accredited test facility (atf) quality assurance manual

TENNESSEE VALLEY

INSTITUTE OF MATERIALS JOINING AND TESTING (TV-IMJAT)

ACCREDITED TEST FACILITY (ATF) QUALITY ASSURANCE MANUAL

CHATTANOOGA STATE COMMUNITY COLLEGE (ChSCC)

CHATTANOOGA, TENNESSEE

Author: IMJAT ATF Quality Assurance /Date

Approval: IMJAT ATF Manager/Date

Approval: Director, Proposal and Project Development /Date

Approval: Dean, Engineering and Information Technologies /Date

Approval: Executive Director, Economic & Workforce Development /Date

Document Number:

QMS-001

Title:

IMJAT ATF Quality Assurance Manual

Effective Date: Revision Date: Revision #: Approval Date: 2 of 18

Table of Contents1 Introduction............................................................................................................................3

2 Quality Policy..........................................................................................................................3

3 Mission Statement..................................................................................................................3

4 Purpose and Scope.................................................................................................................4

5 IMJAT Quality Management System Requirements...............................................................5

6 Test Facility Organization Chart..............................................................................................6

7 Management Responsibilities................................................................................................7

8 Personnel and Responsibilities...............................................................................................7

9 Quality Control Procedures....................................................................................................9

10 Registration and Testing Protocol ……………………………………………………………………………………. 10

11 Equipment Maintenance and Calibration ………………………………………………………………………… 11

12 Feedback and Corrective Action ……………………………………………………………………………………… 12

13 Non conformance …………………………………………………………………………………………………………… 13

14 Procedures for Assessing Customer Satisfaction …………………………………………………………………………. 13

15 Provisions for Subcontracted Activities to Verify Compliance ……………………………………………………… 13

16 Documentation and Record Retention …………………………………………………………………………………………. 13

17 Review of Quality Manual ……………………………………………………………………………………………………………… 14

18 Procedure for Positive Identification of a Candidate …………………………………………………………………….. 14

19 Chattanooga State Community College Policies ………………………………………………………………………….. 16

20 References …………………………………………………………………………………………………………………………………. 16

21 Appendix – A……………………………………………………………………………………………………………………………… 17

22 Revision History …………………………………………………………………………………………………………………………… 16

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1 IntroductionThis manual defines the policies used to ensure the quality management system for weldment and weld inspection meets the requirements of the American Welding Society (AWS) Standards for Accredited Test Facilities (ATF). Specific responsibilities, work tasks and instructions to carry out these policies are contained in the Quality Assurance Procedures listed in the Institute for Materials Joining and Testing (IMJAT) ATF Quality Management System (IQMS) Master Document List.

The IMJAT ATF is a partnership between Economic and Community Development and the Engineering and Information Technologies (EIT) Division’s IMJAT to offer Certified Welder testing to meet the regional workforce needs.

Currently IMJAT has 18 welding machines available for operation Monday through Saturday during Chattanooga State Community College’s (ChSCC) fall, spring and summer semesters. Additionally, IMJAT has two non-destructive and one destructive laboratory for both instruction and testing purposes. EIT offers an AAS in Engineering Systems Technology with a concentration in Welding Engineering Technology which includes five embedded certificates and an AAS in Engineering Technology with a concentration in Non-Destructive Testing which includes three embedded certificates.

2 Quality PolicyIMJAT, a materials joining and testing facility within the ChSCC’s Engineering and Information Technologies Division, is committed to performing testing and calibration services in a professional, quality manner and administering and assessing welder qualification tests in accordance with AWS QC7-93 and QC7-93 supplements C, F and G, Standard for AWS Certified Welders, AWS QC4-89, Standards for Accreditation of Test Facilities for AWS Certified Welder Program, and to all other applicable contract, codes and/or standards. Reference F001, IQR Index of Quality Record Form for all external documents in the IMJAT ATF library.

3 Mission StatementBoth the Economic and Community Development and the Engineering and Information Technologies Divisions serve the constituents of the greater Chattanooga economic region through the delivery, promotion, and advancement of high quality and accredited technology education in the areas of engineering technology, electrical/electronic


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engineering technology, engineering systems technology, as well as pre-engineering preparation. The Divisions accomplish this through:

Highly-qualified faculty who care about students and their success. Dynamic, up-to-date curriculum that has an optimal balance between theory and

application. Laboratories, computer facilities, and instructional classrooms on par with any

engineering technology program in the nation.

