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QUALITY CONTROL MANUAL Section: 15

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FIELD ASSEMBLY Date: 08.09.2015
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15.12. CONTROL OF EQUIPMENT, MEASUREMENT AND TEST EQUIPMENT


15.12.1 All calibration of equipment to be used at field-site shall be handled in accordance with
Section 11 (Calibration of Measurement and Test Equipment) of this Manual. It is the
responsibility of the Field QC Inspector to ensure that only calibrated and identified
equipment is used for field-Site work.

15.13. ADDITIONAL REQUIREMENTS FOR FIELD ASSEMBLY AND CERTIFICATION OF


BOLERS
15.13.1. When GORICA is responsible for only field assembly of parts provided by others; Field
QC Engineer through QC Manager shall ask for shop completed MDR / master MDR
from the main Manufacturer and certify the field assembly part on the MDR / Master
MDR. The responsibility for Certification Mark stamping lies with the main Manufacturer
responsible for the boiler.
15.13.2. The responsibility for stamping of the boiler with Code required Certification Mark
stamping lies with the boiler manufacturer or the engineering contractor. The boiler
manufacturer shall be providing P-3 Master Data Report or the engineering contractor
shall be providing P-3A Master Data Report including all associated MPDR,
15.13.3 GORICA (Company) is responsible for field assembly and certification as per PG-106.7 &
PG-107.2 of ASME Code Section I. Field QC Inspector shall certify the field assembly portion
of Master Data Report and present it along with all examination & inspection records and
MPDR to the AI for his signature.
15.13.4. When engineering contractor provides the metallic master stamping name plate with
Certification Mark, site QC Inspector is responsible to affix it to the boiler at the location
specified in PG-111.13 and on authorization and presence of AI,
15.13.5. GORICA in addition shall provide assembler's name plate with Certification Mark &
Certificate designator and affix it near the Master Name Plate, and shall be done in
presence of AI.
15.13.6. In case GORICA is responsible for partial field assembly, the certification and stamping
shall be as per PG-107.2.3(b) on form P-3, without marking it as Master.
15.13.7. The completed Data Reports for the assembly shall be forwarded to the boiler
manufacturer or engineering contractor responsible for providing Master Data Reports. A
copy shall be provided to the AI upon request and a copy retained in the file for at least 5
years.

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QUALITY CONTROL MANUAL Section: 15
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FIELD ASSEMBLY Date: 08.09.2015
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15.7.6. The completed Data Report, together with the final records is presented to the Al for
review and acceptance. When satisfied that all Code requirements have been met, the
AI shall authorize and verify the application of the Certification Mark Stamp to the
Nameplate or item as applicable and sign the Field Assembly portion of the Data Report.
15.7.7. The Field QC Inspector is responsible for Certification Mark Stamping of field site
assembled items. Field QC inspector obtains the necessary Certification Mark Stamp
from Project Manager and carries out stamping after obtaining authorization from AI. The
Certification Mark stamp is returned to the Project Manager after stamping.
15.78. All records are returned to the QC Manager for retention as described in Section 12
(Records Retention) of this Manual.

15.8. CORRECTION OF NON-CONFORMITES


15.8.1. All Non-conformities found during field-site work shall be handled in accordance with
Section 7 (Correction of Non-Conformities) of this Manual, including involvement of Field
Site AI, except that the Field QC Inspector shall be responsible for preparing the NCR
and approval of the disposition. Field QC Inspector inspects the item after the disposition
is completed and signs in the NCR for verification of correction. All NCR's are sent to QC
Manager for retention as described in Section 12 (Records Retention) of this Manual.
15.9. WELDING CONTROL
15.9.1. The preparation and qualification of WPS, WPQ/WOPQ and Welding Control shall be
handled in accordance with Section 8 (Welding Control) of this Manual.
15.9.2. Welding Procedures shall be qualified in the shop, and welders/welding operators may
be qualified either in the shop or at field-site. The Field QC inspector shall be
responsible for the welder/welding operator qualification and certification at field site.
15.93. All applicable WPS's and supporting PQR's, List of Qualified Welders/Welding operators
shall be sent to the Field Engineer and Field QC Inspector by the QC Manager. All the
documents shall be made available to the AI for review.
15.9.4. The Store keeper at field site is responsible for issuance of welding consumables as
instructed by Field QC Inspector and as described in Section 8 (Welding Contro) of this
Manual.

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QUALITY CONTROL MANUAL Section: 15
Rev: 0
FIELD ASSEMBLY Date: 08.09.2015
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15.6 MATERAL CONTROL


