Document No: ASME – 001

Issue No.: 02
ASME - QUALITY CONTROL MANUAL Preface 1, Rev. No.: 2
Page 1 of 1

Records of Manual Revision

Issue Revision Date Revision Change

1 0 02-Sep-2015 Revised to incorporate ASME Code 2015 Edition Changes.

1 1 24-Mar-2016 Revised as per Joint Team review and recommendation

2 0 31-Oct-2018 Revised to incorporate ASME Code 2017 Edition Changes.

2 1 16-Jan-2019 Revised as per Joint Team review and recommendation

2 2 31-March-2020 Revised to incorporate ASME Code 2019 Edition Changes.

Page 1 of 1
 Document No: ASME – 001
Issue No.: 02
ASME - QUALITY CONTROL MANUAL Preface 02, Rev. No.: 2
Page 1 of 1

TABLE OF CONTENTS

SECTION # DESCRIPTION REV. NO. DATE

-- COVER PAGE 2 31-03-2020
PREFACE 01 RECORDS OF MANUAL REVISION 2 31-03-2020
PREFACE 02 STATEMENT OF TABLE
POLICYOF
AND
CONTENTS
AUTHORITY 0 2 12.11.2000
31-03-2020 STATEME
PREFACE 03 STATEMENT OF POLICY AND AUTHORITY 2 31-03-2020
PREFACE 04 MANUAL CONTROL 1 16-01-2019
1.0 ORGANIZATION AND RESPONSIBILITIES 2 31-03-2020
DRAWINGS, DESIGN CALCULATIONS & SPECIFICATIONS 2 31-03-2020
2.0
CONTROL
3.0 MATERIAL CONTROL 2 31-03-2020
4.0 EXAMINATION AND INSPECTION PROGRAM 2 31-03-2020
5.0 NON-CONFORMANCE AND CORRECTIVE ACTIONS 0 31-10-2018
6.0 WELDING CONTROL 2 31-03-2020
7.0 NON-DESTRUCTIVE EXAMINATION 2 31-03-2020
8.0 HEAT TREATMENT 0 31-10-2018
9.0 CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT 1 16-01-2019
10.0 RECORD RETENTION 2 31-03-2020
11.0 AUTHORIZED INSPECTOR 1 16-01-2019
FIELD FABRICATION & ASSEMBLY OF BOILERS, PRESSURE 0 31-10-2018
12.0
VESSELS & PIPING
13.0 REPAIRS & ALTERATIONS 2 31-03-2020
14.0 ABBREVIATIONS AND DEFINITIONS 2 31-03-2020
15.0 LIST OF EXHIBITS 2 31-03-2020

Prepared by Signature / Reviewed Signature Accepted Signature

Date &Approved / Date / Date
by
QA-HSE QC Authorized
Manager Manager Inspector

Page 1 of 1
 Document No: ASME
ASME - QUALITY CONTROL SYSTEM – 001
Issue No.:02
MANUAL Preface 03, Rev. No.:2
Page 1 of 1
Statement of Policy and Authority
It is the Arabian International Company's (AIC) objective to become and remain the market leader with
respect to the quality of its products and services. To achieve this objective, the Arabian International
Company shall:
• Deliver quality products and services that throughout their life fulfill and exceed the needs and
expectations of our customers at a cost that represents value.
• Achieve Quality by preventing problems rather than by detecting and correcting them after they
occur. Do the work right first time, every time.
• Strive for excellence through sustained effort towards continuous improvement in Quality.
• Empower our employees to respond to each customer needs on time,
• Build high performance teams & provide our employees with a safe environment.
• Have effective and open communication insuring the highest levels of cooperation,
• Encourage career growth for all of our employees,
• Promote a spirit of professionalism, teamwork and mutual respect amongst all employees and with
internal and external stakeholders & Ensure that our suppliers provide quality goods and
services.
This Manual document the Quality Control systems for design, manufacture, assembly, Construction of
Boilers & Pressure Vessels conforming to the requirements of American Society of Mechanical
Engineers for Boiler and Pressure Vessel Code Section I & Section VIII Division 1, ASME B31.1and
metallic repairs and alterations in compliance with NBIC. This Manual maintains compliance with the
ASME Boiler and Pressure Vessel Code and NBIC. This Manual is applicable in the shop and field
sites controlled by the shop.
The Management is wholeheartedly committed to the implementation and support managerial and
operational systems to implement the quality systems documented herein.
The QC Manager has authority and responsibility for approval and administration and implementation
of this manual at shop and field sites. The Management authorizes the QA-HSE Manager to establish
and maintain the various systems described in this Manual. In matters affecting quality, the QC
Manager has the responsibility, authority and organizational freedom to hold production, identify
quality problems, decide suitable corrective actions and ensure their implementation as provided in this
Manual.
In the event of a difference of opinion or disagreement in the implementation of the
Quality System between the QA-HSE Manager and QC Manager and other Managers in AIC, the
matter shall be brought to the attention of the undersigned for resolution, and matter shall be
resolved in a manner that will not conflict with code, jurisdiction/regulatory authority or Quality
System requirements.
. All concerned personnel of this organization shall follow all the requirements of this Manual without
any deviation. It is responsibility of QA-HSE Manager and QC Manger to ensure personnel
performing ASME code works are properly qualified and certified for designated responsibilities.
Design, NDE (only RT), Heat treatment activities are subcontracted under full responsibility of the
company.

_______________
Wasim A. Attieh
President
Date:
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 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Preface 4, Rev. No.:1
MANUAL Page 1 of 2

Manual Control
I.A Scope / Purpose
This section covers the preparation, issue, revision, approval and distribution of this Manual.
I.B Procedure
I.B.1 Preparation, Review, Approval & Acceptance: The Manual shall be prepared by QA-HSE
Manager and reviewed & approved by the QC Manager. The Manual shall be submitted to the
AI for his acceptance before implementation. Their respective signatures on the Table of
Contents shall evidence their review, approval and acceptance effective date of this manual is
the date of acceptance by AI.
.
I.B.2 Revisions: QC Manager and QA-HSE Manager shall review Code Editions this review shall be
documented by Signature in the Summary of changes page of each code. After the review of
Code Edition, revisions to the Manual shall be made, if required. Revisions may be made for
other reasons when necessary. Revisions shall be reviewed, approved and accepted in the same
manner as the original issue. The signatures of the QC Manager and AI on the revised Table of
Contents shall evidence the review, approval and acceptance of revisions. Revisions arising due
to Code Editions shall be issued within Six months of the Editions issue date.
This Manual shall not be revised to meet Customer's requirements.
Where required, Customer's specifications are addressed in the contract specific drawing,
documents and procedures.
When substantial revisions are made to the manual at any time or at the time of joint Review the
issue number of manual will be advanced and the revision number of all sections will be
brought back to “0”.
Manual will be written in English language only.

