MMB Boleo QA Manual.doc

7/30/2019 MMB Boleo QA Manual.doc

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SIN FIN(USA) Limited.

MMB EL BOLEO PROJECT

Quality Plan

Santa Rosalia Plant

Baja Mexico

1October

2012Project Quality plan R Haye

2March

2013Project Quality plan R Haye

3

REV. DATE DESCRIPTION PREPARED BYCHECKED

BY

APPROVED

BY

This quality Plan represents work done by Sin Fin (USA) Limited. The work is based upon the project scope and designinformation as described herein and as provided by the owner. None of the above named parties or individuals shall be


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SIN FINMMB EL BOLEO PROJECT

(USA) LTD.NO: MMB 038-11liable, in negligence or otherwise, for any reliance which may be placed by any other party upon any representations

contained herein.

SIN FIN (USA)

Field QA/QC

Page

1.0 Quality Control Policy 5

1.1 Scope 5

1.2 Purpose 51.3 Laboratory Standards 6

1.4 Test Methods 6

1.5 Operating Procedures 6

1.6 Field Activities 7

1.7 Notification of In-Process Changes 7

2.0 Quality Control Organization 7

2.1 Organizational Definitions 8

2.2 Organizational Responsibility 92.3 Inspector Functions 9

2.4 Certified Individual, Functions 9

2.5 Training of Quality Control Personnel 10

2.6 Training and Qualification of Certified Individuals11

3.0 Contract Review & Design 11

3.1 Minimum Documentation 11

3.2 Document Distribution 11

3.3 Authorized Inspector 123.4 Procedures 13

3.5 Purchasing 13

3.6 Vender Evaluation 14

3.7 Non-Compliant Items/Materials. 14

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(USA) LTD.NO: MMB 038-11

4.0 Materials 14

4.1 Receiving Inspection 14

4.2 Resins 15

4.3 Reinforcements 154.4 Curing Agents 16

4.5 Common Additives 17

5.0 In-Process Inspection 18

5.1 Procedures 18

5.2 Resin Mixing 18

5.3 Material Dispersion 19

5.4 Component Fabrication 19

5.5 Assembly 205.6 Nonconformance 21

6.0 Finished Equipment Inspection 24

6.1 Procedures 24

6.2 Pressure Test 25

6.3 Qualification of Secondary Bonders 25

6.4 Access For Authorized Inspector 25

7.0 Records Retention & Control 267.1 Scope 26

7.2 Application 27

7.3 Records Retention 27

7.4 Procedures for Records Handling 27

7.5 Acetone Sensitivity Test 28

7.6 Barcol Hardness Measurement 29

8.0 Lamination Procedure 29

8.1 Surface Prep 308.2 Structural Layer 30

8.3 Interior Layer Corrosion Resistant Barrier 30

8.4 Inspection of Lamination Material 31

9.0 Attachments

9.1 Inspection Checklist 32

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9.2 Barcol/Acetone Sensitivity Test Record 33

9.3 Cut-Out Thickness Check 34

9.4 Mat Reinforcement Log Sheet 35

9.5 Fabric (Woven Roving) Reinforcement Log Sheet 36

9.6 Common Additives Log Sheet 37

9.7 Peel Bond Test Procedure 38

9.8 Peel Test Report Form 39

9.9 Resin Evaluation & Test Procedure 40

9.10 Daily Resin Gel Test 41

9.11 Resin Dispersment Sheet 42

9.12 Non Conformity Correction Report 43-459.13 Inspection Test Plan 46-49

9.14 Quality Assurance & Control Org Chart 50

1.0 Quality Control Policy

1.1 Scope

This manual applies to the installation only of the

fiberglass components at the MMB Santa Rosalia Plant

Baja SUR Mexico. The work scope is for the field fiber

glassing of the CCD THICKENERS, FRP LINERS AND

LAUNDERS and the manufacturing of components.

Purpose

The purposes of the Quality Control Program are to:

1.1.1 Ensure adherence to the rules and requirements of

the Customer through processing of purchase

orders, drawings, specifications, Users Basic

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Requirements Specification (UBRS), and other

documents at the field locations.

1.1.2 Establish an inspection system to monitor thevariability of workmanship, processes and

materials, in order to produce a consistent product.

1.1.3 Establish and monitor the quality requirements

related to the materials and services of vendors of

subcontractors, based on surveillance and

performance analysis.

1.1.4 Provide a system for the detection of defect trends,

and institute corrective measures.

1.2 Laboratory Standards

1.2.1 It shall be the responsibility of the Quality Control

Manager to ensure that all equipment used in

testing is in good working condition.

1.2.2 All testing equipment will be regularly calibrated, in

accordance with recognized national standards.

Where no national standards exist, the basis for

calibration shall be noted.

1.2.3 Items tested with defective testing equipment shall

be considered non-conforming, and shall be retestedafter (re)calibration of the testing equipment.

1.3 Test Methods

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Specific written inspection procedures will be followed,

for all inspection and test operations.

