEST FORWARDED
PARAGRAPH SCHEDULE LAB ON/OFF DATE TO
NUMBER ACTIVITY ID TEST REQUIRED YES /NO SAMPLED BY TESTED BY SITE/SITE COMPLETED CUSTOMER REMARKS

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M. WORK TASK QUALITY INSPECTIONS
[CompanyName] identifies a list of work tasks which will be quality controlled. Each work task is subject to
a series of inspections; before, during, and after completion.

Each inspection verifies compliance with full scope of the relevant specifications; not limited to inspection
form checkpoints.

The initial work task-ready inspection occurs when work is ready to start and ensures that work begins
only when it does not adversely impact quality results.

Incoming material inspections verify that materials are as specified and meet all requirements necessary
to assure quality results.

Work-in-process inspections continuously verify that work conforms to project specifications and quality
expectations. Work continues only when it does not adversely impact quality results.

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At completion of the work task an inspection verifies that work has been completed in accordance with
project quality requirements.

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Inspection results are recorded and maintained as part of the project files.

The Quality Manager identifies each Task that is a phase of fabrication that requires separate quality
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controls to assure and control quality results. Each Task triggers as set of requirements for quality control
inspections before, during and after work tasks.

Independent quality audits are conducted to verify that the task quality controls are operating effectively.
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Fabrication projects may execute a work task multiple times in a project, in which case a series of quality
inspections are required for each work task.

Independent quality control audits are conducted to verify that the task quality controls are operating
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effectively.
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IDENTIFICATION OF QUALITY INSPECTED WORK TASKS

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A listing of project work tasks is included on the Quality Control work task List and included as an exhibit
in this subsection.

REQUIRED INSPECTIONS FOR EACH WORK TASK

Each work task is subject to a series of inspections before, during, and at completion as described below.
Results of inspections are recorded.

PREPARATORY SITE INSPECTION

The Superintendent performs a quality inspection of the work area and:

• Assesses completion of required prior work

• Verifies field measurements
• Assures availability and receiving quality inspection status of required materials
• Identifies any nonconformances to the requirements for the task to begin
• Identifies potential problems

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TASK-READY INSPECTIONS
For each work task, the Superintendent or a qualified inspector performs job-ready quality inspections to
ensure that work activities begin only when they should begin. Job-ready quality inspections verify that
conditions conform to the project quality requirements.

WORK IN PROCESS QUALITY INSPECTIONS

For each work task, the Superintendent or a qualified inspector performs an initial work in process
inspection when the first representative portion of a work activity is completed.

The Superintendent or a qualified inspector performs ongoing work in process quality inspections to
ensure that work activities continue to conform to project quality requirements.

WORK TASK COMPLETION QUALITY INSPECTIONS

For each work task, the Quality Manager or a qualified inspector inspects the completion of each work
task to verify that work conforms to project quality requirements.

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Completion quality inspections are performed for each work task. Completion quality inspections are

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conducted before starting other work activities that may interfere with an inspection.

Any outstanding punch items remaining after the work task completion inspection is deemed a
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DAILY QUALITY CONTROL REPORT
The Superintendent records a summary of daily work activities. The report will include:
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 Form P-4A Welded Piping Inspection

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QUALITY MANUAL
TABLE OF CONTENTS

1. Quality System Management and Responsibilities ............................................................................... 6

1.1. Overview .............................................................................................................................................. 6

1.2. [CompanyName] Quality Policy ........................................................................................................... 6
1.3. Quality Duties, Responsibilities, and Authority ................................................................................... 6
1.4. Quality System Performance Measures .............................................................................................. 9
1.5. Customer Satisfaction Performance Measures ................................................................................... 9
1.6. Exceptions............................................................................................................................................ 9

2. Project Quality Assurance/Quality Control Plan ................................................................................. 10

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2.1. Overview ............................................................................................................................................ 10

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2.2. [CompanyName] Project License and Qualification Requirements .................................................. 10
2.3. Project Personnel and Qualifications ................................................................................................ 11
2.4. Project Quality Assurance/Quality Control Plan ................................................................................ 12
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2.5. Identification of Quality Controlled Work Tasks................................................................................ 12
2.6. Project Quality Inspection and Test Plan ........................................................................................... 12
2.7. Project Quality Communications Plan ............................................................................................... 12
2.8. Project Quality Training Plan ............................................................................................................. 12
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2.9. Customer Training On Operation and Maintenance ......................................................................... 12