Highlighting of Revisions: The manual will be made by Section wise. Revised text shall be
highlighted in Bold Italics and only the latest revision will be indicated. The latest revision
number and date of revision of each section will be identified in Table of Contents.
Exhibits: Exhibits are revised individually. The latest revision number and date of revision of
each exhibit will be identified in List of Exhibits. Revision number of ‘List of Exhibits’ and
‘Table Contents’ will be advanced when exhibits are revised.
I.B.3 Distribution:
I.B.3.1 Controlled Copies: Controlled Copies shall be issued to all operating departments of AIC
involved in Code work. No uncontrolled copies shall be issued within AIC. A Controlled Copy
shall be made available for the use of AI at the factory and at sites. A Controlled Copy shall be
identified by having a copy number.
Distribution of Controlled Copies: A Distribution Record (Controlled Copy Distribution
Record Exhibit # 1) shall be maintained for all controlled copies of the Quality Control Manual.
The record shall indicate the name and department of the holder and the date of issue of
Revision number on Table of Contents. The QA-HSE Manager shall distribute the Manual
through Document Transmittal (Exhibit # 2). Acknowledgements of receipt shall be obtained
and filed. In case of distribution of revisions, the superseded sections shall be assured against
inadvertent use by being either withdrawn, destroyed or marked “Superseded” by QA-HSE
Manager.
I.B.3.2 Uncontrolled Copies: Uncontrolled Copies of the Manual are distributed only for information,
to customers etc. No record needs to be maintained of distribution of Uncontrolled Copies. An
Uncontrolled Copy does not have a copy number, and shall be marked “Uncontrolled” on the
Cover Page.
Page 1of 2
 Current uncontrolled copy is provided to team leader and AIS during ASME joint review.
Uncontrolled copy is also provided to AIS during AI Annual Audit.

I.B.4 Return: Controlled Copies no longer required by the Manual holder, shall be returned to QA-
HSE Manager. Such returns shall be recorded in the Manual Distribution Record as “Returned”.

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 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 1, Rev. No.: 2
MANUAL Page 1 of 6

Section 1.0 Organization and Responsibilities

Page 1 of 6
 RESPONSIBILITIES
1.1 President:
He is responsible for:
• Establishment and implementation of Company policies
• Development and improvement of Company systems
• Statement of Quality Policy and Quality Objectives
• Operational and effectiveness of the total quality system
• Overall administrative and operational activities for effective performance of the
Company
• Managing Company resources
1.2 General Manger for Plate Work and Piping.
He is responsible for:
• Assisting President
• Performing President duties in his absence
• Operation of Sales, Estimation, Projects, Planning and Coordination, Finance,
Procurement, Engineering, Planning, Production, Maintenance, QA Department and
QC Department.
• Laying out Annual, Quarterly and monthly Sales and Production Plan and review the
same
1.3 Sales & Estimation General Manager
He is responsible for:
• Receipt of inquiries, review of Proposals / Bid Documents
• Evaluation and submission of quotations
• Review of order status
• Co-ordination with clients & attending Technical/Commercial meetings
• Issuance of Work Orders
• Review of contract & analysis of lost bids to improve up on future bidding
• Marketing research
• Maintain good relationships with clients
• Improving Order Status
• Review of Specifications and Design Documents
• Preparation and approval of Quotations

Page 2 of 6
1.4 Procurement Manager
He is responsible for:
• Receipt of Purchase Requests
• Preparation and approval of Purchase orders
• Purchase of material and equipment
• Evaluation of Suppliers
• Promoting New Suppliers
• Market research and updating of Sales and Estimation department with the current
prices and any anticipated variations in prices
• Follow up with the vendors for the ordered materials

1.5 Head of Projects

He is responsible for:
• Review of Contract Documents
• Preparation and implementation of Project Schedules
• Planning of the necessary resources for the project
• Preparation of project budgets, allocation and monitoring of the project budget
• Coordination with various operating departments for effective execution of project
activities
• Continuously monitoring the activities from Raw material procurement through
delivery and invoicing
• Coordination with clients for project activities
• Operations at field site (Section 12)

1.6 Design Engineer (Subcontract)

He provides following services
• Reviews of customer drawings & design input.
• Preparation of design Calculation & detail drawings.
• Verify design software.
• Preparation of TDC.

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1.7 QC Manager
He is responsible for:
• Approval of Quality Control Manual
• Approval of Quality & Welding Plans, Procedures, TDC, CTDC, PR.
• Development of new procedures
• Coordinating with the operating departments for the quality related matters
• Identifying training needs
• Management of controlled documents
• Control issue, revisions, amendments, and distribution of all Quality Control
procedures and Welding Documents
• Overall management of QC department
• Custody and control of ASME certification mark
• Co-ordination with AIA and clients for quality related issues & inspection.

1.8 QC Engineer
He is responsible for:
• Incoming Raw material inspection & MTC check.
• Pre and Post Fabrication Quality checks
• Non Destructive Examination coordination
• Prepare QC Procedures, Quality & Welding Plan.
• Follow up NDT activities with Subcontractor.

1.9 Welding Engineer

• Train and explain the welding requirements to Welders
• Implement the Quality & Weld Plan.
• Welding Inspection.
• Preparation of Weld Map, WPS, PQR, WQTR, Qualified Welder list, Welding data
sheet, Welder Continuity Record & Radiography Map.
• Preparation of PWHT procedure and Heat Treatment Control Sheet.
• Control of Welding Consumable.

Page 4 of 6
1.10 Planning Manager
He is responsible for:
• Co-ordination between Sales, Projects, Engineering, Production and Quality Control
Departments
• Preparation of Monthly, Quarterly and annual production plans
• Preparation of Project Schedules
• Monitoring Production and Project schedules and reporting to the management
• Co-ordination between Production and management regarding resource requirements

1.11 Production Manager

He is responsible for:
• Overall management of work shop and resources
• Day to day planning and optimizing shop floor activities
• Safety of men and equipment
• Timely production of quality products

1.12 Production Welding Supervisor

• Assign the Qualified Welders on the specific Joints.
• Monitor the Welders Performance.
• Ensure the implementation of WPS.
• Guidance to welders and Welding Operators.
• Preparation of Store Consumable section request form.

1.13 Project Manager

• Review of Contract Documents
• Preparation and implementation of Project Schedules
• Planning of the necessary resources for the project
• Preparation of project budgets, allocation and monitoring of the project budget
• Coordination with various operating departments for effective execution of project
activities
• Continuously monitoring the activities from Raw material procurement through
delivery and invoicing
• Coordination with clients for project activities
• Operations at field site (Section 12)

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1.14 QA-HSE Manager
• Preparation, issue, revision and distribution of this Manual
• Issue copies of the Manual with transmittal
• Train and contact with the concerning department manager regarding the
implementation of ASME requirements.
• Monitor and control the calibration
• Monitor the Subcontract & Supplier Performance
• Approval of Design Documents
• Ensures availability of authorized copies of current and applicable Edition of Code
Books at Shop and field site.

1.15 Certification and Delegation of Duties:

1.15.1 Certifications: when required by this manual, certification, approval or acceptance on
any document, exhibit or procedure shall be by dated signatures of relevant personnel.
Authorization or certification shall be in hard copy only.
Electronic approval/ authorization / certification is not used.

1.15.2 Delegations of authorities and responsibilities.

1.15.2.1 Each Manager & In Charge position may delegate the performance of their duties to
competent and when required qualified personnel under their supervision. However,
they may not delegate their responsibility.
1.15.2.2 Each Person in a Supervisory position may carry out the duties of personnel under
their supervision, provided they are qualified and when required certified to perform
this work.