1.4 Operating Procedures.

1.4.1 Parts will be made in accordance with the

conditions specified by the Engineering Manager, as

communicated on the approved shop drawings,

(UBRS), and the inspection requirements check list.

1.4.2 Approved Drawings and the inspection requirements

check list shall be available to the Quality Controlpersonnel.

1.4.3 Procedures shall be prepared and issued, as

specified in section 3 of this manual.

1.5 Field Activities

The field activities performed by SIN FIN (USA) LTD shall

be performed in accordance with the requirements of thisquality control manual. The program responsibilities,

controls, documentation, and authorities shall apply.

1.6 Notification of In-Process Changes

1.6.1 If a change is necessary after the fabrication of an

item has begun, the Engineering Manager shall

issue a written stop work notification to theConstruction/Project Manager and the Quality

Control Manager. The Quality Control Manager shall

remove the item drawing, and the Construction

Manager shall stop work in the area specified by the

Engineering Manager.

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1.6.2 The Engineering Manager shall process the change,

as specified in section 3 of this quality control

manual.

2.0 Quality Control Organization

Responsibility and authority for the implementation of

procedures outlined in this manual shall rest with the

Construction Manager or Project Manager...

The Quality Control Manager shall have the organizational

freedom to identify quality control problems and torecommend solutions. He/She has the responsibility to

report directly to the Construction Manager or Project

Manager matters concerning quality control.

If differences cannot be resolved between Department

Managers and the Quality Control Manager, they shall be

brought to the attention of the Construction Manager or

Project Manager for resolution. In all cases this manual

shall prevail.

2.1 Organizational Definitions

The organization of the quality control department is the

responsibility of the Quality Control Manager. This

section sets forth:

2.1.1 Where Quality Control inspector is referred to, it is

understood to mean the inspector employed by SIN

FIN (USA) LTD.

2.1.2 Where Authorized Inspector is referred to, it is

understood to mean the Inspector mutually agreed

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inspector to ensure conformance to specifications.

Functions include:

a) Review of applicable drawings.b) Inspection of incoming raw materials and

components.

c) Providing Q.C. at various stages of the

fabrication process.

d) Determining product release or rejection.

2.4 Certified Individual, Functions

2.4.1 The Certified Individual shall:

a) Perform an annual audit to verify that SIN FIN

(USA) LTD. Quality Control System is current

and is an effective operation;

b) Verify that the qualifications of the Inspector

and inspectorare in accordance with the SIN

FIN (USA) LTD Quality Control System;c) Verify that corrective actions taken to resolve

nonconformities are in accordance with the

SIN FIN (USA) LTD. Quality Control Program;

d) Verify that the responsibilities and activities of

the Inspectorare in accordance with the

requirements of the Standard;

e) Verify that products are manufactured by

qualified secondary bonders, and

f) Sign the Inspectors Certification on theFabricators Data report and/or the

Fabricators Partial Data Report.

2.5 Training of Quality Control Personnel

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2.5.1 Quality Control personnel shall be provided with

training in the handling of inspection equipment and

tools used by them in the inspection process.

2.5.2 Quality Control personnel shall be provided with

training in the implementing of Quality Control

procedures and the recording, and interpretation of

inspection data.

2.5.3 Quality Control Personnel training shall be

documented in a file maintained by the Q.C.

Manager.

2.6 Training and Qualification of Certified Individuals

2.6.1 Certified Individuals shall be qualified using the

following criteria:

a) A minimum of two years experience with QC

systems in the equipment fabrication industry.This experience need not be direct

employment as QC department personnel.

b) Initial attendance at one internal or external

QC system audit, performed by qualified CI

3.0 Contract Review and design

3.0.1 The Customer job order comes from the Customers

Purchasing Department. The Quality Control

Manager will then prepare a project file.

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3.1 Minimum Documentation

As per agreement of Authorized Inspector

3.2 Document Distribution

3.2.1 Job order documents to be distributed include

(UBRS) drawings, specifications and technical

procedures.

3.2.2 Preliminary design drawings shall be used only forthe following purposes;

a) Review of construction details and

requirements.

b) Preparation of tooling for bonding.

c) Purchase of raw materials.

d) Fabrication of components, on a risk basis,

subject to the express written approval of the

Authorized Inspector.

3.2.3 Fabrication details not shown on design drawings

and details of design drawings, used for purchasing

of subcontracted components, are to be assigned a

sketch number and be placed in the file folder.

3.3 Authorized Inspector

3.3.1 The Authorized Inspector shall be mutually

acceptable to SIN FIN (USA) LTD. and the Customer

(user). This shall be determined during contract

negotiations. If the Authorized Inspector is not

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established by contract, then SIN FIN (USA) LTD.

shall propose a Qualified Authorized Inspector,

and obtain the customers concurrence prior to the

start of fabrication.

3.3.2 Any hold points will be chosen by the Authorized

Inspector prier to work commencing.

