Specification for Quality Management

System Requirements for

Manufacturing Organizations for the
Petroleum and Natural Gas Industry
API SPECIFICATION Q1
NINTH EDITION, JUNE 2013
EFFECTIVE DATE: JUNE 1, 2014
 
 
 
 
 
 
3.1.16 outsource
[Outsourced activity]
 
Function or process that is performed by an
external supplier on behalf of the organization.
4.4 Documentation Requirements
4.4.1 General
The quality management system documentation shall include:
a) statements of quality policy and quality objectives;
b) a quality manual that addresses each requirement of this specification and
includes:
1) the scope of the quality management system, including justification for any
exclusions to specific
quality management system elements (see Section 1);
2) a description of the sequence and interaction between the processes of the quality
management
system;
3) identification of processes that require validation (see 5.7.1.5); and
4) reference to documented procedures that control the quality management system
processes;
c) documented procedures established for the quality management system;
d) documents and records to ensure the effective planning, operation, and control of
its processes and
compliance with specified requirements; and
e) identification of legal and other applicable requirements to which the organization
claims compliance
that are needed to achieve product conformity.
 
4.3.2.3 Training and Awareness
The organization shall:
a) provide for quality management system
training and job training;
b) ensure that customer-specified training
and/or customer-provided training, when
required, is included
in the training program;
c) ensure that the frequency and content of
training is identified;
d) ensure that its personnel are aware of the
relevance and importance of their activities
and how they
contribute to the achievement of the quality
objectives; and
e) maintain appropriate records of education,
training, skills, and experience (see 4.5).
5.6 Purchasing
5.6.1 Purchasing Control
5.6.1.1 Procedure
The organization shall maintain a documented procedure to ensure that purchased products, components or
activities conform to specified requirements.
The procedure shall address:
a) identification of critical products, components, or activities;
b) initial evaluation and selection of suppliers based on their ability to supply products, components, or
activities in accordance with the organization‘s requirements (see 5.6.1.2 and 5.6.1.3);
c) type and extent of control applied to the supply chain for critical products, components, or activities;
NOTE Section 5.6.1.6 contains additional requirements for outsourced activities.
d) criteria, scope, frequency, and methods for reassessment of suppliers;
e) maintaining a list of approved suppliers and scope of approval.
 
 
5.6.1.2 Initial Supplier Evaluation—Critical Purchases
For purchase of critical products, components or activities, the criteria for the initial evaluation of suppliers
by the organization shall be site-specific for each supplier and shall include the following:
a) verification that the supplier’s quality management system conforms to the quality system requirements
specified for suppliers by the organization;
b) verification of the type and extent of control applied by the supplier, internally and to their supply chain, in
order to meet the organization’s requirements; and
c) assessment of the supplier to ensure its capability to meet the organization’s specified requirements by
one or more of the following:
1) performing an on-site evaluation of relevant activities; or
2) performing first article (see 3.1.11) inspection to ensure conformance to stated requirements; or
3) identifying how the supplied product, component, or activity conforms to stated requirements when
limited by proprietary, legal, and/or contractual arrangements.
 
 
 
5.6.1.3 Initial Supplier Evaluation—Noncritical Purchases
For purchase of noncritical products, components, or activities that impact product realization or the final
product, the criteria for evaluation of suppliers by the organization shall meet the requirements of 5.6.1.2 or
satisfy one or more of the following:
a) verification that the supplier’s quality management system conforms to the quality system
requirements specified for suppliers by the organization; or
b) assessment of the supplier to meet the organization’s purchasing requirements; or
c) assessment of the product or component upon delivery, or activity upon completion.
 
 
5.6.1.4 Supplier Reevaluation
The organization shall determine the supplier reevaluation frequency based on supplier risk and supplier
quality performance.
For the reevaluation of suppliers of critical products, components, or activities, the requirements of 5.6.1.2
shall apply.
For the reevaluation of suppliers of noncritical products, components, or activities, the requirements of
5.6.1.3
shall apply.
 
 
 
5.6.1.5 Supplier Evaluation—Records
Records of the results of all evaluations and any necessary actions arising from the evaluations shall be
maintained (see 4.5).
5.6.1.6 Outsourcing
Where an organization chooses to outsource any activity within the scope of its quality
management
system, the organization shall ensure that all applicable elements of its quality
management system are
satisfied and shall maintain responsibility for product conformance to specified
requirements, including
applicable API product specifications, associated with product realization.
NOTE See 5.7.1.5 for requirements when a process requiring validation is outsourced
within the supply chain.
Records of outsourced activities shall be maintained (see 4.5).
 