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 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 2, Rev. No.:2
MANUAL Page 1 of 6

2.0 Drawing, Design Calculations and Specifications Control

2.1 Scope / Purpose
This section covers the requirements for preparation, review, approval, revision and
issue of design documents for construction of Boilers, Pressure Vessels and Power
Piping to Code requirements, preparation of design document are subcontracted.
Design Engineer (Subcontract) referenced in this section refer to subcontractor Design
Engineer (Subcontract).
2.2 Responsibility
The QA-HSE Manager is responsible for the ensuring the compliance of all drawings,
design calculations and other engineering documents with Code requirements, their
issue and revisions etc.
Units of Measurements:
Sales & Estimation Manager shall establish with the Client, the units of measurement
(U.S. customary, SI or local customary units) to be followed for the project. All entries
in the Manufacturer’s Data Report & data for Code required nameplate markings shall
be consistent with the fabrication drawings. Design calculation may be done in any one
set of units. Materials & Standard fittings that have been certified to either U.S.
customary or SI units may be used regardless of the units of measurement used in the
design. Fabrication, Measurement & Test equipment and fabrication documents may be
in U.S. customary, SI or local customary units. Any required conversions shall be made
with conversion factors accurate to at least 4 significant figures. The results of
conversion of units shall be expressed to a minimum 3 significant figures. Whenever
local customary units are used, the Company shall provide the source of conversion
factors, which shall be subject to verification & acceptance by the Authorized Inspector.
Design Engineer (Subcontract) shall make sure that the conversion is in accordance
with appendix GG of Div. 1 or A391 through A393 of Section 1. Units either primary
or alternative may be shown parenthetically.
For any single equation, all variables shall be expressed in a single system of units.
Calculations using any material data published in this Division or Section II, Part D
(e.g., allowable stresses, physical properties, external pressure design factor B) shall
be carried out in one of the standard units given in Table U-4-1 for ASME Sec VIII
DIV 1, & Table PG-4-1 of ASME Sec I. When separate equations are provided for
U.S. Customary and SI units, those equations must be executed using variables in the
units associated with the specific equation. Data expressed in other units shall be
converted to U.S. Customary or SI units for use in these equations. The result
obtained from execution of these equations or any other calculations carried out in
either U.S. Customary or SI units may be converted to other units.

Page 1 of 6
 Governing Code Editions:
QA-HSE Manager is consultation with Design Subcontractor establishes the governing
Code edition using Appendix 43 of Section VIII Div. 1, Appendix VI of section I as
applicable. For boiler external piping, edition of ASME B31.1 referenced in the
governing Code edition of Section I shall be used. Code Edition used for construction of
a boiler or pressure vessel is either the edition that is mandatory on the date the boiler or
pressure vessel is contracted for or the published edition issued by ASME prior to the
contract date, which is not yet mandatory. Governing edition for subcontracted Parts or
Replacement Parts and for assembly shall be decided as per the applicable Appendix/
Annexure above. For parts certified by the Company, design responsibility is identified
in the manufacturer’s partial data report.

2.3 Procedure
2.3.1 Customer Information: Customer drawings, design inputs and specifications are
received from customer through the Head of Projects. Drawings / design
calculations provided by customer shall be submitted to Design Engineer
(Subcontract) for comments and reviewed & approved by QA-HSE Manager for
Code compliance.

2.3.2 Design Calculations and Drawings:

2.3.3.1 Contents: The calculations and drawings shall specify all information
required for Code compliance, including but not limited to:
• Applicable ASME Code Section, Edition and code case
• Code Stamping requirements
• National Board Registration (if required)
• Design Conditions: As applicable for Section I, Section VIII Div.1
and ASME B31.1 mentioned below:

a) MAWP at coincident temperature (Internal and External)

b) MDMT
c) Design Pressure
d) Design Temperature
e) Heating Surface in Boiler
f) Max. Designed Steaming Capacity for boiler
g) Corrosion Allowances
h) Loading conditions
i) Pressure test, test position and test temperature.
• Inspection Openings
• Post Weld Heat Treatment requirements, Heat Treatment
requirements arising out of cold forming
• Non Destructive Examination requirements
• Notch toughness requirements or exemptions
• Name Plate stamping detail & location of stamping
• Dimension & Tolerances

Page 2 of 6
 • Material specification (including type, class and grade,
supplementary / additional requirements as applicable), etc. for
each part number of the drawing.
• Service (Lethal etc.)
• Required welding size as applicable.
• External pressure template dimension & Value of “e”.
• Welding details as per code
• Manufacturing serial no. & equipment tag number.
• Special instructions as applicable (e.g. over pressure protection or
post forming heat treatment requirement)
Where complete details of construction are not given, Design Engineer (sub contract), subject
to the acceptance of the Authorized Inspector, shall provide the appropriate details to be used.
When Design rules do not exist in ASME Section VIII Div.1 Design Engineer (sub contract)
shall use one of the following three methods:
(a) Mandatory Appendix 46.
(b) Proof test in accordance with UG-101.
(c) Other recognized and generally accepted methods, such as those found in other ASME, EN,
ISO, national, and industry standards or codes. This option shall provide details of design
consistent with the allowable stress criteria provided in UG-23.

2.3.3.2 Material Selection:

Only ASME SA and SB materials listed in the stress tables of Section II,
Part D (B31.1 for PP Items) or as otherwise allowed by the code shall be
used for pressure parts. In addition, compatibility of marking and
certification requirements stipulated in the material specification with the
material traceability requirements of the parts shall be taken into
consideration.
For Boiler, replacement part provided “in kind”, guidelines of mandatory
appendix VI of ASME Section I shall be followed.
When design is company’s responsibility, Design Engineer
(Subcontract) shall prepare and QA-HSE Manager shall approve
design calculation and ensure compliance with the applicable
ASME Code Sec 1 adopted Edition and Addenda of ASME B31.1
and customer’s requirements.
Piping systems shall be designed for the most severe condition of
coincident pressure, temperature and loading. The most severe
condition shall be that which results in the greatest required pipe
wall thickness and highest flange rating, and associated valves and
appurtenances to ensure compliance with all the applicable Code
requirements.

Page 3 of 6
 For PP Items material produced under an ASTM specification may be
used, provided that the requirements of the ASTM specification are
identical or more stringent specification for the Grade, Class, or Type
produced. The material manufacturer or component manufacturer shall
certify, with evidence acceptable to the Authorized Inspector, that the
ASME specification requirements have been meet.
Customer supplied design: If design calculation & drawing for
Pressure Vessel External Piping/boiler are supplied by the customer,
QA-HSE Manager shall arrange for review of such engineering
documents by Design Engineer (Subcontract) to ensure the design and
drawings are in compliance with the applicable Code requirements. Any
discrepancy shall be discussed with customer and resolved within Code
requirement. Design responsibility shall be identified on the data report.
Company takes full responsibility for Code certification of boiler
external piping/boiler including providing P-4A/P4 data reports.
2.3.3.3 Preparation, Checking, Review, Approval: The Design Engineer
(Subcontract) shall perform Design calculations as per Code Rules,
based on the design data furnished by the QA-HSE Manager. The
calculations shall be carried out either manually or by using validated
Design Software. The calculations shall be reviewed and approved by
the QA-HSE Manager. Design Engineer (Subcontract) shall prepare the
drawing. The drawing shall be reviewed and approved by QA-HSE
Manager.
2.3.3.4 Preparation of Material Request: The Design Engineer (Subcontract)
shall prepare the material requisition (Exhibit # 33) which includes
Material specification, size, quantity and TDC reference, to be submitted
to QA-HSE Manager for review and approval.
2.3.3.5 Approval by Customer: Where required as per contract, design
documents are sent to Customer for review / approval. Approval by
Customer shall not absolve AIC from its responsibility for Code
compliance and compliance with customer requirements.
2.3.4 Subcontracted Engineering: Preparation of Design, drawings and calculations
meeting the requirements of the Code are subcontracted to an organization that is
competent in the field of designing pressure retaining parts. In this case, the AIC
QA-HSE Manager shall be responsible for the compliance of subcontracted
engineering work with the Code requirements.
2.3.5 Heat Treatment requirements: Heat Treatment requirements shall be stipulated
on the drawings. The requirements of the code (Post weld heat treatment
requirements and heat treatment requirements arising out of forming as per
paragraph UG-79) and contractual requirements shall be taken into consideration
when specifying the heat treatment requirements.
2.3.6 Document Control Record: QA-HSE Manager shall maintain an up to date
Document Control Record (Exhibit #30) for all engineering documents pertaining to
a contract. The record shall include document identification, current revision
number, document status etc.