15.6.1 ORDERING OF CODE MATERIAL
All materials to be used for field-site work shall be ordered in accordance with Section 5
(Material Control) of this Manual. Purchasing of material at field-sites is not permitted.
15.6.2 CONTROL OF CODE MATERIAL TO BESENT TO FIELD SITE
Code material cut to shape in the Shop and to be sent to field-site shall have the following
markings:
a) Job Number
b) Item No.
c) The full material markings as required by the material specification or an acceptable
Coded marking.
d) Part Number
All material from the Shop to the field-site shall be sent with a copy of the Receiving
Inspection Report and the MTR to the field-site which the Field QC Inspector shall use in
verifying the material markings prior to the material being released. Record of coded
marking shall also be forwarded.
For all Code material to be received directly at the field-site, the QC Manager sends to
the Field QC Inspector an approved copy of the Purchase Order with Technical delivery
conditions and the Material Requisition for use in receiving inspection at field-site.
15.6.3 MATERIAL RECEIVNG INSPECTION AT SITE
All materials are subject to receiving inspection in accordance with Section 5 (Material
Control) of this Manual. This shall be performed by the Field QC Inspector and
documented on the Material Receiving Inspection Report,
All Code material, items or Code Parts are unloaded in the assigned lay-down area, and
examined by the Field QC Inspector for
a) Physical damage, which may have occurred during transport.
b) Proper tagging and identification of each item, which provides traceability to assembly
drawings.
c) in case of items supplied with MPDRs, the stamping shall be verified against the Data
Reports. Data Reports shall be submitted to field AI for his review & acceptance.
d) The required material markings as described in Section 5 (Material Control).

QUALITY CONTROL MANUAL Section: 14

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REPAIRS AND ALTERATIONS Date: 08.09.2015
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14.16.4. The relevant R1, R2, R3 or R4 Form shall be prepared and certified by QC Manager
before submitting the same to Inspector (AI) along with all relevant documents for his
review. QC Manager shall also certify the design certificate Section of Form R-2.
14.16.5. On review and endorsement of Inspector (AI), the forms shall be distributed by Project
Manager as follows:
a. Completed R-1 form along with attachments shall be distributed to the owner/user,
inspector (AI), Jurisdiction (when required) and the Authorized Inspection Agency
responsible for the in-service inspection of pressure retaining item (when applicable).
b. Completed R-2 form along with attachments shall be distributed to the owner/user,
Inspector (AI), Jurisdiction (when required), the Authorized Inspection Agency
responsible for the in-service inspection of pressure retaining item (when applicable) and
the R certificate holder responsible for design (when applicable).
14.16.6. For those R forms not registered with National Board, the Project Manager shall retain a
copy of the R Form together with associated documents for a minimum period of 5 years.

14.17. NATIONAL BOARD REGISTRATION


14.17.1. When the repairs or alteration forms are required to be registered with National Board
the R Form number shall be referenced on the applicable Repair/Alteration reports
(Forms R1 & R2). R Form numbers will start from 1 and will be in sequence without any
skips and gaps. NB stamp shall not be applied on the R stamp name plates.
14.17.2. A Log of R Forms of all the R reports issued shall be maintained by QC Manager
indicating Serial number, R Form number (only when registered), description of Job, Job
No and date R form sent to National Board for registration. R Form shall be sent for
registration to the National Board within 30 days from date of signing by the Inspector
(AI) when required. In order to control issue of R Form numbers QC Engineer shall
maintain Log of R Forms (Exhibit-24) of R Stamped Items.
14.17.3. Form R-1 along with attachments shall be registered with National Board when required
by the owner or Jurisdiction.
14.17.4. If the original vessel is registered with National Board, Form R-2 along with
attachments shall be registered with National Board.

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14.11.6. When Liquid Pressure Test is not practicable the QC Manager shall obtain the
acceptance of Inspector (AI) and the owner/user for carrying out alternative test as
described in Section 4 Part 3 of NBIC. This acceptance shall be obtained and recorded
before performing any alternative examination or testing.

14.12. NON CONFORMITY


14.12.1. Non-conformity noticed during execution of repairs and alterations shall be dealt in
accordance with the Section 7 (Correction of Non-Conformities) of this Manual,

14.13. CALIBRATION
14.13.1. All equipment and gauges used for inspection and examination during repair and
alterations shall be maintained and calibrated in accordance with the Section 11
(Calibration of Measurement and Test Equipment) of this Manual.

14.14 ACCEPTANCE AND INSPECTION OF REPAIR AND ALTERATION


14.14.1. Repair and Alteration shall be carried out as per the procedure accepted by Inspector
(AI) and all the stages identified in the ITP shall be offered to him in accordance with his
designated inspection points.
14.14.2. Before acceptance of any repair or alteration, the Inspector (A1) shall be afforded the
right to satisfy himself that all the functions deemed necessary and in compliance with
the requirements of the NBIC, have been performed.

14.15. NAME PLATE AND STAMPING


14.15.1. The "R" stamp is at all times the property of National Board and shall be promptly
returned on demand. In case the agreement with Authorized Inspection Agency has
been discontinued or the certificate of authorization has expired and no new certificate
has been issued, the "R" stamp shall be immediately returned to the National Board.
14.15.2. The Project Manager shall be responsible of the custody and use of the "R" stamp. The
custody of the "R" stamp may be temporarily transferred to the Field QC Inspector when it
is required to be used on field sites. Under no

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QUALITY CONTROL MANUAL Section: 14
Rev: 0
REPAIRS AND ALTERATIONS Date: 08.09.2015
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14.9.4. Examination and tests required during repair shall be in accordance with the original
construction standard. However, if impossible or impractical, alternative methods as
permitted by NBIC and acceptable to the Inspector (AI) and the owner may be used,
149.5. Inspector (AI) shall have access to make such inspections of vessels he deems
necessary in order to ensure that Inspections can be performed, and to accept the repair
and alterations after final inspection.

