Quaality Man
nual   2012
2

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QUALITY CONTROL MANUAL
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Quality Control Manual

Title Page

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Copy No.

Controlled

Uncontrolled

Project Services Company PSC (S.A.E.)

Qarit Oraby, Desert Road, Amria,
Alexandria, Egypt
Phone : +2 03 4482 402
Fax : +2 03 449 9641
E-mail : [email protected]
Web : www.psc-eg.com
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Table of Contents

Table of
Contents

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Table of Contents

(11) Table of Contents

Action Name Title

Quality Assurance
Prepared By Ahmed Nabil
Head
Quality Control
Reviewed By Mahmoud Allam
Manager
Approved By Mohamed Kandil Managing Director C

Reviewed and Authorized

Ibrahim El-desouky
Accepted By Inspector

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Abbreviations

Abbreviations

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Abbreviations
(III) Abbreviations

AI Authorized Inspector
AIA Authorized Inspection Agency
AIS Authorized Inspector Supervisor
ASME American Society of Mechanical Engineers
ASTM American Society of Testing and Materials
The act of approving, by signing-off on a document after verification that all the
APPROVAL
requirements have been met.
An individual authorised by ASME to carry out a joint review with a
ASME DESIGNEE
representative of AIA.
ASNT The American Society for Non-Destructive Testing.
AWS QC1 Standard for AWS certification of Welding Inspectors.
The Act of verifying and attesting in writing that Documents, process, products,
CERTIFY
or personnel qualifications comply with specified requirements.
CMTR Certified - Material Test Report
The ASME Boiler &Pressure Vessel Code of Construction SEC I, SEC VIII DIV 1 Code
Code & Standard Edition and / or Addenda's and Reference Sections.
ASME B31.1 and NBIC-23 applicable edition and addenda.
Company Project Services Company, PSC (S.A.E.)
COM Construction Manager
Dept. Department
Div. Division
DMD Deputy Managing Director
Ed. Edition
Eng. Engineer
FM Factory Manager
HT Hydro Test
ITP Inspection and Test Plan
L1 Level I
L2 Level II
Material manufactured to an SA, SB or SFA Specification or any
MATERIAL
other Specification permitted by the applicable construction Code.
Manual Quality Control / Quality Manual
MAEWP Maximum Allowable External Working Pressure
MAWP Maximum Allowable Working Pressure
MCM Material Control Manager
MD Managing Director
MDR Manufacturer's Data Report
Mgr. Manager
MPDR Manufacturer's Partial Data Report
MRF Material Requisition Form
MRIF Material Receiving Inspection Form
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Abbreviations
MT Magnetic Particle Test
MTR Material Test Report
N/A Not Applicable
NBIC National Board Inspection Code
NDE Non Destructive Examination
OD Operations Director
Para. Paragraph
PFM Planning Head
PM Production Manager
PO Purchase Order
PQR Procedure Qualification Record
PRH Purchasing Head
PSC Project Services Company PSC ( S.A.E.)
PSM Projects Manager
PT Penetrant Test
PWHT Post Weld Heat Treatment
QA Quality Assurance
QAH Quality Assurance Head
QC Quality Control
QCH Quality Control Head
QCI Quality Control Inspector
QCM Quality Control Manager
Rev. Revision
RT Radiographic Test
Sec. Section
SM Site Manager
SPM Sales and Proposal Manager
TOH Technical Office Head
UT Ultrasonic Test
WCRF Welding Consumable Requisition Form
WCRIF Welding Consumables Receiving Inspection Form
WHM Warehouse Manager
WOPQ Welding Operator Performance Qualification Record
WPQ Welder Performance Qualification Record
WPS Welding Procedure Specification
LISL Line Inspection Summary List

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Scope

Scope

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Scope

(IV) Scope

II.1 General

PSC has kept and maintained a Quality Control System which has
been established to provide our custemors with boilers and boiler
parts, boiler external piping, pressure vessels and pressure vessel
parts (such as: towers and heat exchangers) required to be
constructed in accordance with ASME Boiler and Pressure Vessel
Code Section I, ASME B31.1, Section VIII Div.1, AWS, API, EN or
other governing Codes or Standards (hereafter called Code). The
Quality control system has been established to meet the requirements
of ASME Code including design, material, fabrication and
examination by PSC; and inspection by The Authorized Inspector (AI)
for Power Boilers, Power Piping, Pressure Vessels and pressure
vessels parts. The Quality control system has been established to
cover activities in the shop and field sites.

This Manual also is applied to Metallic Repairs and/or Alterations at

this Shop and extended for Field Repairs and/or Alterations controlled
by this Shop”

The scope covers the following: -

1. Construction and erection of boiler, boiler parts, pressure

vessels, towers and heat exchangers in accordance with Code
requirements.
2. Design and fabrication of all pressure vessel accessories, such
as ladders, platforms…etc.
3. Field erection and testing of boilers and pressure vessels.
4. Design, fabrication, erection, testing and inspection of storage
tanks.
5. Repairs , alterations and re-rating of boilers, power piping and
pressure vessels to the requirements of NBIC NB23 and
relevant construction code/standard
6. Design, fabrication and erection of steel structure, plate works
and pressure/non pressure piping.

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Manual Control

Manual Control

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Manual Control

(1) Manual Control

1.1 This Manual shall be prepared by QAH, who collects the Manual
sections prepared by each concerned personal (QCH, TOH & NDE
Level III Examiner), reviewed by QCM, whilst the approval of such
shall be granted by the Managing Director and reviewed and
accepted by the AI of records. The QAH shall issue controlled
copies of this approved Manual with transmittal advice in
accordance with the list of Manual Holders Log (Exhibit No. (01-
01)) maintained by him.

1.2 Each copy of this Manual will bear the same control number on
its title page as shown on the List of Manual Holders Log, and the
same will be done but on the back of each Manual pages. In case
of electronic copies the control number will appear on the title
page and it must be protected against changes and printing.

1.3 When new Code Edition or Addenda is issued; it shall be reviewed

by the concerned personal (QCH, TOH & NDE Level III Examiner)
to determine the need for revisions required to the Quality Control
Manual. The QAH shall document this review by his dated initials
on a copy of the front page of the Edition/Addenda summary of
changes page. This step shall also be recorded in record of Code
Edition and Addenda review form (Exhibit (01-02)).

1.4 Revisions of the Manual – if needed- shall be prepared and

approved the same way as the original and then submitted to the
AI of record for his review and acceptance prior to issue. However,
revisions will be made by sections except for Exhibits.

1.5 Revisions of the Quality Control Manual are distributed to the

List of Manual Holders Log using the Manual Holders Log within
six months of Code Edition/Addenda issue date

1.6 Revisions are indicated in the corresponding pages by bold &

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Manual Control
italic font of the revised text. Only the latest revision will be
indicated.

1.7 Revised sections and Ehibits of the Manual are issued,

distributed and controlled by the QAH in the same manner as
stated through Para. 1.1 And 1.2 of this Section.

1.8 Revised Exhibits pages are issued individually with a revised List
of Exhibits Exhibit No. (1-03) by QAH.

1.9 QCM may, at his discretion advance the edition level of the
Manual at which time all revision status of all sections shall revert
to zero. However, exhibits revision numbers shall remain with the
same revision status.

1.10 Uncontrolled copies of the Manual may be distributed to parties

outside PSC. However, there is no need to distribute a new un-
controlled copies or withdraw the old revisions of the uncontrolled
copies when the Manual is updated.
 
1.11 In case change to the QC Manual are requested by the AI of an
AIA other than that of Record, all such changes shall be
represented by the Quality Control Manager to the AI of the AIA of
Record for his review and acceptance prior to revision of the
Manual and its implementation.

1.12 The Quality Control Manual is issued in English Language only.

Work Instructions may be issued in both English and Arabic
Languages, and in case of conflict between languages, the English
text shall govern.

1.13 One master copy of earlier revision of the Manual marked supereeded
shall be retained by QAH for minimum 3 years.
 
1.14 QAH is responsible to insure that revised copies are retuned and
destroyed.

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Statement of Authority and Responsibility

Statement of
Authority and
Responsibility

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Organization

Organization

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Organization

(3) Organization

3.0 Organization of PSC

The Organization Chart of PSC is attached to this Section.

3.1 Managing Director. (MD)

MD is the responsible person in PSC for all administrative issues and

operations activities within the company scope of works. He is responsible
for monitoring the performance of the department’s heads and managers,
and is responsible to the client for initiating any project and related action,
which is outside of head’s and manager's responsibilities.

MD is responsible for the approval of this QC Manual.

His staff consists of :-

3.1.1 Factory Manager. (FM)

He reports directly to MD. He is responsible for managing all activities and

operations at PSC Workshop.

3.1.1.1 Production Manager. (PM)

He reports directly to Factory Manager. He is responsible for production

activities according to design instruction, procedures and drawings at PSC
Workshop. He will liaise with QCM during production in matters relating to
inspection, testing, examinations and Quality Control.

3.1.2 Purchasing Head. (PRH)

He reports directly to MD He is responsible for following up of purchasing

all Code materials according to Material Requisition Form (Exhibit No. 04-
01), upon review by QCM and approval by TOH He is also responsible for
the time of material arrival to be suitable with project schedule.

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Organization
3.1.3 Technical Office Head. (TOH)

He Reports directly to MD. He is responsible for the Engineering and Design

of Power Boilers, Boiler External Piping, and Pressure Vessels built to ASME
Code Section I, B31.1, and Section VIII-Div.1, including approval of
drawings to show the details of the construction of the Vessel, calculations,
to support the design and specifications to show how these vessels comply
with the applicable Code Section. He is responsible to manage Engineering
and Design documents' transmission (new issues as well as revised issues)
and to arrange with sales department for assigning a job number for each
order of a Code item. He is also responsible for all engineering activities
related to other Construction Codes and re-rating, alteration and repairs in
according to NBIC NB 23. The scope of his responsibility covers both PSC
work shop and sites controlled by it.

3.1.3.1 Design Engineer

The Design Engineer reports directly to the TOH and is responsible for
preparation of design drawings, calculations and Material Requisitions of
Code items being manufactured by the Company as well as repairs and
alternations in according to NBIC NB 23.

3.1.4 Material Control Head. (MCH)

He reports directly to MD. He provides instructions for material controllers

to control the receiving, storage, preservation, issuing, scrap,...etc related
to all Code section materials, except welding consumables.

3.1.5 Warehouse Manager (WHM)

He reports directly to MD. He provides instructions for Warehouse Keeper to

arrange the work of the warehouse (Receiving, storage, preservation,
issuing, scrap,...etc). for all other materials and welding consumables not
included in the scope of Material Control Head.

3.1.6 Planning Head (PFH)

He reports directly to MD. He will define for each contract the following…
a) Fabrication Schedule of assigned work.
b) Preparation of Resource Plan (Material - Labourers - Machines) and
resources activity location.
c) Following-up of all activities.
d) Progress Reports (Daily - Weekly - Monthly).

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Organization
3.1.7 Projects Dept. Manager. (PSM)

He reports directly to MD. He is responsible for managing projects

coordination, contract administration and cost control activities in both
work shop and field sites.

3.1.8 Construction Manager. (COM)

He reports directly to MD. He is responsible for managing project activities

and all operations at field sites.

3.1.8.1 Site Manager. (SM)

He reports directly to Construction Manager and he is responsible for the

site activities according to design instructions, procedures and drawings.

He will liaise with QCM during Construction in matters relating to

Inspection, Testing, Examination and Quality Control. It is the
responsibility of Site Manager to ensure that only calibrated and identified
equipment is used for Site Work.