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 2.3.7 Issue: Engineering documents shall be issued by QA-HSE Manager using
Document Transmittal (Exhibit # 2). The purpose of issue (e.g.: "Preliminary",
"For Construction", "For Information", etc.) shall be noted on the documents in the
revision record as well as on the Document Transmittals. Acknowledgements of
receipt shall be obtained and filed.
2.3.7.1 Issue for Information: Advance copies of drawings may be issued for information
and preliminary work e.g. production planning, welding planning, quality planning
etc.
2.3.7.2 Issue for Construction: Approved drawings shall be issued by QA-HSE Manager
for construction. The drawings shall be issued to Planning Manager, QC Manger
and Construction Manager as applicable.
2.3.7.3 All approved drawings, calculations and procedures shall be available to the AI at
the factory / field sites.
2.3.7.4 Revisions: Engineering documents may be revised from time to time as required.
Review, approval and issue of revised documents shall be done in the same manner
as the first issue.
2.3.7.5 Revision Record: Drawings shall have a revision record indicating revision
number, date, reason / purpose of revision. All revisions are signed/dated by the
persons checking and approving the originals.
2.3.7.6 Superseded Documents: Receiving departments shall destroy superseded
documents or safeguard them against inadvertent use by stamping “Superseded”.

2.4 Engineering Change Request (ECR): Functional areas / departments other than
engineering may propose changes in the design or drawing for several reasons such as:
• To facilitate manufacturing
• To use an alternate material
• To use more economical alternative etc.
The initiating department shall submit the proposed change to the Engineering
Department through Engineering Change Request (Exhibit # 4). The Design Engineer
(Subcontract) shall review and QA-HSE Manager shall approve the ECR to ensure
conformance with code requirements, customer’s requirements and other relevant
requirements. All ECRs will be incorporated in as - built drawing. Any ECR affecting
the design shall be incorporated immediately in the drawing & drawing shall be revised.
Design calculation shall also be revised if required. The disposition of the proposed
changes shall be noted on the ECR and Communicated to the initiating department. If
proposed changes are accepted, design, drawings and material related documents shall
be revised to reflect the changes. ECRs shall be uniquely numbered and maintained in
file, by QA-HSE Manager.

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2.5 Control & Verification of Design Software:
2.5.1 The Computer Software maybe used to produce ASME design Calculations by
Design Engineer (Subcontract). The Software shall be identified by with a program
name, number, revision and version.
2.5.2 QA-HSE Manager shall ensure that the software used for design calculations is of
the correct edition and compatible with Code requirements.
2.5.3 The QA-HSE Manager is responsible for input of correct design data and for the
verification that correct output has been obtained. He is also responsible for all
technical assumptions inherent to the computer program.
2.5.4 The Design Software for each application or module of use shall be verified by
comparison with manual calculations or by comparing with another program.
2.5.5 QA-HSE Manager ensures that the computer program is reviewed for change in
ASME Code Edition by subcontractor for possible revisions of the program. Revised
programs shall be re-verified and be available within six months of the Code
Editions issue date.
2.5.6 Design output shall be complete and unedited as generated by the computer program.
Any warning deficiency notified by the program shall be addressed to meet code
requirements.

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 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 3, Rev. No.:2
MANUAL Page 1 of 6

3.0 Material Control

3.1 Scope / Purpose
This section covers procurement, receipt, inspection, storage of Code materials / parts
and their issue for fabrication and field construction.
3.2 Responsibility
TDC is provided by Design Engineer (Subcontract) & Approved by QC Manager.
MR is prepared and Approved by QA-HSE Manager.
Based on Material Requisition and TDC, the Material Controller is responsible for
allocation of materials from stock and preparation of Purchase Requests (PR) for
unavailable material. PO is approved by General Manager.
The Procurement Manager is responsible for preparation of Purchase Order (PO) and
procurement of materials as per Purchase Request & TDC.
The Stores Supervisor is responsible for receipt, storage and issue of materials.
The QC Engineer / Inspector is responsible for inspection of materials for compliance
with PO, TDC and Code requirements. The Design Engineer (subcontract) shall prepare
the technical delivery condition “TDC” (Exhibit # 3) of the material and the QC
manager is responsible for the Approval.
3.3 Procedure
3.3.1 Raw Materials (Including Pressure Retaining Materials) and Code Parts.
3.3.1.1 Bill of Materials (BOM): is part of the drawing and include material
Specification, quantity, size, thickness, dimensions etc.
3.3.1.2 Purchase Request (PR): A Purchase Request (PR) (Exhibit #5) shall be made
by material controller for unavailable materials. This shall indicate
consolidate quantity of materials required for job and referenced TDC.
(Exhibit # 3). The PR shall be reviewed and approved by the QC Manager for
Code Compliance.
MR shall be send to Store supervisor for reservation of material in stock.
Store supervisor shall inform QC Engineer / Inspector for verification of stock
material against MR & TDC.
PR shall be issued by Material Controller to procurement for arranging
purchase of materials which are not available in stock.
Stock material shall be inspected according to MR & TDC against the
applicable code requirement and the inspection result shall be recorded on
RAW Material Inspection Report (Exhibit # 9).
3.3.1.3 Technical delivery condition (TDC):
TDC shall include:
• Applicable code edition for material and edition of product standard
(B16.5)
• Ordering information from material specification

