QUALITY CONTROL MANUAL

CWI GROUP LLC

PO BOX 2221
Auburndale FL, 33823

PHONE 863-268-3067

FOR

INSPECTION OF CODE FABRICATION ITEM

UNCONTROLLED COPY
 QUALITY CONTROL MANUAL

TABLE OF CONTENTS

SECTION SECTION REV DATE

TITLE PAGE -- 0 01/01/17
TABLE OF CONTENTS 1 0 01/01/17
SCOPE OF WORK 2 0 01/01/17
STATEMENT OF AUTHORITY & RESPONSIBILITY 3 0 01/01/17
MANUAL CONTROL 4 0 01/01/17
ORGANIZATION CHART 5 0 01/01/17
DRAWINGS, CALCULATIONS & SPECIFICATION RECORDS 6 0 01/01/17
MATERIAL CONTROL 7 0 01/01/17
EXAMINATION AND INSPECTION PROGRAM 8 0 01/01/17
NONCONFORMITIES 9 0 01/01/17
WELDING CONTROL 10 0 01/01/17
CALIBRATION 11 0 01/01/17
RECORD RETENTION 12 0 01/01/17
 QUALITY CONTROL MANUAL

SCOPE OF WORK
2.0 SCOPE OF WORK

2.1 The scope of the quality control system outlined in this manual shall be identified as follows:

2.1.1 This manual is put in place to give minimum requirements for the quality control system.
This manual is to be followed but maybe substituted in part when it is deemed necessary
by our customer, or when the fabricator does not have procedures in place for quality
control. If the fabricator has written quality procedure or quality systems in place that
have been accepted by the governing authority those procedures maybe used for work
actives but only when approved in writing, and proper training has been given to the CWI
Group Employee.

2.1.2 CWI Group Inspector may not be responsible for some Sections of this manual when the
fabricator has trained personal to perform the task, this must be confirmed in writing by
our customer.

2.2 The system shall be used in the following conditions.

2.2.1 All new construction shall be built in accordance with applicable ASME/ANSI/AWS or
jurisdictional requirements and customer specifications.
 QUALITY CONTROL MANUAL

STATEMENT OF AUTHORITY & RESPONSIBILITY

3.0 STATEMENT OF AUTHORITY & RESPONSIBILITY

3.1 CWI GROUP LLC, is totally committed to the requirements of the Quality Control System as
outlined in this manual.

3.2 All project in which new construction inspection is performed by this organization, where it has
been deemed this procedure be implemented is held to the minimum standards as set forth in this
manual.

3.3 Operation Manager is responsible for the assigning Lead Tech to project. The Lead Tech may
delegate the performance of their assigned duties to qualified individuals but they shall retain the
responsibility for their assigned activities. Duties may not be delegate to any person that is not
employed by CWI Group LLC without written statement from our customer.

3.4 CWI Group LLC has the responsibility, authority and organizational freedom to identify Quality
Control problems, stop work, provide the channels of communication for their solutions, and
verify resolution of the nonconformance after appropriate solutions have been established.

3.5 In the event of a disagreement in the implementation of this Quality Control System, the problem
shall be brought to the President for resolution and shall not negate the requirements of this
Quality Control Manual.
 MANUAL CONTROL

4.0 MANUAL CONTROL

4.1 The President or his designee is responsible for the preparation, revision, and administration of
this Quality Control Manual. The implementation of the Quality Control System is CWI Groups
Technicians reasonability.

4.2 Revisions will be by complete section with the revision level noted on the Table of Contents
except for the Exhibit Section, which will be by exhibit with the revision level noted on the
Exhibit Section Table of Contents. Revisions of this manual may be issued at the discretion of
the President, at which time all revisions will progress to the next numeric value.

4.3 The Operations Manager or his designee will issue controlled copies of this Quality Control
Manual as it is deemed necessary by the customer, or if management see it necessary for the
project. A list of “Issued Quality Control Manual” will be maintained on file this list will show
issued control numbers and the project its assigned to. When revisions or issued to this manual
the complete QCM will be distributed. Revision shall not be distributed in sections. Each Manual
will bear the same control number on its Title Page as is shown on the list of Manual Holders.