3.1.9. Quality Control Manager. (QCM)

The QCM reports directly to MD. He has the responsibility to ensure that all
the departments within workshop and field sites at all time comply with the
requirements of the applicable ASME Code, National Board Inspection
Code, and this Quality Control Manual.

In addition, it is the responsibility of the QCM to review the applicable Code

Edition after issue for change required by such and to arrange for any
necessary revisions to Quality Control system.

His further duties include but not limited to the following:

a. Ensure of correct preparation, revision, approval and implementation of

Quality Control Manual.
b. Safe custody and controlled use of ASME Certification mark stamp and
National Board R&NB stamps in the work shop, and in site through
the QC specialist at site.
c. Control and issue of National Board serial numbers for shop and site if
registered.

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Organization
d. Preparation of revisions to Quality Control procedures and submission of
the same to the AI for his acceptance prior to inclusion or
implementation.
e. Review and certification of Manufacturer's Data Reports for Code Items.
f. Maintaining contact with the AI and the AIA.
g. Resolution of Nonconformities.
h. Control of all welding activities related to the Code sections ( WPS, PQR,
WPQ and WOPQ).
i. Performing the required inspection, examinations and/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 the space provided on the ITP.
j. Approval of NDE procedures, and execution of required NDE through
qualified and certified personnel.
k. He is responsible for the control and acceptance of all subcontracting
activities directly associated with the Code Items.
l. He has to get assurance through supporting formal documents that the
subcontractor of a Code activity such as forming, PWHT, NDE, etc., is
qualified, experienced and capable to meet the Code requirements while
performing such activity.
m. The certified report of the subcontractor for such activity/activities shall
be reviewed by the QCM and sign if all Code requirements have been met
and the concurrence of the AI shall be obtained.
n. Other responsibilities of the QCM are quoted under individual applicable
sections of this Manual.
o. At his discretion, any of the above duties may be delegated to the
appropriate Quality Control Personnel.

3.1.9.1 Quality Control Head. (QCH)

The Quality Head reports directly to the Quality Control Manager and is
responsible for overall activities related to Quality at workshop or filed.
His further duties include but not limited to the following:

a) Preparation of Code Items ITP and control its implementation after

required approvals.
b) Preparation and control of all welding activities related to the Code
sections (WPS, PQR, WPQ and WOPQ).
c) Control the execution of required NDE through qualified and certified
personnel in according to the approved NDE procedures.
d) Control the execution of required PWHT.
e) Control of Hydrostatic tests required by the Code Section.

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Organization
3.1.9.2 NDE Level III

Appointed NDE level III reports directly to the QC Manager and is

responsible for reviewing and approving documents such as written
practice, procedures, personnel training and certification, records and
certification of demonstrated NDE procedures.

3.1.10. Quality Assurance Head. (QAH)

The QAH reports directly to MD.

His further duties include but not limited to the following:

f) Preparation, control, and distribution of Quality Control Manual.

g) Periodical Calibration of measuring and testing equipment and
maintenance of record of the calibration activities.
h) Safe keeping of records.
i) Other responsibilities of the QAH are quoted under individual
applicable sections of this Manual.
j) At his discretion, any of the above duties may be delegated to the
appropriate Quality Assurance Personnel.
k) Following up the implementation of the Quality Control Manual.

3.1.11. Sales and Proposal Manager (SPM)

The SPM reports directly to MD. He is responsible about all marketing,

estimation and proposal activities. He shall contact and arrange with QCM
for any Quality issues related to ASME certification Mark projects.

3.2 Delegation and Performance of Duties.

3.2.1 Any Manager or Department Head may delegate any of the duties
assigned to him to any of the qualified personnel who reports directly
to him. However, the responsibility of such duties cannot be delegated.

3.2.2 Responsibilities and authorities of personnel shown in the organization

chart and not described here have been detailed in various Sections of
this Manual (If necessary).

3.2.3 Each Person in a supervisory position may carry out the duties of
personnel under their supervision provided they are qualified and when
required are certified to perform the work.

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Design, Calculations, Drawings and Specifications

Design,
Calculations,
Drawings and
Specifications

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Design, Calculations, Drawings and Specifications

(4) Design, Calculations, Drawings and Specifications

4.1 General
Each order received for a Code item is assigned a job or work order
number by the Sales and Proposal Manager, which is used to
identify documents related to the order.

4.2 Design by PSC.

4.2.1. For Code items, to be designed by PSC, the TOH and Quality
Control Manger review the Customer’s Design Specifications for Code
compliance and adequacy of data. Any deficiencies are reconciled
with the Customer to enable proper design work to start and
continue accordingly.

4.2.2. After Their approval to Customer’s Design Specifications, the

TOH shall assign a Design Engineer(s) to prepare the Design
Calculation Sheets, Drawings; Material Requisition forms (Exhibit
No. (04-01) and if required, Material Technical Delivery
Specifications (Exhibit No. (04-03).

4.2.3. The applicable Code Edition and addenda used in design for
Code items according to Sections I and VIII Div. 1 shall be the
applicable Code Edition and addenda on time of contract.

4.2.4. The Design Calculations, Drawings, and Material Requisition

are submitted to TOH for his review and approval.

4.2.5. Any disapproved documents are returned to the Design

Engineer for correction and re-submittal. Final approval is shown by
the dated signature of TOH on the documents. QCM reviews all
design documents to assure compliance with the Code requirements
and his review shall appear on all design documents by signature
and date.

4.2.6. Revisions to the above design documents are prepared and

approved in the same way as the first issue (Rev.0).

4.2.7. Preparation of detailed documents will be done by Design

Engineer and designee, as per detail in the following paragraph 4.4.

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4.3 Design by Others

4.3.1 When design drawings, calculations and material

specifications are provided to PSC by others. The Design Engineer
reviews these documents for compliance with the Code and User's
design requirements; TOH approves the Design Engineer's reviewed
documentation by signature and date on the original drawing and
calculations. Any discrepancies are brought to the attention of the
design concern for correction to meet Code requirements.

Customer drawings shall be issued and controlled as PSC drawings

as per Para 4.4.2 below.

4.3.2 When the design documents (Calculation, drawings, MRF,

..etc.) meet Code requirements, they are approved by the TOH and
forwarded to QCM who will review all design documents to assure
compliance with the Code requirements and his review shall appear
on all design documents by signature and date.

4.3.3 In case of parts where PSC workshop is not responsible for

the design, and the design is prepared and approved by ASME
Certificate Holder Client or other ASME Certificate Holder that
assigned by the Client, no design review shall be performed by PSC,
but review of drawings for adequacy of data, review of customer
material requisition or P.O or Material Technical Delivery
Specification by PSC Design Engineer and approved by TOH; then
submitted to the QCM for his review and consideration. In such case
MPDR shall indicate the Design responsibility.

4.4 Preparation of Shop/Field Drawings and Calculations.

4.4.1 Calculations
4.4.1.1 In case of Design by PSC
The Design Engineer is responsible for the preparation of
calculations, drawings and for issuing of Material Requisition Form
(04-01).

4.4.1.2 In case of Design by OTHERS

In addition to the responsibilities of the Design Engineers mentioned
per paragraph 4.3.1 above, and in case that the MRF is not
submitted by the Customer, the Design Engineer is responsible to
review the engineering documents, prepare the MRF and submit all
to TOH for his approval. After TOH review and approval, the same
documents will be submitted to the QCM for his review and then to
the AI for his review and comments if any.

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4.4.1.3 In both cases

For both cases above, calculation Sheets shall be consecutively
numbered and formulas identified as to the applicable Code
paragraph. Calculations shall identify and consider all loading
required for user’s design requirements and for applicable ASME
Code Construction Section.

4.4.2 Drawings

4.4.2.1 The detailed drawings shall include, but not limited to,
details of welded and bolted joints, Non Destructive Examination,
Post Weld Heat Treatment, material specifications type, class or
grade, dimensions together with tolerances, Impact test requirement
and/or exemption, hydrostatic or pneumatic tests, applicable Code
Section Edition and Addenda, design data including MAWP and
Design Pressure at coincident temperature and minimum design
metal temperature. Drawings shall also indicate certification Mark
details and location.

4.4.2.2 Revisions to the above documents are prepared and

approved in the same way as the first issue.

4.5 Distribution of Design Calculations, Material Specifications,

Shop and Field Assembly Drawings.

4.5.1 Design Engineer files the original of all drawings, calculations,

material specifications and other documents in its job files and logs
them by job number.

4.5.2 After approval, all documents are forwarded to TOH.

4.5.3 Copies of approved drawings are distributed according to the

Distribution list form (Exhibit No.(04-02)) by TOH , recipient shall
sign and date the Distribution List Form as acknowledgment of
receipt of documents listed .

4.5.4 TOH is responsible for providing AI at shop and/or field, with

all design calculations, drawings, material specifications and any
other documents deemed necessary for his review and acceptance.

4.5.5 Revisions to shop and field assembly drawings are prepared,

approved and distributed in the same manner as the originals (First
issued).

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4.5.6 Superseded documents to be returned back by recipient to the

TOH to destroy the same unless containing notes which require their
retention. In this case the documents are marked-up on the
document table with "For Information Only". Destroying of
documents will be confirmed against signature on Distribution List
Form by the concerned recipient(s).

4.5.8 Computer Aided Design.

When computer programs are used to prepare ASME Code

calculations the program output shall be identified with a program
name, number and version.
Each program application/module shall be verified prior to use. A
verification report shall be prepared by Design Engineer and
approved by TOH.

The Verification Report shall…

1. Identify scope or application for which the program is verified.
2. Identify the hardware used.
3. Include comparison of the program output either by:
a- Hand calculations.
b- Test results.
c- Another verified computer program.

ASME Code Edition shall be reviewed by TOH for possible changes to

the program. Revised programs shall identify the reason for the
change.
When calculations are produced using the program, Design Engineer
shall ensure that the program is suitable for the required
application and that all applications to be utilized have been verified.
All program printout will be identified with the program
name/number and version.
When calculations are sub-contracted to an organization which uses
computer programs, Design Engineer or TOH shall review and
accept the program verification report of the sub-contractor. If not
available, the TOH shall prepare verification report for the subcontractor's
computer program

4.6 Units

4.6.1 Either US customary, SI units or local customary units, may

be used to demonstrate compliance with all Code requirements.

4.6.2 A single system of units shall be used for all aspects of design
except where unfeasible or impractical.
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4.6.3 When components are manufactured for different locations

where local customary units are different than those used for the
general design, the local units may be used for the design and
documentations of that component (Please refer to Para. 4.6.9)
below.

4.6.4 For any single equation, all variables shall be expressed in a

single system of units.

4.6.5 When separate equations are provided for US customary and

SI Units, there equations must be executed using variables in the
units associated with the specific equation. Data expressed in other
units shall be converted to US customary or SI units for use in these
equations. The results obtained from execution of these equations
may be converted to other units.

4.6.6 Production, measurements and test equipment, drawings,

WPSs and other fabrication documents may be in US customary
units or SI Units.

4.6.7 Any conversion necessary between different units for

verification of Code compliance and to ensure that dimensional
consistency is maintained, shall be in accordance with the following:

4.6.7.1 Conversion factors shall be accurate to at least four

significant figures.

4.6.7.2 The results of conversions of unit shall be expressed to a

minimum of three significant figures.

4.6.8 Conversion factors between US customary units and SI Units

may be found in non-mandatory appendix, guidance for the use of
US customary and SI Units in the ASME Code.