2.10. Project Records and Documentation Plan ....................................................................................... 13
2.11. Project Audit Plan ............................................................................................................................ 13
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3. Contract Specifications ....................................................................................................................... 14

3.1. Overview ............................................................................................................................................ 14

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3.2. Contract Technical Specifications ...................................................................................................... 14

3.3. Contract Drawings ............................................................................................................................. 14
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3.4. Contract Submittals ........................................................................................................................... 14

3.5. Customer Submittal Approval ........................................................................................................... 16
3.6. Contract Warranty ............................................................................................................................. 16
3.7. Contract Review and Approval .......................................................................................................... 17
4. Design Review and Control ................................................................................................................ 18

4.1. Overview ............................................................................................................................................ 18

4.2. Design Input Review .......................................................................................................................... 18
4.3. Project Design Quality Assurance/Quality Control Plan .................................................................... 18
4.4. Design Progress Reviews ................................................................................................................... 19
4.5. Design Output Verification and Approval .......................................................................................... 19

5. Project-Specific Quality Standards ..................................................................................................... 20

5.1. Overview ............................................................................................................................................ 20

5.2. Regulatory Codes ............................................................................................................................... 20

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 5.3. Industry Quality Standards ................................................................................................................ 20
5.4. Material Specifications ...................................................................................................................... 20
5.5. Equipment Specifications .................................................................................................................. 21
5.6. Work Process Specifications .............................................................................................................. 21
5.7. Controlled Material Identification and Traceability .......................................................................... 21
5.8. Measuring Device Control and Calibration ........................................................................................ 22
5.9. [CompanyName] Quality Standards .................................................................................................. 22
5.10. Application of Multiple Sources of Specifications ........................................................................... 22

6. Project Purchasing ............................................................................................................................. 23

6.1. Overview ............................................................................................................................................ 23

6.2. Qualification of Outside Organizations and Company Departments ................................................ 23
6.3. Quality Responsibilities of Key Subcontractor and Supplier Personnel............................................. 24
6.4. Requirements for Subcontractor QC Plan ......................................................................................... 25
6.5. Subcontractor and Supplier Quality Policy ........................................................................................ 25

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6.6. Project Subcontractor and Supplier List ............................................................................................ 26
6.7. Purchase Order Requirements .......................................................................................................... 26

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6.8. Project Purchase Order Approvals..................................................................................................... 26

7. Process Controls ................................................................................................................................. 27

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7.1. Overview ............................................................................................................................................ 27
7.2. Project Startup and Quality Control Coordination Meeting .............................................................. 27
7.3. Preparatory Project Quality Assurance/Quality Control Plan Planning ............................................. 27
7.4. Weekly Quality Planning and Coordination Meetings ....................................................................... 28
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7.5. Process Control Standards ................................................................................................................. 28

7.6. Daily Quality Control Report .............................................................................................................. 30
7.7. Monthly Quality Control Report ........................................................................................................ 30
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8. Inspections and Tests ......................................................................................................................... 32

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8.1. Overview ............................................................................................................................................ 32

8.2. Required Work Task Quality Inspections and Tests........................................................................... 32
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8.3. Material Inspections and Tests .......................................................................................................... 32

8.4. Work in Process Inspections .............................................................................................................. 33
8.5. Work Task Completion Inspections ................................................................................................... 33
8.6. Inspection of Special Processes ......................................................................................................... 34
8.7. Independent Measurement and Tests .............................................................................................. 34
8.8. Commissioning Functional Acceptance Tests .................................................................................... 34
8.9. Hold Points for Customer Inspection ................................................................................................. 34
8.10. Quality Inspection and Test Specifications ...................................................................................... 34
8.11. Inspection and Test Acceptance Criteria ......................................................................................... 35
8.12. Inspection and Test Status............................................................................................................... 35
8.13. Independent Quality Assurance Inspections ................................................................................... 35
8.14. Inspection and Test Records ............................................................................................................ 35
8.15. Project Completion and Closeout Inspection .................................................................................. 36

9. Nonconformances and Corrective Actions ......................................................................................... 38