Page 1 of 6
 • Applicable supplementary and additional tests (Impact / Heat treatment
/ NDE)
• Requirements of material test reports
• Requirements of pressure part documentation to be made available by
supplier
• Additional customer requirements
• For welded parts, requirements of code part stamping and partial data
reports
3.3.2 Welding Material: The CTDC (Exhibit # 3a) shall be prepared by Welding
Engineer as per the requirement of construction code and shall be approved by
QC Manager. PR shall be prepared by Store Supervisor as per CTDC for
unavailable consumables and shall be approved by QC Manager for code
compliance. PR shall be sent to procurement for preparation of PO and
purchase of consumables. PR and PO shall specify CTDC reference. Receipt
and inspection of consumables shall be done as per 3.3.7, 3.3.8 & 3.3.9 of this
manual.
3.3.3 Customer Supply Material: In case of Customer Supply Material, the
Material Controller shall prepare a Dummy Purchase Order (DPO) (Exhibit #6)
as per TDC. The DPO shall include the material specification and additional /
supplementary requirements as specified in the TDC. The DPO shall be
reviewed and approved by the QC Manager for compliance with contractual
and Code requirements. The DPO shall be used for the purpose of inspection of
in-coming customer supply material.
3.3.4 Material Substitution: Substitution of material shall be done only after QA-
HSE Manager has obtained comments from Design Subcontractor and has
approved the substitution through ECR (Exhibit # 4). The QC Manager shall
obtain the concurrence of the Customer (if required by the contract) and the AI.
Accepted material substitution shall be incorporated in the revised drawings /
calculations. (Refer Section 2.0 Cl.2.4)
3.3.5 Purchase Order (PO): The Procurement Manager shall prepare the PO
(Exhibit#7). The PO shall include all the requirements stipulated in the PR and
TDC, including any additional / supplementary requirements, inspection,
certification etc. as applicable. The General Manager shall approve the PO; the
TDC requirements are included or attached to the PO. PO shall be amended for
any Revision in TDC and changes shall be mentioned in the remarks section in
the PO.
3.3.6 Inspection at Supplier's Premises: Upon information from Procurement
Manager and the QC Manager shall arrange for necessary inspection as
required.
3.3.7 Material Receipt: Incoming raw material is received at the Raw Material
Store. Incoming welding material is received in the Consumable Store. The
Stores Supervisor shall check the following against PO requirements:
• Visual check of the overall condition of the materials.
• Size & quantity check.
A Goods Receipt Note (GRN) (Exhibit #8) shall be prepared for the material
received.
Page 2 of 6
3.3.8 Material Documentation: The following documentation shall be made
available to the QC Engineer / Inspector to enable him to inspect the in-coming
materials:
• Purchase Order and TDC: By Procurement Manager
• Dummy Purchase Order (for Customer Supply Material): By QC Manager
• Supplier documents (including partial data reports (for welded parts),
material test certificate / Certificate of compliance): By the Procurement
Manager.
• Documentation for Customer Supply Material: By the Project
Manager/Planning Manager.
3.3.9 Inspection of Incoming Material: The material along with GRN, PO & TDC
shall be offered to the QC Engineer / Inspector for inspection. When required,
the material shall be handled / arranged to permit access for inspection.
All Material Certificates / Partial Data Reports shall be reviewed, stamped
"Reviewed", signed off and dated by QC Engineer / Inspector after his review
and acceptance. The QC Engineer / Inspector shall check the material for
quality attributes (e.g. general condition / appearance, freedom from visible
damage / distortion, appropriate dimensional checks etc.).

The QC Engineer / Inspector shall check the material for identification marks
as per the requirements of the specifications / PO, TDC and for correlation of
the material with supplier / customer documents, Material Certificate where
appropriate.

Acceptable material shall be released for further work. The QC Engineer /

Inspector shall prepare and sign of the Raw Material Inspection Report
(Exhibit# 9) to indicate that the material is accepted. Actual material marking is
recorded on material inspection report. All examination / Inspection shall be
performed using calibrated equipment’s. Visual and dimensional inspection
shall be recorded on raw material inspection report.
3.3.10 If the material received is certified to either ASTM specification only or
certified to ASME specification with year, date different from Material Sub-
Order Specification, the acceptance shall be based upon Appendix II of ASME
Section II part A or B. Alternatively, material can be recertified by QC
Engineer / Inspector to the applicable Edition of the Code (UG10 of ASME Sec
VIII DIVI)
3.3.11 Welded parts that require design to be performed by the part manufacturer (for
example Quick Actuating Closures or Quick Opening Closures, Heat
Exchanger Bellows Expansion Joint); shall be ordered from a manufacturer
having appropriate certificate of authorization (S, U) with Partial Data Report.
Welded Parts, where design responsibility is not taken by the part
manufacturers (For example welded heads); shall be ordered from a
manufacturer having either PRT certificate of authorization or from a
manufacturer having appropriate certificate of authorization (S, U). TDC shall
include the type of MPDR required.
For Quick Actuating Closures or Quick Opening Closures (Welded or non-
welded)
Page 3 of 6
 TDC shall include a requirement of the applicable MPDR and the requirements
for installation, Operation and Maintenance manual from the Part
Manufacturer. TDC shall instruct the Part manufacturer to ensure that this
installation, Operation and Maintenance manual includes the applicable
guidelines given in Code (e.g. Appendix FF of Section VIII Div. 1).
3.3.12 When Vessel shells, heads or other pressure boundary parts of carbon or alloy
steel are cold formed by the Subcontractor, the needed certification for the parts
shall indicate whether or not the requirements of heat treatment are met (UG-79
of Section VIII Div. 1). Cold formed parts shall receive heat treatment after
final forming operation as required by code para PG 20 of ASME Sec I &,
UG 79 of ASME Sec VIII Div 1.
3.3.13 If any additional material testing/examination is required, the QC manager shall
establish which tests must be performed in order to assure code compliance.
Test and examination should be done and results should be documented and
attached to applicable MTC.
All examinations shall be performed utilizing calibrated equipment.
3.3.14 Storage of Accepted Material: Accepted material shall be marked with the
Work Order number. As far as possible, material is stored job-wise in
designated areas. Care shall be taken to ensure that identification of the
material remains intact during storage.
3.3.15 Non-Conforming Material: Non-conforming material shall be handled as per
the Non Conformance procedure (Refer Section 5 of this manual).
3.3.16 Rejected Material: Rejected material shall be moved to a designated area for
return to supplier / customer.
3.3.17 Material Issue:
3.3.17.1 Raw Material Requisition (RMR): The Material Controller shall
prepare RMR (Exhibit #10) indicating the material specification,
size, quantity etc. and the Work Order for which the material is to
be used. The Material Controller shall forward RMR’s to Stores as
per the requirements of manufacturing schedule.
3.3.17.2 Inspection Prior to Issue: Upon receiving the RMR, the Stores
Supervisor locates the correct material to be issued by checking
Work Order, markings on the material etc. and offers it to the QC
Engineer / Inspector. The QC Engineer / Inspector shall check the
material to be issued, the material test reports, inspection reports
etc. for compliance with the requirements stipulated in the drawing.
The QC Engineer / Inspector shall release acceptable material for
issue by signing the RMR.
3.3.17.3 Material Identification Prior to Processing: Before using the
material, Production Supervisor shall confirm the correct material
by checking the Work Order, markings on the material and copy of
RMR signed by QC Engineer / Inspector.
3.3.17.4 Traceability Requirements: Material identification for all pressure
parts & attachments to pressure parts shall be maintained throughout
the process of manufacturing on material and material traceability
(Exhibit # 16) report shall be maintained. The following are
minimum guidelines.
Page 4 of 6
 Class 1: This class shall be specified for all pressure parts, (e.g.
Plate, pipe), except for “standard pressure parts” as defined in the
Code, which are covered under Class 2.
Class 2: This class shall be specified for “standard pressure parts”
(flanges, fittings), as defined in the Code and other important parts
(e.g. Externals / Internals attachments directly welded to the
pressure parts) which are not subject to stressing due to pressure.
Class 3: This class is specified for non-critical parts, not falling in
Class 1 or Class 2. (Parts not welded directly to the pressure parts)
3.3.17.5 Marking shall be transferred as follow
➢ Traceability class 1 – (pipe & plate)
Material specification, grade, heat no/ plate no.
➢ Traceability class 1 – (Tube)
Tubes (Lot): Tags shall be retained till the last tube item is utilized
➢ Traceability class 2 – (for attachment to pressure parts)
Material specification, grade & heat no /plate no.
➢ For standard (flanges and fitting)
Original identification is required during fabrication. When required
transcript of original marking shall be kept on file.
➢ Traceability class 3 – (non-pressure part attachment)
Material specification or P no.
If the material is to be cut identification marking shall be transferred on all
parts before cutting.
When the original marking be removed off due to an operation of production
process, the marking shall be transferred prior to the operation to the location
where the marking is clearly visible permanently on the part or vessel.
QC Engineer / Inspector shall verify transferred marking. Materials may also be
marked with work order no, part no by paint marker or stenciled.
Temporary attachment:
●Temporary attachment shall be identified by color code for P Number or
material specification as per QW-422.
Permanent attachment of small parts:
●Small parts directly welded to pressure parts may be stored in a box having
identification traceable to coded making. When taken from the box, they shall
be attached immediately to the vessel or item.
3.3.18 Return of Off Cuts / Balance Material: The off Cuts / balance material shall
be returned to stores with off cut Return slip (Exhibit#11). Prior to being
returned to the stores, off-cuts and balance material shall be marked with the
following:
• The original markings on material e.g. material specification, grade, heat
number, plate number etc. where available.
Page 5 of 6
3.3.19 Method of Marking: Required marking shall be done by “hard stamping”. For
steel plates less than 6mm and for nonferrous plates less than 13mm hard
stamping is not allowed. Also if required engraving, stenciling or other suitable
method can be employed for marking. Other details such W.O No, position No.
can be marked by paint marker.
3.3.20 All documents pertaining to Code material including un-priced copies of
Purchase Orders shall be made available to the AI when required.