4.6.9 Whenever local customary units are used the manufacturer

shall provide the source of the conversion factors which shall be
subject to verification and acceptance by the AI

4.6.10 All entries on a Manufacturer's Data Report and data for

Code required nameplate marking shall be in units consistent with
the fabrication drawings for the component using US customary
units, SI Units, or local customary units, it is acceptable to show
alternate unit parenthetically.

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4.7 Additional requirements of ASME Code Sec.I

When the pressure parts of a forced-flow steam generator according

to Section I, with no fixed steam and waterline are designed for
different pressure levels, as permitted by PG 21.2 in Section I, the
owner shall provide or cause to provide a boiler pressure system
design diagram, certified by a Professional Engineer experienced in
the mechanical design of power plants, which supplies the following
information:-

a) The relative location of the various pressure parts, within the

scope of Code section, shall be defined with respect to the path
of water-steam flow.
b) A line showing the expected maximum sustained pressure, as
described by PG 21.2 in Section I, indicating the expected
variation in pressure along the path of water-steam flow.
c) The maximum allowable working pressure of the various
pressure parts.
d) The location and set pressure of the overpressure protection
devices.
e) Copy of this diagram shall be attached to the Master Data
Report.

For an isolable or separately fired superheater which discharges

steam directly to a process stream, the required stop valve and
safety valves may be omitted when, flow and pressure calculations
demonstrating that the superheater will not be overpressurized
under any steam flow.

TOH shall assure that the pressure system design diagram or the
calculations are certified by a Professional Engineer experienced in
the mechanical design of power plants. TOH shall make the same
documents available to the Authorized Inspector for review.

4.8 Subcontracting design:

a) Design work may be subcontracted to an experienced individual

or organization evaluated by the TOH

b) TOH shall be responsible to provide suitable information to the

design subcontractor and shall review and approve the design
documents prepared by subcontractor.

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Design, Calculations, Drawings and Specifications

c) The responsibility of the design work carried out by the
subcontractor shall always remain with the company PSC.

4.9 Change of drawings

In case the drawing has revised, Design Engineer shall review any effect of
the change on the calculations and sign off the cover page as an evidence of
review.

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Material Control

Material
Control

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Material Control

(5) Material Control

5.1 Requisitions

5.1.1 Design Engineer prepares the Material Requisition Form

(Exhibit (04-01)) for all material except welding material which is
prepared by the QCH, who uses Welding Consumables Requisition
Form – WCRF (Exhibit (05-01)).

5.1.2 Design Engineer is responsible to prepare, in accordance with

the applicable documents and the Code requirements, The Material
Requisition Form that are then approved by the TOH and reviewed
by QCM.

5.1.3 The Material Requisition Form shall include as a minimum, all

Code requirements; this includes material specification, type/grade,
permitted by the applicable construction Code Section and of that
specification given in Section II, marking and material test report
requirements, and any additional requirements of the Code Section,
such as UG-79, UCS-79 when cold formed, special testing, and
charpy impact tests at minimum design metal temperature is
required and grain size and the supplementary requirements of the
design if any, and any other instructions to the supplier. However,
when required, a Technical Delivery Specification Exhibit No.(04-03)
may be made giving information required and this document shall
be referenced in the MRF with its revision number.

5.1.4 Selection of materials according to ASME B31.1 which is

based on their inherent properties to:-

5.1.4.1 Listed materials.

Materials meeting the requirements of Para. 123.2.2 shall be
acceptable materials to use in Boiler External Piping.

5.1.5 Completed Material Requisition Forms (MRF) are to be signed

and dated by Design Engineer and forwarded to TOH for approval
then to be forwarded to QCM for review, and, finally submitted to the
Material Control Head who verify the material available at store to
deduct it from the quantity required to be purchased for each item
then to be forwarded to Purchasing Head.

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5.1.6 For stock material one copy of MRF is distributed by Material

Control Head to the QCH.

5.1.7 Completed WCRF Exhibit No. (05-01) is to be signed and

dated by the QCH who will forward it to QCM to approve; then to
Warehouse Manager who verify the material available at the store to
deduct it from the quantity required to be purchased for each item
then to be forwarded to Purchasing Head.

5.1.8 For stock material one copy of WCRF is distributed by

Warehouse Manager to the QCH.

5.2 Purchase Orders

5.2.1 For all Code material that must be ordered, Purchasing Head,
prepares the Purchase Order (Exhibit (05-02)) and attaches a copy of
the approved MRF, and submit this to one of the selected vendors.
However, purchase of welding consumable will be conducted with
the same way and in according to the final WCRF.

5.2.2 The requirements for certification Marking and Partial Data

Reports shall be included either in the Purchase Order (Exhibit (05-
02)) or reference the attached MRF when purchasing Parts that
required ASME Certification Mark Which shall be ordered on the
Manufacturer who has ASME authorization for application of
required ASME stamp

5.2.3 Upon receiving the subject documents from Design Engineer,

TOH then transmits a copy from MRF, to QCM for use during
receiving inspection.

5.2.4 For material to be sent to a Field Site, copy of the Purchase

Orders or MRF and WCRF shall be sent to the Site QC Engineer.

5.2.5 Changes to Purchase Order will be prepared, reviewed and

approved from revised MRF or WCRF in the same way as the Initial
/Original issue.

5.2.6 Substitution of Material is not permitted without the prior

approval of Design Engineer. Revision of design documents including
MRF is to be issued and submitted to the AI for review. The AI shall
be informed on a substitution by Design Engineer.

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5.3 Material Receiving Inspection

5.3.1 All Code Materials received at the shop or site are placed in
the material inspection storage area arranged by the Material
Control Head. This area is a part of the main storage area which
subdivided into three main areas; “Material Inspection Area”,
“Accepted Material Area” and “Hold Material Area”.

5.3.2 The Material Control Head makes a preliminary receiving of

the incoming materials comparing the coming packing list against
the actual incoming materials to detect any discrepancy may be
occurred on the Material Receiving Report (MRR) (exhibit (05-05));
then submit a copy to the QCH to execute the required inspection.

5.3.3 The Quality Control Eng., using his copy of the Material
Specification, MRR Exhibit (05-05) and MRF, examines all Code
Materials, except welding materials, for dimensions, marking,
condition and quantity. The result of inspection shall be recorded on
Material Receiving Inspection Form –MRIF-(exhibit (05-03)).The
Quality Control Engineer shall record the measuring
instruction used during incoming material inspection on the
MRIF report.

5.3.4 The Quality Control Engineer reviews the Material Certificate,

Chemical Analysis and Physical Properties and other test results,
against those listed in the applicable Material Specifications when
Material test Report / Certificate is required. He shall also verify the
marking required by the material specification and the Material
Requisition Form MRF. The material marking should be verified
against the mill test certificate.

5.3.5 When acceptable, the Quality Control Eng. signs and dates
the MRIF and the Material Certificate or the Material test report
MRIF should be forwarded to the QCH for approval by signature and
date; then a copy is forwarded to Material Control Head to release
the materials to the work shop or site.

5.3.6 The Material Control Head will notify the concerned shop and
site Material Control Eng., the Site Manager or the Production
Manager of all materials released, by sending to them a copy of the
approved MRIF.

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5.3.7 Material which does not meet the requirements of Material

Requisition Forms, Purchase Orders and applicable ASME Code
Section shall be transferred to the "Hold Material Area", and
controlled as described in Section 7 of this Manual (Dealing with
Correction of Non-conformities).

5.3.8 In case of any ASTM materials, the Quality Control Eng. shall
review the year of acceptable Edition according to the applicable
ASME Code Section, then review all the requirements of the ASTM
specification, sign and date Material Test Report (MTR) if acceptable
the material shall be recertified to required ASME specification
on the Material Test Certificate and material stamped
accordingly next to original stamping where ASTM material
are not according to acceptable Edition either older or newer
then acceptable shall be considered as non conforming and
dealt with as per Sec.7 of this Manual dealing with correction
of Nonconformities .In case of any deviation or rejection the usual
receiving procedure shall be followed.

5.3.9 Before cutting Material into two or more pieces, the entire
material marking is to be transferred by the layout foreman and
verified by the Quality Control Eng. a coded marking traceable to
the original required material marking and to the Material Certificate
or material specification, as required for the product form, may be
used to identify each piece. The method and extent of marking shall
be acceptable to the AI. The said marking shall be done as a
minimum by paint marking and a material map contains heat
number, designation, grade, manufacturing name and certification
number (if required) shall be used for all Code items for the purpose
of maintaining material traceability (Vessels/Tanks Material Map -
Exhibit (05-06)) or (Piping Material Map- Exhibit (05-07)).

5.3.10 Hard stamp shall not be done on ferrous materials under

6mm and non-ferrous materials under 13mm thickness.

5.3.11 Permanent attachments welded to pressure parts shall be

identified as in Para 5.3.9 above

5.3.12 Temporary attachments welded to pressure parts shall be

identified or kept in a container with at least mark with the P-
Number of the material. For material, which has no assigned P-
Number, a WPS shall be established as described in Section 8
dealing with welding control of this Manual to prove weldability
of the material and use of the WPS while welding of the same
material
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5.3.13 For receiving inspection of welding materials, the QCH, using

his copy of WCRF (Exhibit (05-01)), is responsible for inspection of
welding materials using Welding Consumables Receiving Inspection
Form (Exhibit (05-04)).

5.4 Receiving Inspection of Code Boiler and Pressure Vessel

Parts.

5.4.1 Code Parts are unloaded in the Inspection Area, and

examined by the Quality Control Eng. for damage, ASME
Certification Mark and identification marking to provide traceability
to Manufacturer's Partial Data Reports and drawings when required.

5.4.2 Manufacturer's Serial Numbers, piece mark numbers and

National Board Numbers; if registered, for each item received are
recorded by the Quality Control Eng., who will enter the date of
receipt of Manufacturer's Partial Data Reports and name of
Manufacturer who certified the Parts, in MRIF.

5.4.3 The Applicable Manufacturer's Partial Data Report (MPDR)

must be received and verified against the Part certification mark by
the Quality Control Eng. before the item can be released for
installation or further fabrication.

5.4.4 AI shall be afforded the right to inspect and verify all Parts
against the applicable Manufacturer's Partial Data Report prior to
use.

5.4.5 Parts that do not meet Code and Customer Requirements are
considered nonconforming and shall be dealt with as described in
Section 7 of this Manual. (Dealing with Correction of Non-
conformities)

5.5 Customer Supplied Material.

5.5.1 All Code Material supplied by the Customer or his designee is

received and inspected by the Quality Control Eng. as described
above; using either a copy of the Customer Purchase Order or MRF
approved as stated in Para. 5.1, or packing list with the client
Technical Delivery Specification or MRF or P.O. reviewed and
accepted as per Section 4 of this Manual to verify compliance with
all Code and customer requirements. (Dealing with Design,
Calculations, Drawings and Specifications, Para. 4.3.3)of Section 4.

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5.6 Stock Material.

5.6.1 The Quality Control Eng. verifies that stock material

purchased to an earlier material specification meets all the
requirements of the Code Edition & Addenda for the new contract.
The Quality Control Inspector verifies the compliance of the MTR
against the applicable material specifications for the new contract,
he shall sign and date the Material Test Report/Certificate for
recertification when acceptable and inspect the material as per
Para. 5.3 above.

5.7 Material Records.

All records referenced in this Section are available for the AI review,
and are filed in the job file by the Quality Control Eng..

5.8 Warehouse and Material Storage Area.

Warehouse Manager and Material Control Eng. guides store

Keepers and Material concerning Control Specialist :-
1. Classification of material places inside warehouse.
2. Follow cards for each kind of material.
3. Special conditions of storing for specific materials (Welding
Material).
4. Special Material is not mixed with similar product of unknown
or dissimilar quality.
5. Contamination inside warehouse and how to minimize such.

