Springer and Springer, Inc.

Quality Manual
“If You Can Dream It…We Can Build It”
Springer and Springer, Inc
SNS Fabricators, LLC
11799 Lena Dr
Cleveland, TX 77328

Record of Revisions and Issuance

Rev
Date Description Prepared By Approved By
#

Original Draft Issued to D. Springer for

0 03/05/2019 J. Basham D. Springer
Review and Approval
 Document History: Original Version Drafted on March, 2019
Prepared by James Basham CWI/CWE #16040701 – Contract Inspector/Consultant

Record of Amendment
Rev Section Description of Change

2
 Table of Contents

Section 1: Management Support and Responsibility ………………………………………………………………………… 5

Section 1.2: Welding Codes …………………………………………………………………………………………………………………. 6

Section 1.3: Management Support of Quality Control ……………………………………………………………………….… 7

Section 1.4: Authority Given to Quality Control Personnel ………………………………………………………………….. 8

Section 1.5: Management Review and Approval …………………………………………………..…………………………….. 9

Section 2: Organizational Chart ………………………………………………………………………………………………………… 10

Section 2.1: Duties of Executive Management ………………………………………………………………………………….… 11

Section 2.2: Delegation of Authority by Executive Management …………………………………………………………. 12

Section 2.3: Duties of Management ……………………………………………………………………………………………….…… 13

Section 2.4: Executive Management Contact Information ………………………………………………………………….. 14

Section 3: Document Control .…………………………………………………………………………………………………………. 15

Section 3.1: The Quality Manual …………………………………………………………………………………………………………. 16

Section 3.2: Contract Documents ………………………………………………………………………………………………………… 18

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Section 3.3: Drawings …………………………………………………………………………………………………………………………. 20

Section 3.4: Quality Records, Forms, and Reports ………………………………………………………………………………. 21

Welder Performance Qualification Record (WPQR) …………………………………………………………. 22

Welding Procedure Specification (WPS) …………………………………………………………………………… 23

Procedure Qualification Record (PQR) ...………………………………………………………………………….. 24

Material Test Report (MTR) ……………………………………………………………………………………………… 25

Nondestructive Examination Report (NDE) ………………………………………………………………………. 26

NDE Personnel Qualification/Certification Record …………………………………………………………… 27

Quality Control Checklist …………………………………………………………………………………………………. 29

Material Inspection Report-Shipping and Receiving …………………………………………………………. 31

Nonconformance Report (NCR) ……………………………………………………………………………………….. 32

Equipment Calibration Record …………………………………………………………………………………………. 33

Weekly Measuring Equipment Verification Log………………………………………………………………… 34

Internal Audit Report ………………………………………………………………………………………………………. 35

Welder Continuity Log ……………………………………………………………………………………………………… 37

Section 3.5: Document and Record Retention …………………………………………………………………………………….. 38

Section 4: Material Control ………………………………………………………………………………………………………………. 39

Materials Document-Purchasing ……………………………………………………………………………………… 40

Materials Document-Production …………………………………………………………………………………….. 41

Section 5: Welding …………………………………………………………………………………………………………………………… 42

Section 6: Welding Procedure Specifications and Procedure Qualification Records………………………….. 43

Section 6.1: Welder Performance Qualification …………………………………………………………………………………… 44

Section 6.2: Filler Metal ………………………………………………………………………………………………………………………. 45

Section 7: Inspection ………………………………………………………………………………………………………………………… 46

Section 7.1: Weld Inspector Qualifications ………………………………………………………………………………………….. 47

Section 7.2: NDE Inspector Qualifications …………………………………………………………………………………………… 48

Section 7.3: NDE Procedures ………………………………………………………………………………………………………………. 49

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Section 7.4: Subcontract Inspectors and NDE/NDT Technicians ………………………………………………………….. 50

Table of Contents-Continued

Section 8: Nonconformance …………………………………………………………………………………………………………….. 51

Section 9: Calibration ……………………………………………………………………………………………………………………….. 52

Section 10: Internal Quality Audits …………………………………………………………………………………………………….. 53

Section 11: Sample Forms ………………………………………………………………………………………………………………….. 54

Section 12: Library ……………………………………………………………………………………………………………………………… 55

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 Section 1: Management Support and Responsibility

It is and will remain the purpose, position, and intention of the ownership and management
of Springer and Springer, Inc. and SNS Fabricators, LLC to promote, support, and maintain the
establishment and implementation of a Quality Management System which includes this
Quality Manual. The documents, records, principles, standards, specifications, and
philosophies contained in this manual shall receive the full support of ownership and
management, which requires that all departments operate independently and without

6
manipulation from another, while working together in order to achieve fulfillment of contract
documents and customer satisfaction.

All departments shall be provided with the necessary documents, records, forms,
standards, equipment, and the ability to meet requirements as outlined in the AWS B5.17
standard, and shall have full support of Ownership and Management.

Section 1.2: Welding Codes

Springer and Springer, Inc. and SNS Fabricators, LLC incorporates the use of the following
welding codes and standards for controlling welding processes, weld joint design, fabrication
requirements, and weld acceptance criteria into the manufacturing process. As requested or
required by client and customer contract documents, the use of other welding codes and
standards will be considered as specified in AWS QC17:2015-Specification for AWS
Accreditation of Certified Welding Fabricators.
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1) AWS D1.1/D1.1 M:2015 Structural Welding Code-Steel
2) AWS D1.2/D1.2M:2014 Structural Welding Code-Aluminum
3) AWS D1.6/D1.6M:2017 Structural Welding Code-Stainless Steel

Section 1.3: Management Support of Quality Control

In order to insure that safe and reliable products are manufactured to and in accordance
with client contract documents, as well as all applicable welding codes, specifications, and
standards, the Quality Control Department and it’s personnel shall have the full and complete
support of management, and must be allowed to function without being manipulated in any
way which will cause a compromise in any of the duties and functions it performs. The Quality
Control Department shall report to Executive Management to insure a system of checks and

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balances as well as an internal compliance with the applicable contents, procedures, practices,
standards, and specifications contained within this manual, and as they apply to the particular
job duties and functions of all Quality Control Personnel.