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 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 4, Rev. No.:2
MANUAL Page 1 of 6

4.0 Examination and Inspection Program

4.1 Scope / Purpose
This section covers the requirements of Examination and Inspection to be followed for
construction as per Code.
4.2 Responsibility
The QC Engineer is responsible for preparation & implementation of Quality & Welding
Plan (Exhibit # 12).
The QC Manager is responsible for approval of the Quality & Welding Plan.
The Production Manager / Production Supervisor / Foreman / Construction Manager /
Construction Supervisor are responsible for carrying out all fabrication operations and for
offering the job for examination as per the Quality & Welding Plan.
The QC Engineer / Inspector is responsible for performing examination and arranging
inspection by AI as per the Quality & Welding Plan. QC Engineer / Inspector shall notify
AI well in advance for the upcoming inspection stages.
4.3 Procedure
4.3.1 Preparation of Quality & Welding Plans
4.3.1.2 Information Input: The Project Manager shall furnish contractual quality
requirements and customer’s documents. The QA-HSE Manager shall
furnish drawings and other relevant engineering documents. The QC
Engineer shall prepare the Quality and Welding Plan on the basis of these
documents / information.
4.3.1.2 Quality & Welding Plan: The QC Engineer shall prepare Quality &
Welding Plan (Exhibit #12). It shall include the following information /
requirements:
I: Quality Requirements:
• Material identification / traceability requirements for traceability class 1,
2 & 3 parts.
• Visual & dimensional examination at appropriate stages of manufacture.
• Non-destructive examination, including non-destructive examination of
welds with reference to the weld seam numbers given in the weld map
(Exhibit # 13).
• Mechanical testing of production test plates (if applicable).
• Examination of Post Weld Heat Treatment and review of PWHT records
(if applicable).
• Examination of internal & external surfaces prior to pressure testing /
closure.
• Pressure testing.
• Name Plate and certification of MDR.
• Final cleaning, painting, packing.

Page 1 of 6
 The applicable documents, examination procedures and acceptance
standards shall be indicated as appropriate.
“Hold”, “Witness”, “Review” points by AIC QC Engineer / Inspector and
customer’s representative shall be indicated as required. Prior to fabrication
Quality &Welding plan shall be provided to AI for review and assignment
of AI’s “Hold”, “Witness” and “review” points.
Authorized Inspector (AI) inspection points are designated on the Quality
and Welding Plan as follows:
• H Hold Point – No work shall proceed beyond this operation
until the Authorized Inspector (AI) accepts. Advance notification
shall be issued for all HOLD points.
• W Witness Point – No work shall proceed beyond this
operation until the Authorized Inspector (AI) has accepted it or has
given his permission to waive this inspection point and proceed
further. Advance notifications shall be issued for all witness stages.
• R Review Point – Is a review point, which would cover the
review of documents and would not require acceptance of the
Authorized Inspector (AI) before proceeding with the next
operation, but must be seen prior to the stamping of the item.
AI shall sign Quality &Welding Plan to indicate his acceptance and
identification of his inspection stages.
Over and above those inspection stages assigned for the Authorized
Inspector (AI), authorized Inspector (AI) is free to make any
inspections he considers necessary.
II: Welding Requirements: The Welding Engineer shall prepare Weld
map (Exhibit # 13). Welding position, whether single or double welded,
applicable WPS etc. shall be indicated with reference to the weld seam
numbers given in the weld map. Weld Map is approved by QC Manager.
4.3.1.3 The approved Quality, Welding and Weld Map Plan shall be issued to
Planning Manager, Production Manager / Production Supervisor /
Construction Manager / Construction Supervisor and QC Engineer /
Inspector.
4.3.2 Manufacturing, Examination, Inspection
4.3.2.1 Material: Material details are recorded on material traceability report
(Exhibit # 16) as per section 3 of this manual.
4.3.2.2 Manufacturing: Production Manager / Production Supervisor shall ensure
that all manufacturing operations are done as per the drawing requirements.
At the stages of manufacture indicated in the Quality & Welding Plan, the
Production Supervisor shall prepare the appropriate Assembly & Welding
endorsements and offer the job for checking / examination by the QC
Engineer / Inspector. Quality and welding plan, WPS, PQR, Weld Map,
Qualified Welder List, WQTR and fabrication Drawing shall be kept near
Code Items.

Page 2 of 6
 4.3.2.3 Examination, Inspection: The QC Engineer / Inspector shall perform the
appropriate checks / examinations at the designated stages. The result of the
check / examination shall be signed off on the Quality and welding plan.
Where required, QC Engineer / Inspector shall coordinate and arrange for
inspection by AI / examination by Customer’s inspector. Work beyond the
Hold points designated in the Quality & Welding Plan shall commence only
after the Hold point has been cleared by the AIC QC Engineer / Inspector /
Customer’s inspector / AI (as applicable). All in process inspection will be
recorded (Exhibit # 32).
4.3.2.4 Weld fit up to weld examination including NDE Report reference and
welder ID are recorded on record of stage inspection of welds (Exhibit #
17).
4.3.2.5 All NDT of welds shall be done in accordance with section 7 of this
manual.
4.3.2.6 When required by the code or client specification, PWHT shall be done in
accordance with section 8 of this manual.
4.3.2.7 QC Engineer/ Inspector shall perform final visual and dimension inspection
and record the results on final dimension report (Exhibit # 34) and final
visual report (Exhibit # 35).
4.3.3 Final Inspection:
• The Authorized Inspector will make the final inspection before the hydrostatic or
pneumatic test required by the code.
After satisfactory completion of all fabrication work, NDE and PWHT (if
Applicable), Closing of NCR, except those examinations required after the test,
Verification of all records including Stages identified on Quality and Welding Plan
are signed and dated by the designated authorities, the equipment shall be released
for pressure tests by QC Engineer / Inspector. Material traceability report, record of
stage inspection of welds, final dimension and visual reports, NCR (if any) shall be
provided to AI for his review and acceptance.
• For parts not tested, the inspection is made after fabrication of the part is completed
prior to being code stamped.
• For items not tested until field assembly is completed, the inspection is made after
fabrication of the item is completed, prior to being shipped to the field.
• Defects in material may be repaired provided acceptance by the Client, Authorized
Inspector is first obtained for the method and extent of repairs. Defective material
that cannot be satisfactory repaired shall be rejected.
• When a pressure vessel is not provided with an opening or other means of access to
inspect internal surfaces, an inspection point for the QC Engineer / Inspector and
the Authorized Inspector (AI) will be indicated on the Quality and Welding Plan to
permit internal inspection before starting the final closure weld.
• Visual examination of exposed surface on boiler and parts with unaided eye to be
performed at approximately 24 inches within the surface and not less than
approximately 30 degrees to the surface. Alternatively, visual examination may be
performed in accordance with section V, Article 9.