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 9.1. Overview ............................................................................................................................................ 38
9.2. Nonconformances ............................................................................................................................. 38
9.3. Corrective Actions ............................................................................................................................. 39

10. Preventive Actions ........................................................................................................................... 41

10.1. Overview .......................................................................................................................................... 41

10.2. Identify Preventive Actions for Improvement ................................................................................. 41
10.3. Train Preventive Actions for Improvement ..................................................................................... 41

11. Quality System Audits ...................................................................................................................... 43

11.1. Overview .......................................................................................................................................... 43

11.2. Project Quality System Audit ........................................................................................................... 43
11.3. Company-wide Quality System Audit .............................................................................................. 43

12. Record and Document Controls........................................................................................................ 45

12.1. Overview .......................................................................................................................................... 45

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12.2. Quality System Documents ............................................................................................................. 45

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12.3. Document Controls .......................................................................................................................... 45
12.4. Record Controls ............................................................................................................................... 46
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13. Appendix .......................................................................................................................................... 48

13.1. Definitions of Terms ........................................................................................................................ 48

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 7. PROCESS CONTROLS
HOW WORK IS CARRIED OUT

7.1. OVERVIEW
The fabrication process plan defines how project work is to be done and approved for the overall project.
The fabrication process plan is communicated to all key personnel, subcontractors and suppliers in a
startup meeting. As the project proceeds, work task plans provide additional details of how each
individual work task is carried out. Work tasks planning meetings are used to communicate expectations
of the work task plan to key personnel responsible for carrying out the work task.

7.2. PROJECT STARTUP AND QUALITY CONTROL COORDINATION MEETING

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Prior to the commencement of work, the Project Manager holds a meeting to discuss and coordinate how

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project work will be performed and controlled. Key personnel from [CompanyName], subcontractors and
suppliers meet to review expectations for project quality results as well as quality assurance and quality
control policies and procedures including:

•
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Key requirements of the project
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The Project Quality Assurance/Quality Control Plan
• Required quality inspections and tests
• The project submittal schedule
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• Quality policies and heightened awareness of critical quality requirements

• Project organization chart and job responsibilities
• Methods of communication and contact information
• Location of project documents and records
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7.3. PREPARATORY PROJECT QUALITY ASSURANCE/QUALITY CONTROL PLAN PLANNING

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7.3.1. WORK TASK REQUIREMENTS REVIEW

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In preparation for the start of an upcoming work task, the Superintendent reviews an integrated and
coordinated set of documents that collectively define quality requirements for the work task including:

• Objectives and acceptance criteria of the work task

• Quality standards that apply to the work task
• Work instructions, process steps, and product installation instructions that apply to the work task
• Shop drawings
• Submittals
• Tools and equipment necessary to perform the work
• License, certification, or other qualification requirements of personnel assigned to work
• Required records of the process and resulting product
• The subcontractor contracted to perform the work, if applicable
• Customer contract requirements
• Required quality inspections and tests
• Method for clearly marking nonconformances to prevent inadvertent use
• Location of quality system records and documents
• Personnel training

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7.3.2. PREPARATORY SITE INSPECTION
The Superintendent also performs a quality inspection of the work area and:

• Assesses completion of required prior work

• Verifies field measurements
• Assures availability and receiving quality inspection status of required materials
• Identifies any nonconformances to the requirements for the work task to begin
• Identifies potential problems

7.3.3. WORK TASK PREPARATORY QUALITY PLANNING MEETINGS

Prior to the start of a work task, the Superintendent conducts a meeting with key company, subcontractor
personnel responsible for carrying out, supervising, or inspecting the work, and interested customer
representatives.

During the meeting, the Superintendent communicates the work task quality requirements and reinforces
heightened awareness for critical requirements. Topics for a work task quality plan meeting include:

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• Conflicts that need resolution

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• Required quality documents and a verification of availability to personnel carrying out,
supervising, or inspecting the work task
• Record keeping requirements and the availability of necessary forms
• Review methods and sequences of installation
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• Special details and conditions
• Standards of workmanship
• Heightened awareness of critical quality requirements
• Quality risks
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• Work tasks quality inspection form

7.4. WEEKLY QUALITY PLANNING AND COORDINATION MEETINGS

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The Superintendent conducts a meeting with key company, subcontractor and supplier personnel
responsible for carrying out, supervising, or inspecting the work, and interested customer representatives.
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The meeting is held on a nominal weekly schedule. During the meeting, the Superintendent facilitates
coordination among the participants, communication among the participants, and reinforces heightened
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awareness for critical requirements.