 
5.7.1.5 Validation of Processes for Production and Servicing
The organization shall validate processes for production and servicing where the resulting output cannot
be verified by subsequent monitoring or measurement, and as a consequence, deficiencies become
apparent only after the product is in use or the servicing has been delivered. Validation shall demonstrate
the ability of these processes to achieve planned results. Where an organization chooses to outsource a
process that requires validation, the organization shall require that the supplier conform to these
requirements (see 5.6.1.6).
 
The organization shall maintain a documented procedure to address methods for review and approval of
the processes including:
a) required equipment;
b) qualification of personnel;
c) use of specific methods, including identified operating parameters;
d) identification of acceptance criteria;
e) requirements for records (see 4.5); and
f) revalidation.
The organization shall validate those processes identified by the applicable product specification as
requiring validation. If these processes are not identified, or there is no product specification involved, the
processes requiring validation shall include, as a minimum, nondestructive examination, welding, and
heat treating, if applicable to the product.
Specification for Pipeline and Piping Valves
API SPECIFICATION 6D
TWENTY-FOURTH EDITION, AUGUST 2014
EFFECTIVE DATE: AUGUST 1, 2015
 Processes Requiring Validation
 
The following operations performed during
manufacturing shall be validated, by the
manufacturer, in accordance with their quality
system as applicable:
 
nondestructive examination (NDE)—reference
8.1;
 
welding—reference Section 7;
 
heat treating—reference 6.1;
 
external coating/component plating that may
impact product performance, by agreement.
 
 
Normative References
 
ASME Boiler and Pressure Vessel Code (BPVC), Section IX: Welding and Brazing
Qualifications, 2013
ASNT SNT-TC-1A 2, Recommended Practice No. SNT-TC-1A—Personnel Qualification and

Certification in Non- Destructive Testing

AWS QC1 4, Standard for AWS Certification of Welding Inspectors
EN 287-1 5, Qualification test of welders—Fusion welding—Part 1: Steels
ISO 9606-1, Approval testing of welders—Fusion welding—Part 1: Steels
ISO 9712, Non-destructive testing—Qualification and certification of personnel
ISO 15607, Specification and qualification of welding procedures for metallic materials—General
rules
 
ISO TR 15608:2013, Welding—Guidelines for a Metallic Materials Grouping System
 
ISO 15609 (all parts), Specification and qualification of welding procedures for metallic materials—
Welding procedure specification
 
ISO 15614-1, Specification and qualification of welding procedures for metallic materials—Welding
procedure test— Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys
 
ISO 15614-7, Specification and qualification of welding procedures for metallic materials—Welding
procedure test— Part 7: Overlay welding
Out Source Activity:
 
Function or process that is performed by an
external supplier on behalf of the
assembler/manufacturer.
 
 
pressure-containing parts
A part whose failure to function as intended
results in a release of contained fluid into the
environment and as a minimum includes
bodies, end connections, bonnets/covers, and
stems.
 
 
pressure-controlling parts
A part intended to prevent or permit the flow
of fluids and as a minimum includes ball, disc,
plug, gate, and seat.
Welding : Activities on parts or final
assemblies.
 
Plug valves shall have a cylindrical or conical
obturator that rotates about an axis
perpendicular to the direction of flow.
 
7.2 : Welding consumables shall conform to
the American Welding Society's or
manufacturer's specifications. The
manufacturer shall have a written procedure
for storage and control of welding
consumables. Materials of low- hydrogen type
(including electrodes, wires, and fluxes) shall
be stored and used as recommended by the
manufacturer of the welding consumable to
retain their original low-hydrogen properties.
 Welding Procedure and Welder/Welding Operator Qualifications
 
Welding, including repair welding, of pressure-containing and pressure-controlling parts shall be performed in
accordance with procedures qualified to ASME BPVC, Section IX and 7.2 and 7.3 of this specification, or ISO 15607,
ISO 15609, and ISO 15614-1.
 
Welders and welding operators shall be qualified in accordance with ASME BPVC, Section IX or ISO 9606-1, or EN
287-1.
 
NOTE The purchaser, pipeline or piping design standards, material specifications, and/or local requirements may
specify additional requirements.
 
The results of all qualification tests shall be documented in a PQR.
 
PWHT shall be performed in accordance with the applicable material specification or design code.
 
For weld overlay, qualification shall be in accordance with ASME BPVC, Section IX, Articles II and III or ISO 15614-7.
 