Unique co-curricular opportunities for students such as participation in student design competitions, professional student organizations, and pre-professional employment.

Mutually beneficial partnerships with regional business & industry partners who take advantage of our location and capabilities in the pursuit of economic development and growth.

Strong cooperative relationships with universities, colleges, and local high schools.

Both the Economic and Community Development and the Engineering and Information Technologies Divisions focus on meeting the technical workforce needs of eleven TN counties (Bledsoe, Bradley, Grundy, Hamilton, Marion, McMinn, Meigs, Monroe, Polk, Rhea, and Sequatchie) and six Northwest Georgia counties (Catoosa, Dade, Fannin, Murray, Walker, and Whitfield) that make up the Chattanooga Metropolitan Statistical Area. Faculty and staff promote ideals of cooperation, reasonable discourse, social responsibility, curiosity, ongoing learning, and collaboration among students, faculty, community, customers and industry partners. Both Divisions strive to instill a positive spirit for change and culture of improvement in developing opportunities for all interested parties.

4 Purpose and ScopeThe IMJAT ATF Quality Assurance Manual contains documentation and references for the IMJAT ATF Quality Management System (IQMS). The IQMS is an ATF quality system that primarily supports material joining and testing. All activities associated with welding, destructive and nondestructive testing are within the IQMS. Conformance with standards referenced in the ATF application and other required standards, codes and/or regulations are listed on the IQMS Master Document List.


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5 IMJAT ATF Quality Management System RequirementsIMJAT and Workforce Development and Training ATF Management are responsible for activities carried out at the testing facility and laboratory located at the college. These activities enable the IMJAT ATF certified facility to perform the testing and laboratory technical functions.

The IMJAT ATF quality system is established, implemented and maintained by Economic and Community Development Division through the Director, Proposal and Project Development, and the IMJAT ATF Manager and Quality Manager. They will ensure the ATF quality management system includes professional practices, statements of testing and laboratory services and conformance to established standards. Management system objectives are established and all associated personnel are familiar with the IQMS. Key personnel including management, test supervisors, quality personnel and technicians identified in the ATF organizational chart in the Quality Assurance Manual participate in professional development and meet all job requirements for their positions. The organization is responsible for ensuring no undue pressure of personnel occurs and that confidential information, including customers, is protected. Policies and procedures shall be in place to ensure confidentiality and security of customer or proprietary information.


6 IMJAT ATF Organization Chart

Tennessee Board of Regents

ChSCC PresidentDr. Flora Tydings

Executive Director, Economic & Workforce Development ,

Lulu Copeland

Director, Proposal and Project Development,

Oscar Brock

Contractor -Test Supervisors, Larry Craig (Contracted CWI Certification # 11060291- exp date 1 Jun

2017)Jeffrey T Iley (Contracted CWI Certification #15090831 exp date 1 Sep

2018

Contractor - NDE Level II

Dean of Engineering and Information Technologies,

Tim McGhee

ET Department Head Beth Ruta

Test Facility Manager,Val deOlloqui

Quality Manager, Tracie Clifford

Laboratory Technician

EST Department Head, Lyn Potter

Facility Welding Lab Technician,James "Talion" Johnson (CWE

#1503017E - exp date 1 Mar 2019)

7 Management ResponsibilitiesSpecific responsibilities for managing testing, calibration, quality and accreditation programs are included in the job descriptions. These documents are listed on the IQMS Master Document List (Reference F013-MDL) and the IMJAT ATF organizational chart. The organization is structured to prevent conflict of interest and segregation of quality duties. Management is responsible to ensure the quality of certification, test and/or calibration results. Also, management is responsible for the documentation (including records) used to communicate further understanding of the scope of the IQMS. Review of the IQMS will be done annually by management in the management review procedure (Reference P004-MR, Management Review Procedure).