5.9 Nonconformities.
Quality Control Eng. must report any nonconformity to QCH and
QCM to take action and solution as described in Section "7" of this
Manual. (Dealing with Correction of Non-conformities).

5.10 Additional Tests.

Any additional tests required during receiving inspection or
fabrication shall be sub-contracted to approved laboratory by QCM,
relevant report(s) shall be reviewed by QCH and approved by QCM
with his dated signature.

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Examination and
Inspection
Program

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(6) Examination and Inspection Program

6.1 Shop Fabrication:

6.2 Scope:

This Section describes the system used to ensure that

manufacturing, examination and inspection activities are planned,
performed and documented in accordance with established
procedures, instructions and drawings.

6.3 Inspection & Test Plan (ITP):

6.3.1 Inspection & Test Plan (Exhibit (06-01)) is established to control the
examination and inspection program system. It shall be prepared by
QCH from the approved shop drawings and shall list the sequence of
fabrication, examination and inspection operations for each item in
the spaces provided. Approval of this document shall be granted by
QCM. It shall be presented to the AI for his review and designation of
inspection points and, if required, the client acceptance prior to
release for fabrication.

6.3.2 For each inspection and test point, the plan shall indicate the
applicable procedure, which details the characteristics to be
inspected, inspection technique and acceptance criteria.

6.3.3 The ITP shall be the master document for controlling and
documenting the status of operations in PSC workshop and include
the inspection points, in addition to the following:

a) Lists the fabrication, examination and inspection operations in

sequence.
b) Identifies applicable drawings
c) Identifies procedures and instructions for example: Inspection &
NDE procedure, welding procedure, and specifications for each
operation.
d) Provide space for indicating inspection points.
e) Provide space for sign-off inspection points.
f) When completed and signed off, document the fabrication history
of the product.

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6.3.4 When approved shop drawings revised; the QCH shall review
the ITP for any required changes and if these drawings revisions not
affected the contents of the ITP; this shall be documented on the
cover sheet of the ITP and signed and dated by all concerns (QCH,
QCM and the AI).

6.3.5 The Inspection & Test Plan contains columns for the initials
and date of the Quality Control Eng. on the applicable line for those
operations he accepts, and for the Authorized Inspector to initial and
date in the column provided for him to signify those operations he
accepts.

6.4 Hold Points.

A Hold Point is an Inspection Point beyond which fabrication shall

not proceed until signed off as satisfactory by the Quality Control
Eng., client Inspector and/or the Authorized Inspector as
designated.

6.5 Witness Point.

6.5.1 A witness Point is an Inspection Point beyond which

fabrication may proceed, provided the Authorized Inspector has been
notified on time, and when he is not able to attend, he waives the
inspection and is able to review the inspection records at a later
date.

6.5.2 In case the Authorized Inspector has verbally agreed to waive

witness point inspection, QCM shall make an entry in the
Inspection & Test Plan and provide the Authorized Inspector with
documented evidence of the inspection carried out by the Quality
Control Eng..

6.6 Review Point.

A Review point is an Inspection Point related to documents' review.

Fabrication can proceed and such documents will be reviewed by the
Authorized Inspector prior to his signature on MDR.

6.7 Monitoring Point.

It is a random and unscheduled Inspection Point which would be

monitored by the AI and/or Client's Inspector during progress of
fabrication.

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6.8 Final inspection

6.8.1 During the different stages of fabrication the Production

Engineer shall notify the Quality Control Eng. to carry out the
required inspection according to ITP, these inspections shall include,
but not limited to, preparation, cutting edges, fit up, weld monitoring
and NDE tests. These inspections shall be recorded in appropriate
form. All MTR or certificates of compliance, examination reports, test
records, and other fabrication records shall be available to the AI for
review.

6.8.2 When shop fabrication or field assembly of a Pressure Vessel

is completed, the Quality Control Eng. performs his final inspection.
He initials and dates the Inspection & Test Plan when the item
meets all Code and contractual requirements, the measurement
and test equipment used during examination shall be recorded
in the relevant reports.

6.8.3 For parts not tested until field assembly is completed, the AI
makes his inspection after fabrication of the part is completed at
the shop.

6.8.4 When a Pressure Vessel is not provided with an opening or

other means of access to inspect internal surfaces, a Hold Point for
the Quality Control Eng. and the AI shall be shown on the
Inspection & Test Plan to permit internal inspection before starting
the final closure fit up.

6.9 Pressure Tests

6.9.1 QCM shall verify that the AI has been notified sufficiently in
advance of each test so that he shall witness them, and complete his
inspections; pressure test shall be performed according to a written
procedure prepared by the QCH and approved by QCM, the gage
identification number shall recorded on the pressure test
report by the QC Eng.

6.9.2 Upon completion of the test and final inspection, the

Inspection & Test Plan and supporting documents are returned to
QCM for review and filing as described in Section 12 which deals
with the Record Retention of this Manual.

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6.10 TEST GAUGES :

6.10.1.One directly connected calibrated indicating test gauge,

visible to the operator controlling the pressure, and having a dial
graduated over a range of about double the intended maximum test
pressure but not less than 1½ nor more than 4 times that pressure
for Sec. VIII, div. 1 items, double the test pressure and not less than
1½ the test pressure for Sec. I items, shall be used for all types of
test.

6.10.2.An additional indicating gauge may be necessary to allow the

pressure to be visible to the operator at all times during the test, and
to prevent excessive pressure being applied.

6.11 Certification Marking and Manufacturer's Data Report.

6.11.1 The QCM has the responsibility for the safe custody and
control of the ASME Certification Mark stamps and National
Board NB stamp to prevent loss or unauthorized use.

6.11.2 QCM shall be responsible to collect all required records and

reports and verify that ITP has been completed and signed off to
satisfy the requirements of the Code and Customer. The required
Certification Mark will be applied, in the presence of the AI, and
obtaining the authorization only when all fabrication,
examinations and inspections are completed.

6.11.3 For Section VIII Div.1, the Certification Mark is applied on a

Nameplate (Exhibit No.(06-02)) which is permanently attached to the
vessel. For Section I items the Certification Marking as shown in
(Exhibit No.(06-02)) shall be directly Marked on the item or as
otherwise permitted by the Code. TOH shall specify the information
required on the Nameplate or Certification Marking on the Code item
in the Item drawings.

6.11.4 Certification Marking details for S and U part items are

shown in (Exhibit (06-02)). For boiler external piping the certification
marking shall be as per the requirement of PG-109 of Section I
,when required to be registered with the National Board,
National Board number shall be issued by QCM and stamped on
the Name Plate or Code item after authorization of the AI

6.11.5 Manufacture DATA REPORT (MDR).

Upon Completion of a Code Item QCM shall review the MDR, which
had been prepared by the QC Eng. or Head, for correctness and
completeness and shall certify the Manufacture Data Report.

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6.11.6 The completed MDR together with the drawings, design

documents and QC records are then presented to the AI for review
and signature

6.11.7 the completed MDRs shall be distributed as follows:-

a) One copy to the AI and duplicate to the code item
manufacturer.
b) One copy to the user or his designated agent.
c) One copy shall be retained as per Sec.12 of this Manual
(Records Retention)
d) One copy for the appropriate enforcement authority in the
jurisdiction in which the vessel is to be installed, where
required by law.
Part MPDR shall be distributed as follow:
One copy to the AI and in duplicate to the complete Code
item manufacturer
6.11.8 A log of code item manufactured shall be maintained by
the QCM titled ASME & National Board Code Item Log with
following details, entry number, NB number ,NB number issue
date ,description of Code items, Manufacturer Serial Number
,customer details ,location of installation if known ,date of
data report signed by the AI ,date of data report posted to NB
and signature of QCM.

6.12 Nonconformities
All Nonconformities found during fabrication or field assembly are
controlled and corrected as described in Section 7 which deals with
Correction of Non-conformities of this Manual.

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Correction Of
Nonconformities

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(7) Correction Of Nonconformities

7.1 Identification of Nonconformities.

7.1.1 Nonconformity is any condition that does not meet the

applicable Code, Quality Manual and Customer mandatory
requirements; during the preparation/ fabrication/assembly of the
Code item.

7.1.2 It is the duty of all PSC work shop and Field Site Employees to
report nonconformities to their supervisor, who will notify to the
Quality Control Head or Site Quality Control Eng.; who shall identify
ether the Nonconformity related to work procedures or fabrication.

7.1.3 As soon as a non conforming condition is reported to the QCH

or Site QC Eng., he will inspect the item, and if verified as
nonconformity, he will identify it by tagging or marking "HOLD",
preparing a Nonconformance Report (Exhibit (07-01)) and informing
the AI about the nonconforming condition. If practicable, the
nonconforming item is moved to a segregated "HOLD" Area.

7.1.4 Nonconformance Reports are identified with sequential

numbers Nonconformities Log Exhibit no. (07-02) and this
number shall be placed on the Inspection Test Plan in the
"REMARK" Column at that step where the Nonconformity occurred.

7.1.5 A Nonconformity can be raised up during be monitoring by the

AI , auditing by the AIS or the ASME designee during joint review.

7.2 Recommended Disposition.

The Nonconformance Report, also containing the QCH suggested
disposition for correction of the condition, it is signed and dated by a
QCH and forwarded to QCM for review and approval. If the design is
affected, QCM shall consult with, and obtain the approval of the
TOH.

7.3 Correction of Nonconformities.

After approval of disposition and as a result of the verification of
disposition, one of the following cases may take place :-

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7.3.1 USE-AS-IS.
When the disposition is USE-AS-IS regarding any item affects the
design aspects, the decision, in this respect, shall be approved by
TOH.

7.3.2 REPAIR.
Repair shall be carried out using written procedures approved by the
QCM and accepted by the AI .

7.3.2.1 For repairs to material, the proposed repair procedure is

submitted to the AI for his acceptance of the method and extent-of
repair.

7.3.2.2 A supplementary Inspection Test Plan, if found necessary,

shall be issued and inspection points designated by QCH& the AI.

7.3.3 SCRAP.
This disposition requires the QCH to verify and document on the
Nonconformance Report that the Item has been removed from the
work area and tagged or clearly marked "HOLD" to prevent its
inadvertent use before disposal.

7.3.4 RETURN TO VENDOR.

Hold, subsequently return to vendor.

7.3.5 OTHER.
Any other dispositions not defined above.

7.4 Verification of correction.

QCM shall re-inspect items after completion of dispositions
described in 7.3.1, 7.3.2 and 7.3.5 when he is satisfied that the item
meets Code requirements, including acceptance of operations which
the AI designated as inspection points, he signs the Nonconformance
Report, remove the HOLD Tag or marking, and permits the item to
return to the next operation on the Inspection Test Plan.

7.5 Records
7.5.1 Where AI involvement is required by the Code, the procedure
is agreed upon with the AI.

7.5.2 Completed Nonconformance Reports are returned to the QCM

for his review and filing in the job file. (See Sec. 12 of this Manual)

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Welding Control

Welding Control

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(8) Welding Control

8.1 General

All welding on Code work is performed using Welding Procedure

Specification (WPS), Welders & Welding Operators, hereafter called
Welders, qualified in accordance with the ASME Code Section IX and
the applicable Code Section.