Section 1.4: Authority Given to Quality Control Personnel

All Quality Control Personnel shall have the authority to perform the following duties and
functions with full support from management, and receives that authority from Executive
Management.

 Identify quality problems

 Verify implementation of solutions

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  Limit or control further processing and delivery of nonconforming items until proper
disposition has occurred

In the event a dispute or disagreement occurs between Quality Control and other
departments, Doyle or Robert Springer will provide mediation as the owners and Executive
Managers of Springer and Springer, Inc. and SNS Fabricators, LLC in an attempt to mitigate any
issues which will cause compromise to the principles contained within this manual.

Section 1.5: Management Review and Approval

Springer and Springer, Inc. and SNS Fabricators, LLC is owned and operated by Doyle and
Robert Springer who hold executive management roles within the company. This document
has been designed and fabricated with the full consent of each, has been reviewed, and finally
has been approved as the Standard Operating Procedure which serves as the Quality Manual
for all operations pertaining to the contents contained within.

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Signed: Doyle Springer________________________________Date______________________

Signed: Robert Springer_______________________________Date______________________

Section 2: Organization Chart

The following is a depiction of the order of operations within Springer and Springer, Inc. and
SNS Fabricators, LLC.

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 Executive Management
-----Owners-----

Doyle Springer Robert Springer

All Departments

QC Project Shaker/ Welding Welding Field Coating/ CNC

Management Feeder And And Service Finishing
Department Fabrication Fabrication
Aluminum Carbon

Section 2.1 Duties of Executive Management

Executive Management of Springer and Springer, Inc. and SNS Fabricators, LLC consists of
Doyle and Robert Springer. All business operations are overseen by executive management
who delegates departmental duties to department managers.

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 Section 2.2: Delegation of Authority by Executive
Management
Each department has been assigned personnel who manage and execute all supervisory
duties by the authority given by Executive Management. In the event that a department
manager is unavailable, standard practice is to have the department lead as interim manager
until the full time manager returns.
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 Section 2.3 Duties of Management
Each department is assigned a Department Manager who is assigned the responsibility of
overseeing the day to day functions and duties of each department in which it represents.
Those duties include communicating with Executive Management regarding scheduling and
workload, delegating daily tasks to department personnel, and communicating with other
departments as required. In addition, all departments are independently responsible for

14
implementing the following policies, duties, and practices and are carried out by direction
from each department manager.

Safety: Each department is responsible for ordering and maintaining the required and desired
PPE necessary for promoting and enforcing all safety rules and regulations according to
company guidelines and safety policy, ANSI Z49.1, Safety in Welding, Cutting, and Allied
Processes, as well as all applicable OSHA regulations and standards for workplace safety.

Purchasing: Handled by each department manager in accordance with contract documents,

fabrication drawings, and material requirements.

Material Handling: Unloading material and supplies from delivery trucks, movement of
material for layout and fabrication, transporting product throughout the manufacturing
process, and loading for transport and shipping is carried out through personnel who are
qualified to operate loading and unloading equipment.

Assembly: Each department handles the process of assembly within its own structure and is
carried out by trained personnel within that department.

Section 2.4 Executive Management Contact Information

Doyle Springer Robert Springer

281-659-1501 281-659-1501
Mobile: 281-728-9523 Mobile: 281-414-1855
Email: doyle@snsfabs.com Email: Robert@snsfabs.com
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 Section 2.5 Managers Management Contact Information

Quality Control: Project Management:

Kenneth Carter Robert Springer
Mobile: 832-923-2067 Mobile: 281-414-1855
kennethcarter455@gmail.com robert@snsfabs.com

Welding and Fabrication: Aluminum Welding and Fabrication: Carbon Department

Francisco “Paco” Ramirez
Mobile: 281-755-8040
pacrmi@yahoo.com
Shaker/Feeder Department
Kenneth Carter
Mobile: 832-923-2067
kennethcarter455@gmail.com
Francisco “Pancho”
Sosa Kyle Raymond
Mobile: 832-401-5425
Natural Gas Filter Department
Francisco “Pancho” Sosa
Mobile: 832-401-5425

Waste Water Treatment Plant Department

Field Service
Kyle Raymond

CNC Cutting Department

Coating and Finishing
Enrique Garcia
George Roch

Section 3: Document Control

This section consists of information regarding the quality manual, contract documents,
drawings, quality records, forms, reports, and record retention and how these documents are
managed within the company. Review of documents are the responsibility of a designee who
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is found to be competent and qualified, and considered by the company to be a subject matter
expert in the area of operation and with the information being reviewed. No matter the source
or author of any document, including this quality manual, it is and will remain the
responsibility of Executive Management to approve any final version or revision that is put into
rotation or service as part of the Quality Management System.