Documentation will include statements regarding the demonstration of top management commitments of development, maintenance and improvement of:

The IMJAT ATF quality management system (IQMS) Customer requirements Statutory and regulatory requirements

8 Personnel and Responsibilities8.1. The Executive Director, Economic & Workforce Development is responsible for the

administrative aspects of all IMJAT ATF programs and services. The Director can make legally binding commitments and statements on behalf of the IMJAT ATF. The responsibilities include, but are not limited to:

8.2. Provide organizational structure, including a quality control program, planning, development and management for all IMJAT ATF programs.

8.3.8.4. Director, Proposal and Project Development, is responsible for the administrative

aspects of all IMJAT ATF programs and services. The Director can make legally binding commitments and statements on behalf of the IMJAT ATF. The responsibilities include, but are not limited to:

8.4.1. Oversee the development and management of the IMJAT ATF budget.8.4.2. Supervise all IMJAT ATF contract staff and communicate operational and testing

activities with the IMJAT ATF Manager.8.4.3. Approve manuals, procedures, and protocols along with the IMJAT ATF

Manager, or submit same to the Executive Director Economic and Community Development and the Dean of Engineering and Information Technologies for approval, as appropriate.

8.4.4. Be a contact person for grievances and complaints, assist in their resolutions, and function as a liaison for complaints.

8.4.5. Conduct and document a systematic review of the ATF Quality Assurance Manual, along with the IMJAT Test Facility Manager, at a minimum frequency of

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once a year, stipulating areas for corrective action and the results of previous corrective actions.

8.4.6. Keep information on the relevant qualification, training, and experience of the technical staff.

8.5. The Accredited Test Facility Manager oversees the technical operation of the ATF. The ATF manager is a full-time employee at the college, with at least five (5) documented years of technical experience testing in materials or welding. Duties include:

8.5.1. Assist in the preparation and supervision of the quality assurance procedures listed in the ATF Quality Assurance Manual to ensure the continued effectiveness of the organization, personnel and procedures.

8.5.2. Assist with upkeep and maintenance of all equipment in the labs.8.5.3. Oversee the inspection and testing services of the ATF.

8.6. The Test Supervisor of Welding is a contracted ChSCC employee, who holds current credentials as a Certified Welding Inspector (CWI) under the AWS Standard QC.I. Duties include:

8.6.1. Responsible for inspection and testing services, including administering and assessing test results.

8.6.2. Review and approve applications for certification.8.6.3. Creates, reviews, completes, utilizes and understands Welding Qualification Test

Records (WQTRs), Welding Procedure Qualification Records (WPQRs) and Welding Procedure Specifications (WPSs).

8.6.4. Check base and filler metal materials prior to assembly.8.6.5. Verify proper fit up of test assemblies.8.6.6. Visually inspect test specimen to requirements of the specific code: Code AWS

D1.1 for structural plate steel and Code AWS D1.5 for bridge plate steel.8.6.7. Conduct destructive testing as qualified.8.6.8. Assist and review the preparation of all reports.8.6.9. Verify the proper documentation to send to AWS Qualifications and

Certifications Department.8.6.10. Oversee conditions including the use of appropriate equipment and assurances

that prerequisites for the given activity have been satisfied8.7. The Facility Welding Lab Technician is responsible for the operation of the Welding Lab

used for any testing. The Technician may hold credentials as a Certified Welding Educator (CWE) or CWI. The Technician is a full-time employee of the college who maintains the lab and provides laboratory instruction. Duties include:


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8.7.1. Order materials and services as required in accordance with approved procedures.

8.7.2. Oversee upkeep and maintenance for equipment.8.7.3. Assist in planning and accomplishment of activities that affect quality under

controlled conditions.8.7.4. Assist in a systematic review of the quality system, at a minimum frequency of

once a year.8.8. The ATF Quality Manager is responsible to oversee the IMJAT ATF quality system and

ensure it is appropriate to the type, range and volume of work performed. Duties include:

8.8.1. Maintaining a documented quality assurance manual, including the quality policy.

8.8.2. Maintain and supervise the internal audit schedule.8.8.3. Maintenance of quality system records.8.8.4. Assist the Facility Welding Lab Technician with the calibration and maintenance

programs.8.8.5. Facilitate and document an annual management review (minimum annually)

and report to the ATF Manager and the Director, Proposal and Project Development overall status of the IMJAT ATF.