8.2 PQRs and WPSs

8.2.1 WPSs (Exhibit No. (08-02)) and PQRs Exhibit No. (08-03) are
prepared by the QCH and shall include all welding variables required
for the welding process by ASME Code Sec. IX and the intended range
of production welding. The required test welds are made under the
supervision of the QCH or his designee. Preparation and testing of
the required test specimens are performed by approved testing
laboratory, witnessed during performance by the QCH or his
designee. If the test results are acceptable to Code Sec. IX
requirements the QCH shall prepare and certify, by signature and
date, the Procedure Qualification Record (PQR). The PQR shall
include at least all essential actual variables used in making the
qualification test welds.

8.2.2 The QCH prepares a list of approved WPSs using WPSs Log
Exhibited no. (08-06). Copies of the WPSs Log and the qualified WPSs
are provided to the Production Manager or Site Manager or his
designee, who make it available to the welder in the work area to be
used during welding of allocated weld joint.

8.2.3 WPSs may be revised whenever there is a change in a non-

essential variable. Whenever there is a change in an essential or
supplementary essential variable, a new WPS will be prepared and
qualified. However, PQRs and WPSs issued in according to an old
ASME Edition/Addenda can be used for Code items constructed
according to new ASME Edition/Addenda if there are no changes in
the essential and supplementary essential variables. Revision for
WPS will be required if a change in the non essential variable have
been detected.

8.2.4 WPSs and PQRs are made available to the Authorized Inspector
for his review who may request re-qualification of a WPS for cause.

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8.3 Qualification of Welders and Welding Operators

8.3.1 All Welders involved in Code welding at shop or site are

qualified to ASME Code Sec. IX and the applicable Code Section,
under the supervision of the QCH or his designee. Qualification can
be by radiography, or mechanical testing of the required specimens of
the test weld performed by approved testing laboratory. RT report and
film interpretation or mechanical test report is reviewed by the QCH,
and if acceptable, he prepares and certifies the Welder Performance
Qualification Record (WPQ) Exhibit No. (08-04) or The Welding
Operator Performance Qualification Record (WOPQ) Exhibit No. (08-
05). The WPQ or WOPQ documents the performance essential
variables actually used for the test welds and ranges qualified for
production welding, QCH allocate welder identification number to
each qualified welder using welding identification welder issue
register.

8.3.2 A WPQ/WOPQ is also issued for any Welder/Welding Operator

who has welded a test coupon to qualify a WPS, based on the
performance essential variables used, and provided the test results
meet the Code requirements.

8.3.3 Copies of the ASME Qualified Welders List (Exhibit (08-01),

prepared by the QCH and approved by QCM, are sent to the
Production Manager or Site Manager or their welding designee, for
their respective welders. The original Qualified welders List and
certificates are maintained by the QCH and appropriately revised
upon welder qualification.

8.4 Re-Qualification of Welders:

8.4.1 The performance qualification of a welder or welding operator

shall be affected when one of the following conditions occurs:

a) When he has not welded with a process during a period of 6

months or more, his qualifications for that process shall expire;
unless, within the 6 month period, prior to his expiration of
qualification

1) The welder has welded with that process using manual or

semiautomatic welding, under the supervision and control of the
qualifying manufacturer or contractor or participating
organization(s) as identified in QW-300.3; that will extend his
qualification for an additional 6 months.

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2) The welding operator has welded with that process using

machine or automatic welding, under the supervision and control
of the qualifying manufacturer or contractor or participating
organization(s) as identified in QW-300.3; that will extend his
qualification for an additional 6 months.

However, the extension period shall be recorded in the qualification

certificates by the signature and date of the QCH or his designee or
of the qualifying manufacturer or the designated supervisor of the
contractor or participating organization(s) controlling his work.

(b) When there is a specific reason to question his ability to make

welds that meet the specification, the qualifications that support the
welding, which he welded, shall be revoked. All other qualifications
not questioned remain in effect.

8.4.2 Renewal of Qualification

8.4.2.1 Renewal of qualification expired under 8.4.1.(a) may be made

for any process by welding a single test coupon (or production work)
of either plate or pipe, of any material, thickness or diameter, in any
position, and by testing that coupon as required by Section IX. A
successful test renews the Welder or Welding Operator his previous
qualification.

8.4.2.2 Welders and Welding Operators whose qualifications have

been revoked under 8.4.1.(b) shall be re-qualified.

8.5. Maintenance Of Welder's Qualification

8.5.1 Each qualified Welder who performs welding is listed on ASME

Qualified Welders List maintained by the QCH with the Performance
Qualification Records.

8.5.2 The QCH determines from the ASME Qualified Welders List
when the Welder's qualification will expire, so as to ensure he
performs production welding, or is re-qualified, when production
welding is used for conformity of welder qualification copies of
production welding records such as NDE reports, etc.

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8.6. Production Welding

8.6.1 The QCH and Production Manager verifies that all production
Welders are qualified for the performance essential variables to be
used, and the Welding Production Manager designee is responsible
for instructing the welders in the correct use of the WPSs listed on the
WPSs approved Log and for which weld it will be used.

8.6.2 The QC Eng. uses the Welding Map Exhibit (08-07) or Piping
Welding Summary Exhibit (08-08) prepared by QC Eng. And
approved by QCH using approved DWG for the proper follows up of
welding activities and welding traceability records whenever
approved DWG revised the Welding Map reviewed by QC Eng. For
changes and if no changes the review is documented on the
cover sheet of Welding Map.

8.6.3 Each qualified Welder is issued a unique welder number by the

QCH or his delegated, by which each weld made by a Welder is
identified by hard marking the welder number, provided it is not
harmful to the material, at intervals not exceeding 90 cm; or by paint
marking the welder identification number with the same intervals
considering that the welder identification number is recorded on the
Welding Map or Piping Welding Summary, depending on the
application, to assure proper traceability. However, when a Welder
leaves the PSC, his identification number will not be reissued.

8.7 Tack Welds

8.7.1 Tack welds, whether left in place or completely removed, are

made by qualified Welders using the qualified WPS designated on the
Welding Map or Piping Welding Summary.

8.7.2 If left in place, the ends of each tack weld are ground or
suitably prepared to ensure complete fusion into the final weld.

8.7.3 After preparation, each tack weld is visually examined by the

Quality Control Eng., and if cracked or otherwise defective, is
completely removed.

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8.8 Welding consumables

8.8.1 All welding consumables are purchased and received as
described in Section 5 of this Manual (Dealing with Material Control).

8.8.2 Welding consumables is stocked in dry storage space and

issued to Welders by the Storekeeper as specified on the designated
WPSs and against a Withdrawal Slip Exhibit No.(08-09) prepared
by the Production Manager Welding designee.

8.8.3 Low hydrogen electrodes are received and stored in hermetically

sealed containers. When opened, the electrodes are placed in heated
oven maintained at the temperature recommended by their
manufacturer, before issue to welders.

8.8.4 Coated low hydrogen electrodes are issued only in a quantity

sufficient to complete the welds during the shift and maintained by
the welder in the portable oven at the recommended temperature.

8.8.5 Unconsumed coated low hydrogen electrodes returned for

storage are examined for condition, cleanliness and identification
before return to storage in holding furnace in a segregated area in
the holding oven to be backed along with other electrodes.
8.8.6 The hermetically sealed electrode by store keeper
container shall be examined for change and if damaged
container is observed, the electrodes shall be backed at Temp.
and time recommended by the manufacturer or as
recommended by ASME Section II Part C Damaged or
unidentified electrodes are not used for Code work.

8.9 Production Test Plates

8.9.1 When required, production test plates are prepared in

accordance with a procedure prepared by the QCH or his designee,
which includes Number, identification, type, orientation, location and
dimensions of required specimens. Required preheat temperature,
PWHT conditions, minimum design metal temperature and Charpy
impact test temperatures.

8.9.2 The QCH or his designee supervises the welding of the test
plates from which specimens are prepared and tested by approved
testing laboratory whose test report is reviewed by the QCH for
acceptance of results or need for retest.

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8.9.3 Test results are made available to the AI for his review and
acceptance. The Authorized Inspector may witness the tests if he
desires.

8.10 Welding Records

All records mentioned in this Section are made available for review by
the AI and are retained in the job file maintained by the QCH (See
Sec. 12 of this Manual dealing with the Records Retention).

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Non Destructive Examination

Non Destructive
Examination

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(9) Non Destructive Examination

9. Scope

9.0.1 This Section describes system for Code required Non Destructive
Examination activities.
9.0.2 Company has in-house NDE capabilities except performance of RT
which is subcontracted to an approved subcontractor having proven
experience; however the final interpretation and evaluation shall be
done by PSC qualified and certified level II personnel or accepted
subcontractor inspectors as per 9.2 below.
9.0.3 Visual examination for Powerpiping which shall be carried out by
examiners qualified as per 9.7 below.
9.0.4 PSC Company may use subcontractor to perform and evaluate NDE as
needed, however the performance and evaluation of results shall be
per PSC NDE Procedure.

9.1 NDE Level III & Written Practice

9.1.1 Company uses services of NDE Level III as an outside agency to

control and monitor the NDE activities on behalf of the company. The
NDE Level III is appointed by the QC Manager by issuing a letter of
appointment.

9.1.2 The appointment of the NDE Level III shall be based on the following:
• Educational qualification based on SNT-TC-1A requirements.
• Valid endorsement on his ASNT level III or ACCP Professional Level
III certificate for RT, UT, MT and PT methods.
• Experience in providing Level III services to other ASME Code
Stamp holders.
• Experience in developing NDE procedures and monitoring NDE
activities on boilers, pressure vessel and piping products.

9.1.3 The appointment shall be valid for a maximum of 3 years but the QC
Manager shall have the authority to extend the validity or to cancel it
any time.

9.1.4 The level III shall maintain the validity of his ASNT certificate during
appointment period and responsible for:

• Reviewing company and subcontractor’s Written Practice for

Training, Qualification and Certification of their NDE personnel.

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• Reviewing company RT, UT, PT and MT procedures

• Demonstration, qualification and certification of NDE procedures
as per applicable Code requirements
• Resolve NDE related issues on behalf of company

9.1.5 The Company and subcontractor’s Written Practice shall be based on

Code adopted Edition of SNT-TC-1A.

9.2 Control Of NDE Activities

9.2.1 The Company shall provide the following documents for review and
verification
• Written Practice in accordance with Code adopted Edition of SNT-
TC-1A.
• Personnel qualification and certification records in accordance with
his written practice.
• NDE procedures including their demonstration, qualification and
certification records.
• Calibration records of the instruments to be used.
• Eye examination records.

9.2.2 All above documents shall be Prepared & reviewed by NDE Level III on
behalf of the Company and approved by QC Manager and a copy of all
the above documents shall be kept for records and for review by the
AI.
9.2.3 Based on the review by NDE Level III, QC Manager shall certify that
the NDE personnel are qualified and certified based on the written
practice.
9.2.4 Subcontractor shall submit the same documents mentioned in Para
9.2.1, subjected to PSC Level III review and PSC QCM approval, except
NDE Procedures, as the subcontractor shall use the approved PSC
NDE procedures for carrying out all assigned NDE activities. However,
evaluation of results shall be carried out by the qualified PSC
personnel as per the applicable Codes and procedures or accepted
subcontractor inspectors as per 9.3 below.
9.2.5 A copy of NDE Subcontractor's documents shall be kept for records
and for review by the AI.

9.3 NDE Procedures

9.3.1 The NDE Procedures for UT, PT and MT shall be demonstrated to the
satisfaction of the AI for producing meaningful results. NDE Level III
shall certify the NDE procedures to be in accordance with T-150 of
ASME Code Section V.

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9.3.2 When required by the construction Code, these procedures shall also
be qualified by demonstration for the range of essential variables
intended to be used. Any change in the essential variable shall require
re-qualification by demonstration.
9.3.3 RT procedure does not require demonstration and achieving the
required density and penetrameter image on technique or production
radiographs is considered as satisfactory demonstration of technique.
9.3.4 QC Manager shall be responsible to maintain the records of procedure
demonstration and qualifications.