Section 3.1: The Quality Manual

Preparation and Revision of the Quality Manual: This Quality Manual was prepared, written,
and drafted by James Basham, CWI/CWE of On-Site Certification who provides consulting,
welder certification, training, and third party visual inspection services for Springer and

17
Springer, Inc. and SNS Fabricators, LLC. By nature of a consistent change that is present in the
dynamics and structure of business, personnel, policies, procedures, customer requirements,
codes, standards, and governmental laws, it is necessary to subject this manual to an annual
internal audit, and perform the necessary revisions to its content. The revision process is as
follows:

1. The recognition of a need for change in any of the content of the Quality Manual by
Executive Management or Department Managers, either during an internal annual
audit or at any time in which a need or concern arises.
2. An informative meeting with Executive Management and Department Manager in
order to discuss the proposed changes for revision of the Quality Manual.
3. Once approved, the physical changes to the Quality Manual are implemented by the
Quality Control Department and recorded in the “Record of Amendment” table
located on page 2 of this manual. The individual who make the physical changes will
appear in the “Prepared By” section of the “Revisions and Issuance” table located on
the front page of this manual, and will be accompanied by the date of that revision.
NOTE: Changes to the forms, records, and other documents contained in this manual
are subjected to a separate review process listed in Section 10 of this document.

Approval Process for Revision of the Quality Manual: Revisions to this Quality Manual are
authorized by Executive Management and maintained by the Quality Control Department. The
process for approval involves a final review of the proposed revisions to the document by a
member of Executive Management, who’s name will appear in the “Approved By” section of
the “Revisions and Issuance” table located on the front page of this manual and accompanied
by the date of that approval.

Replacement of Quality Manuals: Following the official approval for revision to the Quality
Manual, the Quality Control Department will dispatch personnel to recover or delete all
obsolete copies (electronic and paper form), and replace them with newly revised versions of
this manual.

Availability of the Quality Manual: All departments shall have in its possession, a current copy
of the latest version and revision of the Quality Manual for presentation and viewing upon
request by all personnel, customers, clients, potential clients, and auditors as approved by
Executive Management. Traceability, tracking, distribution, and management of all copies of

18
the Quality Manuals that are in rotation or in use shall be the responsibility of the Quality
Control Department and is achieved through the implementation of an Excel spreadsheet.

Section 3.2: Contract Documents

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How Contract Documents are Received: Executive Management receives contract documents
from the client in either electronic and/or paper form through email or parcel service, and
retains the original and all revised or amended contracts in an electronic and/or physical file
folder system. Contract documents are considered to be items of a proprietary and sensitive
nature, and are treated with confidentiality. After a period of no longer than two years from
the final written approval and acceptance of the project and all services by the client, contract
documents will be shredded and either recycled or disposed of in a proper receptacle.

Review of Contract Documents: Executive Management is ultimately responsible for the

review and distribution of all contract documents, as well as any amendments or changes to
those documents made by the client. However, Project Management and Department
Managers will be included in the review process as needed, and will also receive copies of the
contract documents in either electronic and/or paper form for reference throughout the
manufacturing process of the particular project that the documents are in reference to.

Changes and Amendments to Contract Documents: In the event that a need arises for either
party (the company or the client) to deviate from the contract documents, additions and
changes will be in the form of an amendment, and will be added to the original contract
documents. There will be no limit to the number of amendments allowed. However, in the
event that both parties agree, a new contract document containing all of the amendments
may be drafted and adopted in order to reorganize and restructure the terms and agreements
required for a particular project.

 Changes Initiated by The Company: In the event that any deviation is found necessary
or desirable by company personnel, and can be carried out without cause or
compromise to safety, quality, structural integrity, or serviceability to the product, the
Project Manager or Executive Management shall issue a formal written request to the
client indicating the cause or need for deviation or change, and will include a request for
an amendment to the original contract documents. Executive Management shall insure
that new or amended contract documents are received, reviewed, and distributed
according to the process described within this section.

 Changes Initiated by The Client: In the event that any deviation is found necessary or
desirable by the client, Executive Management shall insure that either new or amended
20
contract documents are received, reviewed, and distributed to Project Management
and in the proper method as indicated in this section. It is the responsibility of Executive
Management to insure that new or amended contract documents are issued to Project
Management, who will then issue contract documents to department managers.

Section 3.3: Drawings

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How Drawings are Distributed: Executive Management shall be responsible for insuring that
Project Management has current customer and client drawings as needed. Project
Management will insure that each department manager has current drawings as they pertain
to the particular phase of each project. Each department manager will insure that all
personnel have access to current drawings as needed in order to perform the work in
accordance to contract documents.

How Drawing are Issued: Drawings may be issued in either electronic or paper form, or both.

Revised Drawings: Executive Management will insure that Project Management has current
drawings with the latest revisions. Project Management will insure that all department
managers have current drawings with the latest revisions. Department managers will insure
that all department personnel have current drawings with the latest revisions. Quality Control
will verify and document that all drawings in use are current with the latest revisions.

Section 3.4: Quality Records, Forms, and Reports

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 The following types of forms and records are used as a system of documentation
throughout the manufacturing process, and as a means of insuring that codes, standards,
specifications, and contract documents are adhered to.

 Welder Performance Qualification Record (WPQR) or Welder Qualification Test Record

(WQTR)
 Welding Procedure Specification (WPS)
 Procedure Qualification Record (PQR)
 Material Test Report (MTR)
 Nondestructive Examination Report (NDE)
 Nondestructive Examination-Personnel Qualification/Certification Record
 Traveler/Record of Final Inspection
 Traveler/Record of Final Inspection and QC Checklist
 Material Inspection Reports for Shipping and Receiving
 Nonconformance Record (NCR)
 Equipment Calibration Record
 Measuring Equipment Calibration/Verification Record
 Internal Quality Audit Report
 Welder Continuity Log

Welder Performance Qualification Record (WPQR): Written verification that a welder or

welding operator has produced welds meeting a prescribed standard of welder performance.
23
 SAMPLE WPQR FORM

Welding Procedure Specification (WPS): Document providing the required welding variables
for a specific application to assure repeatability by properly trained welders and welding
operators.