14.10. WELDING, NDE AND HEAT TREATMENT


14.10.1. Welding controls including qualification of welding procedures and welders, control of
welding consumables, welder's identity & Continuity control and shop/ field welding
controls for repairs and alterations shall be in accordance with Section 8 (Welding
Control) of this Manual.
14.10.2. The welding procedures and welder's qualification shall conform to original construction
standard. If this is not possible or practicable, WPS and welders qualified in accordance
with ASME Code Section LX can be used. Records of approved WPS and welder's
qualification tests shall be made available to Inspector (AI) for his review and
acceptance before carrying out welding work.
14.103, Standard WPS shown in NBIC Part 3, Section 2, Para 2.3 can be used without
supporting PQR for repairs or for performance qualification. Such WPS shall be
documented and certified by QC Manager for use. When required, owners or
jurisdiction's acceptance will be obtained for use of standard WPS.
14.10.4. NDE requirements including technique, extent of coverage, procedures, personnel
qualification and acceptance criteria shall be in accordance with original construction
standard. Weld repairs and alterations shall be subjected to same NDE requirements as
the original welds. When this is not possible or practicable, alternative NDE methods
acceptable to Inspector (AI) and owner or jurisdiction as applicable may be used.
14.10.5. NDE personnel shall be qualified in accordance with the requirements of original
construction standard. When this is not possible or practicable, personnel qualified in
accordance with latest NBIC adopted edition of SINTTC-1A may be used,
14.10.6. Other NDE controls shall be as per Section 9 (Non-Destructive Examination) of this
Manual.

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Clearly identify the Code/Standard used including their year and addenda date.
14.7.4 Drawings for alterations (and when required for repairs) shall be approved by Project
Manager. In addition to the applicable details given in Section 4 (Drawings, Design
Calculations & Specifications), the drawings shall also indicate the original
construction Code, construction Code used for repairs/alterations, applicable National
Board Inspection Code addenda and name plate stamping details. Distribution and
revision to the drawings shall be controlled in the manner described in Section 4 (Drawings,
Design Calculations & Specifications).
14.7.5 Design Engineer is also responsible for verifying the identification of the existing materials
from the original Data Reports, original drawings and other such documents. Material
specification for the existing material and material to be installed shall be clearly indicated on
the drawings.
14.7.6 When any material or part is to be replaced during repairs or alteration, Technical
specifications for material shall be prepared and approved by Design Engineer and
Project Manager as described in Section 5 (Material Control) of this Manual.
14.7.7 Project Manager with the help of Design Engineer is responsible for selection of units
based on the requirements of the clients, units used for the original item and the
original construction Code. However one system of units shall be used throughout the
repair and alteration process,
14.7.8 All design documents shall be submitted to the Inspector (AI) for his review before
proceeding further with repairs or alterations.

14.8. MATERIALS AND REPLACEMENT PARTS


14.8.1 Consideration shall be given to the condition of existing material especially in the weld
preparation area. If the existing material cannot be verified by the Design Engineer, QC
Manager shall arrange to perform sufficient chemical & mechanical tests to identify the
material and its weld ability,
14.8.2 Use of stock material, procurement, receipt inspection, storage, issue and identification
of material shall be as described in Section 5 (Material Control) of this Manual.
14.8.3 All materials used in making repair or alteration shall conform in So far as possible to the
requirements of original construction standards or as specified in 14.6 above.

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Compromise a meaningful pressure test shall be removed, to the extent identified


by the QC Manager.
14.2.9. In lieu of pressure testing, alternative methods can be used to assure the structural
integrity of the re-rated pressure retaining item. The alternative methods shall be
documented and subject to review and approval by the jurisdiction.

14.3. STATEMENT OF AUTHORITY AND RESPONSBLITY


14.3.1. The authority of control of this Manual and implementation of Quality Control System is
vested with the Project Manager, as described in Section 1 (Statement of Authority and
Responsibility) of this Manual.
14.3.2. Production manager is responsible to ensure that Repairs and Alterations on pressure
retaining items are performed in compliance with this Manual and Code requirements in
shop and at field locations.
14.3.3. Sub-contracted activities are identified in applicable Section of this Manual and those
Sections are referenced in this System. Sub-Contracted activities shall meet all the
requirements of NBIC Part3 Para 1.6.5. Company shall take full responsibility for work
carried out by Sub-contractors

14.4. MANUAL CONTROL


14.4.1. Preparation and revision of this Quality Control Manual shall be the responsibility of the
QC Manager. Issuance and administration of the Manual is the responsibility of the
Project Manager. The system has been detailed in Section TV (Manual Control) of this
Manual.

14.5. ORGANIZATION
14.5.1. Organization Chart for carrying out repair and alteration in shop and at field sites
controlled from shop shall be as shown in Section 3 (Organization) of this Manual and
the Quality Control responsibilities are as detailed in Section 6 (Examination and
Inspection Program) of this Manual.

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Note 3: Records that present information to substantiate the statement used to describe
the Scope of work completed on pressure retaining item including design, material
compliance or certification, NDT reports, PWHT charts, WPS/PQR, WPQ,
Continuity records, drawings, sketches and photographs shall be retained
for 5 years.