9.4 NDE Execution

9.4.1 Type and Extent of NDE requirements shall be specified on the

drawings and ITP.
9.4.2 QC Manager shall ensure that the required NDE is carried out at the
appropriate stage.
9.4.3 When NDE is required, QC Head shall make NDE Request (Exhibit No.
(09-01)) and send it to the Subcontractor. This request shall clearly
indicate the Job details and type, location and extent of NDE.
9.4.4 In case of spot radiography, the spots shall be clearly marked on the
job with identification of the spot. The AI shall be given the opportunity
to mark the spots for spot radiography.

9.5 NDE Evaluation And Report

9.5.1 Evaluation and acceptance of NDE results shall be as per the

applicable Codes and NDE procedures.
9.5.2 Evaluation shall be done by PSC NDE Level II or Level III or accepted
Subcontractor's NDE Level II . The names of the persons who carried
out and evaluated the results shall be clearly indicated on reports
with their level of qualification
9.5.3 Subcontractor shall use PSC format of NDE reports (as approved by
NDE Level III).

9.6 Review By the AI

9.6.1 Written practice, NDE procedures and NDE Personnel Qualification

Records shall be available for review by the AI.
9.6.2 Results of all NDE including radiographs and other related documents
shall be made available to the AI for his review.
9.6.3 The AI may ask for re-qualification of any NDE personnel or re-
qualification and/or re-demonstration of NDE procedures for cause.

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9.7 Examiner For Visual Examination

9.7.1 All personnel that perform visual examination of power piping to

B31.1 welds shall be qualified and certified in compliance with the
followings requirements:
9.7.1.1 Four (4) hours instruction in the fundamentals of visual welding
inspection methods.

9.7.1.2 Each Examiner shall have an eye examination performed each year
to determine optical capability to perform the required examinations.
Examiners shall be at least capable of reading Jaeger No. 1, with or
without correction, and capable of distinguishing contrast between
colors.
9.7.1.3 On the job training for 2 days (4 hours each day) to familiarize the
Examiner with the appearance and interpretation of indications of
weld defects.
9.7.1.4 Upon completion of 9.7.1.1 thru 9.7.1.3 above, the Examiner shall
be given a written examination of 15 questions and a performance
examination to determine if they are qualified to perform the required
examinations and interpretation of results.
9.7.1.5 An oral examination may be given in place of the written one
consisting of the same number of predetermined questions as the
written examination and the answers documented by the Quality
Control Manager or the Company NDE Level III.
9.7.1.6 Visual examination personnel who have not performed power piping
inspections for a period of one year or more shall be reexamined as
required by 9.7.1.4 or 9.7.1.5 and also pass the eye examination of
9.7.1.2 above and be recertified prior to performing any weld
inspections.
9.7.1.7 The following may be used as alternatives to the preceeding
program, as applicable: SNT-TC-1A or CP-198; and personnel
qualified to AWS QC1 may be used for visual examinations of power
piping weld.

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Heat treatment

Heat Treatment

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Heat treatment
(10) Heat Treatment

10.1 General

10.1.1 Heat treatment required by Code, is performed either by PSC

or by a qualified subcontractor in accordance with PSC's
procedures, using calibrated equipment.

10.1.2 QCM will review and approve the Heat Treatment

subcontractor's controls, experienced operators record and the
equipment calibration records before placing any Purchase Order for
Heat Treatment.

10.2 Procedures.
All Code Heat Treatment is performed as specified in a written
procedure prepared by QC Engineer approved by the QCH, which
describes the placement and method of attachment of
thermocouples, temperature gradients for heating and cooling,
soaking time at temperature as well as the records required as a
minimum.

10.3 Heat Treatment Records

10.3.1 All Heat Treatment Records shall be noted on Heat Treatment
Report (Exhibit No. (10-01), either performed by PSC or
subcontractor, these records shall be the actual output charts which
record the conditions, orientation, method of attachment to the work
piece, identification of thermocouples and items treated, and shall
be prepared, signed and dated by the heat treatment operator
accepted by the Quality Control Engineer and approved by the
QCH.

10.3.2 All Heat Treatment Records are reviewed and approved by

QCM when the Heat Treatment complies with Code and procedures.

10.3.3 Heat Treatment Procedure and Records shall be made

available to the Authorized Inspector.

10.4 Receiving Inspection.

Heat treated parts by subcontractor when returned, if any, shall be
examined by the Quality Control Engineer, for damage or loss of
identification. Nonconforming Items shall be controlled as described
in section 7 of this Manual (Dealing with correction of
Nonconformities).

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Calibration of
Measurement and Test Equipment

Calibration of
Measurement and
Test Equipment

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Calibration of
Measurement and Test Equipment

(11) Calibration of Measurement and Test Equipment

11.1 General
All measurement, examination and test equipment used for
fulfillment of Code requirements is calibrated in accordance with
this Section and written Calibration Procedures approved by the
QCM.

11.2 Calibration Procedures

11.2.1 All measurement, examination and test equipment are

identified by marking the Item or its container with a unique serial
number.

11.2.2 QAH is responsible for maintaining all measurement/test

equipment in Calibration, unless out of service and clearly marked
"NOT CALIBRATED-DO NOT USE" or "WILL BE CALIBRATED
BEFOR USE".

11.2.3 Calibration may be performed by approved testing laboratory

which provides certified records of Calibration, and has suitable
standards whose accuracy is traceable to National / International
Standards.

11.2.4 The frequency of Calibration is as determined from the

Manufacturer's Recommendations, or from experience with the
measurement/test equipment, unless addressed in the Code.

11.2.5 Pressure gauges used for hydrostatic, proof testing are

calibrated against a dead-weight tester or calibrated master gauge.

11.2.6 Calibration of Radiographic densitometer is verified by the RT

Level II or Level III Examiner as specified in Section V (T-262).

11.3 Calibration Records

11.3.1 Each Calibrated measurement/test equipment has a

Calibration Certificate maintained by QAH. All internally Calibrated
measurement/test equipment has a Calibration Report (Exhibit No.
(11-03))

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Calibration of
Measurement and Test Equipment

11.3.2 All measurement/test equipment are identified with Internal

Calibration Label (Exhibit No. (11-02)) which records the due date
for the next calibration in the Equipment Calibration Log (Exhibit
No. (11-01)). Equipment not calibrated shall not have label.

11.3.3 Calibration Records, including those of subcontractors who

perform HT, and Mechanical Testing, are kept by QAH. A copy as
necessary shall be maintained with the QCM.

11.3.4 QCM shall verify calibration of the subcontractors' Impact

test equipment in accordance with ASTM E23 or ISO 148-1,2&3 and
Universal Testing M/C in accordance with ASTM E4.

11.4 Discrepant Equipment.

11.4.1 When measurement/test equipment are found out of

calibration or damaged, QAH tags the item "HOLD", removes it from
the work area and arranges for calibration or replacement.

11.4.2 All Code Items checked with such discrepant

measurement/test equipment are considered non-conforming; NCR
shall be issued and dealt with in accordance with Sec.7 of this
Manual (Dealing with the correction of nonconformities).

11.4.3 The record of use of such discrepant instrument shall

be obtained from inspection reports at receiving material stage
and during construction stage inspection records.

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Record Retention

Records
Retention

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Record Retention

(12) Records Retention

12.1 QCM collects all records described in this Manual on

completion of the job, and reviews them for completeness,
correctness and Code compliance before he prepares MDR.

12.2 Certified Manufacturer's Data Reports, are distributed to the

User or his designated Agent, Purchaser, Boiler or Pressure Vessel
Manufacturer, Jurisdiction at the location of installation (if known)
and The Authorized Inspector as required by the Code

12.3 All records shall be retained as follows:-

SEC I B31.1 VIII-1 NBIC

Material certification yes yes yes yes

Manufacturer's Partial Data Report yes yes yes yes
Manufacturer Data Report yes yes yes yes
Examination & Testing Procedures yes yes yes yes
Heat Treatment Records yes yes yes yes
Design Calculation yes yes yes yes
Hydrostatic Records yes yes yes yes
Manufacturing Procedures yes yes yes yes
ITP Plan N.A N.A N.A yes
Radiographs test films yes yes yes*1 yes
NDE Reports yes yes yes yes
Drawing yes yes yes yes
Production Test Plate Results, if
yes yes yes yes
applicable
NCRs yes yes yes yes
WPS, PQR, Welding Map, WPQ & WPOQ yes yes yes yes
N.D.E Personnel record yes yes yes yes
Record Retention Period 5 years 5 years 3 years 5 years

*1 Until MDR has been signed for Radiographs.

12.4 The QCM shall maintain a file after stamping of the vessel, and
furnish to the user and, upon request, to the AI, the reports and
records shown in the following :-

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Record Retention

a) Manufacturer's Data Report with Manufacturer's Partial Data

Report.

b) Manufacturer's Construction Records and Partial Data Reports

shown in the following:-

1) Tabulated list of all material used for fabrication with

Materials Certifications and Material Test Reports (CMTRs)&
(MTRs) as required and a record of any repairs along with the
repair procedures.

2) Fabrication information including all heat treatment

requirements, forming and rolling procedure when prepared,
an Inspection and Test Plan identifying all inspection points
required by the user, and signed inspection reports.

3) List of any subcontracted services, if applicable.

4) WPSs, PQRs, weld map and WPQs and WOPQs.

5) Record of all heat treatments including post weld heat

treatment.

6) Results of production test plates, if applicable.

7) NDE procedures, records of procedure demonstrations, and

records of personnel certifications.

8) All reports stating the results of inspection, non-destructive

examinations and testing including RT, UT, MT, PT and VT
examination and hardness tests, if applicable.

9) All non-conformance reports including resolution and a

detailed description of any repairs including repair
procedures, a sketch, photo, or drawing indicating the
location and size of the repaired area.

10) Charts or other records of required hydrostatic, pneumatic,

or other tests. Test logs shall include the test date, testing
fluid, duration of the test, temperature of the test fluid, and
test pressure.

11) Dimensional drawings of the as-built condition.

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12.5 National Board serial numbers, for each Code Item to be

registered, are controlled and issued consecutively from 1 by QCM,
who maintains a record of each number with date issued, type of
Boiler, Vessel or part, name and location of Purchaser, and
Manufacturer's serial number. National Board numbers are issued
at the time of hydrostatic or pneumatic test completion. When not
tested in the shop, the National Board serial number shall be issued
at the time of MDR signing. These numbers shall be issued without
skips or gaps of unused numbers or duplications or prefixes or
suffixes.

12.6 QCM sends the originals of Manufacturer's Data Report with

attached Manufacturer's Partial Data Reports, to the National Board
for each Code stamped Boiler, Vessel or Part to be registered within
sixty days of certification date by the AI.

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Authorized Inspector

Authorized Inspector

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Authorized Inspector

(13) Authorized Inspector

13.1 The Authorized Inspector is the Inspector required by the

Code, employed by the ASME Accredited Authorized Inspection
Agency (AIA) with whom PSC has an inspection contract or valid
written agreement to perform the inspection services required by
the Code, he holds a valid Certificate of Competency issued by a
State of the United States of America or a Province of Canada and
a valid National Board Commission with an "A" Endorsement.

13.2 The Authorized Inspection Agency of Record shall perform all

required inspections at the shop location. Alternatively at the
request of the purchaser another Authorized Inspection Agency
may perform inspections in the shop on its project or Code job.