3.3.3 The Quality Control Manager shall keep the

Authorized Inspector informed of the work progress

and schedule, for hold point inspections.

3.4 Procedures

3.4.1 Technical procedures that effect the job

requirements shall be prepared by the Engineering

Department, and distributed to appropriate

personnel.

3.5 Purchasing

3.5.1 Purchase orders are prepared by the Purchasing

Department in accordance with a Bill of Materials.

3.5.2 Stock materials, such as resin and reinforcement

materials are detailed on equipment drawings.

These materials are purchased by the Purchasing

department.

3.5.3 If the item to be purchased is a fabricated FRP part,

it shall be furnished with a Partial Data Report and

supporting documents, signed by the sub

contractors Quality Control Manager.

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3.5.4 Purchase order copies supplied to the receiving and

Quality Control departments do not show pricing

information.

3.5.5 The Quality Control department retains all copies of

purchase orders. These are NOT supplied to the

user with the Fabricators Data Report.

3.6 Vendor Evaluation

The Quality Control Manager shall evaluate the Material

Manufacturer by review of material inspections atreceiving. The Quality Control Manager maintains the

records of these evaluations. Since only acceptable

materials are used, the material Manufacturer is

evaluated on each shipment. An annual report of these

evaluations is prepared by the Quality Control Manager

and distributed to appropriate management.

3.7 Non-Compliant Items/Materials.

All items/materials received, that are not in compliance

with the purchasing and contract documents, shall not be

accepted during the receiving inspection process, and

shall not be used in the fabrication process. These

items/materials shall be returned to the Vendor.

4.0 Materials

4.1 Receiving Inspection

All resins, reinforcements, curing agents, purchased and

sub vended items, and common additives shall be

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received and checked under the control of the Quality

Control Manager. The checks shall include:

4.1.1 Check to assure they are the products ordered, bycomparing the items with the purchase order.

4.1.2 Check for proper labeling:

4.1.3 Manufacturers product name.

A) Manufacturers Specific Product

Identification (MSPI)

4.1.4 Verify the receipt of a Manufacturers Certificate ofAnalysis or Certificate of Compliance as applicable

for each lot received, when certificates are

required. Verify that the lot number on the

certificate matches that on the item(s).

4.1.5 Check the packaging for visible damage.

4.1.6 For acceptable items, sign and date the appropriate

receiving documents, and forward to purchasing.

4.1.7 Unacceptable items shall be handled as non-

conforming.

4.2 Resins

The Quality Control Manager prior to use in the

fabrication process shall review the results of the

following inspection and confirm the Material Testreports specify the proper material.

4.2.1 Check for normal color and clarity for the specific

resin type, and that it is free of solids or gelled

particles and contaminants of any type.

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4.2.2 A sample from each resin lot shall be used for

checking specific gravity, viscosity, and room

temperature gel time; that they are within the resin

manufactures specified range of limits. The resultsof these resin analysis shall be compared with the

Resin Manufacturers Certificate of Analysis, and

documented.

4.2.3 Log the lot number and the date received for each

lot, gel time, viscosity and specific gravity.

4.2.4 The storage environment of the resin must be incompliance with the resin manufacturers

recommendations.

4.3 Reinforcements

The results of the following shall be recorded by the

Quality Control Manager on the reinforcement log sheets,

prior to use in the fabrication process.

4.3.1 All reinforcements shall be visually inspected under

suitable overhead lighting, as they are dispersed for

imperfections such as holes, cuts, thin spots,

separation, and for contaminants such as

inclusions, dirt, oil and grease. Dimensions,

weights, and identifying numbers shall be recorded

on Material Reinforcement Log Sheet.

4.3.2 The storage environment of the reinforcement must

be in compliance with the reinforcement

manufacturers recommendations and all material

supplied will be with certified material test report.

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4.4 Curing Agents


Quality Control Manager on the Common

Additives/Curing Agents log sheet, prior to use in

the fabrication process.

4.4.1 Check for stratification of material into two or more

phases. In the case of liquids, they shall be free ofsediment or suspended solids.

4.4.2 The curing activity of curing agents shall be tested

generaly in accordance with ASME RTP-1, Appendix

M-3, and Article E.

4.4.3 The storage environment of the curing agent must

be in compliance with the curing agent

manufacturers recommendations.

4.5 Common Additives


Quality Control Manager on the Common Additives/Curing

Agents log sheet prior to use in the fabrication process.

4.5.1 Record date received manufacturer, product name,

quantity, and lot number. As additives are used,

record the start use and end use dates.

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4.5.2 The storage environment of common additives must

be in compliance with the additive manufacturers

recommendations.

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5.0 In Process Inspection

5.1 Procedures

5.1.1 The Construction Manager is issued the Approved

for Construction drawings from the Project

Manager, and the Inspection requirements Checklist

from the Quality Control Manager. These

documents, together with the Construction/Project

Managers file, authorize the fabrication process tobegin.