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9. NONCONFORMANCES AND CORRECTIVE ACTIONS
9.1. OVERVIEW
Should a nonconformance be identified by an inspection there is a systematic method to control the item,
correct it, and ensure that project quality is not adversely impacted by the event.

A nonconformance is any item that does not meet project specifications or [CompanyName] Quality
System requirements.

9.2. NONCONFORMANCES

9.2.1. MARKING OF NONCONFORMANCES AND OBSERVATIONS

When the Quality Manager, Superintendent, inspector, or customer identifies a nonconformance or an

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observation, the item is quickly and clearly marked by tape, tag, or other easily observable signal to
prevent inadvertent cover-up.

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9.2.2. CONTROL THE CONTINUATION OF WORK
After the item is marked, the Superintendent determines if work can continue in the affected area:
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CONTINUE WORK: When continuing work does not adversely affect quality or hide the defect, work may
continue in the affected area while the disposition of the item is resolved. The Superintendent may place
limitations on the continuation of work.
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STOP WORK ORDER: When continuing work can adversely affect quality or hide the defect, work must
stop in the affected area until the disposition of the item resolved. The Superintendent identifies the
limits of the affected area. The Superintendent quickly and clearly identifies the boundaries of the stop
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9.2.3. NONCONFORMANCE REPORT

9.2.3.1. RECORDING OF NONCONFORMANCES
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If nonconformances or observed items exist by the work task completion inspection, the Superintendent
or inspector records the nonconformances on a nonconformance report.

The Superintendent sends the nonconformance report to the Quality Manager.

9.2.3.2. QUALITY MANAGER DISPOSITION OF NONCONFORMANCE REPORTS

When the Quality Manager receives a Nonconformance Report, he or she makes an assessment of the
affect the reported nonconformance has on form, fit, and function. The Quality Manager may assign a
disposition of either:

REPLACE: The nonconformance can be brought into conformance with the original specification
requirements by replacing the nonconforming item with a conforming item.

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 Questions? Call First Time Quality 410-451-8006

List of Included Forms

Standard Forms:

 Point Of Contact List

 Project Organization Chart
 Project Quality Communications Plan
 Quality Manager Appointment Letter
 Project Manager Appointment Letter
 Superintendent Appointment Letter
 Personnel Certifications and Licenses
 Project Personnel Resumes

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 Project Subcontractor and Supplier List

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 Training Plan
 Training Log
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
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Regulatory Codes and Industry Standards
Project Regulatory Building Codes
 Controlled Materials Form

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Metals Material Receiving Inspection Report

 Material Inspection and Receiving Report
 Inspection and Testing Standards
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 Quality Inspection and Test Plan

 Test Equipment Calibration Plan and Log
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 Quality Controlled Work Task List

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 Daily Production Report

 Work Task Inspection Form
 Nonconformance Report
 Punch List
 Project Completion Inspection Form
 System Document Control Form
 Project Records Control Form
 Project Quality System Audit Form
 Questions? Call First Time Quality 410-451-8006

[CompanyName][CompanySuffix]
Nonconformance Report
Version 20131125

Nonconformance Report
Control ID Project ID Project Name
[ProjectNumber] [ProjectName]

Preparer Signature/ Submit Date Quality Manager Signature / Disposition Date

Description of the requirement or

specification

Description of the nonconformance,

location, affected area, and marking

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Replace Repair Rework Use As-is

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Disposition

Approval of disposition required by customer representative? Yes No

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Customer approval signature /date: ___________________________________
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Corrective Actions
Corrective actions completed Name/Date:_________________________
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Customer acceptance of corrective actions required? Yes No

Name/Date:_________________________
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Preventive Actions

Preventive actions completed Name/Date:_________________________

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 For More Information:
Contact: FirstTimeQuality

410-451-8006

www.FirstTimeQuality.com

EdC@FirstTimeQuality.com

For More Information, contact: CaldeiraQuality, LLC • First TimeQuality℠.

410‐451‐8006 • www.firsttimequality.com • EdC@FirstTimeQuality.com