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QUALITY CONTROL MANUAL Section: 11
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CALIBRATION OF MEASUREMENT
Date: 08.09.2015
AND TEST EQUIPMENTS
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11.3.2. All equipment are attached with a Calibration Label, which indicates as a minimum; Item
serial no, the Laboratory name, Date of Calibration and the Due Date for the next
calibration.

11.4. DISCREPANT EQUIPMENT


11.4.1. When equipment are found out of calibration or damaged, the QC Engineer tags the item
with a "HOLD" label, removes it from the work area and arranges for calibration or
replacement.
11.4.2. If a Code item is checked using discrepant instruments, a NCR shall be issued and dealt
with as described in Section 7 (Correction of Non-Conformities) of this Manual.
11.43. Discrepant instruments are traced from the Inspection / Test Reports which records the
instrument used.

11.5. RECORDS
11.5.1. Calibration records/ Certificates maintained by QC Manager shall be made available to the
AI for his review.

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QUALITY CONTROL MANUAL Section: 10
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10.4 RECEIVING INSPECTION


10.4.1. When Items are heat treated by Subcontractor in his facility and returned, the Items shall
be examined by the QC Engineer for damage or loss of identification and details are
recorded in the receiving inspection report. Non-Conforming items shall be controlled as
described in Section 7 (Corrections of Non Conformities) of this Manual.

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QUALITY CONTROL MANUAL Section: 9
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A change of requirement identified as a nonessential variable from the specified value or range of
values does not require re-qualification of the written procedure,
9.2.6 All changes of essential and nonessential variable from the value or range of values, by
written procedure shall require supplements to the written procedure.
9.2.7 AI may ask for re-qualification of NDE procedure for cause.
9.2.8 Equipment used for NDE shall have valid calibration certificates.

9.3 NDE PERSONNEL


9.3.1 QC Manager shall verify that personnel used for Code NDE work are qualified and
certified for the methods in accordance with their employer's written practice which is
prepared using the latest Code accepted edition of SNT-TC-1A as guideline. NDE Level III
is appointed by the Managing Director after satisfactory review for his qualification and
certification records through an appointment letter which describes his responsibilities.
9.3.2 The following NDE Personnel qualification records shall be available on file for review by
Al and ASME designee:-
a. Sub contractor's employer's written practice.
b. NDE Level III training, examination, qualification, certification, evidence of
experience and eye test records.
c. NDE Level I and II training, examination, qualification, certification, evidence of
experience, Eye test records, technical performance evaluation records and
continuity records.
9.3.3 QC personnel who perform visual examination on power piping spools and welds shall be
qualified by NDE Level III and certified as per procedure (GI-NDE-VT) by the QC
Manager. Personnel qualified as per SNT-TC-1A and to AWS QC-1- Certified Welding
Inspector (CWI) or Senior Welding Inspector (SCWI) may be used for the visual
examination of welds.
9.3.4 AI may ask for re-qualification of NDE personnel if there is a reason to question their ability
to perform examination.

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QUALITY CONTROL MANUAL Section: 8
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WELDING CONTROL Date: 08.09.2015
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8.7. TACK WELDS


8.7.1 Tack welds used to secure alignment shall either be completely removed when they have
served their purpose or their stopping and starting ends shall be properly prepared by
grinding or other suitable means so that they may be satisfactorily incorporated into the
final weld. Tack welds whether removed or left in place shall be made using a fillet or butt
weld procedure qualified in accordance with Sec IX. Tack welds shall be made by Welders
qualified in accordance with Section IX and shall be examined visually for defects and, if
found to be defective, shall be removed.
8.7.2 All tack welds are visually examined by the QC Engineer.

8.8 WELDING MATERAL


8.8.1 All welding material is purchased and received as described in Section 5 (Material Control)
of this Manual.
8.8.2 Welding material specified by SFA/AWS or otherwise permitted by the Code shall be used.
8.8.3. Welding material is stored in dry storage space and issued to Welders by the Storekeeper
against entry in the Welding Consumable Issue Register that is authorized by the
Production Engineer/Field QC Inspector.
8.8.4 The Storage, handling and issue of Welding consumables are controlled using Welding
Consumable Control Procedure (PRO-03).

8.9 PRODUCTION TEST PLATES


8.9.1 Welding of test plates in accordance with applicable WPS as required by the Code, impact
tests of weld metal and heat affected Zones are done to a procedure prepared by the QC
Engineer, which includes Number, identification, type, orientation, location and dimensions
of required specimens and Charpy impact temperature. Test-plates if required are also
identified in the Weld Map and ITP,
8.9.2 The QC Engineer supervises the welding of the test plates from which specimens are
prepared and tested by a qualified testing laboratory whose test report is reviewed by the
QC Manager for acceptance of results or need for retest.