5.1.2 All construction requirements shall be specified on

the drawing, or on a document specified on the

drawings.

5.1.3 Preliminary activities that may proceed prior to the

issue of Approved for Construction drawings are

identified in 3.4.2.

5.2 Resin Mixing

The resin mixing and dispersion operator, on the Mixing

Data sheet, shall record the following data.

5.2.1 Resin promotion and primary preparation must bedone in the assigned resin mixing area.

5.2.2 Formulas for each particular type of resin mixture

are those recommended by the resin manufacturer

or as predetermined by experience. The

predetermined formulas shall be kept in a log book.

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5.2.3 Resin mixing data shall be completed for each

batch, and recorded on a mixing data sheet withreference to particular Job Number.

5.3 Material Dispersion

5.3.1 Resin shall be dispersed in containers clearly

marked by the resin mixing and dispersion operator,

identifying their contents. Resin type must beentered on the component data sheet for parts

utilizing that resin.

5.3.2 After materials have been fabricated, the identifying

numbers of the materials used in their fabrication,

shall be recorded.

5.4 Component Fabrication

The Quality Control Manager is responsible to have the

following data recorded on the component data sheet

prior to assembly.

5.4.1 The types of materials used in fabrication shall be

recorded, and verified as being correct.

5.4.2 The lamination sequence of a particular component

shall be recorded, and verified as being correct.

5.4.3 Laminate sequences for standard flanges are not

specifically recorded. Structural adequacy is

determined by thickness checks.

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5.5 Assembly

The following inspections shall be done, and the data

shall be recorded by the Quality Control Manager on the

inspection checklist.

5.5.1 All corrosion liners, and repairs to corrosion liners,

shall be inspected on the molds by the Q.C.

Department, prior to continuing the installationprocess. The installation department shall be

immediately notified of the results of these

inspections.

5.5.2 Laminate sequence lay-ups shall be compared with

the drawings, to ensure that all sequence layers are

present and the proper materials are used.

5.5.3 Inspect all equipment nozzles for the following,before installation:

-Corrosion liner quality -Number and size of bolt holes

-Flange and wall thickness -Bolt circle diameter

-Spot facing of flange -Resin in bolt holes

-Flange face drawback -Hub thickness

-Nozzle identification -Hub shear length

5.5.4 Inspect nozzle orientation and layout on allequipment before holes are cut for installation.

5.5.5 Inspect corrosion liners completely for air,

imperfections and inclusions, from the equipment

interior immediately after the parts are removed

from the mold.

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5.5.6 Collect all nozzle cutouts and measure them for

thickness. Confirm that the thicknesses are asspecified and record them on the quality control

report. Retain cutouts for physical properties

testing, as required, & review with the Authorized

Inspector.

5.5.7 Record laminate sequences for both interior and

exterior body welds, when used.

5.5.8 Record resin hardness (Barcol) readings.

5.5.9 Inspect all equipment nozzles after initial

installation (before the nozzle attachment welds are

completed) for the following:

a) Bolt holes straddle major centerlines.

b) Orientation meets specification requirements.

c) Elevation meets specification requirements.

d) Projection meets specification requirements.e) Nozzles are square and level.

5.6 Nonconformance

5.6.1 When a nonconformance is detected, the item shall

be tagged by the Quality Control Inspector and

segregated, when practical. The Quality Control

Inspector notifies the Quality Control Manager andthe Construction/Project Manager, and prepares the

non-conformities correction report, and forwards

the report to the Quality Control Manager. The

detected nonconformance may be cause to reject

items and/or initiate a vendor incident report. The

Vendor Incident Report shall be used for receiving

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inspection on material rejection prior too

acceptance of the material.

5.6.2 The Quality Control Manager may propose the

following dispositions in lieu of forwarding the non-

conformities correction report to the Engineering

Manager.

a) Return to vender

b) Scrap.

c) Repair visual defects (corrosion liner) or

exterior cosmetic defects

5.6.3 For all other dispositions, the report is forwarded to

the Engineering Manager who provides the

disposition. The registered Professional Engineer

(RPE) shall approve all repairs affecting design and

structure.

5.6.4 Dispositions shall be one of the following:

Use as is This is permitted when the item is in full

compliance with the (UBRS) and the

customer order.

Repair The repair shall be fully described on the

Nonconformity report. Only repairs,

which are listed in RTP-1 M7 300, shallbe made. The Authorized Inspector shall

approve the repair. The result of the

repair shall make the part to be in

accordance with the (UBRS) and the

customer order. The Quality Control

Inspector re inspects all repairs.

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Return to vendor Applicable to purchased materials, which

are found to be unacceptable for their

intended use.

Scrap Applicable when the nonconformity is not

repairable or is found to be unacceptable

for its intended use.

Other Other information, not covered by the

above listed categories.

