Procedure No.

OPERATING PROCEDURE 7.003

Title
VISUAL INSPECTION AND WORKMANSHIP STANDARD

Revised “NOTES” in Para. 6.10.3 and

Para. 6.11.3 8/22/00 A

ORIGINAL RELEASE – Completely

revised old SOP 3.007 to address
changes in ISO 9001:2000. 5/8/00 --

V.P. of V.P. of Director of V.P. of Sales/

Manufacturing Engineering QA/QC Marketing Revision Description Release Date Rev. Ltr
Written By Revised By
S. Herfurth – 8/22/00
Steve Herfurth
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1.0 PURPOSE

To describe the workmanship standards and visual inspection criteria to be

used in the production of parts manufactured at National Oilwell Varco
Pressure Control Group (NOV PCG).

2.0 APPLICABILITY

This procedure is directive in nature to all parts manufactured or delivered to

NOV PCG.

3.0 REFERENCED DOCUMENTS

3.1 NOV PCG Quality System Manual

3.2 Design Engineering prints and specifications

3.3 Process routings

3.4 SOP 7.005, "Control of Non-Conforming Material"

4.0 GENERAL

Maintaining superior workmanship standards can only be accomplished if each

department that is responsible for production follows the methods established
for their area. This would include strict adherence to published engineering
drawings and specifications and uncompromisingly following the
manufacturing process as outlined by Manufacturing Engineering on the
process routing.

5.0 RESPONSIBILITIES

5.1 Design Engineering shall be responsible for putting specific

instructions, including or referencing acceptance criteria, on prints in
reference to standards on workmanship, e.g., finishes, tolerances,
marking instructions, etc.

5.2 Quality Control shall be responsible for:

5.2.1 Inspecting parts and determining if they meet the acceptance

criteria.

5.2.2 Reporting parts that are found to be nonconforming.

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5.2.3 Re-inspecting those parts that were rejected and have been
reworked and are ready for acceptance now to the
workmanship standards.

5.2.4 Provide accurate documentation for all characteristics on

engineering drawing/specifications.

6.0 METHODS

The following is a description of items to observe during the manufacturing

process.

6.1 All finish machine surfaces shall meet the requirements as specified on
the drawing.

6.2 All finished machine parts shall be free of dings, gouges, tool marks,
chatter, chuck marks, or any other defects that would give the
appearance of poor or careless workmanship.

6.3 All torch cut surfaces which are not machined shall be free of undercuts,
gouges, slag and no sharp edges at all.

6.4 All pressure containing, pressure retaining, and load bearing structural
welds shall be visually inspected by a certified weld inspector.

6.4.1 This includes:

6.4.1.1 Visual inspection of 100% of the weld preparation

surface before welding.
6.4.1.2 Examination shall include 1/2" of adjacent base on
both sides of the weld.
6.4.1.3 Visual inspection of 100% of the finished weld is also
a requirement.

6.4.2 Acceptance of the weld preparation and the finished weld will
be documented by signing, initialing, or stamping in the margin
of the process router at the weld operation by the certified weld
inspector.

6.4.3 Weld Visual Acceptance Criteria – Pressure containing and

pressure retaining welds.

6.4.3.1 Visible cracks - none permitted.

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6.4.3.2 Sealing surfaces, or within 1/8 inch of sealing

surfaces -- visible porosity, undercut, weld overlaps
or arc strokes are not permitted.

6.4.3.3 Non-sealing surfaces - no visible rounded indications

greater than 1/8 inch for welds whose depth is 5/8
inch or less or 3/16 inch for welds whose depth is
greater than 5/8 inch are permitted.

Tightly adhered weld splatter is acceptable unless its

removal is required to accomplish other
nondestructive testing.

Undercuts shall not be greater than 1/32 inch deep or

shall not reduce the thickness in the area
(considering both sides) to below minimum
thickness.

Weld overlaps - none permitted.

6.4.4 Visual Welding Inspection Acceptance Criteria: Structural

Welds.

6.4.4.1 Crack Prohibition: The weld shall have no cracks.

6.4.4.2 Weld/Base Metal Fusion: Thorough fusion shall

exist between adjacent layers of weld metal and
between weld metal and base metal.

6.4.4.3 Crater Cross Section: All craters shall be filled to

the full cross section of the weld, except for the
ends of intermittent fillet welds outside of their
effective length.

6.4.4.4 Weld Size: Weld size shall be in accordance with

the design documentation.

6.4.4.5 Time of Inspection: Visual inspection of welds in

all steels may begin immediately after the
completed welds have cooled to ambient
temperature. Acceptance criteria for ASTM A514
and A517 shall be based on visual inspection
performed not less than 48 hours after completion
of the weld.
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6.4.4.6 Underrun: A fillet weld in any single continuous

weld shall be permitted to underrun the nominal
fillet size by 1/16” without correction, provided that
the undersized portion of the weld does not exceed
10% of the length of the weld. On weld-to-flange
welds on girders, no underrun is permitted at the
ends for a length equal to twice the width of the
flange.