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8.3. QUALIFICATION OF WELDERS


8.3.1 All Welders to be used for Code welding in shop or at field-site are qualified and certified
to ASME Code Section IX and the applicable Code Section, under the supervision of the
QC Engineer or Field QC Inspector. Preparation and testing of the required specimens or
Volumetric Examination of the test weld, is performed by an approved testing laboratory.
Their report is reviewed by QC Manager or Field QC Inspector, and if acceptable, the QC
Manager prepares and certifies the WPQ/WOPQ (Exhibit No. 11 & 12). The WPQ/WOPQ
documents the performance essential variables actually used for the test welds and range
qualified for production welding.
8.3.2. A WPQ/WOPQ is also issued for any Welder who has welded a test coupon to qualify a
WPS, based on the performance essential variables used, and provided the test results
meets the Code requirements.
8.3.3. Copy of List of Qualified Welders/Welding Operators is sent to the Production Engineer.
The original WPQ(s)/WOPQ(s) and list are retained in the QC Manager's file.
8.3.4. Production Engineer in consultation with QC Engineer assigns welders. Production
Engineer ensures that only qualified welders are used on Code items,

8.4 REQUALIFICATION OFWELDERS


8.4.1 Welders are re-qualified in accordance with paragraph 8.3, above if:
a) A Performance essential variable changes
b) A Welder has not welded with a process during a period of six months or more, Unless
Within the six months period, prior to his expiration of qualification:
i) A Welder who welds using manual or semiautomatic will maintain his manual or
semiautomatic welding with that process for additional 6 months.
ii) A Welding Operator who welds with machine welding or automatic welding process will
maintain his qualification for machine or automatic welding with that process for additional
6 months.
c) When there is a specific reason to question his ability to make welds that meet
specification, the qualifications which support the welding he is doing will be revoked. All
other qualifications not questioned remain in effect. d) The AI has reason to question a
Welder's ability to make welds that meets the Code requirements.

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QUALITY CONTROL MANUAL Section: 7
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CORRECTION OF
Date: 08.09.2015
NON-CONFORMITIES
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for his designation of required inspection points prior to carrying out such repairs.
7.2.2. A supplementary ITP shall be issued, when found necessary, by the QC Engineer which
details the sequence of repair operations. This supplementary ITP shall be submitted to
the AI for his designation of inspection points prior to carrying out such repairs.
7.2.3 SCRAP/REPLACE: This disposition requires the Production Manager and QC Engineer to
verify and document on the NCR that the item has been removed from the work area and
tagged or clearly marked "HOLD" to prevent its inadvertent use before disposal. The
involvement of AI is not required in this case.
7.2.4 Others: This disposition is used where the area of Non-conformity does not fall under the
definitions of above stated dispositions. For example, in the event of nonconformance with
the Manual or in the case of a drawing error or omission etc, this disposition can be used.
Involvement of AF is required in this case.

7.3 VERIFICATION OF CORRECTION


7.3.1 The QC Engineer re-inspects the items after completion of dispositions, described above.
When he is satisfied that the item meets Code requirements, including acceptance of
operations which the AI designated as inspection points, he completes the space provided
in the NCR for verification of correction, and removes the HOLD tag or marking and
permits the item to return to the next operation on the ITP. The QC Manager reviews and
approves the closure of the Non-conformance

7.4 RECORDS
7.4.1 All records of non-conformance reports are made available to the AI for his review and
acceptance.
7.4.2 Completed NCRs are returned to the QC Manager for his filing in the job file.

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EXAMINATION AND INSPECTION
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PRORAM
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used. All other boilers, parts or piping shall have the required marking Stamped directly on
the item. In addition, a metallic nameplate with the required data shall be furnished for all
boilers except when the original Stamping is so located on the completed or assembled
boiler unit that will be relatively visible from one place on the operating floor or platform.
6.8.5 Small parts with 125mm (5') outer diameter and under may be marked with identification
acceptable to the AI and traceable to the Form P-4, MPDR. Such marking shall be of a
type that will remain visible until the part is installed. The Certification Mark Stamp is not
required.
6.8.6 Where the Company acts as assembler of boiler components only the required Stamping
shall be supplemented with the Certification Mark Stamp of Company together with the
Company's name. The Stamping shall be placed near the Stamping of the manufacturer
responsible for the completed boiler, only after the required inspection and hydrostatic test
of the complete boiler unit have been performed satisfactorily and authorized by the AI.
6.8.7 Boiler external piping over DN50 (NPS2) shall be Stamped with a Certification Mark with
the Company's name and Serial Number. This Stamping shall be on the pipe, valve or
fitting adjacent to the weld joint farthest from the boiler. For piping operating at
temperatures above 425oC(800°F), the Certification Mark may be Stamped on a name
plate that is irremovably attached by welding, provided such welding is post weld heat
treated or on a circular metal band atleast 6mm thick. This band around the pipe shall be
secured in such a manner that slipping off is prevented during handling and installation.
6.8.8 Welded piping DN50 (NPS 2) or less shall be marked with an identification acceptable to
the AI and traceable to required Data Report. Such marking shall be of a type that will
remain visible until the piping has been installed.
6.8.9 Upon completion of fabrication of a Code item, the QC Engineer prepares and the QC
Manager certifies the MDR from the inspection final records.
6.8.10 The completed MDR, together with the final records, are then presented to the AI for his
review and acceptance. After signing of MDR/MPDR, ASME Stamped items shall be
entered in the ASME Code Jobs Log (Exhibit No. 21). When required by the customer or
jurisdiction after the final inspections, the QC Manager issues a NB Serial number
consecutively starting from '1' without skips or gaps of unused numbers or duplication of
numbers. The Project Manager will be responsible for registering the original MDR and/or
MPDR with NB within 30 days after MDR / MPDR is signed by the AI along with NB
Commission number.
6.8.11 When registration is not required, QC Manager files original MDR/MPDR. MDR and all
associated MPDR shall be furnished to the purchaser/user or his designated