5.6.5 The disposition non conformity report is returned tothe Quality Control Inspector, who causes the

action to be completed. When completed, the

Quality Control Inspector signs and dates the Non

conformity report, to record that the disposition has

been satisfactorily completed. In the case of

repair, the Authorized Inspector also signs and

dates the completed disposition.

5.6.6 The nonconformity report shall record as aminimum:

a) Date of correction

b) Specific location on the equipment

c) Description of the nonconformance

d) Method of correction

e) Name of qualified laminator/secondary bonder

who affected the repairf) Signatures of approvers

5.6.7 The Engineering Manager shall reconcile any

affected design documents, to reflect the current

status.

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6.0 Finished Equipment Inspection

6.1 Procedures

SIN FIN (USA) LTD. shall perform inspection of items

being installed, as necessary to determine that the items

are in compliance with the (UBRS) and the customer

order. These inspections will be done by the Quality

Control Inspector, and recorded on the inspection

requirements checklist. When complete, the Quality

Control Manager shall advise the Authorized Inspector

that the item is complete, and ready for final inspection.The Quality Control Manager prepares the Data Report

and the required supporting documentation. The Quality

Control Manager certifies the data report Certificate of

Compliance. All documents are then presented to the

Authorized Inspector

The Authorized Inspector performs the final inspection of

the item(s) as required. SIN FIN (USA) LTD. shall make

available its applicable inspection reports. TheAuthorized Inspector shall then record the results of

his/her inspections on the SIN FIN (USA) LTD. reports.

When the final inspection has been completed, the

Authorized Inspector shall prepare a brief report

summarizing his/her inspection activities and findings.

He/she then submits a copy of this report to the SIN FIN

(USA) LTD. Quality Control Manager as an attachment to

the Certificate of Compliance. When satisfied that the

item is fabricated within the requirements, the AuthorizedInspector signs and dates the Inspectors Certification,

then returns it to the Quality Control Manager. Once

these actions are completed, and all required testing, is

complete, The Certified Individual then signs and dates

the Contractors Certificate of Compliance, and the

Inspectors Certification.

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6.2 Pressure Test. (NOT APPLICABLE TO CONTRACT)

6.3 Qualification of Secondary Bonders

Secondary Bonders shall be qualified as required by

ASME RTP 1, Appendix M-5 400.This meets or exceeds

the requirements of ASME B-31-3. The Quality Control

Manager shall select the personnel to be qualified and

supply the necessary training. The qualification samples

shall be inspected and tested by the Quality ControlManager. Test results shall be reviewed, and approved

by signature and date, if acceptable. The Quality Control

Manager shall maintain the qualification records. The

Secondary Bonders names are recorded on applicable

reports. The reports shall be available to all parties

involved in the procurement and inspection activities.

Secondary Bonders shall be re-qualified at a three year

frequency, 18 months if inactive, or when the Quality

Control Manager or Certified Individual has cause toquestion their ability to produce quality items.

6.4 Access For Authorized Inspector

6.4.1 The Authorized Inspector shall be allowed access to

areas of the field, where the item is being installed,

at any time during the process.

6.4.2 The Authorized Inspector shall have access at anytime to all documents relating to the design and

quality control of the item being installed.

6.4.3 Access for final inspection to the inside and outside

of the item being installed shall be arranged for the

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Authorized Inspector, at a mutually agreed upon

time.

6.4.4 A clean safe working environment shall be provided

for the Authorized Inspector, with adequate lighting,

scaffolding, and other equipment required for

access to inspect the item being installed.

6.4.5 Adequate safety equipment, such as ventilation

fans, shall be made available for the Authorized

Inspector.

7.0 Records Retention and Controls

7.1 Scope

7.1.1 This procedure shall ensure that the records

retained, are complete and reliable.

7.1.2 Inspection and testing records shall as a minimum,

indicate the nature and number of observations

made. All inspection documentation shall be clearly

identified, indicating the job order number, part

number, part description, or in any manner that will

link the inspection results to a specific part.

7.1.3 Records shall be available for review, as one of the

principal forms of objective evidence of the qualityassurance program at SIN FIN (USA) LTD. office.

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7.2 Application

All records shall reflect the product conformance. The

records shall reflect acceptability of the product, andworkmanship, and what action was taken to correct any

non-conformity.

7.3 Records Retention

All records shall be retained by the quality control

department for a period of not less than five (5) years, or

longer as necessary for compliance of contractualrequirements.

7.4 Procedures for Records Handling

7.4.1 Records shall be identified and filed according to

job order number.

7.4.2 Any items supplied by sub venders shall be recordedby part number, with cross reference to the job

order number.

7.4.3 Records shall form an analysis basis, and

management action regarding the quality assurance

program.

7.5 AcetoneSensitivity Test

Should be applied to any secondary laminate surface,

within the following parameters:

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7.5.1 Perform three (3) tests per joint.

7.5.2 Acetone used for testing must be clean.

7.5.3 Acetone Testing Procedure (Note test location--

elevation and radial location (in degrees--see

drawings for reference) on the Acetone Sensitivity

Report Form).

