Bloom Engineering Quality Assurance
Bloom Engineering Quality Assurance Program
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Introduction Bloom Engineering is committed to providing high quality, state-of-the-art combustion equipment and product design to our customers. All Bloom equipment is designed specifically to optimize performance at the operating conditions for the specific furnace to which the equipment is to be applied. Our Quality Assurance Program provides a description of quality assurance activities and organizational interfaces with Bloom Engineering Company. It defines requirements and provides guidance pertaining to activities being perfom1Cd which affect me quality of components and systems including: design. Fabrication, testing, shipment. operation, repair, procurement, inspection. cleaning. Installation. Maintenance and modification. Quality assurance is comprised of all planned systematic actions required to provide adequate confidence that a component or system will perform satisfactorily in service to specified requirements. |
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Additional Information |
Organization
The Bloom Quality Assurance program is administered by the Manager of Operations. who has corporate-level quality responsibility and reports directly to the President.
Quality objectives are accomplished by the personnel who have been assigned responsibility for performing the work such as the Project Engineer, the Welder or me Painter.
A person who is assigned the responsibility for an activity may delegate this duty to a responsible designee.
Personnel performing activities receive their training and develop proficiency by virtue of information provided to them by their immediate supervisor, as well as others of authority 2nd experience throughout the company.
Design Control
The Manager of Engineering administers the design control program. Direct functions and implementations are delegated along line responsibility paths starting with Manager-Project Engineering.
The Manager-Project Engineering is responsible for die design. Upon receipt of an order, this person reviews die job folder and verifies that die design of units or systems complies with specific standards, codes and requirements. He prepares a design layout of the units or systems and forwards die job documents to the assigned Project Engineer.
The Manager / Project Engineering has line responsibility to review designs and supervise Project Engineering. This person issues procedures and instructions that establish design/project control measures and interfaces. He provides guidelines for design control of specialized equipment and technical services.
The Project Engineer designs components, units or systems in accordance with specified standards, codes and requirements. This person selects materials, parts, equipment and processes that are suitable for the application and essential to die function of die components, units or systems. His responsibilities arc as follows:
- Review the job tile including Bloom's proposal, die customer's purchase order and customer/ project specification’s.
- Check for deviations between the customer's purchase order and Bloom's proposal.
- Insure that Bloom drawings and specifications adhere to customer/project specifications.
- Specify appropriate quality standards to be included in design documents.
- Identify, document and control changes or deviations from specified design requirements or quality standards.
- Identify and select applicable codes, specifications and standards for die design.
- Obtain customer approval of drawings, specifications and procedures when applicable.
- Responsible for approving all project drawings for concept.
The Draftsperson prepares and revises the drawings in accordance with the Project Engineer's instructions. The Project Engineer must sign off on all new General Arrangement Drawings.
Design changes, including any field changes, are governed by design control measures commensurate with those applied to the original design.
Procurement Control
The Project Engineer is responsible for incorporation of design specifications, codes and customer requirements on drawings, specifications and Engineering Specification Reports for release to the Drafting, Production and Purchasing Departments. When necessary, this person prepares purchasing requisitions for special materials, equipment and services.
The Purchasing Agent requests competitive bids and prepares Purchase Orders from the Engineering Specifications Report or special purchasing requisitions provided by the Project Engineer. This person issues Purchase Orders to vendors who have been proven or approved. The Purchasing Agent must check for applicable project specifications to be included.
- Purchase Orders shall include the following items, as applicable:
- Identification of quality requirements.
- Drawings, specifications, codes and industry standards with applicable inspection requirements and special instructions for designing, fabricating, cleaning, packaging handling and shipping.
- Provisions for access to plant facilities.
- Documents to be Prepared and submitted for review, such as drawings, specifications, procedures, inspection and test records, personnel and procedure qualifications.
Changes to Purchase Orders are subject to the same degree of control as is used in the preparation of the original Purchase Order.
Document Control
The Drawing Room Supervisor is responsible for the maintenance and control of all drawings.
The Data Processing Department transmits the Order Acknowledgment to the customer.
The Drawing Room Supervisor transmits all technical documents, drawings and instructions to the customer with a Transmittal Form.
It is the vendor's responsibility to maintain and control Bloom documents in accordance with the vendor's quality program.
All Bloom, customer and vendor correspondence is filed and maintained in the job folders.
Control of Purchased Materials, Equipment and Services
The Purchase Agent and/or Project Engineer review activities in the procurement cycle to ensure compliance to the requirements specified in Purchase Orders. They assure that required documentation meets and is furnished per Purchase Order requirements.
Procurement of spare or replacement material receives the same degree of procurement control as the original procurement.
Purchase Orders to all vendors providing raw materials such as castings, carbon steel plate, alloy steel plate, etc. will specify that certified chemical
analysis for the materials being supplied be submitted by the vendor when specified by Engineering.
A certified chemical analysis will be provided by casting foundries for recuperator castings for all radiant tube burners.
Payment for materials received will be withheld pending receipt of such certifications.
Destructive testing is required for new casting patterns. Castings for each type (2 - 3 sample castings) will be subjected to destructive analysis as follows:
- Cut casting through all possible locations which will permit measurement of wall thickness and check for porosity.
- If cut casting passes above checks, foundry will be given authorization for production. If cut castings do not pass, drawings are marked-up as to problems and sent to foundry.