4.4 Uncontrolled manuals, which are not maintained current after the time of issue, may be issued to
parties outside the organization. These manuals shall be marked “UNCONTROLLED” on the
cover page.
 QUALITY CONTROL MANUAL

5.ORGANIZATION CHART

PRESIDENT

Vice President

NDT Level III Operations Manager

Lead Technician

NDT Level II / CWI

NDT Level I / Trainee

* THIS ORGANIZATION CHART PERTAINS TO THIS OPERATION ONLY *

 QUALITY CONTROL MANUAL

DRAWINGS, CALCULATIONS & SPECIFICATION CONTROL

6.0 For each project there shall be an established line of communication in which quality question or concerns
may be directed. For all projects, sufficient quality related documents must be available such as
Drawings, Code Requirements, Customer Specifications and/or any other document that states a quality
requirement of the project.

6.1 INSPECTIONS BY CWI GROUP LLC.

6.1.1 Upon request of service for an item or items to be inspected by this organization, the customer’s
specification is reviewed for the quality requirements by the Operations Manager, any question or
concerns regarding CWI GROUP LLC’s responsibility shall be discussed with the customer prior
to starting any Inspection work.

6.1.2 Upon receipt of approved design documents, the Operations Manager is to assign a Lead Tech to
the project.

6.1.3 Revisions to design documents shall be submitted to CWI Group by our customer and then will
be distributed by the Operation Manager to Lead Tech of the project.

6.1.4 Lead Tech, you shall review design documents to ensure that all needed quality related
information is available. The drawings, specification or other quality related documents shall at a
minimum, list the following information: Applicable Code, Welding Procedures, Revisions,
Dimensions and dimensional tolerances, Welding Symbols, Material Specifications, and method
of NDT or other inspection methods.

6.1.5 Revisions to shop and field drawings are handled in the same manner as the originals.
 DRAWINGS, CALCULATIONS & SPECIFICATION CONTROL

6.2 DISTRIBUTION OF DOCUMENTS AND DRAWINGS

6.2.1 All documents described in this manual shall be distributed throughout this organization by either
a Transmittal or hand carried to the described individual.

MATERIAL CONTROL

7.1 Material List

7.1.1 A List for all materials, including welding material, shall be reviewed from approved material
specifications by the Lead Tech or his designee, to assure that only acceptable materials are used
in accordance with the design documents.

7.1.2 A material lists should include all requirements including the material specification, grade, or
type to be used for construction.

7.2 RECEIVING INSPECTION

7.2.1 When CWI Group LLC is responsible for received materials at a shop or field site the material
shall be placed on “HOLD” pending the Inspector receiving inspection.

7.2.2 The Inspector using the Quality Control copy of the PO or other form of the material list,
examines all materials for dimensions, marking, condition and quality

7.2.4 For plate material and for other product forms for which the material specification requires heat
number traceability, the Inspector shall verifiy the heat number listed on the item matches the one
on the PO/ material test report.

7.2.5 When acceptable, the Lead Tech signs and dates the material test report then releases the material
to the shop and/or field.

7.2.6 Material that does not meet all requirements is tagged with a Hold Tag, or marked HOLD on the
item and retained in a segregated area and controlled as described in Section 8 of this manual.

7.2.7 Small parts and items will be placed in bags, boxes, or bins marked with the ID number and the
required material identification.

7.2.8 Prior to cutting of any material into two or more pieces the entire material marking is transferred
to each piece, and verified. In some cases, a coded marking traceable to the material test report or
 material specification may be required.

7.2.9 Parts and material that do not meet all requirements are nonconforming and are handled per
Section 9 of this Manual.

7.3 MATERIAL SUBSTITUTIONS

7.3.1 Material substitutions are only allowed when approved by the customer and revision are made to
applicable documents per the requirements of this Manual.

7.4 MATERIAL RECORDS

7.4.1 All records described in this Section are filed in the customer folder in the project file.

EXAMINATION AND INSPECTION PROGRAM

8.1 SHOP FABRICATION

8.1.1 Shop Fabrication items are controlled by means of the shop drawings.

8.1.2 The shop drawings are sent to the Operation Manager for review of Quality Control requirements.
When completed he reviews the shop drawings with the assigned inspector for designation of the
Hold Points.

8.1.3 The Lead Tech is to review drawing prior to the start of fabrication and insure all inspectors
understand their activity’s.

8.2 FINAL INSPECTION

8.2.1 When the fabrication or assembly of an item is completed the assigned inspector will make their
final inspection and will complete a report when the item meets all quality requirements.
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Section: 8
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QUALITY CONTROL MANUAL

EXAMINATION AND INSPECTION PROGRAM

8.3 PRESSURE TEST

8.3.1 The final pressure test, if required, will be witnessed by the Inspector assigned by the lead tech
and will be applied by the fabricator as specified on the drawings or specifications.