Sample WPS FORM

24
Procedure Qualification Record (PQR): A record of welding variables used to produce an
acceptable test weldment and the results of tests conducted on the weldment to qualify a
welding procedure specification.

SAMPLE PQR FORM

25
Material Test Report (MTR):  Quality assurance document that certifies a
material's compliance with applicable standards.

SAMPLE MTR
26
Nondestructive Examination Report (NDE): A document of record showing the determined
suitability of a material or a component for its intended purpose using techniques not affecting
its serviceability.

Sample Nondestructive Examination Report

27
 Client/Owner

Project

Serial/Part/Spool Number

Job or Contract Number

Drawings/Approval Date

Examiner’s Name: _____________________________________________Signature:_______________________________________

Department: _________________________________________________ Location: _______________________________________

Date of Examination

Examination Method

Examination Procedure

Examiner and ID Stamp

Joint Identification

Joint Design

Service Class/Weld Class

Base Metal (1) Specification

Heat/Lot Number

S Number

Base Metal (2) Specification

Heat/Lot Number

S Number

Welding Procedure Specification

Filler Metal

Heat/Lot Number

Pre-Heat Interpass

Post-Weld Heat Treatment

Welder Stamp or ID Number

Fit-up

Root Opening/Clearance

Root Face/Pull-Back (Suck-Back)

Groove Angle

Alignment

Welding Attributes

28
 Reentrant Angle

Fillet Weld Face-Convexity/Concavity

Groove Face/Root Reinforcement

Length/Size

Cracks

Burn-Through

Melt-Through

Incomplete Fusion

Crater Pit

Oxidation

End or Corner Melt

Undercut

Porosity

Spatter/Arc Strike

Surface Condition

Paint, Oxidation, Grinding Marks, Gouges

Spatter/Arc Strikes

Nondestructive Examination-Personnel Qualification/Certification Record: Document of

record indicating the individual who has successfully completed sufficient training, and has
met the requirements for qualification as outlined in ASNT-SNT-TC-1A Personnel Qualification
and Certification in Nondestructive Testing or company policies and practices.

Sample NDE Personnel Qualification and Certification Record

Name: I.D. Number

Current Certification Status: Trainee Level I Level II Level III Limited

Method: Recertification Due Date:

Recertified by Continuing Satisfactory Experience Date: By:

Education
High School or Equivalent Advanced

29
 Certificates:

Degrees:

NDT Training
Course Date Hours Instructor

Experience
Employer Method(s) Dates (From/To) Months or Hours

To

To

To

Qualification Examination Results

General Specific Practical Composite Score Date Administered By

We certify that the above named employee has satisfactorily met the qualification requirements of the SNS Fabricators, LLC and
Springer and Springer, Inc. certification procedure and in accordance with ASNT SNT-TC-1A.

Company Representative: ____________________________Title: _____________________

Signed: ___________________________________________Date: _____________________

Weld Mapping: Weld mapping uses identifiers to designate which WPS’s are applicable
throughout different areas of a weld joint or production piece. Weld mapping can be
incorporated into any project upon request, but at this time SNS Fabricators, LLC and Springer
and Springer, Inc. does not use weld mapping as a standard part of the fabrication and welding
process.

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Record of Final Inspection and QC Checklist: As a method of logging inspection activities
performed on a product as well as final inspection, a traveler packet can be kept and
maintained throughout the entire fabrication and welding process. The packet will consist of a
Quality Control Checklist which includes a first article, hold points, inspections throughout,
final inspection, and any other applicable article deemed necessary.

Sample Quality Control Checklist

Client/Owner

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 Project

Serial/Part/Spool Number

Job or Contract Number

Drawings/Approval Date

Examiner’s Name: _____________________________Signature:_____________________________________

Department: _________________________________ Location: _____________________________________

Date of Verification
Unacceptab
Acceptable Unacceptable Acceptable Unacceptable Acceptable
le

First Article Inspection: Correct

Material Verified?

First Article Inspection:

Dimensions and Fit-up

First Article Inspection: Welds

Production Inspections and

Hold Points

Production Inspections and

Hold Points

Final Inspection: Dimensions

Final Inspection: Welds

Approve Product for Final Release

Print Name:_____________________________
Approved By
Signed: _________________________________

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Heat Treatment or Stress Relieving: When required by contract documents, governing code,
or specification, heat treating or stress relieving will be performed by a third party company
who specializes in the process and proper documentation will be retained.

33
Material Inspection Reports for Shipping and Receiving: As a standard, each department
orders and receives its own material, hardware, and parts that are used in the fabrication,
manufacturing, and assembly process. An initial Material Inspection Report is used to
document that the type and size of material received is correct and to record the condition in
which it was received in.

Sample Material Inspection Report-Shipping and Receiving

Client: Project No.
Serial
Project Name: Contract No. No.

Drawing No. Part No. Date:

Disposition
Description of Activities Special Remarks
Accept Reject Hold

Check Delivery Ticket

Verify and Receive MTR ffg

Verify Heat Numbers

Verify Quantity

Overall Condition of Shipment

Check QC Certificate from Supplier (if req) fs

Verify Coating and Finishes

Method of Securing Shipment (Shipping)

Structural Fitting Manufactured Coating or Blasting

Grade of Material Plate Pipe
or Extruded or Flange Item Product

Al CS SS NA Other

Checked or Verified By Inspected By Witnessed By

Name
Name: Name:
:

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 Dept: Dept: Dept:

Title: Title: Title:

Item (s) Were: Shipped Received Notes:

Nonconformance Report: A document of record that is a written identifier of deficiencies in

items, materials, or a process that does not conform to the quality manual, approved
procedures, and applicable codes or specifications, and may address possible methods and
ways of mitigating the issue from being repeated.