8.8.6. Communicate as needed to top management information regarding the quality system and its processes comply with requirements.

8.9. The NDE Level II will be a contract employee, qualified and certified in accordance with SNT-TC-1A Recommended Practice for Nondestructive Personnel or ASME Nondestructive Examination (ANDE-1) to perform NDE testing. Individuals holding this position will be qualified NDT Level II.

9 General Quality Control Procedures9.1. Purchase and Storage of Materials

9.1.1. Metals and materials will only be purchased from vendors that stock metal and materials that meet the AWS A5.01, Class F standard for testing.

9.1.2. The Facility Welding Lab Technician will prepare requisitions of base and filler metals and services. All requirements such as material specifications, grades or classifications, heat numbers, documentation and delivery requirements of materials will be specified and included in the final purchase requisition by the Test Supervisor.


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9.1.3. The Facility Welding Lab Technician is responsible for ordering metals and materials.

9.1.4. When metals and materials are delivered, a formal inspection and order review will be completed by the Facility Welding Lab Technician or other designated personnel. The order will be checked, compared to the purchase order and given a lot number that indicates delivery date and vendor name. Specific steps for purchasing and receipt of materials along with a sample purchase order request is included in P009-PUR, Purchasing procedure.

9.1.5. The metals and materials will be stored in a secure dry storage area once received.

9.1.6. Receipt of materials will be checked and filed by the Welding Lab Technician using the purchase requisition checklist, as described in P009-PUR, Purchasing procedure.

9.1.7. Any materials, i.e. electrode and flux that are nonconforming will be segregated, labeled and returned or designated for disposal.

9.2. Material Control9.2.1. Materials will be identified by the lot number, heat number, and American

Society for Testing Materials (ASTM) number and stored in a secure location.9.2.2. When the examinee's application, F010, AWS Certified Welder Application, is

complete, cutting tickets are prepared and issued for the required materials by the Facility Welding Lab Technician in accordance with the Test Supervisor’s specifications. The ASTM number and heat number of the base material and the AWS classification of the filler metal will be recorded on the cutting tickets.

9.3. Employee Qualifications9.3.1. ATF personnel will have the necessary education, training, technical

knowledge and experience for their functions.

10 Registration and Testing Protocol10.1. Registration Protocol

10.1.1. The applicant begins the certification process by filling out F005-TR, AWS Test Request and returning it to the IMJAT ATF Office. A completed sample application will be available upon request. Upon receiving the completed Test Request Form, the Test Supervisor and the Facility


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Welding Lab Technician will schedule the applicant's test date and notify the applicant. The applicant may provide his/her tools, and related accessories.

10.2. Testing Protocol10.2.1. The candidate AWS Certified Welder Application is accepted and approved

by AWS and communicated to the IMJAT ATF. The IMJAT ATF office will notify the applicant to meet with the Test Supervisor to review the following information prior to fitting the assembly. Reference the IQMS Master Document List for specific documents, including external documents.

Safety Checklist (FR002-SCL) F016-SCL Visual Inspection Acceptance Criteria (DOC001-VIAC) F012-VIAC All related cutting tickets (F006, F007, and F008) Fitting procedures (P007, P008) Assembly and drawings (See D1.1 2010) Evaluation process (F009-PQC) Performance Qualification Check List

10.2.2. The welding examinee shall assemble the test assembly by using the fitting procedures for the 1 inch plate tests, and for the 6G pipe test.

10.2.3. The Test Supervisor will stencil the assigned identification code for the examinee on the metal. The examinee will position the test plate(s) in the welding position(s) for inspection by the Test Supervisor. The Test Supervisor will confirm, through random observation, that the test plates are not re-positioned during the test.

10.2.4. After the above stated inspection by the Test Supervisor, the examinee welds the test plates. The welding procedure specifications will be available to each examinee at each test station. The Test Supervisor will confirm, through random observation, that the test plates are not re-positioned during the test.

10.2.5. The Test Supervisor will document the test plate and test pipe activities on the test plate or test pipe checklist.

10.2.6. Upon completion of the test weldments, the Test Supervisor will visually inspect the weldments per, F012-VIAC, Visual Inspection Acceptance Criteria Form. Additional documents, such as supplements are available through the AWS library.