8.3.2 When the pressure test is completed satisfactory the Inspector is to complete a Hydro Test Report.

8.3.3 At least one directly connected pressure gauge visible to the operation controlling the pressure
test and having a range of about double the intended maximum test pressure but not less than one
and one half (1-1/2) nor more than four (4) times the test pressure shall be used for the test.
Hydrostatic head on the gauge shall be considered depending on the location of the gauge.

8.3.4 An additional pressure gauge may be necessary to allow the pressure to be visible to the operator
always during the test to prevent excessive pressure being applied.

8.4 RECORDS

8.4.1 All records described in this Section are collected at the completion of the job and placed into the
project folder.

8.5 NONCONFORMITIES

8.5.1 All nonconformities found during fabrication, installation, or assembly are handled as described
in Section 9 of this Manual.
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Section: 9
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QUALITY CONTROL MANUAL

CORRECTIONS OF NONCONFORMITIES

9.1 IDENTIFICATION OF NONCONFORMITIES

9.1.1 A nonconformity is any condition in material or fabrication that does not meet all the
requirements of the material specifications, design specifications, manufacturing control
documents, or the requirements of this Quality Control Manual

9.1.2 It is the duty of all employees of this organization to report nonconformities to their supervisor
who shall notify the Lead Tech. The Lead Tech shall verify the nonconforming condition and tag
the material or fabrication with a Hold Tag or mark the item HOLD, complete a Nonconformance
Report. If practicable, the nonconforming item or material shall be moved to a segregated
“HOLD” area.

9.1.3 The completed Nonconformance Report together with suggested disposition, signed by the Lead
Tech is forwarded to the Operations Manager for review and then submitted to the customer for
approval.

9.2 CORRECTION OF NONCONFORMITIES

9.2.1 USE-AS-IS: When the disposition is use-as-being the Lead Tech will consult with the Fabricator,
who may consult with their customer for clarification if needed. Any required revisions to
drawings, calculation and procurement documents will be done as described in this Manual prior
to proceeding with work.

9.2.2 REPAIR: When the disposition requires they may be made using approved standard procedures
or special procedures and approved by the Customer.

9.2.3 FOR REPAIRS TO MATERIAL: The proposed disposition is submitted to the Customer for their
acceptance of the method and extent of repairs, and designation of Hold Points.

9.2.4 SCRAP OR RETURN TO VENDOR: When the disposition is scrap or return to vendor the
Inspector shall verify that the item has been removed from the work area and is clearly marked
“SCRAP/RETURN TO VENDOR” to prevent its inadvertent use prior to disposal.

9.2.5 The Inspector shall re-inspect the item or material as dispositioned above and when he has
satisfied himself that they meet requirements and hold points have been accepted, he will sign the
Nonconformance Report, remove the Hold Tag or marking, and permit the item or material to
return to its proper sequence of fabrication.
 9.2.6 Completed Nonconformance Reports are returned to the Inspector for review and when they are
satisfied that it has been completed as required they shall forward them to the Lead Tech for
filing in the Project folder.

WELDING CONTROL

10.0 GENERAL

10.0.1 All welding, if applicable, shall be performed using Welding Procedure Specifications (WPS) and
qualified welders in accordance with applicable Codes and specifications.

10.1 WELDING PROCEDURE SPECIFICATION (WPS)

10.1.1 WPS are Reviewed by the Lead Tech and test welds are made under his supervision when
required. Preparation and testing of the required specimens is performed to the applicable
requirements by a qualified testing laboratory. The test report submitted by the laboratory is
reviewed by the Lead Tech and if acceptable he prepares and certifies the Procedure Qualification
Record (PQR).

10.1.2 Original copies of qualified WPS and PQR and laboratory test reports are maintained on file in
the customer folder. Copies of the WPS are provided to the Inspector for verification of welding
process, position, parameters, exc.

10.1.3 WPS are revised when there is a change in a nonessential variable and requalified when there is a
change in an essential or supplementary essential variable.

10.1.4 WPS and PQR shall be supplied by request to the Lead Tech for review and acceptance. The
Lead Tech may request requalification of a WPS at any time.

10.2 QUALIFICATION OF WELDERS AND WELDING OPERATORS

10.2.1 All welders and welding operators to be used for Code welding shall be qualified to the
applicable Code Section used for Construction. The preparation and testing of the required
specimens shall be performed by a qualified testing laboratory. The report of test is reviewed by
the Operations Manager and if acceptable he prepares and certifies the Manufacturer’s Record of
Welder/Welding Operator Performance Qualification. (If applicable)

10.2.2 Each qualified welder shall have unique stamp with which they identify each weld they make.
When conditions prevent such stamping, or as an alternative to stamping, the welder enters his
stamp number on the item for each weld they make.