Page 3 of 6
 4.3.4 Pressure Test:
4.3.4.2 Requirements for Hydrostatic Testing
• The QC Engineer / Inspector shall witness the Hydrostatic Test & offer
to the same to AI.

• Hydrostatic tests shall be conducted using two Calibrated pressure

gauges. The gauges shall have a range preferably double the intended
pressure but not less than one-and-half times the test pressure & the
range shall not exceed four times the test pressure for ASME sec VIII
Div 1 & ASME Sec I(Boiler/BEP).
• For Pressure Vessels, the temperature of the metal shall be maintained
at least 17 o C above the MDMT but need not exceed 48 o C
• For Boilers, the temperature of water shall be not less than ambient
temperature but in no case less than 20 o C. The metal temperature shall
not exceed 120 ° F (50° C) during close visual examination.
• The pressure gauges shall be calibrated as required by the Section 9 of
this Manual.
• After successful application of the test pressure, the inspection shall be
made at a pressure not less than the test pressure divided by 1.3 for
Section VIII Div.1 Vessels and at MAWP for Section I items.
4.3.4.2 Requirements for Pneumatic Testing: (Not Permitted for ASME Sec. I
and B 31.1 Construction)
a) The QC Engineer / Inspector shall witness the pneumatic test and offer
the same to AI.
b) Pneumatic test may be conducted in lieu of hydrostatic test. In such a
case the provisions of UG-100 of ASME Section VIII Div.1 shall be
complied with. The QC Manager shall issue a written pneumatic test
procedure. This procedure shall cover requirements pertaining to minimum
metal test temperature (minimum 17 o C above MDMT), test pressure and
holding time, pressure increase increments, range and number of gauges
and any other special requirements.
c) Requirements specified in UW-50 of ASME Section VIII Div.1 shall be
complied with prior to pneumatic testing.
4.3.4.3 Hydrostatic test/ Pressure test is recorded on exhibit # 14. Pneumatic Test /
Leak Test is recorded on Exhibit # 15.

4.4 Data Reports and Stamping

4.4.1 After completion of shop fabrication or field construction, the QC Engineer shall
prepare applicable Manufacturer's Data Report (MDR) (Standard format given in
Code shall be used) which shall be certified by QC Manager.
4.4.2 The completed MDR along with the Final Inspection Records shall be presented to
AI for his review and acceptance. When AI has satisfied himself that all Code
requirements have been met, he shall sign and date the Manufacturer's Data Report
and authorize application of ASME Certification Mark.
4.4.3 The QC Manager shall have custody and control of the Code Symbol Stamps. He
shall issue the stamp for use at the shop or field site when fabrication, field
assembly are completed.
4.4.4 The QC Engineer / Inspector & AI shall witness the application of the Code Name
Plate (Exhibit#18) / Code stamping to the item.
Page 4 of 6
4.5 Certification and Stamping of Boiler / Boiler parts as per ASME Section-I
4.5.1 When AIC is responsible for complete boiler including assembly at shop or at
field site, Design Engineer (Subcontract) shall prepare and QC Manger shall
certify Master Data Report (Form P-3). All Boilers marking shall be applied by
direct stamping at code required location as per PG-106 in addition to Master
Nameplate.
4.5.2 When AIC is responsible for boiler assembly only, QC Manager shall certify field
assembly portion of the Master Data Report (Form-P3 / P3A) provided by Main
Boiler manufacturer or Engineering contractor as per PG-107.2 / PG-106.7. The
name plate and stamping shall be provided as per PG-108.2 / PG-106.7.1 or PG-
106.7.2.
4.5.3 When AIC is responsible for partial assembly of boiler, certification and Stamping
shall be as per PG-107.2.3 (b) on Form P-3 (without marking it as ‘Master’). QC
Manager shall arrange for direct stamping of certification mark with S Designator
together with Company Name and words “Partial Field Assembly” on a major
pressure part and install the partial assembly nameplate in presence of AI, once
authorized by him.
4.5.4 For Boiler parts fabricated by the AIC, certification shall be done on Form P-4 &
stamped as per PG-106.8.
4.5.5 Certification for Shop or field fabricated boiler power piping & external piping
shall be done on form P-4A for shop portion. Markings & stamping shall be done
as per PG-109.1 & PG-109.2.
4.5.6 Field assembly of boiler external piping shall be certified on the field assembly
portion of the Form P4A. Shop or field fabricated spools by other manufacturer
shall be received by Company with Form P4A duly certified for shop / field
fabrication & inspection. QC Engineer / Inspector shall verify that certification
mark with appropriate ‘S’ or ‘PP’ designator area available on the piping spools.
4.5.7 When AIC documents the piping on Form P4A, responsibility for the design
shall be assumed by AIC even if the design has been performed by others.
4.5.8 When AIC is contractually responsible to the boiler Manufacturer or
Engineering Contractor and fabricates BEP, Piping shall be documented on
Form P4 in accordance with PG 112.2.4 and design responsibilities shall be
detailed in Remarks.

4.6 National Board

4.6.1. The QC Manager has the custody and control of NB stamp. This stamp will be
issued for use, only when item is registered with National Board for stamping in
the area as shown in Exhibit # 18.
4.6.2 Generally, Boiler manufacturer or Engineering Contractor responsible to sign
Master Data Report decides the requirements for registration of data reports.
4.6.3 If required by contract or jurisdiction, company certified data reports (for A, PP &
U items) shall be registered with the National Board of Boiler and Pressure Vessel
Inspectors.
4.6.4 The National Board serial numbers shall be controlled and issued by the QC
Manager.
Page 5 of 6
 4.6.5 The National Board serial numbers shall be issued in a progressive numerical order
from 1 without Skips or gaps of unused numbers or duplication of numbers. The
NB numbers are assigned on completion of pressure test or when the pressure test
is not in the scope of company, the NB numbers are assigned at the time of
certification of data reports.
4.6.6 The QC Manager shall maintain a NB Registration Log of NB Registered Code
Items (Exhibit # 37) issued, showing National Board serial number, description of
the item stamped, customer and location, date MDR certified and the date of
dispatch of MDR to the National Board for registration.
4.6.7 All data reports shall bear signature, NB commission number & endorsements of
AI.
4.6.8 When items are registered with the National Board, the QC Manager shall send the
original MDR with PDR’s (if applicable) to the National Board within 30 days of
signing of MDR by AI. The data reports shall be sent to:

NATIONAL BOARD OF BOILERS & PRESSURE VESSEL INSPECTORS

1055, CRUPPERS AVENUE,
COLUMBUS, OHIO 43229, USA.
4.7 Distribution of Manufacturers Data Reports: The MDR’s shall be distributed as detailed
in Section 10 of this manual.