7.5.4 Apply 5 drops of acetone to a small area of the

laminate surface.

7.5.5 With a clean finger, rub the acetone into the surface

until the liquid evaporates.

7.5.6 Check the laminate surface for tackiness.

7.5.7 If the laminate feels tacky, note a fail on the test

report. If not, indicate passage by checking OK on

the report.

7.5.8 Sign the report.

7.60 Barcol Hardness Measurement ASTM D 2583

.

Following is a summary of the test method. Refer to the

indicated ASTM for specific instructions on performing

this test.

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7.61 Fill out background information on the Barcol

Hardness Report, including date of test, description of

sample, and the specified Barcol for the test.

7.62 Note and record the areas from which the readings

have been taken (shell interior, bottom interior,

overlays, etc.) in the boxes labeled A through H.

7.63 Check the calibration of the Barcol Impressor with an

aluminum calibration disc before taking any readings.

7.64 Take ten (12) readings from each area listed. Record

each reading in lines 1-12 on the report.

7.65 Discard the lowest and highest readings, and average

the remaining 10 readings.

7.66 Compare the averages for each location to the

specified Barcol for the test.

7.67 Make a note of whether or not they conform. Make any

necessary comments and sign.

8.0 Lamination Procedure

Laminating Construction shall be in accordance with the

tabulated lay-up sequence according to the drawing or

specifications provided by the client.

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8.1 Surface Prep

8.1.1 Surface material must be pre-ground with a 35-50grit sandpaper or equivalent before applying any

structural material

8.1.2 All holes or crevasses shall be filled with resin

paste and left to exotherm and cool before applying

structural lamination

8.2 Structural Layer

8.2.1 Application of the structural layer shall not alter the

corrosion resistant barrier

8.2.2 The first ply of the structural layer of the laminate

shall be 1 or more plies of non-continuous glass

fibers totaling 450 Gram per m comprised of

Chopped Strand Mat and or Woven Roving or as per

owner specification.

8.2.3 Continue layup sequence of plies stated as perdrawing or specification supplied by owner

8.2.4 After each layup sequence is applied allow to

exotherm and cool before next layup sequence

8.3 Interior Layer Corrosion Resistant Barrier

8.3.1 The inner surface layer exposed to the contentsshall be a resin rich layer reinforced with a surface

veil providing a thickness of minimum 0.25 mm

0.50 mm or as per drawing or owner specification.

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8.3.2 After corrosion barrier has reached its peak

exotherm and cooled a resin rich wax coating will

be applied to seal or protect the corrosion barrier.

8.4 Inspection of Lamination Material

8.4.1 All fiber material must be pre inspected and signed

off by quality control before use of product

8.4.2 All resin must have gel test and approved by quality

control before use.

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Attachment 9.1

Inspection Checklist

-

Inspected Item Layout By

(initial/date)Checked By

(initial/date)Verified By

(initial/date)

Proper fit

Pre groundbefore lay-up

Nozzle size &

orientation

Elevation

Material

Lay up sequence

Barcol

Wax coat

Paperwork

completed

ProjectNumber:

CUSTOMER:Customer

Number:Location

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Turnover

Comments:

Attachment 9.2

Barcol/Acetone Sensitivity

Test Record

Component:

1

2

3

4

5

6

78

9

10

11

12

ProjectNumber:

CUSTOMER:CustomerNumber:

EquipmentNumber:

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Average

Note: A minimum of 12 Barcol readings for each component is required for RTP 1 see 6-910

ACETONE SENSITIVITY RECORD

COMPONENT

NUMBER

DATE

RESULT

INITALS

1Attachment 9.3

Cut-Out Thickness Check

Mk Qty Id Service Location DrawingThickness

ActualThickness

ProjectNumber:


EquipmentNumber:

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1

1Attachment 9.4

Mat Reinforcement Log Sheet

Mat Manufacturer:

Mat Nomenclature:

Mat Treatment (if given)[Note 1]:

Mat Weight [Note 2]:

Q.C. File No.:

ProjectNumber:


EquipmentNumber:

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RollNo.

Reinforcement

ProductionDate

Lot No.[Note

1]

Width Weightof

Sampl

e3

PropertyInspection3

VisualInspectio

n

(if given) (grams) By Date By Date

(3) Inspection Protocol: If no defects have been recorded in the previous 80 rolls,Sample the 1st roll on each skid. If defects are recorded, inspect every roll until 80rolls without defects have been recorded.Complete visual inspection for every roll as used.

Comments on visual and packaging inspection (indicate which roll):

Notes :( 1) Lot, batch, product code, or other label identification. (2)

Manufacturers label weight.