Sample Nonconformance Report

Client/Owner

Project

Serial/Part/Spool Number

Job or Contract Number

Drawings/Approval Date

Cause or Reason for Nonconformance

Noncompliance with Inspection Procedure Safety

Material Failure Inadequate Training

Equipment Failure or Malfunction Personnel Issue

Calibration Issue Communication or Interpretation

Noncompliance with WPS PreHeat or Interpass Temperature

Examination/Testing Method Result of Nonconformance

Visual Inspection Base Metal or Material Failure

Dye Penetrant Incorrect Filler Metal or Electrode

Magnetic Particle Incomplete Fusion

Ultrasonic Misalignment (Weld Joint Prep) or Improper Fit-up

Eddy Current Weld Porosity of any Type

Radiographic/X-Ray Cracks (Includes Crater Cracks)

Pressure Testing/Leak Test Undercut

Audit Weld Face (Convexity or Concavity)

Other Arc Strike/Spatter

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 Paint or Coating Issue

Identified By: Date

Accepted
Recommended
Corrective Action
Rejected

Accepted
Recommended
Training
Rejected

Corrective Action or Completion

Training Verified By Date

Equipment Calibration Record: Documented proof that equipment is maintained and

calibrated, and if found to be out of calibration what was done to correct it.

Sample Equipment Calibration Record

Manufacturer:____________________________
Type: ______________________________

Model:_____________________________ Serial or Tag No. __________________________

Date of Purchase: ____________________

Calibration Standard: ___________________________________________________________

Dept. or Location: __________________________________

Calibration Details

Reason Performed By Date of Service

 Repair
 Routine Maintenance
Company: ___________________________________
 Questionable Reading
or Indication
Name:_______________________________________
 Annual as Required Next Service Due

36
 Signed:______________________________________

 Internal Company Personnel

Calibration Results
Remarks or Comments:
 Successful/Within Allowable Limits
 Unsuccessful/Recommend Additional Service
 Unsuccessful/Recommend Replacing Entire Unit

Approved By: _______________________________________Date: _____________________

Position or Title of Representative: _______________________________________________

-Sample Weekly Measuring Equipment Verification Log-

Fitting and Fabrication
Equipment
Verification Method Acceptable/Unacceptable Name of Personnel Date
Description
EX: Tape Verification Scale in Dept
Acceptable John Doe 02-25-2019
Measure Managers Office

37
Internal Quality Audit Report: Document of record verifying the process of systematic
examination of a quality system carried out by an internal quality auditor or an audit team.

Sample Internal Quality Audit Report

Auditor Information

Auditor Name: _________________________________ Sign: ____________________________________

Auditor Title: _________________________________ Auditor Department: __________________________

Auditor Qualifications/Qualified by (Check All That Apply)

 Certification  Training  Experience  Education  In-House  Other ________________________
 Audit Authorized By Executive Management

Representative: Print ________________________________Sign:___________________________________

Reason for Audit

 Annual  Result of Incident  Investigation  Cause for Question

 Quality Control
 Project Management
 Shaker/Feeder Department
Area Audited
 Coating/Finishing
 Welding and Fabrication/Aluminum
 CNC Cutting
 Welding and Fabrication/Carbon Steel
 Natural Gas Filter
 Field Service
 Waste Water Treatment
Level of Audit

 Quality Management System  Departmental

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 Items Audited
 Documentation  Forms  Records  Facility  Equipment  Personnel Qualifications/Certifications
Results

Recommendation or Course of Action to Improve or Reach Goal Completion Date

Recommendation or Course of Action Approved By

Print: ______________________________ Sign: _____________________________ Date:
Course of Action Completed Terms of Extension
 Yes-Completion Date:__________________
 No-Recommend Extension

Completion Verified by Executive Management

Print:_______________________________________ Title:_______________________________________
_

Sign:______________________________________ Date: _____________________

Welder Continuity Log: Document of record that serves as the first part of data entry for the
purpose of tracking welder performance to insure currency and documentable activity within a
six month period on a particular process and to a specific WPS.

39
 Sample Welder Continuity-Daily Log
Client/Owner

Project

Serial/Part/Spool Number

Job or Contract Number

Drawings/Approval Date

Area, Location, or
Department

Welding Department Manager-Print: __________________________________________Sign: _________________________________________Date: _______________

Material Specification Welder Stamp

Joint Type Thickness Pipe OD Type of Material WPS # Date
............... TO ............... or ID

40
 This continuity log is used to track welder activity which is used to insure currency of a welder’s certification or the need to recertify in the event that six consecutive months
have passed since welding on a particular process, material, or electrode as in accordance with any one Weld Procedure Specification. By signing, the Quality Control Manager
acknowledges receipt of this form and insures the accurate recording and input of all of the information and data it contains onto the Welder Continuity Spreadsheet.

Quality Control Manager-Print: ______________________________________Sign: _______________________________________Date: ____________________

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 Section 3.5: Document and Record Retention
All quality documents and records are stored both electronically as well as in paper form.
Electronic versions are stored on a shared drive within the company system, and paper forms
are stored in a physical file folder system. Original templates are kept and maintained in the
form of a document booklet designed for each one. This booklet includes a table for recording
the author of the document, revisions during the life of the document, and information on the
approval. The documents and their booklets are subjected to an annual internal audit by a
panel which consists of Executive Management and department managers, and shall be
documented on an internal audit form. During this time, suggestions for changes to any
documents are discussed and drafted into the document booklets, which is signed by
Executive Management for final approval on the revisions table located on the front page of
each document booklet. Ultimately, the Quality Control Department oversees and maintains
all quality documents under the authority of Executive Management, and incorporates the use
of an Excel spreadsheet to record and calculate retention data such as when a document that
is no longer in use can be destroyed.