Chemical analysis of the weld metal shall be performed in accordance with the requirements of ASME BPVC, Section
IX at the minimum overlay thickness as specified by the manufacturer for the finished component.
 
NOTE To assure minimum thickness of 0.12 in. (3.0 mm), the weld overlay typically requires two passes to achieve
the required dilution.
For weld overlay or clad welding with nickel-
based alloy UNS N06625, the weld overlay or
clad thickness chemical composition shall meet
one of the classes listed below:
 
Class Fe 10: iron mass fraction 10.0 %
maximum; or
 
Class Fe 5: iron mass fraction 5.0 % maximum,
when specified by the purchaser.
 
For all other composition, the chemical
analysis of the weld overlay or clad welding
shall conform to the manufacturer’s written
specification.
 
NOTE Some pipeline welding standards have
more stringent requirements for the essential
variables of welding. It may be necessary to
provide full weld test rings, in the same heat-
treatment condition as the finished valve, for
weld procedure qualification.
 Impact Testing
 
Qualifications of procedures for welding, including repair welding, of, pressure-containing and pressure-controlling parts
shall meet the following toughness test requirements.
 
Impact testing shall be carried out for the qualification of procedures for welding on valves with a design temperature
below –20 °F (–29 °C).
 
NOTE Design standards and/or local requirements might require impact testing at minimum design temperatures above –
20 °F (–29 °C).
 
As a minimum, one set of three weld metal (WM) impact specimens shall be taken from the WM at the location shown in
Figure 3. The specimens shall be oriented with the notch perpendicular to the surface of the material. Multiple sets of weld
metal impact specimens shall be required when more than one welding process is used. Weld metal impact testing must be
performed to represent each welding process being qualified.
 
A set of three impact specimens shall be taken from the heat-affected zone (HAZ) at the location shown in Figure 4. The
notch shall be placed perpendicularly to the material surface at a location resulting in a maximum amount of HAZ material
located in the resulting fracture.
 
HAZ tests shall be conducted for each of the materials being joined when the base materials being joined are of a different
P-number and/or group number in accordance with ASME BPVC, Section IX or ISO 9606-1, ISO 15607, ISO 15609, ISO
15614-1, and ISO 15608 or when one or both of the base materials being joined are not listed in the P- number and/or
group number.
 
Impact testing shall be performed in accordance with ASTM A370 or ISO 148-1 using the Charpy V-notch technique.
Specimens shall be etched to determine the location of the weld and HAZ.
 
The impact test temperature for welds and HAZs shall be at or below the minimum design temperature specified for the
valve. Impact test results for full-size specimens shall meet the requirements of 6.6. If the material specification requires
higher impact values than those shown in 6.6, the higher values shall apply.
 Hardness Testing
 
Hardness testing shall be carried out as part of
the welding procedure qualification on
pressure-containing and pressure-controlling
parts in valves required to meet NACE
MR0175, ISO 15156 (all parts), or NACE
MR0103, as applicable.
 
Hardness surveys shall be performed on base
metal (BM), WM, and HAZ in accordance with
the requirements of NACE MR0175, ISO 15156
(all parts), or NACE MR0103, as applicable.
Repair: Minor defects may be removed by grinding provided there is a smooth
transition between the ground area and the original contour and the minimum wall
thickness requirements are not affected.
 
Repair of defects shall be performed in accordance with a documented procedure
specifying requirements for defect removal, welding, heat treatment, NDE, and
reporting as applicable.
 
Weld repair of forgings and plates shall not be performed to correct material defects,
unless otherwise agreed. However, weld repair can be used to correct machining errors.
The weld repair shall be in accordance with the applicable material standard, including
any PWHT, if applicable.
 
Weld repair of castings shall be in accordance with the applicable material standard,
including any PWHT, if applicable.
 
Repair of welds
 
Repair of welds shall be performed in accordance with the applicable design code or
standard listed in 5.1, including any PWHT where applicable.
 Quality Control
NDE Requirements
 
Final surface (MT and PT) and ultrasonic (UT) NDE activities shall be conducted after final heat treatment or postweld
heat treatment. Final radiography (RT) NDE activities shall be conducted after final heat treatment, unless otherwise
agreed.
 
Calibration Intervals
 
Calibration intervals shall be established for calibrations based on repeatability and degree of usage.
 
Calibration intervals shall be a maximum of three months until recorded calibration history can be established by the
manufacturer.
 
Intervals shall be shortened and may be lengthened based on review of the calibration history and determination of
interval adjustments as defined in the manufacturer’s written procedure. Increments to establish longer intervals shall
be limited to three months maximum.
 