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1Attachment 9.5

1Fabric (Woven Roving) Reinforcement Log Sheet

Fabric Manufacturer:

Fabric Nomenclature:

Fabric Weight:

Fabric Construction:

Roll No.Reinforcem

entProduction

Date

(if given)

Lot No.[Note(1)]

Width

Weight

Gram

s3

Construction3

PropertyInspection

Cols 4,5, and63

VisualInspection

1 2 3 4 5 6 By Date By Date

(3) Inspection Protocol: If no defects have been recorded in the previous 80 rolls,Sample the 1st roll on each skid. If defects are recorded, inspect every roll until 80rolls without defects have been recorded.Complete visual inspection for every roll as used.

Comments on visual and packaging inspection (indicate which roll):

ProjectNumber:


EquipmentNumber:

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Notes:(1) Lot, batch, product code, or other label identification.

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1Attachment 9.6

1

Common Additives Log Sheet

Manufacturer: Raw Materials Inspection Inspector Date

As Received

Product Name:

Lot Number:

Additive Purpose:


As Received

Product Name:

Lot Number:

Additive Purpose: Catalyst


As Received

Product Name: I

Lot Number:

Additive Purpose:


As Received

ProjectNumber:

MMB 038-11

CUSTOMER: MMB El Boleo MiningCustomerNumber:

EquipmentNumber:

CCD 01

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(USA) LTD.NO: MMB 038-11Product Name:

Lot Number:

Additive Purpose:

Attachment 9.7 Peel Bond Test Procedure

.

General Method for Performing Peel Test

A Peel Bond Test is performed to test secondary bondingperformance. It should also be run prior to the start of work toverify proper application technique.

1: First the area to be bonded is properly prepared by grindingwith a 16 or 24 grit disk. This removes any paraffinatedresin/concrete laitance or contaminants. Or in the case of themoulded surfaces, it roughens the surface and exposes glassfibers.

2: A piece of Mylar is taped over 1/2 of the area to be tested.Next a laminate is prepared consisting of 3 layers of 450 GramChopped Strand Matt cut to 150mm x 300mm along with a properamount of resin and catalyst.

3: The glass is wet out and applied over the test area being carefulto center the laminate over the prepared area and the Mylar area,i.e., 150mm x 150mm over the Mylar and 150mm x 150mm over theprepared area.

4: After the laminate has properly cured, the laminate is removedby lifting along the no bond (Mylar) side and pulling the laminatefree from the test area.

5: If the laminate pops free from the test area with little or no fiberstearing, it has failed the test. The prepared area needs to beinspected to see if it was ground properly to the right profile andto see if all contaminants have been removed.

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6: If the laminate tears loose exposing numerous fibers along thissubstrate, the test show that a proper bond has been achieved.

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1Attachment 9.8

Peel Test Report

Location Accepted Rejected Comments

Inspectors Name ____________________ Date:_____________________________

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Attachment 9.9

Resin Evaluation & Test Procedure ASTM D2471

Following is a summary of the test method. Refer to the

indicated ASTM for specific instructions on performing

this test.

Gel Time:

Gel time is defined as the timer interval between the

mixing of a resin with catalyst and promoter, and the

point where the mixture becomes unworkable due to

gelation. Gel time tests follow this procedure:

1. Make a note of all information on the resin to be

tested, including type of resin, resin manufacturer, date

of manufacture, batch and drum numbers, and date of

test. If required, note type of promotion and type of

catalyst, including percent used in the test. Also, if

required, include temperature at time of test.

2. Set gel time counter to zero.

3. a. When using a Gel Timer, weigh and place 100g

sample of resin in a paper cup, measure and add an

appropriate amount of catalyst and mix for at least one

minute.

b. When using a Hot Pot Gel Timer, set the thermostat

at the desired test temperature (usually 20 deg. C to 25

deg. C). Weight and place a 100g resin sample in an

aluminum gel cap. Measure and add an appropriate

amount of catalyst and mix for at least one minute.

4. Place the sample in the gel timer.

5. Insert a wire utensil and stir.

6. When the resin gels, note the time shown on the

counter and record it on the Resin Evaluation & Test Log.

7. Record comments, if any, and sign the log.

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1Attachment 9.10

Resin Dispersement Sheet

Project Number MMB 038/11

Customer MMB El Boleo Mining

Equipment Number CCD 01

1Manufacturer: Ashland Chemicals Q.C. contact:

Resin: Derakane 411-350 VE Address:

Spindle No.: Telephone No.:

Emergency telephone

No.:

Date Lot No.

Gel Time @25oc

(min)

Viscosity

@25oc (cps)

Specific Gravity

@25oc VisualExamination

Manufacturers

Specification

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1Attachment 9.11

Daily Resin Gel Test

Resin Type: Derakane 411/350 VE

Catalyst Used: _Norox 922H (Red) __

Additives Amount

Mass

% Comments

D 411/350 1000 gram 100%

Cobalt (6%) 20 ml 2%

BYK A 515 1.5 ml 0.15%

2.4p (Acetyl Acetone) 0.2 ml 0.02%

MEKP ( Norox) To be added for Gel test.

Gel Test

TimeofTest

% ofCatalyst

CatalystMass

ResinMass

RelativeHumidity

AmbientTemp

GelTime

InspectorsInitials

1.25% 1.25ml.

