Jim Harris Continuous Improvement Leader

Transcription

1 Approved By: Jerry Longmire Global Quality Leader Jim Harris Continuous Improvement Leader Document Revision Chart The following chart lists the revisions made to this document tracked by version. Use this to describe the changes and additions each time this document is re-published. The description should include as many details of the changes as possible. #.# Section Modified and Revision Description Date Author 1.0 Initial release 7/13/2011 Celine McCulloch Revised requirement for sub-suppliers used for calibration services to comply with GEE QMS 7.6. Changed responsibility for approval of welding procedures from Headquarters Quality to Drilling & Surface Materials & Process Engineering. Changed responsibility for approval of welding and associated heat treatment suppliers from Headquarters Quality to Supplier Quality. Changed Engineering Data Code (EDC) to Engineering Product Specification (EPS) to reflect current terminology. 9/26/2012 Celine McCulloch 01/06/2014 Ashley Weatherington GE PROPRIETARY UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY PAGE 1 OF 8

2 Table of Contents 1.0 PURPOSE SCOPE / APPLICATION PROCEDURE RESPONSIBILITIES QUALITY RECORDS DEFINITIONS REFERENCES COMPLIANCE REQUIREMENTS... 8 GE PROPRIETARY UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY PAGE 2 OF 8

3 1.0 Purpose This specification defines the minimum quality requirements for suppliers providing welding and associated heat-treatment services to Operating Units. 2.0 Scope / Application This specification is applicable to all suppliers of welding and associated heat treatment services used by Operating Units. 3.0 Supplier Quality Requirements - Welding and Associated Heat Treatment Operations 3.1 General Requirements Quality Program Verification The supplier's quality system shall be described in a written manual or procedure with revision control and identification. The quality system manual should be approved and supported by the supplier's management and cover the requirements of either ANSI/API Spec Q1 or ISO 9001 as a minimum. The quality system manual shall be submitted to the Supplier Quality Team for review and approval upon initial issue and/or revision. When the supplier is the holder of a current API License, ASME Certificate of Authorization, or ISO 9001 Registration Certificate, a copy of the applicable certificate may be submitted to the Supplier Quality Team in lieu of the quality system manual as objective evidence of quality system implementation. When a supplier is approved by based on an API License, ASME Certificate of Authorization, or ISO Registration Certificate, the supplier is required by this specification to invoke the provisions of the applicable API License, ASME Certificate of Authorization, or ISO Registration to the work performed for Pressure Control facilities Use of Sub-Tier Suppliers The use of sub-tier suppliers to perform welding or associated heat treatment operations for facilities is expressly prohibited by this specification unless written authorization is obtained from the Supplier Quality Team. GE PROPRIETARY UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY PAGE 3 OF 8

4 3.1.3 Conflicts in Specified Requirements In cases where the purchase order disagrees with the referenced drawings or specifications, the supplier shall contact the buyer at the location that issued the affected purchase order to discuss and resolve the issue. 3.2 Specific Quality Control Program Requirements Qualification of Welding Procedure Specifications and Preparation of Procedure Qualification Records Prior to performing work for a facility, the supplier is required to submit a copy of the Welding Procedure Specification (WPS), Procedure Qualification Record (PQR), Welder Performance Qualification (WPQ), and all associated material test reports and lab reports to the Supplier Quality Team. The Supplier Quality Team coordinates the review and approval of these documents by the Drilling & Surface MPE Team. The WPS shall be developed and qualified in accordance with the requirements of ASME B&PV Code, Section IX and ANSI/API Specification 6A, latest editions and applicable weld specification form requirements Qualification of Welders and Welding Operators Welders and welding operators shall be qualified in accordance with the requirements of ASME B&PV Code, Section IX Article 3. Additionally, suppliers shall maintain welder continuity records. In addition, when boltholes are repair welded for ANSI/API Specification 6A, PSL-2 and PSL-3 Bodies, Bonnets, End and Outlet Connections, a bolthole repair qualification is required according to the requirements of ANSI/API Specification 6A, latest edition Material Control and Identification The supplier shall ensure that materials are properly identified and supported with documentation as required by the purchase order and WPS (i.e., heat-treat charts; materials test reports, hardness test reports). Welding consumables shall be controlled through supplier s quality system procedures. Traceability requirements shall be identifiable by heat number and/or heat lot through supplier s work order. GE PROPRIETARY UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY PAGE 4 OF 8