6.4.4.7 Undercut:

A. For materials less than 1” thick, undercut

shall not exceed 1/32” except that a
maximum 1/16” is permitted for an
accumulated length of 2” in any 12”. For
material equal to or greater than 1” thick,
undercut shall not exceed 1/16” for any
length of weld.

B. In primary members, undercut shall be no

more than 0.01” deep when the weld is
transverse to tensile stress under any design
loading condition. Undercut shall be no
more than 1/32” deep for all other cases.

6.4.4.8 Porosity:

A. Complete joint penetration groove welds in

butt joints transverse to the direction of
computed tensile stress shall have no visible
piping porosity. For all other groove welds
and for fillet welds, the sum of the visible
piping porosity 1/32” or greater in diameter
shall not exceed 3/8” in any linear inch of
weld and shall not exceed 3/4” in any 12”
length of weld.

B. The frequency of piping porosity in fillet

welds shall not exceed one in each 4” of weld
length and maximum diameter shall not
exceed 3/32”. Exception: for fillet welds
connecting stiffeners to web, the sum of the
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diameters of piping porosity shall not exceed

3/8” in any linear inch of weld and shall not
exceed 3/4” in any 12” length of weld.

C. Complete joint penetration groove welds in

butt joints transverse to the direction of
computed tensile stress shall have no piping
porosity. For all other groove welds, the
frequency of piping porosity shall not exceed
one in 4” of length and the maximum
diameter shall not exceed 3/32”.

6.5 All parts shall be marked or stamped as indicated by the engineering

drawing.

6.5.1 All stamping shall be done with low stress stamps (dotted
stamps are NOT acceptable).

6.5.2 All stamping shall be legible and in approximate straight lines.

6.5.3 Areas where stamping is to be done should be smooth and free

of any surface defect that would interfere with legibility of the
stamping.

6.5.4 Any corrections that might need to be made--that area is to be

ground clean first before re-stamping. Re-stamping over
another character is not acceptable.

6.6 All parts shall be deburred according to engineering drawings.

6.6.1 All sharp edges shall be broken unless a sharp edge is called
for on the print.

6.6.2 All drilled and tapped holes shall be chamfered.

6.6.3 All machined surfaces shall be free of nicks, gouges, tool

marks, chuck marks or any other defects.

6.6.4 All holes shall be free of chips and shavings.

6.7 All parts shall be cleaned and preserved as stated by engineering

specifications before going to stock or a customer.

6.7.1 Parts shall be free of any shavings or chips

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6.7.2 Parts subject to rust shall be treated with a rust preventative.

6.7.3 Any residue from manufacturing or NDT shall be removed

completely.

6.7.4 All “paint stick” marking shall be removed prior to stocking or

shipping.

6.8 All painting and coating shall be applied according to engineering

specifications.

6.8.1 Parts are to be clean and rust free before any coating is applied.

6.8.2 Coverage shall be uniform, no visible defects showing.

6.9 All parts are to be handled in a manner to protect them from being
damaged.

6.9.1 Parts, or areas of parts that are recognized as critical, shall be

protected to prevent damage.

6.9.2 Parts that are to be shipped shall be properly packaged to

prevent damage while in transit.

6.9.3 Material handlers in the plant shall be instructed on proper

handling procedures.

6.10 Visual inspection of castings.

6.10.1 Only those cosmetic blemishes that exceed 3/16” shall be

considered relevant. Cosmetic blemishes that do not exceed
3/16" diameter shall be acceptable.

6.10.2 Cosmetic blemishes that exceed 3/16" diameter shall be

blended, buffed, polished, or ground to a depth no greater than
0.060" for an area no greater than one (1) inch square.

(R) 6.10.3 No more than four (4) relevant blemishes in any 25 square inch
area shall be acceptable.
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NOTE: Wellbore wetted and/or sealing surfaces of castings

shall be inspected per SOP 8.002 or SOP 8.003 with acceptance
criteria that is defined in the SOP.

6.10.4 All castings shall meet the visual acceptance criteria of MSS SP
55.

6.11 Visual inspection of forgings.

6.11.1 Only those cosmetic blemishes that exceed 3/16” shall be

considered relevant. Cosmetic blemishes that do not exceed
3/16" diameter shall be acceptable.

6.11.2 Cosmetic blemishes that exceed 3/16" diameter shall be

blended, buffed, polished, or ground to a depth no greater than
0.060" for an area no greater than one (1) inch square.

(R) 6.11.3 No more than four (4) relevant blemishes in any 25 square inch
area shall be acceptable.

NOTE: Wellbore wetted and/or sealing surfaces of forgings

shall be inspected per SOP 8.002 or SOP 8.003 with
acceptance criteria that is defined in the SOP.

(R) – Indicates revised item