 Current and active documents are maintained using an annual auditing and revision
system.
 Obsolete documents are destroyed after a period of no more than 2 years of inactivity.
 The Quality Control Manager is responsible for maintaining all documents under the
authority of Executive Management.
 Documents are stored electronically on a shared company system and/or in paper form
in a file folder system located in the Quality Control office.
 During the annual audit, the Quality Control department will shred all obsolete
documents and either recycle or discard of them in the proper manner.

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 Section 4: Material Control
Springer and Springer, Inc. and SNS Fabricators, LLC employees a material control system to
insure that proper material is ordered, stored, received, released, and introduced into and
tracked throughout the fabrication and manufacturing process. As a part of this process, the
following is implemented:

 Materials Document-Purchasing
 Materials Document-Production

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Materials Document-Purchasing: As a method of acknowledging the materials required for each project and ensuring that
correct materials (or an acceptable substitute) are purchased, ordered, and received, a Materials Document for Purchasing is
used to record the process.

Sample Materials Document-Purchasing

Client or Customer

Project

Drawings/Approval Date: Purchase Order (PO) #:

Serial/Part/Spool Number: Job or Contract Number:

Company Order for Stock?  YES  Springer and Springer, Inc.  SNS Fabricators, LLC.

Material Certification Required?  YES  NO If YES, Requested By:

 Plate  Pipe  Electrodes (Conforms to AWS Spec)  Part or Item  Hardware  Paint or Coating  Other

Description of Material or Item Needed Actual Material or Item Ordered Date Purchased Date Received

I acknowledge that the above Item(s) were purchased and received in accordance to drawing specifications, standards, and/or contract
requirements.

Dept. Manager-Print: _________________________________________ Sign:____________________________________________________

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Date: ________________________
Materials Document-Production: As a method of ensuring the correct materials are released into the production process, a
Materials Document for Production is implemented as a document of record.

Sample Materials Document-Production

Client or Customer

Project

Drawings/Approval Date: Purchase Order (PO) #:

Serial/Part/Spool Number: Job or Contract Number:

Were MTRs Verified?  YES  NO Were Material Certifications Verified if Required?  YES  NO

Description of Material or Item Needed Actual Material or Item Released Date Released

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 I acknowledge that the above information is accurate and the Item(s) were released into production as in accordance to drawing, specifications,
standards, and/or contract requirements.

Dept. Manager-Print: _________________________________________ Sign:____________________________________________________

Date: ________________________

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 Section 5: Welding
Springer and Springer, Inc. and SNS Fabricators, LLC incorporate the use of welding codes,
specifications, and standards as required by contract documents and customer/client
preferences. As a standard, American Welding Society welding codes are used, but others such
as ASME are also used when preferred or required.

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 Section 6: Welding Procedure Specifications and Procedure
Qualification Records
Springer and Springer, Inc. and SNS Fabricators, LLC incorporates the use of both qualified
and prequalified Weld Procedure Specifications within the manufacturing, welding, and
fabrication processes, and uses the latest versions of AWS D1.1 Structural Welding Code-Steel
and AWS D1.2 Structural Welding Code-Aluminum for WPSs, PQRs, and Welder Performance
Qualifications. All Welding Procedure Specifications (WPS) are kept and maintained within an
official weld book. When prequalified WPSs are used, it is not required to have a written
Procedure Qualification Record (PQR). However, one may still be written and included in the
weld book as additional documentation. A WPS that requires qualification through testing
shall include a PQR as a document of record for the qualification of that WPS, and is included
in the weld book. When a particular code allows, AWS Standard Welding Procedure
Specifications (SWPS) may also be used, and will be included in a weld book for that particular
procedure. Each weld book is audited annually by an auditing committee comprised of
Executive Management and department managers, and includes a table of record that
documents any and all revisions and changes. A CWI shall be the designee responsible for
insuring that any proposed changes or revisions are in accordance to the welding code in
which they are written to before any physical changes are made. The QC manager shall be
responsible for physical changes, but a member of Executive Management will approve all
final changes and revisions. The Project Manager approves all shop drawings and ensures that
the correct WPS of reference is listed on all shop drawings. However, a member of quality
control will verify that the correct WPS is listed and is being used as a part of the visual
inspection process.

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 Section 6.1: Welder Performance Qualification
As required by contract documents or a particular welding code, all welders, welding
operators, and tackers are subjected to a performance qualification test in accordance to a
qualified or prequalified WPS, which is administered by an AWS Certified Welding Inspector.
All acceptable weld tests performed by personnel are documented by a written Welder
Performance Qualification Record (WPQR). An AWS Certified Welding Inspector shall be the
designee responsible writing and reviewing WPQRs for compliance to welding codes,
standards, and specifications, and a member of Executive Management will approve and
authorize those documents.

Welders, Welding Operators, and Tackers:

 Qualified to AWS D1.1 Structural Welding Code-Steel and AWS D1.2 Structural Welding
Code-Aluminum.
 Identified by two letters, two numbers, or a combination of one letter and one number.
 Quality Control personnel are responsible for verifying that only qualified welders,
welding operators, and tackers are assigned to specific jobs. However, it is the
responsibility of the fabrication and welding department manager to assign personnel to
the specific jobs in which they are qualified for.
 The Quality Control department is responsible for verifying the currency and continuity
of welders, welding operators, and tackers. The fabrication and welding department
manager is responsible for recording daily activity onto a production form, which is
submitted to the QC department on a weekly basis. The QC department enters this
information onto an Excel spreadsheet which tracks continuity to ensure that personnel
are current. In the event a welder, welding operator, or tacker has not demonstrated
documentable activity within a consecutive six month period or as required by a
particular code, that individual must requalify.