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6.3.2 QC Manager notifies the AI for the necessary inspection involvement and ensures that no
AI inspection point is bypassed.
6.3.3 All areas of NDE are selected by the QC Manager to Code and customer's specification.
Location of spot RT is decided by the AI. QC Manager and AI may designate additional
inspection. When AI has been notified in advance and cannot be present or otherwise
make the selection, the QC Manager may exercise his own judgment in selecting the
spots.

6.4 FINAL EXAMINATION


6.4.1 When fabrication of a Code item is completed, the QC Engineer performs his final
examination, and initials the ITP when the item meets all Code and contractual
requirements.
6.4.2 The AI makes his final inspection following the pressure test required by the Code. For
parts not tested until field assembly is completed, he makes his inspection after fabrication
of the part is completed.
6.4.3 When a pressure vessel is not provided with an opening or any other means of access to
inspect the internal surface, a Hold point shall be shown on the ITP, for the QC Engineer
and the AI, to permit internal inspection before the final closure of the vessel.

6.5 HYDROSTATICTEST
6.5.1 Code required hydrostatic tests are performed by the Production Engineer and witnessed
by the QC Engineer and the AI.
6.5.2 The QC Manager shall ensure that the AI has been notified sufficiently in advance of each
test to enable him to witness the test and complete his inspection.
6.5.3 The pressure test shall be carried out in accordance with the applicable written procedure
(PRO-02) which covers the applicable Code requirements.
6.5.4 When the test meets Code requirements and is approved by the QC Engineer and
accepted by the AI, the QC Engineer shall initial and date the ITP in the space provided
and submits to the AI.
6.5.5 Upon completion of test and final inspection, the ITP is retained by the QC Manager for
review and filing as described in Section 12 (Records Retention) of this Manual.

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QUALITY CONTROL MANUAL Section: 5
Rev: 0
MATERIAL CONTROL Date: 08.09.2015
Page: 4 of 5

5.4. RECEIVING EXAMINATION OF CODE PARTS


5.4.1 Code Parts are unloaded in the "ASME Material Storage Area", and examined by the QC
Engineer for damage, Certificate Mark stamp with Certification designator and
identification marking to provide traceability to the manufacturer's MPDR and drawing.
5.4.2 Manufacturer's Serial Number and NB Serial Number (if registered) for each item received
is recorded by the QC Engineer on the Receiving Inspection Report.
5.4.3 Welded parts for Section XII Tanks shall be procured as required by Section XII (Refer
TM-110.10). Alternatively, PARTS stamped to Section VIII Div 1 can be used for
Construction of Tanks, as long as requirements of Section XII are met, except for
Stamping and Reporting. Refer TG120.2.
5.4.4 The applicable MPDR must be received, verified against the PART Stamping and
reviewed before it can be released by the QC Engineer for installation or further
fabrication.
5.4.5 The AI shall be afforded the right to inspect and verify all PARTS against the applicable
MPDR prior to further use.
5.4.6 PARTS and material that do not meet all Code and the Purchase Order requirements are
considered nonconforming and are controlled as described in Section 7 (Correction of
Non-Conformities) of this Manual.

5.5 CUSTOMER SUPPLIED MATERIAL


All Code material supplied by the customer or his designee is received and examined by
the QC Engineer as described above, using the Company's Material Requisition and MTR
provided by the Customer to verify compliance with Code and customer requirements.
Customer's Purchase Order if provided shall be reviewed by the Project Manager for Code
compliance.
5.6 FURTHER MATERIAL TESTING
5.6.1 Further material testing, if required, to be performed at receiving inspection or during
manufacturing operations is carried out by the QC Manager. He shall identify the number,
size, location and orientation of the test pieces required. The test shall be performed by an
approved testing laboratory which provides test reports. Test reports are reviewed by the
QC Manager and approved on satisfactory test results. The test reports shall be made
available by the QC Manager to the AI for his review.

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QUALITY CONTROL MANUAL Section: 5
Rev: 0
MATERIAL CONTROL Date: 08.09.2015
Page: 2 of 5

Manager. The Purchase Manager prepares the Purchase Order (Exhibit No. 4) and gets it
approved by the Managing Director.
5.2.2 Copy of approved Purchase Order along with copy of TDC is sent to the QC Manager for
use during receiving inspection and record purposes. Prices in Purchase Order may be
masked prior to distribution. Original Purchase Order and copy of TDC is sent to selected
Supplier,
5.2.3 For material to be sent to a field-site, the Purchase Manager forwards a copy of the un-
priced Purchase Order along with the TDC to the Field QC inspector.
5.2.4 Changes to Purchase Orders will be prepared, reviewed and approved from revised
Material Requisition in the same manner as the original done.
5.2.5 Substitution of material is not permitted without the prior approval of the Design Engineer
and Project Manager. In such case, revised drawings, calculations, Material Requisition
shall be prepared as necessary and approved as originals. The Al shall be informed of any
material Substitution.