- Foundry corrects problems and sends new sample castings to Bloom for analysis. Procedure continues until acceptable samples have been received.
Manufacturing/Production Control
1. Specific quality control procedures/requirements for each item of each purchase order are defined in an "Engineering Specification Report" (ESR) developed by the Project Engineering Department during the process of each purchase order received by Bloom Engineering Company, Inc.
2. The ESR serves as the basis for establishing specifications for:
- a. preparation of the manufacturing drawings.
- b. preparing purchase orders for the raw materials and resale items.
3. Quality control specifications for Bloom manufactured products are contained in the manufacturing drawings prepared by .he Drafting Engineering Department.
5. Route sheet shows each manufacturing operation required.
6. The Operators are responsible for quality assurance on each operation they perform.
7. The Operators sign off the route sheet for each operation performed.
8. The sign off by an Operator indicates the initial piece has been inspected by the Operator; also, a sampling thereafter (every tenth piece) by the Operator and random sampling of the order by a Shop Supervisor. This assures a product conforming to the drawing and quality appearance.
9. Supervisors make quality checks on large runs and close tolerance items (firSt piece inspection) to ensure setups and procedures.
10. Deviation from drawings during manufacturing on the shop floor is documented on "Manufacturing Variance Request Form" (Exhibit VI, attached). The Manufacturing Variance Request Form is reviewed by the Engineering Department to determine acceptance, rejection or corrective action to be taken. The Manufacturing Variance Request Form is filed in the order file.
11. Supervisors make quality checks to ensure appearance of product.
12. Final assembly again is the responsibility of the Operator. The initial assembly is inspected by the Operator. Thereafter, every tenth piece will be inspected by the Operator and random sampling of the order will be inspected by a Shop Supervisor. The sign off of route sheets by the Operator Will indicate correct drawing dimension and quality appearance.
13. Final products (after painting) are spot checked by Shipping Foreman, Plant Superintendent, or Manager of Operations for quality appearance.
14. Machine shop instrument calibration is checked periodically to ensure correct dimensional checks.
15. Machine shop outside and inside micrometers are calibrated each time a close tolerance machining operation is started. Also, dial calipers are calibrated.
Outside micrometers are calibrated with standards. Inside micrometers are calibrated with outside micrometers. Dial calipers are calibrated with standards.
Numerically Controlled Machining Center Set Up Procedure:
- First piece is machined per computer program. Dimensional checks are made per drawing. Deviations from drawing are corrected by editing program at the machine. Once piece conforms to drawing, production run continues.
Numerical Controlled Lathe: Set up Procedure:
- Same as above
16. Completed route sheets are returned to Production Planning for filing in order file.
Inspection
In-process and final inspections are performed by the Operators with Spot checks by the Shop Supervisors in accordance with dr11wings, specifications and purchase order requirements.
Each fabrication, refractory installation, control panel and pipe rack are manufactured/inspected in compliance with the following manufacturing specifications and/or the customer's project specifications.
- Welding Procedure Specifications
- Refractory Installation Procedures
- Pipe Rack Quality Assurance Information Sheet
- Controls Engineering Department Inspection report
- Phosphate Bonded Materials Production Procedures and Quality System
Special attention is given to detail as follows:
Fabrication:
- Check all connections, including couplings and nipples for proper size, orientation and location.
- Perform complete dimensional check including customer interfaces and mounting points.
- Check weld appearance and quality.
- Check assembly.
- Check paint appearance.
Refractory:
- Perform complete dimensional check of refractory configuration including internal diameter of all holes and openings.
- Perform complete dimensional check of all burner baffle holes including size, angle, orientation and number.
- Check for proper refractory installation and materials.
Piping:
- Check proper component installation and leak- tight assembly.
- Check weld quality on all welded connections.
Nonconforming Materials or Components and Corrective Action
The Manager of Operations and/or Manager of Engineering administers the policy directly to assure that conditions adverse to quality, such as failures, defective materials and nonconformance’s arc promptly identified and corrected. The Project Engineer verifies that dispositions of non- conformances comply with applicable specifications, codes, standards and contract requirements..
The Purchasing Agent monitors the performance of vendors in an effort to update their suitability as a supplier and to prevent recurrence of nonconformances that are considered significant conditions adverse to quality. 1.f the vendor repeatedly proves to be unreliable regarding quality related activities, Bloom discontinues using them as a supplier.
Nonconformances may be disposed of by repairing the defective item, by reworking the defective item to approved drawings or specifications or by scrapping. Where the nonconfonnance is found to be better than the specified requirements and/ or not adverse to quality, it can be disposed by using as is.
All activities related to nonconformance are documented and maintained in the job folder.
Installation, Operation and Maintenance Manuals
Instruction manuals are assembled by the Drafting Room personnel under the direction of the Project Engineer, to include installation, operation and maintenance information for components, units and systems as follows:
- Job data sheets prepared by Project Engineer are comprised of general project and performance data, air and fuel requirements, pilot data, fuel air ratio tables, electrical data and drawing list.
- Installation instructions.
- Dry out instructions for refractory, when applicable.
- Initial start-up instructions.
- Normal operation instructions.
- Maintenance instructions.
- Vendor data.
- Control sequence.
- Drawings.
Instruction manuals are checked by the Project Engineer for correctness of calculations/tables, compliance with project requirements and completeness as a reference guide for the care and
operation of the equipment.