The maximum calibration period shall not exceed one calendar year.
 
Temperature-measuring Devices
 
Temperature-measuring devices shall be capable of indicating and recording temperature fluctuations of 9 °F (5 °C).
 
Heat-treatment Equipment Calibration
 
Heat-treatment equipment calibration shall be performed prior to putting the equipment in service and shall be
recalibrated at a frequency not longer than 12 months from the last calibration.
 Qualification of Personnel
NDE Personnel
 
NDE personnel shall be qualified in accordance
with the manufacturer’s documented training
program that is based on the requirements
specified in ASNT SNT-TC-1A or ISO 9712.
 
NOTE Alternative standards are acceptable
provided they meet the minimum
requirements of ASNT SNT-TC-1A.
 Visual Examination Personnel
 
Personnel performing visual inspection for
acceptance shall take and pass an annual vision
examination in accordance with the
manufacturer’s documented procedures that
meet the applicable requirements of ASNT
SNT- TC-1A or ISO 9712.
 
NOTE Alternative standards are acceptable
provided they meet the minimum
requirements of ASNT SNT-TC-1A.
 
Other Personnel
 
All personnel performing other quality control
activities directly affecting material and
product quality shall be qualified in accordance
with manufacturer’s documented
requirements.
 
 
 Welding Inspectors
 
Personnel performing visual inspections of welding operations and
completed welds shall be qualified and certified by one of the
following:
 
AWS QC1 or equivalent certified welding
inspector, or
 
AWS QC1 or equivalent senior certified welding
inspector, or
 
AWS QC1 or equivalent certified associated
welding inspector, or
 
welding inspector certified by the
manufacturer’s documented training program.
 NDE of Repairs
 
After defect removal, the excavated area shall be examined by magnetic-particle (MT) or
liquid-penetrant (PT) methods in accordance with Annex G.
 
Repair welds on pressure-containing parts shall be examined using the same NDE
method that was used to identify the defect with a minimum of MT or PT.
Acceptance criteria shall be as specified in Annex G for the appropriate product form.
The final NDE activities shall be conducted after postweld heat treatment, unless
otherwise agreed.
 
The NDE requirements specified by the purchaser in 8.1 shall also apply to repair
welding.
 
Weld End NDE
 
If the purchaser specifies that weld ends be subjected to volumetric and/or surface NDE,
the examination and acceptance criteria shall be in accordance with G.24, G.26, or G.27,
as specified.
 
Visual Inspection of Castings
 
All castings as a minimum shall be visually
inspected in accordance with MSS SP-55 with
the following acceptance criteria:
 
Type 1: none acceptable;
 
Type 2 to 12: A and B only.
Minimum Documentation and Retention
 
The documentation listed below shall be retained by the manufacturer for a minimum of 10 years following the date of
manufacture:
 
design documentation;
 
weld procedure specification (WPS);
 
weld procedure qualification record (PQR);
 
welder performance qualification (WPQ);
 
qualification records of NDE personnel;
 
records of test equipment calibration;
 
NDE records [for radiographic testing (RT), minimum NDE records are reader sheets and technique sheet];
 
for valves NPS 2 (DN 50) and larger:
 
material test report for body, bonnet/cover(s), and end connector(s)/closure(s) traceable to the unique valve
serial number;
 
serial number;
 
pressure test results (including hydrostatic and or pneumatic);
 
for sour service valves, certificate of conformance to NACE MR0175, ISO 15156 (all parts), or NACE MR0103.
 
NOTE Purchaser or regulatory requirements can specify a longer record retention period.
 Item Process Activity Location

1 Product design Performed on-site, off-site, and/or outsourced

1b Product design validation Performed on-site and/or off-site

2 Material procurement Performed on-site, off-site, and/or outsourced

3 Receiving verification Performed on-site

4 Machining Performed
Table on-site, off-site,
8—Minimum and/or Requirements
Facility outsourced

5 In-process inspection Performed on-site, off-site, and/or outsourced

6 Welding Performed on-site, off-site, and/or outsourced

7 Assembly Performed on-site

8 Verification testing (Section 9) Performed on-site

9 Supplementary NDE and testing (Annexes G, H, I, and J) Performed on-site, off-site, and/or outsourced

10 Marking/tagging/nameplate Performed on-site

11 Painting/coating Performed on-site, off-site, and/or outsourced

12 Preparation for shipment Performed on-site

13 Final inspection Performed on-site

Calibration
 
Temperature-controlling and temperature-
recording instruments shall be calibrated at least once every three
months.