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 Section 6.2: Filler Metal
Springer and Springer, Inc. and SNS Fabricators, LLC uses electrodes and filler metal which
conforms to AWS A5.XX and stores all electrodes and filler materials in dry boxes. Cross
contamination is prevented by storing like filler metals and electrodes within the same dry
box. For production purposes, electrode ovens are used when conditions exist that promote
discontinuities within a weld as a result of ambient electrode temperature and/or as a
contract requirement or client preference. Filler metals and electrodes that are not required
to bake or be heated may stay at ambient temperature during storage or use, but those that
must be heated will be stored in an oven, stay in a rod box while being used in production, or
returned to the oven at the end of the shift for redrying and baking. To ensure correct filler
metal is ordered, purchased, received, and used, a system of documentation and verification is
implemented. Filler Metal and electrodes that are unusable or damaged are recycled.

 Ordering/Purchasing: A purchasing document is used to record the filler

metal/electrodes that are ordered or purchased.
 Received: In order to ensure that the correct filler metal/electrodes have been received
in good order, a shipping and receiving document is used to verify the product upon
delivery and record the condition.
 Production: The fabrication and welding department managers are responsible for
ensuring that the correct electrodes are distributed for use in production. A document is
used to record the electrodes used in production, and the QC department or contract
inspector verifies them during the visual inspection process.

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 Section 7: Inspection
As a method of ensuring quality, efficiency, and adherence to contract documents, welding
codes, standards, and specifications, Springer and Springer, Inc. and SNS Fabricators, LLC
implements and incorporates the use of visual inspection practices and procedures as required
by contract documents throughout the manufacturing process. Inspection personnel are
trained and qualified in accordance to ASNT-SNT-TC-1A Standard for Qualification and
Certification of Nondestructive Testing Personnel, and incorporate the methods of visual
inspection as found in AWS B5.11 Guide for the Visual Examination of Welds.

 Visual Inspection: When contract documents require, the QC department or

department manager schedules a contract AWS CWI for visual inspection services which
are carried out using a written and approved visual inspection procedure. A Quality
Control Checklist is used to record the phase that each inspection was performed. This
checklist consists of:

A) First article inspection for material, filler metal and electrode verification,
dimensional conformance, fit-up, and may include welds within that first
article.
B) Production inspections and/or Hold Points throughout as required.
C) Final dimensional and weld inspections.

 Frequency of Inspections: As a standard, the welding and fabrication supervisor is

responsible for verifying dimensional conformity and weld inspection. When contract
documents require, first article inspections, production inspections, and final
inspections are carried out by an AWS CWI.

 Acceptance Criteria: Weld inspection is carried out by a qualified AWS CWI, and in
accordance to AWS B5.11 Guide for the Visual Examination of Welds. Acceptance
criteria is in accordance to AWS D1.1 and AWS D1.2. However, it is acceptable for other
acceptance criteria to be adhered to from other welding codes, even if that code differs
from those in which personnel have qualified to. For example, a welder may be qualified

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 to AWS D1.1 and the visual inspection criteria may be used from API 1104 if the
customer requires.

Section 7.1: Weld Inspector Qualifications

When required by contract documents, Springer and Springer, Inc. and SNS Fabricators, LLC
uses third party, contract, and consultant based AWS Certified Welding Inspectors for visual
inspection (VI or VT) of weldments. In the event an in-house welding inspector program is
implemented, personnel should be qualified to the education, training, experience, and testing
provisions as outlined in ASNT-SNT-TC-1A Standard for Qualification and Certification of
Nondestructive Testing Personnel.

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 Section 7.2: NDE Inspector Qualifications
Springer and Springer, Inc. and SNS Fabricators, LLC contracts all of the following
Nondestructive Examination (NDE) and Nondestructive Testing NDT Methods to qualified
technicians, interpreters, and inspectors. Inspectors and technicians are qualified and certified
in each method they perform, and in accordance to ASNT-SNT-TC-1A Standard for
Qualification and Certification of Nondestructive Testing Personnel, and may also be require to
meet the qualification requirements of AWS B5.15 Specification for the Qualification of
Radiographic Interpreters for those inspectors or technicians performing RT functions.

 Radiographic Testing (RT)

 Ultrasonic Testing (UT)
 Dye Penetrant Testing (PT)
 Mag Particle Testing (MT)
 Visual Inspection or Visual Testing (VI or VT)

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 Section 7.3: NDE Procedures
Springer and Springer, Inc. and SNS Fabricators, LLC utilizes a written Visual Inspection
procedure that the contract AWS CWI performs visual inspections in accordance to. This visual
inspection procedure is audited annually and kept and maintained in a Visual Inspection
Procedure Book that utilizes a table for recording authorized changes and revisions done to
the document. Next, it is reviewed by an AWS CWI for conformance to code requirements.
Then the QC manager implements the physical changes, and finally a member of Executive
Management approves the revision. When other methods of NDE or NDT are used such as RT,
UT, MT, and PT, the contract inspector or technician provides the procedures for those
methods. However, it is the responsibility of the company to verify the credentials,
certifications, and procedures of any individual performing inspection services.