10.2.7. After visual inspection, the test weldment(s) will be laid out for saw cutting. The examinee identification code will be stenciled on the bend specimens prior to their removal from the test weldment(s).


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10.2.8. The bend specimens will be prepared and tested using the bend test procedures of ANSI/AWS B4.0 (D1.1) for plate. Written procedures or additional checklist (reference FO13-MDL, Master Document List) are available for preparation and inspection of bend specimens.

10.2.9. The Test Supervisor will document the bend test activities on the bend test checklist, F011-CLPLP, Checklist 1 Inch Test Plate & 6G Pipe, for the plate test. Written procedures or checklist (reference FO13-MDL, Master Document List) are available for testing and evaluation of bend specimens.

10.2.10. The Bend Test Report will include the following: Examinee's name and last four digits of social security number Identification code Cutting ticket Test Plate checklist (F011) Bend Test checklist (See D1.1)

10.2.11. Off-site testing will be supervised by the Test Supervisor who will transport all necessary testing materials and follow all procedures in the Quality Manual.

10.3. Other Test Methods of Test Specimens10.3.1. Other test methods are controlled by written procedures and conducted by

qualified IMJAT ATF or contracted personnel. Current test methods are developed to ensure test methods meet the current standard and are maintained in the IMJAT library.

11 Equipment Maintenance and Calibration11.1. All equipment shall be properly maintained to ensure protection from corrosion,

other causes of deterioration, misuse and damage that affects the functionality of the equipment.

11.2. The ATF Quality Assurance Manager and the Facility Welding Lab Technician are responsible for setting up any required maintenance including contract maintenance.

11.3. All welding machines will have a maintenance and calibration tag on the machine indicating any work or calibration done to the machine along with a scheduled date for the next maintenance a n d / or calibration due date.

11.4. When a machine receives maintenance, whether in-house or with an outside vendor, a copy of the maintenance record will go into the equipment file on that machine.


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11.5. When a machine is calibrated, whether in-house or with an outside vendor, a copy of the calibration record will go into the equipment file on that machine.

11.6. Records of each machine F014, WCML Welder Calibration and Maintenance Log shall be filed and maintained. The record will include name of equipment, manufacturer's name, identification and serial number, date of the last calibration and previous records, current location of machine, details of maintenance, and will show the maximum period of time permitted between calibrations.

11.7. Power supply systems will be calibrated annually by a contracted service provider to show correlation of volt/amp meter readings compared to actual test meter values.

11.8. Cutting equipment will be maintained as indicated by the equipment manual and if required, calibration and maintenance information (including records) will be maintained in the equipment file.

11.9. Measuring and testing equipment used in the welder qualification process will be calibrated annually by a contracted service provider.

11.10. Damaged or malfunctioning equipment will be re-calibrated after repair and before equipment is placed back in service.

11.11. Calibration tags will be used to verify the status of the calibrated equipment.11.12. A calibration and maintenance log will be maintained.

12 Feedback and Corrective Action12.1. Timely Feedback and Corrective Action

12.1.1. After a weld inspection, the results will be immediately communicated to the examinee.

12.1.2. If the weld does not meet AWS standards, the Test Supervisor will explain the retest policy to the examinee.

12.1.3. If the examinee disagrees with the test results and is a ChCSS student, there is a formal grievance process (ChSCC Policies and Procedures Manual 04:26:00) whenever the situation cannot be resolved informally.

12.1.4. If the examinee disagrees with the test results and is not a ChSCC student, and the situation cannot be resolved informally, the examinee may appeal by filing a formal complaint with the American Welding Society. The inquiry shall include the name, address and affiliation of the inquirer and provide enough information for the committee to understand the point of concern of the inquiry. The appeal is sent to:


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American Welding Society Certification Department550 NW LeJuene RoadMiami, FL 33126

13 Nonconformance13.1. All non-conformances will be reported to the ATF Test Supervisor and the Quality

Manager.13.2. The ATF Quality Manager will investigate the non-conformances (Reference P005-

CP, Corrective & Preventative Action and P006-NCPS, Non-Conforming Product & Services), their causes and consequences, and will propose a disposition of the non-conforming items. When necessary, implement corrective action, which may include possible revisions to procedures or forms, to prevent re-occurrence of similar non-conformances.