100 Gr.

Project

Number:MMB 038/11

CUSTOMER: MMB El Boleo MiningCustomerNumber:EquipmentNumber:

CCD 01

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Inspectors Name ____________________ Date:_____________________________

Attachment 9.12

Nonconformity Correction Report (Page 1 of 2)

Project Number:

Customer:

Customer PO Number:

Equipment Number:

Sequence No.: Initiation Date:

Description of equipment

Work area or responsible laminator(s) or secondary bonder(s):

Description of nonconformity (i.e. size, type, location, etc.):

Identified by: Date:

Method of repair or corrective action (Use back of form if necessary. If other attachments,sketches, or drawings are required, they must be referenced here and attached),

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Check off approvals required (see ASME RTP-1, Appendix M-7 for stamped equipment):

Registered Professional Design Engineer Date

: Fabricators Engineering Manager Date

:

Inspector Date:

Fabricators Quality Control Manager Date

:

Other Date

Project Number:

Customer:

Customer PO Number:Equipment Number:

Nonconformity Correction Report (Page 2 of 2)

CorrectiveWorkdoneby:

Name Title Employee

No.

Supervisorssignature:

Date completed:

Required quality control inspections and approvals (check off approvals required):

Inspector Date

:

Fabricators Quality Control Manager Date

:

Other Date

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:

Date

:

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Attachment 9.13Project Number:

Customer:

Customer PO Number:

Equipment Number:

Receiving Inspection / Material Verification x 1Verify all resin and additives received comply topurchase orders x Standard 1

Verify all glass received complies to purchase orders x 1

Unacceptable material is reported to purchasing x 1 Purchasing to mark non conforming material as: use as

is, rework, or return to vendor x1

Lamination Process Inspection x

Resin inspection as per field order x 1

Fiberglass inspection as per field order x 1

Resin Additives inspection as per field order x 1Final cure Thickness Dimensions, Appearance, BarcolHardness x 1

Component inspection (covers, flanged nozzles,

bosses, gussets, ribs, stiffeners, etc. X 3Submit Report x

Assembly Inspection x

Production layouts for flanged nozzles, fittings,manholes, vents, filling ports prior to bonding sub-assemblies, Assembly fixtures, leveling devices, Drill

jigs properly oriented, Locating pins and stops usedproperly.

x 3

Sanding (applies to all sanded parts /areas) x

Smooth surface, Critical wall thicknesses aremaintained after sanding, Areas requiring secondarybonding are completely sanded, Air bubbles have beensanded through are repaired

x 1

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Drilling x

Drill patterns to match drawings, Jigs to matchdrawings, Resin wipe all holes, Exposed fibers are

sealed, Check size, Check location, Check number,Check orientation x

1

Trimming x

Trimmed to correct dimensional lines, Check fordelamination where trimmed, Resin wipe trimmededges are wiped to seal exposed fiber

x 1

Hydrostatic Testing (if required) 2

Check pressure to meet specification 2

Check vacuum to meet specification 2

Log time test begins 2

Log time test ends 2

Check Hourly: 2

Liquid level 2

Pressure Gauge 2

Submit Report 2

Manway Covers and Fittings x 3

Top Center Manway Covers, Smooth inner surface, Noentrapped air or dry spots, Hole pattern, Edge distance x 1

Sidewall Manway Covers, Smooth inner surface, Boltpattern, O.D. Trimming, Thickness, No entrapped air ordry spots

x 1

Molded Fittings x Tie down brackets smooth, no dry spots, internal voidsor delamination x 3

Fittings not meeting the above criteria may besubmitted for rework. x 3

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Purchased Parts x

Reinforced Plastic Sub Assemblies x

Threaded assemblies have clean threads

x

Nipples, elbows, flange faces have no cracks, airpockets or damage of any kind, Ends are cut squareand smooth

x

Sub-Assemblies x Dimensions and angles meet engineering drawings,specifications and tolerances x

Mating joints are fully and firmly seated, Evidence offiller squeeze out around circumference of joint x

Cut edges are sanded and resin coated x Excess filler is removed from outside and inside

assembly x

Resin fillers are smooth, even and fully cured, no tackyor soft spots x

Acceptable sub-assemblies marked OK,Unacceptable sub-assemblies marked REJECTED,Unacceptable sub-assemblies removed for rework ordisposal

x

Tank Bottoms x

Material requirements are verified to drawing x Inspect surface preparation prior to application x

Exterior surface has no protrusions above 1/8 x Seams and overlays are blended to form a smooth anduniform transition area x

No voids or delaminations between liner and structurallaminate larger than visual inspection criteria. x

Pits are filled prior to bottom installation x

Submit Report x

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Attachment 9.14

George White

Project Manager

Robert Haye

QA/QC(Manager)

TBDField QAManager

TBDQC Inspector

Documents

MMB Boleo QA Manual.doc