5.3 RECEIVING INSPECTION:


5.3.1 All Code materials received in the shop are unloaded in an area identified with the sign
board "ASME Material Storage Area. Incoming materials shall not be released before the
receiving Inspection is done and accepted by the QC Engineer.
5.3.2 The QC Engineer, using his copy of the Purchase Order and TDC examines all Code
materials for dimensions including formed heads and shell radii using correct templates
and marking. He verifies the quantity and inspects for physical damages, if any.
5.3.3 All material marking and dimensions are recorded on the Receiving Inspection Report,
5.3.4 Material traceability shall be recorded in the Receiving Inspection Report as it has been
marked on the item concerned. That marking shall be fully in compliance with the
applicable Code requirements. If not, the item concerned shall be dealt with as per
paragraph 5.3.8 of this Section.
5.3.5 For all plate material and for other products for which the material specification, or Code
section requires markings traceability, the QC Engineer reviews the MTR, chemical
composition, mechanical properties and other test results against those listed in the
applicable specification & the Purchase Order. The marking on the Receiving Inspection
Report is verified as being traceable to the MTR and complies

Edition: 2015
QUALITY CONTROL MANUAL Section: 6
Rev: 0
DRAWING, DESIGN CALCULATIONS &
Date: 08.09.2015
SPECIFICATIONS
Page: 2 of 5

ASME Sec I Boilers shall include heating surface (Boiler & water walls) and maximum
designated steaming capacity.
4.5.2 For tanks, Design Engineer shall designate the Class of the vessel for Transport Tanks
(Ref Sec. XII) based on the information provided by the user and as defined in the
applicable Modal Appendix of the Code. It is determined by the hazard class of the
dangerous goods, pressure and mode of transport as required by the Competent Authority
(e.g. Code of Federal Regulations, Title 49, Part 173, Sub Part F)
4.5.3 For tanks, In addition to general requirements of Part-TG, all applicable requirements of
Modal Appendices which address unique service conditions of the Vessel, shall be met.
Pressures normally incident to transportation, including loading & unloading operations
shall be considered. Transport Tanks shall be designed to withstand loadings that are
expected from the Vessel's use as both a stationary Vessel and as a vessel subjected to
inertial force (including vibratory forces) specified in the applicable Modal Appendices. AII
applicable Primary Design Loads and additional Dynamic Loads (TD200) shall be
considered. The allowable stresses given in Subpart I of Section II Part D for Section VIII
Division 1 shall be used in the design of Tanks.

4.6 DESTRIBUTION OF DRAWINGS DESIGN CALCULATIONS


4.6.1 The Design Engineer submits the originals of all drawings, calculations and Material
Requisitions to the Project Manager. All the details shall be sent to Technical Manager for
verification, After verification by Technical Manager, the Project Manager approves and
files in the print storage cabinet and logs them by job number.
4.6.2 Drawings are distributed by the Project Manager to the Production Manager, QC Manager
and Planning Manager through Document Transmittal Note (Exhibit No. 26)
4.6.3 Fabrication drawings shall be stamped ASME and Approved for Construction
HOLD" shall be shown on drawing near to information which still requires final clarification/
acceptance.
4.6.4 Upon receipt of new revisions, superseded drawings and documents are destroyed by the
receiving person. If Project Manager wishes to retain superseded documents for record
purposes, then these documents shall clearly be identified as 'Superseded' and For
Record Purposes only'.

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QUALITY CONTROL MANUAL Section: 4
Rev: 0
DRAWING, DESIGN CALCULATIONS &
Date: 08.09.2015
SPECIFICATIONS
Page: 2 of 4

4.2.6 The Design Engineer prepares the Code calculations, non-mandatory calculations,
drawings and Material Requisitions (Exhibit No. 2). The calculation sheets are
consecutively numbered and formulae identified to the applicable Code paragraph.
Calculations shall consider all loadings required for the order and charpy impact test
requirements.
4.2.7 Drawings, design calculations and Material Requisitions that are prepared by the Design
Engineer are received by the Technical Manager for verification and submitted to the
Project Manager for his approval for Code compliance, including verification that design
temperature, MDMT, PWHT, impact test requirements and additional loadings have been
considered and that tolerances have been addressed.
4.2.8 Any disapproved documents are returned to the Design Engineer for correction to meet
the Code requirements and resubmitted. Approval is indicated by dated signature of the
Project Manager on each document,
4.2.9 Project Manager submits the design documents to the AI for his verification prior to start of
fabrication. Dated signature of AI on the documents is a record of his review and
acceptance.
4.2.10 Revision to the above mentioned design documents are prepared and approved in the
same manner as the originals. Whenever revisions are made in one design document, the
impact of revisions on the other design documents shall be reviewed by the Design
Engineer and approved by the Project Manager. If necessary, the other design documents
are revised. Revisions to design documents shall be identified on the revised document.
Area / Text changed shall be marked by arrows/circles/clouds etc. Revised portions of the
drawings shall be marked with the revision number.
4.2.11 Only SA, SB, SFA materials or other materials permitted by the Code or Code Cases shall
be used in the construction of items to be stamped with ASME Certification Mark. Their
use is restricted to the temperature ranges and stress values listed in ASME Code Section
II Part-D, B31.1 or Code Cases as applicable.