14 Procedures for Assessing Customer Satisfaction14.1. Each customer (internal and external) has an opportunity to evaluate each activity

associated with the IMJAT ATF. This is completed through a survey. The survey gauges overall customer satisfaction with personnel, facilities and / or IMJAT ATF processes.

15 Provisions for Subcontracted Activities to Verify Compliance


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15.1. Chattanooga State Community College will endeavor to keep all required testing, monitoring, supervision and administration under the auspices of full-time staff and faculty. In the event that sub-contract work is deemed necessary, (ref. P003-CS Contract Services) will be updated to reflect that the necessary education, training, experience and qualification of contractors meets ATF requirements.

16 Documentation and Record Retention16.1 The ATF will maintain a library of internal and external documents (including forms

and records) for welder application, setup, testing and certification and listed on the IQMS Master Document List.

16.2 The ATF will have access to an online library of all standards referenced by AWS QC4-89, QC7-93, and B5.4:2005, and all supplements published by AWS through the Chattanooga State Community College library.

16.3 The ATF maintains procedures for document and record creation, revision, maintenance, security and approval. The procedures will include methods to purge obsolete documents and records.

16.4 All electronic controlled documents will be stored on the Engineering and Information Technologies Division server (eeet) which is a secure drive for the IMJAT ATF. All users must have permission to access this drive through the Dean of Engineering and Information Technologies’ office.

16.5 The Welder's Performance Qualification Test Record will be completed by the Test Supervisor.

16.6 The welder's file, which contains the Welder Application, Test Checklist, Bend Test Report, Welding Procedure Specification and Welder Performance Qualification Record, will be reviewed and approved by the Quality Assurance Manager and Facility Welding Lab Technician.

16.7 The Welder Performance Qualification Record and Application will be copied and sent to the AWS Qualifications and Certifications Department with the appropriate fee.

16.8 The welder's file will be kept for a minimum of five years and include: any applications and examination results, experience summaries, previous certification (where applicable),


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education and experience verification, diplomas and other training certificates and employers job performance evaluations.

16.9 A summary file that contains the welder's name, test date, and test results will be kept indefinitely.

16.10 Each applicant will receive and sign the Safety Checklist.16.11 The weld samples will be stored until the Test Supervisor accepts them. Upon

acceptance, proper disposal of the weld samples will occur.

17 Review of Quality Manual17.1. The Director of Economic and Community Development, the ATF Facility Manager

and the ATF Quality Manager will review the Quality Manual at a minimum frequency of once a year. Any revisions will be included in the new manual.

18 Procedure for Positive Identification of a Candidate18.1. The welding examinee must provide identification through a state or

federal photo identification.

19 Chattanooga State Community College PoliciesWelding examinees, who are students, have rights and responsibilities by virtue of their status as students. Rights and responsibilities are published annually in the ChSCC Catalog. Welding examinees who are not students are subject to certain obligations while on campus. ChSCC is a drug free and alcohol free workplace. College personnel have the authority to ask any examinee who is exhibiting disruptive or unsafe behavior to leave the testing area immediately.

20 ReferencesThe ATF will maintain a library of all standards referenced by AWS: QC4-89, QC7-93, B5.4:2005,QC.l, QC7-93 supplement C, QC7-93 supplement F, QC7-93 supplement G, ANSI Z-49.1, and any additional supplements published by AWS or other professional organizations applicable to the materials and services offered by the IMJAT ATF. Students can access all publications by online services through the ChSCC library.


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21 Appendix – AExample List of Referenced Documents

Sec. Document Title7 F013-MDL Master Document List

P004-MR Management Review9.2.2 F010 AWS Certified Welder Application

10.1.1 F005 Test Request Form10.1.2 FR002-SCL Safety Checklist

DOC001-VAC Visual Inspection Acceptance CriteriaF006, F007, F008 Cutting Tickets

P007, P008 Fitting ProceduresF009-PQC Evaluation Process

10.2.9 F011 Test Plate Checklist11.6 F014-WCML Welder Calibration and Maintenance Log13.2 P005-CP Corrective and Preventative

P006-NCPS Non-Conforming Product & Services

22 Revision HistoryDate Rev. # Description of Revision