5 3.2.4 Manufacturing Processes Process Control System The welding and associated heat-treatment operations shall be controlled and documented in accordance with the requirements of the supplier s quality system manual, API License, ASME Certificate of Authorization or ISO Registration used as the basis for supplier approval by Welding and Welding and associated heat treatment operations shall be performed in accordance with the requirements of procedures approved by the Drilling & Surface MPE Team as required by the purchase order. purchase orders for welding and associated heat treatment operations are required to identify the supplier s procedure by WPS identifying number or code and revision level. Welding machines shall be calibrated at periodic intervals in accordance with suppliers documented procedure. Furnaces shall have temperature uniformity surveys performed at least annually according to the requirements of either SAE-AMS-H or SQ-07. Furnaces which are used for tempering, ageing and/or stress-relieving shall not vary by more than ± 8 C (15 F) from the furnace set-point temperature after the furnace working zone has been brought up to temperature. Furnace controllers and recorders shall be calibrated at periodic intervals to ensure proper control of the furnaces. Stress relief furnace qualification and controller/recorder calibration records supporting the verification of furnace capability shall be made available to the Supplier Quality Team upon request Inspection and Testing The welding and associated heat treatment operations shall be inspected by the supplier to ensure compliance with the Pressure Control purchase order requirements and the approved WPS. The supplier s welding inspection program shall be in accordance with ANSI/API Specification 6A and the applicable specifications for visual examination (see VGS or QC-103) and nondestructive examination. Suppliers of Nondestructive Testing services shall be qualified in accordance with SQ-10. GE PROPRIETARY UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY PAGE 5 OF 8

6 4.0 Responsibility Control of Nonconforming Products When suppliers detect nonconformities to purchase order requirements or the approved WPS that cannot be corrected without the use of additional welding or heat treatment operations, or if the supplier wishes to have an issue reviewed for possible concession, the supplier shall prepare and submit a Supplier Deviation Request for review and disposition prior to shipment of the affected items. Note: Contact your Purchasing Buyer for guidance in submitting these requests Inspection, Measuring and Test Equipment Inspection, measuring and testing equipment used in these inspections shall be calibrated and traceable to national standards. Physical constants may be used as the basis for calibration reference in case where national standards do not exist. Sub-suppliers used for calibration services shall comply with the requirements of ISO or equivalent international or national standard Marking of Products When the purchase order, EPS (replaces EDC), and/or drawing require marking, such marking shall be applied using low stress steel stamps. 4.1 The Supplier Quality Leader and the personnel responsible for the purchasing of products and services for each Operating Unit are jointly responsible for ensuring complete implementation and compliance with this procedure. 4.2 The MPE Leader is responsible for the review and approval of welding procedures. 5.0 Quality Records The following records produced by this procedure are considered Quality Records and shall be maintained and controlled according to the requirements in OGQ Record Control: 5.1 Certification and Documentation Requirements The following documentation shall be submitted to via the method instructed in the purchase order: Certificate of compliance with purchase order and approved WPS GE PROPRIETARY UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY PAGE 6 OF 8

7 Heat Treat Charts, if applicable 6.0 Definitions and Acronyms Heat Treat Records, if applicable (showing type, method, times, temperatures, furnace thermocouple and set point of soak temperature.) Hardness Test reports, if applicable Italicized terms have been defined in the GE O&G QMS Lexicon. Their definitions have been repeated here for convenience purposes. In case of conflict, the GE O&G QMS Lexicon will take precedence. 6.1 Definitions 6.2 Acronyms Heat Treat Charts uneditable graphical representation of the temperature-time cycle including heat up and cool down. It includes legible scale markings for time and temperature. Operating Unit identifies the various organizations and operating companies that make up. Operating Unit Manager the individual in charge of a operating unit. Quality Management Representative refers to the designated management representatives for each of the Operating Units. Product the result of a process. Whenever the term product occurs, it can also mean service or any deliverable associated with fulfillment of a contract. The following acronyms are applicable to the use and implementation of this procedure: EPS Engineering Part Specification located in epims (replaces EDC in Syteline) MPE Materials & Process Engineering GE PROPRIETARY UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY PAGE 7 OF 8

8 7.0 References The latest effective editions of the following specifications are included by reference in the text of this specification: ANSI/API Specification Q1 - Specification for Quality Programs ANSI/API Specification 6A - Specification for Wellhead and Christmas Tree Equipment ISO/IEC General Requirements for the Competence of Calibration and Testing Laboratories ISO Quality System Standards ASME B&PV Code, Section IX - Welding and Brazing Qualifications NACE MR Standard Material Requirements - Sulfide Stress Cracking Resistant Metallic Materials for Oilfield Equipment SQ-07 - Supplier Quality Requirements - Heat Treatment Operations SQ-10 Supplier Quality Requirements Nondestructive Testing Services SAE-AMS-H Process for Heat Treatment of Steels 8.0 Compliance Requirements Full compliance required by 06-Feb-2014 Title: Associated Heat Treatment Operations Reference: Revision: 1.2 Application Date: 01/06/2014 Expiration Date: 01/06/2017 Author: Ashley Weatherington External References: GE PROPRIETARY UNCONTROLLED WHEN PRINTED OR TRANSMITTED ELECTRONICALLY PAGE 8 OF 8