13.3 The Authorized Inspection Agency of Records shall perform all

inspections at field site location. The AIA of Record would not
perform the inspections at the field site when…

13.3.1 The purchaser requests another Authorized Inspection

Agency to perform inspections on its project or Code jobs.

13.3.2 Whenever the AIA of Record cannot provide coverage for

inspections at a specific field site.

13.4 When an AIA other than the AIA of Record performs

inspections…

13.4.1 The AIA that will perform the activities shall perform it in
accordance with the Quality Control Manual of PSC, in case of any
difference than the Quality Control Manual; PSC shall notify the
AIA of Record and take his acceptance for the difference.

13.4.2 A Contract or written agreement will be made between PSC

and the AIA performing field/shop activities for that specific
Code work.

13.4.3 PSC shall notify the AIA of Record and ASME Organization
whenever the written agreement has been canceled, or changing to
another inspection agency.

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Authorized Inspector
13.5 The rules of the Code shall serve as the basis for The AI to…
1. Perform his required duties.
2. Authorize and witness the application of Code Symbol
Stamp.
3. Sign the MDR of Shop Inspection and / or Field Assembly.

13.6 QCM arranges for The Authorized Inspector and the AI

Supervisor to have free access to the Shop and Field Site and
Subcontractors facilities to assure that all Code required
inspections by the AI are performed.

13.7 When requested by The Authorized Inspector, inspection

points will be inserted in ITP for those operations he may wish to
witness or verify before work proceeds.

13.8 QCM is liaison with The Authorized Inspector, and is

responsible for keeping him informed of the progress of Code
Work so that he may make his designated inspections.

13.9 The Authorized Inspector has access to and is provided with

all drawings, calculations, specifications, procedures, process
sheets, repair records, test and examination results, inspection
records and any other documents required to perform his duties.

13.10 All Nonconformance Reports for Code Nonconformities are

submitted to The Authorized Inspector with proposal for
resolution of Nonconformities for his review and acceptance.

13.11 QCM will notify the Authorized Inspector in advance of Code

required pressure test so that he will be present to witness such.

13.12 The final records, together with the completed MDR certified
by QCM, are submitted to AI for his authorization to apply the
Code Symbol Stamp and Signature, when he has satisfied himself
that all Code Requirements have been met.

13.13 A current controlled copy of the Quality Control Manual is

made available for use by the AI at the Shop and Field Site.

13.14 All changes to Quality Control Manual to be submitted to the

AI for his review prior to implementation.

13.15 QCM will assist the Authorized Inspector Supervisor (AIS)

during his required audits and the Authorized Inspector whilst
periodic monitoring the Quality Control System.

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Field Assembly

Field Assembly

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Field Assembly
(14) Field Assembly

14.1 Scope
This Section describes the system for assuring that all requirements
of the Code and Client's Specifications are met with respect to Site
work required in connection with the construction of Boiler, Power
Piping and Pressure Vessels.
Site Work will only consist of completion or assembly of Vessels,
Boiler or Piping Systems which, because of size or convenience
cannot be completed at the Shop.

14.2 Organization.
As indicated in the PSC Organization Chart Section "3" of this
Quality Control Manual, Construction Manager is responsible for all
activities concerning each site on the basis of the documents
transmitted by TOH and by QCM.
The Site Quality Control Engineer reports directly to Site
Manager administratively and for all Site quality Control
activities and to the QCH at the shop.
Directly under the Authority of the Construction Manager there is
the Site Manager who is responsible for the Field assembly activities
on Site.

14.3 Preparation of Drawings, Design, Calculations, Fabrication

Specifications and Procedures.
The preparation and review of these documents shall be handled in
accordance with Section 4 of this Quality Control Manual (Dealing
with Design, Calculations, Drawings and Specifications). All
documents for ASME Site Work orders shall be marked with the
"SITE WORK ONLY" Stamp.

14.4 Revision of Documents.

All revisions of documents shall be handled in the same manner as
the original documents.

14.5 Distribution and Revision of Site Assembly Data.

The distribution of Site Fabrication Data as well as the distribution
of revisions to Site Fabrication Data shall be handled in accordance
with Section "4" of this Quality Control Manual Dealing with
Design, Calculations, Drawings and Specifications)..

4.6 Material Control

14.6.1 Ordering of Code Material.
All materials to be used for Site Work shall be ordered in accordance
with Section "5" of this Quality Control Manual (Dealing with the
Material Control). Purchasing of material at Field Sites is not
permitted.
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14.6.2 Material Receiving Inspection.

All Materials are subjected to receiving inspection in accordance
with Section "5" of this Quality Control Manual at Site. This shall be
performed by the Site Quality Control Engineer and documented on
the Material Receiving Inspection Form.

14.6.3 Control of Code Material.

Only material procured, inspected and released by PSC shall be
used on Code Site Work and the general procedure shall be in
accordance with Section "5" of this Quality Control Manual dealing
with Material Control.

14.6.4 Ordering of Welding Material.

Welding Material shall be ordered in accordance with Section "5" of
this Quality Control Manual (Dealing with the material control).

14.6.5 Receiving Inspection of Welding Material.

All incoming welding materials shall be subject to receiving
inspection by Site Quality Control Engineer in accordance with
Section "5” of this Quality Control Manual dealing with Material
Control. .

14.6.6 Storage of Welding Material.

Welding Material shall be stored in accordance with Section "8" of
this Quality Control Manual. The Site Quality Control Engineer shall
be responsible for correct storage dealing with Welding Control.

14.7 Examination and Inspection Program.

All Site Work shall be controlled through the use of the field ITP
together with Line Inspection Summary List (LISL) Exhibit No.(14-
01) in accordance with Section "6" of this Quality Control Manual
dealing with Examination and Inspection Program. It is the
responsibility of the Site Quality Control Engineer to review ITP/LISL
with the Authorized Inspector prior to begin of assembly, erection or
any other field work.
After hydrotesting of completed Code items, which is offered to
the site AI for witness, the ASME stamp obtained from QCM by
the site QC Eng. Shall be applied to the Name Plate after
authorization from the site AI, The ASME stamp shall be
returned by the site QC Eng. To the QCM at shop for safe
keeping.
The MDR for Code item completed at the site location after
final inspection and testing field assembly portion of the MDR
is signed y the QC Eng. And presented to the site AI for his
signature ,the complete MDR is send to the QCM at shop for
distribution as required

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All originals of Site Work Inspection reports shall be submitted to

Site QC engineer for his review and signature.

14.8 Nonconformities.
All Non-conformities found during Site work shall be handled in
accordance with Section "7" of this Quality Control Manual dealing
with Correction of Non-conformities. Except that the Site Quality
Control Engineer shall be responsible for preparing the
Nonconformance Report including approval of disposition.

14.9 Welding Control.

The Welding Control and the preparation and qualification of WPS &
WPQ shall be handled in accordance with Section "8" of this Quality
Control Manual dealing with Welding Control. Except that the
Site Quality Control Engineer is responsible for Qualification of the
Welding Procedures and Welders. Copies of Welding Procedure
Specifications (WPSs), Procedure Qualification Records (PQRs) and
Welder/Welding Operator Performance Qualification Records (WPQs)
shall be available to the Authorized Inspector on Site for review.

14.10 Post Weld Heat Treatment.

When it is necessary to perform PWHT at a Field Site it shall be by
PSC or by Subcontractor.
PSC QCH is responsible for the development of PWHT Procedures
and approval in accordance with Section “10".
Site QC Engineer shall be responsible for verifying calibration of
subcontractor's PWHT equipment. Copies of time/temperature
charts and other PWHT records will be reviewed and approved by
Site QC Engineer and made available to the Authorized Inspector
for review.

14.11 Non-Destructive Examination.

The Control and Implementation of NDE Procedures on Site shall be
handled in accordance with Section "9" of this Quality Control
Manual dealing with Non Destructive Examination.

14.12 Control of Measuring and Test Equipment.

All Calibration of PSC measuring and test equipment to be used at
site shall be handled in accordance with Section "11" of this Quality
Control Manual dealing with Calibration of Measurement &Test
Equipment. Measuring and test equipment from Subcontractor
shall be calibrated in accordance with their procedures which have
been accepted by PSC QCM. It is the responsibility of Site Manager
to ensure that only calibrated and identified equipment is used for
Site Work.

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14.13 Records Retention.
Quality Control Documents shall be prepared and maintained in
accordance with Section "12" of this Quality Control Manual dealing
with Record Retention.

14.14 Authorized Inspector (AI).

The contractual relationship with an Authorized Inspection Agency,
access for the Authorized Inspector at site and coordination with the
Authorized Inspector shall be handled in accordance with Section
"13" of this Quality Control Manual dealing with Authorized
Inspector.

The Site QC Engineer is the liaison officer with the AI at site. PSC
shall provide suitable working facilities for AI and AIS at site.

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Repairs and
Alterations

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(15) Repairs and Alterations

15.1. General :

15.1.1. Repairs and Alteration can be carried out on ASME Code

stamped/Certification Marked boiler and pressure vessels and also on
other vessels not designed to ASME Codes.

15.1.2. Shop or field repairs and alterations to boilers, power piping or

pressure vessels when required by the Owner, User, Jurisdiction or AIA
responsible for in-service inspection of the unit, are made in
accordance with the applicable requirements of the National Board
Inspection Code (NBIC) and this Quality Control Manual.

15.1.3. “REPAIR” is defined as the work necessary to restore pressure

retaining item to a safe and satisfactory operating condition.

15.1.4. “ALTERATION” is defined as change in the item described on the

original Manufacturer’s Data Report which affects the pressure
containing capability of the pressure retaining item. Non-physical
changes such as an increase in the MAWP OR MAEWP or design
temperature or a reduction in the minimum design metal temperature
of a pressure retaining item shall also be considered an Alteration.

15.1.5. “RE-RATING” is an Alteration, rerating shall be applicable only when

the current inspection records indicate the vessel is in satisfactory
condition, its design with the existing condition is verified and the
vessel is pressure tested to the rerated condition (Part 3 Ref 3.4.1 of
NBIC)

15.2. Statement Of Authority And Responsibility

15.2.1. QCM is responsible for compliance with this Manual for shop or field
repairs and alterations to pressure vessels. (See Section 2 of this
Manual)dealing with statement of Authorty and Resposiblity.

15.3. Manual Control

15.3.1 The preparation, revision and issue of this Quality Control Manual
shall be the responsibility of QAH. The system has been detailed in
Section-1 of this Manual dealing with Manual control.

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15.4. Organization

15.4.1 The Organization Chart for carrying out repair and alteration at shop
and field sites controlled from shop shall be as shown in Section-3 of
this Manual and the Quality Control responsibilities are as detailed in
Section-3 of this Manual dealing with Organization.

15.5. Construction Standards

15.5.1. When original equipment is constructed to the ASME Code, repairs

and alterations shall conform insofar as possible to the section and
Edition of the ASME Code most appropriate to the work performed.

15.5.2. When the original equipment is not constructed to the ASME Code,
repairs and alterations shall conform insofar as possible to the edition
of the construction standard or specification most appropriate to the
work. Where use of original construction code is not possible or
practicable, other codes, standards, specifications including ASME
Code with latest Edition and Addenda may be used provided prior
concurrence of the AI has been obtained. When applicable prior
concurrence of Jurisdiction and Owner shall also be obtained for use of
standards other that original construction standard.

15.6. Drawings, Design And Specifications

15.6.1. On receiving the order for carrying out Repairs or Alteration, it shall
be the responsibility of assigned Design Engineer ( See Section 4 of this
Manual) dealing with Design,Calculation,Drawing and
Specification to identify and confirm whether the required work is
categorized as Repair or Alteration or Rerating in accordance with the
requirements of NBIC NB23.