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 Section 7.4: Subcontract Inspectors and NDE/NDT
Technicians
Executive Management for Springer and Springer, Inc. and SNS Fabricators, LLC authorizes
the use of Subcontractors for Nondestructive Examination (NDE) and Nondestructive Testing
(NDT) methods. When contract documents require the implementation of NDE or NDT,
inspectors and technicians shall meet the requirements of ASNT-SNT-TC-1A Standard for
Qualification and Certification of Nondestructive Testing Personnel. The Quality Control
department or department manager is responsible for scheduling NDE and NDT services. The
QC department is responsible for verifying the credentials of each subcontract inspector and
technician. Verification is recorded on the NDE Personnel Qualification and Certification
Record form.

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 Section 8: Nonconformance
As a standard within the company, any employee reserves the right to bring forth and
address a cause for concern with safety, fabrication, welding, production, and manufacturing.
In the event an issue of nonconformance is recognized, there is a system and process in place:

 Production personnel who recognize areas of nonconformance are encouraged to

report the matter to their department lead or manager who will address the matter
with the QC department.
 Department Managers who recognize areas of nonconformance are encouraged to
report the matter to the QC department.
 Any member of Executive Management who recognizes areas of nonconformance is
encouraged to report the matter to the QC department.
 The QC department is responsible for documenting and recording nonconformance
records on the company NCR form.
 When a production item is identified as having issues of nonconformancy, the item is
unauthorized for release into service until corrective action has been verified on the
NCR form.

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 Section 9: Calibration
As a means of ensuring production, measuring, and testing equipment is functional and
operating correctly and within allowed tolerances, as well as producing optimal results and
indications, a calibration system is implemented within the company. Results and
identification information is recorded on different calibration records depending on the type
of item being serviced. Verifications are also implemented in order to insure that measuring
equipment and tools are producing correct measurements. The QC department is responsible
for monitoring and implementing calibration requirements and services.

 Production Equipment Calibration: Welding machines are calibrated on an annual basis

and are tracked by an Excel spreadsheet. CNC cutting and burning equipment,
machining and drilling equipment, and other precision equipment is calibrated and/or
verified for accuracy on an “as needed” basis or as required by contract documents.
 Testing Equipment Calibration: Nondestructive Testing and Nondestructive Examination
is subcontracted and the calibration responsibility lies within the company or individuals
that are contracted to do the testing and examination. However, it is the responsibility
of the QC department to verify that testing equipment has been calibrated upon
inspection services.
 Measuring Equipment Calibration and/or Verification: Measuring equipment such as
tape measures or other measuring devices used in layout and fabrication should be
verified weekly for correct measurements. A standard verification scale or rule is located
in the welding and fabrication manager’s office, and all fitters and fabricators should
verify the measuring equipment that they use in production. A verification log is used to
record the verification of each type of device and is submitted to the QC department at
the end of each work week.

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 Section 10: Internal Quality Audits
Springer and Springer, Inc. and SNS Fabricators, LLC implements an annual internal audit
which includes but is not limited to:

 The Quality Management System

 All Quality Control Documents, Forms, and Records which include:
A. Weld Procedure Specifications
B. Welder Performance Qualification Record (WPQR)
C. Welding Procedure Specification (WPS)
D. Procedure Qualification Record (PQR)
E. Material Test Report (MTR)
F. Nondestructive Examination Report (NDE)
G. Nondestructive Examination-Personnel Qualification/Certification Record
H. Traveler/Record of Final Inspection
I. Traveler/Record of Final Inspection and QC Checklist
J. Material Inspection Reports for Shipping and Receiving
K. Nonconformance Record (NCR)
L. Equipment Calibration
M. Measuring Equipment Calibration/Verification Record
N. Internal Quality Audit Report
O. Welder Continuity Log
P. The Quality Manual
 All Departments
 Facility Condition

These documents, records, reports, forms, and departments are subjected to an annual
internal audit by a panel which consists of Executive management and department managers,
and is documented on an internal audit form. During this time, suggestions for changes to any
document is discussed and introduced. If agreed upon and approved, the changes are
reviewed by an AWS CWI when necessary, those changes are physically made to the
documents by the QC manager, and then signed by Executive Management for final approval

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on the revisions table located on the front page of each document booklet. Ultimately, the
Quality Control Department oversees and maintains all quality documents under the authority
of Executive Management, and incorporates the use of an Excel spreadsheet to record and
calculate retention and auditing data.
Section 11: Sample Forms
The following forms, records, and reports are presented in Section 3.4 as an example of the
actual forms or types of forms that are used in the quality management system.

 Welder Performance Qualification Record (WPQR)

 Welding Procedure Specification (WPS)
 Procedure Qualification Record (PQR)
 Material Test Report (MTR)
 Nondestructive Examination Report (NDE)
 Nondestructive Examination-Personnel Qualification/Certification Record
 Traveler/Record of Final Inspection
 Traveler/Record of Final Inspection and QC Checklist
 Material Inspection Reports for Shipping and Receiving
 Nonconformance Record (NCR)
 Equipment Calibration Record
 Measuring Equipment Calibration/Verification Record
 Internal Quality Audit Report
 Welder Continuity Log

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 Section 12: Library
The following publications are available for viewing and reference, and are kept in the
Quality Control department in electronic and/or paper form.

 AWS A2.4: Standard Symbols for Welding, Brazing, and Nondestructive Examination
 AWS A3.0: Standard Welding Terms and Definitions, Including Terms for Adhesive
Bonding, Brazing, Soldering, Thermal Cutting, and Thermal Spraying
 ANSI Z49.1: Safety in Welding, Cutting, and Allied Processes
 AWS D1.1: Structural Welding Code-Steel
 AWS D1.2: Structural Welding Code-Aluminum
 ASNT-SNT-TC-1A: Standard for Qualification and Certification of Nondestructive Testing
Personnel
 AWS QC1: Standard for AWS Certification of Welding Inspectors
 AWS B5.1: Specification for the Qualification of Welding Inspectors

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