4.3 DESIGN BYCLIENT / OTHERS:


4.3.1 When drawings, design calculations and material specifications are provided to Company
by client/others, the Project Manager shall forward these documents to the Design
Engineer to review these documents for compliance with the applicable Code and client's
design specifications. Any discrepancies are brought to the attention of the client/others for
correction to meet Code requirements.
4.3.2 When the design documents meet Code requirements, they are verified by the Technical
Manager and approved by the Project Manager who signs and dates each document.

Edition: 2015
QUALITY CONTROL MANUAL Section: 3
Rev: 0
ORGANIZATION Date: 08.09.2015
Page: 2 of 4

3.4 TECHNICAL MANAGER


Technical Manager is directly reporting to the Managing Director and is responsible for the
co-ordination of Technical activities including Production & Planning.
Technical Manager is responsible for:
1. Reviewing the Customer specifications, drawings and any other Technical documents.
2. Selection of qualified Design Engineer for Design activities.
3. Checking of design calculations, design changes, Material Requisition and Drawings
from Design Engineer
3.5 QC MANAGER
The QC Manager reports to the Managing Director and has the responsibility to ensure
that all necessary and current Code Sections are available. His further responsibilities
include, but are not limited, to the following:
1. Preparation and revision of QC Manual.
2. Administration and Implementation of the QC Manual.
3. Liaison with the AI and AIA.
4. Control and issue of NB Serial Numbers and 'R' numbers.
5. Preparation and revisions to QC Procedures and submission of same to the AI for his
acceptance prior to inclusion or implementation.
6. Review and approval of calibration records.
7. Safekeeping of records.
8. Resolution of NCR's.
9. Preparation of ITP and performance of required inspection, examination or tests by
himself or through his personnel and signifying completion of the inspections,
examination and tests and acceptance of production function by signing or initialing in
the space provided in the Inspection and Test Plan.
10. Submission of the Inspection and Test Plan to the AI for his review and designation of
inspection points prior to commencement of fabrication.
11. Authorization of subcontractor's NDE procedures and Written Practice, and to ensure
performance of NDE by qualified and certified NDE personnel.
12. Qualification of WPS and certification of PQR and WPQ/WOPQ.
13. Review and certification of MDR/MPDR for Code items manufactured and or
Assembled by the company.
14. Other responsibilities which are quoted under individual applicable Sections of this
Manual.

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QUALITY CONTROL MANUAL Section: IV
Rev: 0
MANUAL CONTROL Date: 08.09.2015
Page: 2 of 2

revisions in Exhibits will be shown with cloud marks. This cloud mark will appear only on
exhibits in the Manual and not in the exhibit in use.
11.0 The revision status of the Manual shall be that of the Table Of Contents Section and Cover
Page.
12.0 At the discretion of the Project Manager, the Manual may be issued as a new edition. At
such time all revisions including exhibits shall revert to zero.
13.0 The edition number will be Calendar year in which the Manual Edition is advanced /
issued.
14.0 Only Uncontrolled Manuals are distributed outside by the Project Manager. They are for
external use only. Uncontrolled Manual issued is up to date at the time of issue and do not
require further distribution of revised Manual. These copies are marked on the Cover Page
and do not require a Manual copy number or controlled distribution.
15.0 Project Manager shall keep the Master copy of all Manual revisions for a period of not less
than 3 years.
16.0 An uncontrolled copy of this Manual is provided by the Project Manager to the ASME
designee and AIS for his use in performing Audit/Review.
17.0 In case of any work instruction or procedures are used in languages other than English,
and then the QC Manager shall ensure that they are in line with the English version.
Document in English language shall be mandatory version.

Edition: 2015
QUALITY CONTROL MANUAL Section: III
Rev: 0
GLOSSARY Date: 08.09.2015
Page: 2 of 4

CODE
COMPANY

Design Certifying Engineer


Exantitation
ISSUE
ITP

Inspection
MANUAL
MATERIA
MAWP
MDMT
MIDR
MPDR
MT
MTR
NB
Edition: 2015
QUALITY CONTROL Section : II VANUAL Rew : 0

Date : 08.09.2015
GLOSSARY Fage 2 of 4

The ASME Boiler & Pressure Vessel Code of Construction and reference Sections.

A qualified person approved as such by a competent authority to prepare, review


and certify Cargo tanks design, as meeting the requirements of said competent
authority.
Quality Control functions performed by Personnel employed by the Company,
To issue a document, with signature and date.
Inspection and Test Plan
Functions performed by AI.
This Quality Control Manual
Material manufactured to an SA, SB or SFA specification or any other specification
permitted by the applicable Construction
Code

Maximum Allowable Working Pressure (Internal / External) at coincident temperature an

Edition: 2015
item is permitted to operate at
Minimum Design Metal Temperature at MAWP, the lowest expected temperature the
vessel is expected to be operated at when in service.
Manufacturer's Data Report
Manufacturer's Partial Data Report
Magnetic Particle Examination
Material Test Report
The National Board of Boiler and Pressure Vessel Inspectors

Edition: 2015