15.6.2. He shall also be responsible to ensure that sufficient information

has been provided by the owner or user along with the order so that
repair or alteration work can progress. He shall ensure availability of
the MDR, drawings, data sheets and similar other documents required
to undertake the repair or alteration work. If data reports are not
available and the vessel is registered with National Board (as verified
from the vessel name plate/stamping or Certification Marking), he shall
arrange a copy from the National Board by providing the necessary
information like name of the manufacturer, Code item serial number,
year make and NB number.

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15.6.3. The system of preparation of design calculations shall be as

explained in Section-4 of this Manual dealing with
Design,Calculation,Drawing and Specification. The design
calculations for repair or alteration shall be based on the original
construction standard or as otherwise specified in Para.15.5 above.
Reference for design shall be based on MDR and other details like
drawings, data sheet etc., given by the owner. Design calculations shall
clearly identify the Code/Standard used including their year date and
addenda.

15.6.4. Drawings for alterations (and when required for repairs) shall be
approved by TOH. In addition to the applicable details given in Section-
4 , 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 dealing with
Design,Calculation,Drawing and Specification.

15.6.5. Design Engineer is also responsible for verifying the identification of

the existing materials from the original MDR, original drawings and
other such documents. Material specification for the existing material
and material to be installed shall be clearly indicated on the drawings.

15.6.6. When any material or part is to be replaced during repairs or

alteration, Technical specifications for material shall be prepared by the
Design Engineer and approved by TOH as described in Section-4 of this
Manual dealing with Design,Calculation,Drawing and
Specification.

15.6.7. All design documents shall be submitted to the AI for his review
before proceeding further with repairs or alterations.

15.7. Materials

15.7.1. The use of stock material, procurement, receipt inspection, storage,

issue and identification of material shall be as described in Section-5 of
this Manual dealing with Material Control.
15.7.2. All materials used in making repair or alteration shall conform to
the requirements of original construction standards or as specified in
Para.15.5 above.

15.7.3. The relevant material test reports or certificate of compliance shall

be obtained and submitted to the AI for his review and acceptance.

15.7.4. Carbon or alloy steels having carbon content more than 0.35% shall

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not be used for items requiring welding.

15.7.5. Replacement parts shall meet the requirements of Sec. 3 of Part 3 of

NBIC NB23.

15.7.6. When ASME is the original Code of construction, replacement parts

which require welding shall be fabricated, inspected and documented
as per ASME Code as parts. When original Code of construction is not
ASME, replacement parts which require welding shall be fabricated,
inspected and documented as per the original construction Code and if
this is not practicable, such items can be constructed and stamped R
by the R symbol stamp holder and documented on Form R-3 of NBIC
NB23.

15.8. Welding, NDE And Heat Treatment

15.8.1. 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 of this Manual dealing with Welding,
NDE and Heat Treatment.

15.8.2. 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 Sec. IX can
be used. Records of approved WPS and welder’s qualification tests shall
be made available to the AI for his review and acceptance before
carrying out welding work.

15.8.3. Standard WPS shown in Part 3, Table 2.3 of the NBIC NB23 can be
used for repairs or for performance qualification. Such WPS shall be
documented and certified by QC Head for use. When required, owners
or jurisdiction’s acceptance will be obtained for use of standard WPS.

15.8.4. 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 the AI and owner or jurisdiction as applicable
may be used.

15.8.5. 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
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NBIC adopted edition of SNT-TC-1A may be used.

15.8.6. Other NDE controls shall be as per Section-9 of this Manual

dealing with Welding, NDE and Heat Treatment

15.8.7. Preheat temperature requirements shall be as specified in the

applicable WPS.

15.8.8. PWHT shall be performed as required by the original construction

standard or as per original manufacturer’s data report. PWHT shall be
in accordance with procedure and instructions prepared and approved
as detailed in Section-10 of this Manual dealing with Welding, NDE
and Heat Treatment. Local PWHT that is not specified by the original
construction code may be performed as per Sec. 2, Part 3 of NBIC NB23
with prior acceptance of the AI and when required by the owner and
Jurisdiction.

15.8.9. Under certain conditions, when PWHT in accordance with original

construction standard is inadvisable or impractical, alternative
methods of PWHT or special welding methods as described in Part RD
of NBIC NB23 and acceptable to the AI may be used.

15.9. Examination And Tests

15.9.1. All examination and tests required during and after repairs or
alterations shall be identified on the Repair procedure and ITP.

15.9.2. Requirements for the pressure tests including test medium, test
pressure, holding time, and temperature limits etc. shall be specified in
the repair procedure.

15.9.3. All pressure tests shall be witnessed by the QC Head and shall be
offered to the AI.

15.9.4. The extent of Pressure Testing shall be as acceptable to the AI and

the owner/user. When it is not possible or practicable to pressure test
the whole equipment on which repairs or alterations have been carried
out, only connecting welds (defined as welds attaching replacement
parts and pressure retaining item) may be tested.

15.9.5. The metal temperature during Pressure Test shall not be less than
60°F (16°C) or more than 120°F (50°C). Care shall be taken to ensure
that the pressure relief devices on the equipment are either removed or
gaged before test. Test pressure shall be held for minimum of 10
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minutes prior to the examination. The AI shall be afforded the right to

carry out the close examination after reducing the pressure to MAWP.

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

15.10. Non-Conformities

15.10.1. Any non-conformity noticed during execution of repairs and

alterations shall be dealt in accordance with Section-7 of this Manual
dealing with Correction Of Nonconfomities.

15.11. Calibration

15.11.1. All equipment and gauges used for inspection and examination
during repair and alterations shall be maintained and calibrated in
accordance with Section-11 of this Manual dealing with Calibration
Of Measurementand Test Equipment.

15.12. Procedure :

15.12.1. All repairs and alterations to Code pressure vessels are subject to
acceptance of the Authorized Inspector, who may require that evidence
of acceptance of the method and extent of repairs or alteration by the
jurisdiction or insurance carrier responsible for in-service inspection be
provided before starting work.

15.12.2. The Quality Control Manager, prior to the start of work, provides the
Authorized Inspector with drawings, calculations, procedures, Repair
Inspection and test plan (ITP), copy of the original Manufacturer’s Data
Report (for ASME Code stamped items) for the item and any other
documents necessary for the Authorized Inspector to review and accept
the method of repair or alteration and to designate his required
inspection points.

15.12.3. For alterations consisting only of re-rating, calculations can be

obtained from the original manufacturer.

15.12.4. The Quality Control Manager, if requested by the Authorized

Inspector, arranges for his access to make such inspections of the
vessel he deems necessary in order to accept the method of repair or
alteration.
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15.12.5. The Quality Control Manager keeps the Authorized Inspector

informed of the progress and completion of the work so he may make
his designated inspections, and accept the repair or alteration after his
final inspection of the completed work.

15.12.6. All examinations and tests required by the Code for the original
construction of the pressure vessel are required for repair or alteration,
except that if impossible or impracticable, alternative method
acceptable to the Authorized Inspector may be used.

15.12.7. For alterations, if the original Manufacturer's Data Report cannot be

obtained, agreements on the method of establishing design basis for
alteration shall be obtained from the Inspector and the jurisdiction.

15.13. Records :

15.13.1. The repair or alteration including a description of the relocation of

Code Stamping or Nameplate is documented on the current National
Board Form R1-Report of repair or Form R2-Report for alteration.

15.13.2. When the work is complete, the Form R1 or R2 is certified by the

Quality Control Manager.

15.13.3. The final records together with the completed Form R1 or R2 as

applicable; and the original Manufacturer’s Data Report are presented
to the Authorized Inspector for his review. When he has satisfied
himself that all NBIC and Manual requirements have been met, he will
authorize the application of the “R” symbol to the appropriate NBIC
stamping and sign the Form R1 or R2.

15.13.3.1. When altration /rerating is carried out Design

Certification Section of form R2 shall be designed by TOH
(Technical Office Head) prior to presenting the same to the AI for
his review and acceptance with his signature.

15.13.4. All records referenced in this Section are available for review by the
Authorized Inspector. Forms R1 or R2 is distributed as described in
15.6.

15.13.5. LOG OF R- FORMS (Exhibit No. 15-01) shall be used to record

details of all R-Forms issued .The "R" Form Number shall be assigned
by the Quality Control Manager sequentially starting from 'R1' (then
after R2, R3, etc.). 1 without any skips and gaps of unused number.

15.14. Stamping :

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15.14.1. If, during repair or alteration of a pressure vessel, it is necessary to

remove the original Manufacturer’s Code stamping/Certification
Marking or Nameplate, the Authorized Inspector will, subject to the
approval of the jurisdiction:

(a) Witness the marking of a facsimile or rubbing of the old and new
stamping;
(b) Witness obliteration or removal of the old stamping, and transfer of
the stamping to the new part or location on the item, less the original
Code symbol/Certification Marking. The Code symbol/Certification
marking is not re-stamped.

15.14.2. When stamping is on a Nameplate, the Authorized Inspector will

witness the transfer of the Nameplate to its new location.

15.14.3. The Quality Control Manager retains custody and control of the “R”-
Stamp. Stamping may either be on the Code item or on a name plate.
Marking shall be as indicated in Marking/Name Plate for ‘R’ stamp
(Exhibit No. 15-02.). This symbol is the property of the national Board
and shall be retained on demond to National Board.

15.15. Distribution Of Forms R1 Or R2 :

15.15.1. Legible copies of completed Form R1 (for Repairs) together with

attachments shall be distributed to the Owner or user, the Authorized
Inspector, the jurisdiction (if required) and the AIA responsible for in-
service inspection.

15.15.2. Form R1 may be registered with the National Board, regardless of

the pressure-retaining item is originaly registered or not registered with
the National Board.

15.15.3. Legible copies of completed R2 (for Alteration) together with

attachments, shall be distributed to the Inspector, the AIA responsible
for in-service inspection, Owner or user, the 'R' Certificate holder
responsible for design and the jurisdiction (if required).

15.15.4. If the pressure-retaining was registered originaly with the National

Board, one original Form R2 together with attachments shall be
registered with the National Board.

15.15.5. If the pressure-retaining item is not registered with the National

Board, one original Form R2 together with attachments may be
registered with the National Board.

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15.16. Replacement Parts

15.16.1. When the original Code of construction is ASME, any replacement

part of boiler or pressure vessel required shall be constructed, certified
and Marking as per the rules of the ASME construction Code.When the
original Code of construction is other than ASME, any replacement part
of boiler or pressure vessel required shall be constructed to the original
Code of construction and shall be stamped “R”. Replacement parts shall
be reported on Form R-3 which shall be certified by the Quality Control
Manager and presented to the AI for review and signature.

15.17. Routine Repairs

15.17.1. When routine repairs, as defined in NBIC, Part 3, 3.3.2 are required,
the Quality Control Manager shall ensure that the routine repairs are
acceptable to the jurisdiction.

15.17.2. The Jurisdiction ( if required) or the Inspector may waive the

involvment of the AI in the routine repairs. Application of the ‘R’
symbol Stamp on the item repaired may also be waived as
determined by jurisdiction or the AI.Routine repairs shall be
documented on form R-1 with this statement in the Remarks
section : “Routine repair”

15.17.3. Repair procedure / ITP for routine repairs shall be prepared and
submitted to the AI for his acceptance and signature.

15.17.4. Form R-1 shall be prepared and certified by the Quality Control
Manager, and shall include a statement “Routine Repairs” in the
Remarks column in the R-Form. R-1 form shall be submitted to AI for
his signature

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