10.2.4 WPQ shall be available for review upon request.

 WELDING CONTROL

10.3 REQUALIFICATION OF WELDERS AND WELDING OPERATORS

10.3.1 Welders and welding operator are requalified when:

a) A change in Performance Essential Variable occurs.

b) They have not welded with a process for a period of six (6) months or more their
qualification for that process shall expire.
c) Where there is reason to question their ability to make welds that meet the specification,
the requalification’s that support the welding they are doing shall be revoked. All other
qualification not questioned may remain in effect.

10.4 MAINTENANCE OF WELDER QUALIFICATION

10.4.1 Each welder and welding operator is listed on the Welder Log maintained by the fabricator and
shall be maintained. The log shall indicate the last date on which the welder or welding operator
has welded in each process.

10.5 PRODUCTION WELDING

10.5.1 The Lead Tech is responsible for verifying that all production welders are properly qualified by
using the WPQ and the Welders Log. The fabricator instructs the welders in the WPS they are to
use as listed on the drawings for each weld.

10.5.2 Tack welds whether left in place or removed are made by qualified welders using qualified
procedures.

10.5.3 Welders making tack welds that are left in place shall identify each weld he makes by entering his
stamp number on the drawings are other suitable means.

10.5.4 Tack welds left in place shall be properly prepared for inclusion into the weld, inspected by an
individual other than the welder, and if found defective they shall be removed.

10.6 WELDING MATERIAL

WELDING CONTROL

10.6.1 All welding materials shall be stored in a dry storage area and issued to the shop as per
Fabricators procedures.

10.6.2 Low hydrogen coated electrodes shall be received and stored in sealed containers. When the
containers are opened the electrodes shall be placed in heated ovens maintained at the
temperature recommended by their manufacturer.
 10.6.3 Low hydrogen electrodes shall be issued by the fabricator only in a quantity sufficient to
complete the weld or four a four-hour period whichever is less. When issued in heated portable
ovens the period is extended to eight hours.

10.6.4 Unconsumed electrodes shall be returned and if their exposure limit has been exceeded, the
electrodes are not used for Code work until proper bake out has been performed as restricted by
the applicable code requirements.

10.7 WELDING RECORDS

10.7.1 All records referenced in this section are available for review and acceptance.

CALIBRATION

11.0 GENERAL

11.1 All measurement test and examination equipment used for final acceptance of items shall be
calibrated in accordance with this Section.

11.2 CALIBRATION PROCEDURE

11.2.1 Each item of measurement test and examination equipment which requires calibration is
identified by a unique serial number on the item and which is recorded on the applicable
Calibration Sticker.

11.2.2 The Operation Manager is responsible for maintaining all equipment in calibration, unless out of
service and clearly marked "NOT CALIBRATED - DO NOT USE". Out of calibration
equipment shall also be marked in the same manner.

11.2.3 Calibration may be performed by a qualified testing laboratory having adequate standards and
who provides certified records of calibration.

11.2.4 Pressure gauges used for final pressure tests are compared to a calibrated master pressure gauge
prior to each use on a job.

11.2.5 The frequency of calibration for other equipment is as recommended by the equipment
manufacturer or from experience with the equipment.

11.3 RECORDS

11.3.1 Each piece of calibrated equipment shall have a Calibration Card maintained by the Operations
Manager in the calibration folder.

11.3.2 Calibration equipment shall be identified using a Calibration Sticker attached to the equipment or
the equipment container if to small for the decal to be attached. The decal shall list the date
 calibrated, the date calibration is due, and the person who performed the calibration.

13.4 DISCREPANT EQUIPMENT

13.4.1 When equipment requiring calibration is found to be out of calibration it shall be tagged "NOT
CALIBRATED DO NOT USE" by the person that found it in its un-working state, removed from
the work area, repaired, recalibrated, or replaced.

11.4.2 Prior to completion of a field job, all calibrated equipment used at the job will be verified if
possible, that the equipment was in calibration when last used on the field site.

RECORDS RETENTION

14.1 All records described in this manual are filed as described in this Section and collected at the completion
of the job by the Operations Manager. The Operations Manager performs the final review to assure the
records are complete and correct before submitting to the customer.