4.8 Nonconformities: any deviation with respect to the Quality and Welding Plan
requirements shall be identified as Nonconformance and handled as described in Section 5
of this QC manual.
4.9 Retention of Records: The QC Manager shall retain records as described in Section 10 of
this Manual.
4.10 Revisions of Quality and Welding Plan: Approved Quality and Welding Plan already in
use may be revised. If any revision is necessary, shall be prepared as an annexure to the
Quality and Welding Plan and Authorized Inspector (AI) acceptance obtained.

Page 6 of 6
 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 5, Rev. No.:0
MANUAL Page 1 of 2

5.0 Non-Conformances and Corrective Actions

5.1 Scope / Purpose
This section covers the requirements to be followed to identify, resolve, document and control
all non-conformances in materials, fabrication, documentation, field construction.
5.2 Responsibility
The QC Manager is responsible for processing, resolving and controlling all non-conformances
and taking appropriate corrective actions.
5.3 Definitions
Non-Conformity: Non-conformity is any condition which does not comply with the applicable
rules of the Code, QC Manual or other specified requirements. Nonconformities must be
corrected before the completed component can be considered to comply with the code.
Correction: the act of offering an improvement to replace a mistake; setting right.

Corrective Action: Action to eliminate the cause of a detected nonconformity or other

undesirable situation.

5.4 Procedure
5.4.1 Reporting of Non Conformity
5.4.1.1 Non-Conformity at Materials Receiving: The QC Engineer / Inspector /
Stores Supervisor shall identify non-conforming materials and parts at receiving
inspection stage. The non-conforming materials and parts shall be marked
“HOLD” with NCR number by QC Engineer / Inspector. The marking shall be
with a metal marker or paint marking or any other suitable means appropriate to
size, shape & quantity. The non-conforming material shall be segregated from
materials that have been accepted and stored in quarantine area until a
disposition is agreed upon.
5.4.1.2 In–Process & Final Inspection Non-Conformity: The QC Engineer /
Inspector / Production Supervisor shall identify non-conforming items found
during in process and final inspection. The non-conforming materials and parts
shall be marked “HOLD” with NCR number by QC Engineer / Inspector. The
marking shall be with a metal marker or paint marking or any other suitable
means. The identified material /parts shall not be further processed until a
disposition is agreed upon.
5.4.1.3 Preparation of Non Conformance Report (NCR): The QC Engineer /
Inspector shall prepare NCR (Exhibit#19). The NCR shall be recorded in the
NCR log and assigned a number. The NCR shall be forwarded to the concerned
operating department. NCR reference is also Marked on quality & weld plan
against the affected stages.
5.4.2 Resolution of Non-Conformity
5.4.2.1 Proposing a Resolution: The concerned department manager shall propose
suitable action to resolve the non-conformity. If necessary, he shall consult the
design / detailing / quality / welding or other departments for this purpose.
Where required, he shall prepare a procedure or method statement for
performing repair or rectification. The proposed resolution shall be recorded on
the NCR.
Page 1 of 2
 5.4.2.2 Review & Recommendation on Proposed Resolution: The QC Manager shall
review the proposed resolution and ensure that any changes to the design are
verified for compliance with customer’s requirements and Code. The Project
Manager shall obtain customer approvals where necessary. The Design Engineer
(Subcontract) shall note his recommendation on the proposed correction on the
NCR (If Applicable).
5.4.2.3 Disposition: The QC Manager / QC Engineer shall review the NCR and decide
the disposition of the non-conformity after obtaining AI’s concurrence. The
disposition and any inspection stages required by AI shall be noted on the NCR.
5.4.2.4 Repairs: All repairs shall be performed using written repair procedures. In case
of repairs of Surface imperfection (e.g. pitting, gouges, scratches etc.), repair of
weld defects etc., these may be covered by standard repair procedures. In case of
major defects in materials are to be repaired by welding, specific repair
procedures shall be prepared. The repair procedures shall include the
requirements for examination, testing of repairs. Repair procedures shall be
reviewed and accepted by AI prior to being used. Any repair to the materials
requires prior concurrence of AI for method and extent of repairs.
5.4.2.5 Performance and Verification of Approved Corrections:
• Scrap: If it has been decided to reject the non-conforming product, it shall
be removed to a designated area for storage / disposal of scrap. The QC
Engineer / Inspector shall sign the NCR after confirming the removal of the
scrapped product to the scrap storage / disposal area.
• Repair/Rework: The production shop personnel shall carry out the
approved repairs. The QC Engineer / Inspector shall perform the appropriate
examination / testing (including examination / testing by customer’s
inspector where required), and verify the satisfactory completion of repairs.
The QC Engineer / Inspector shall arrange for inspection by AI if required.
The QC Engineer / Inspector shall sign the NCR and permit the item to
return to the next process.
• Accept as it is: The item is returned to the next process. (The Code
requirements shall not be neglected) QC Manager/Design Engineer
(Subcontract) approval and AI acceptance shall be ensured before disposal
of NCR.
5.4.3 Retention of Records: Completed NCR’s shall be reviewed by the QC Manager. All
the original NCR's shall be filed in the NCR master file for statistical analysis.

Page 2 of 2
 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 6, Rev. No.:2
MANUAL Page 1 of 5

6.0 Welding Control

6.1 Scope / Purpose
This section covers the requirements for control of welding during the fabrication and
assembly of Code works to comply with ASME Section IX and the Construction Code.
6.2 Responsibility
The Welding Engineer is responsible for preparation of Welding Procedure Specifications,
Weld Map, qualification of welding procedures, welders, welding operators and development
of new welding techniques. QC Manager is responsible for approval of welding documents.
Welding Engineer is responsible for employing qualified welders on the jobs.
The Welding Engineer is responsible for welding consumable control, Welders Performance.
The Welding Foreman is responsible for equipment maintenance and surveillance during
production welding.
Personnel Performing NDE for qualification of procedure or Welder/Welding Operator
shall be qualified as required by Section 7 of This QC Manual. All records of NDE shall be
retained as required for applicable construction code specified in Section 10 of this
Manual.
Personnel (welding Engineer) having responsibility of supervision during qualification
and testing of WPS or Welders/Operators shall have sufficient level of competence and
shall meet education, training and experience requirements of AIC procedure # which is
approved by QC Manager. Related records of competency shall be kept by QC Manager.
No production welding shall be undertaken until after welding procedures and welder /
Welding operator which are to be used, have been qualified.
6.3 Procedure
6.3.1 Planning: The Welding Engineer shall plan welding activities on the basis of the
following information & documents:
• Contractual requirements/Customer’s documents received from Project Manager.
• Drawings and other engineering documents received from QA-HSE Manager.
The Welding Engineer shall prepare Welding Procedure Specification’s (WPS)
(Exhibit #20) to cover welding required for the job in the light of the above
information. The available Procedure Qualification Record’s (PQR) (Exhibit #21)
shall be reviewed. In case the essential / supplementary essential variables expressed
in the WPS are not covered within the limits of the PQR’s, the Welding Engineer
shall arrange for new procedure qualifications to meet the code requirements.
The list of available qualified welders / welding operators shall be reviewed by
Welding Engineer. In case the available qualified welders / welding operators are not
qualified for welding as per WPS or if more welders / welding operators are required,
the Welding Engineer shall arrange for additional training, testing and qualifications
to meet the requirements.
The approved WPS and Qualified Welder List (Exhibit # 22) shall be issued to
Planning Manager, Production Manager and QC Engineer.
6.3.2 Qualification of Welding Procedures
6.3.2.1 All materials and consumables used for qualification shall have proper
documentation as detailed in Section 3 of this Manual.
Page 1 of 05
 6.3.2.2 Test coupons shall be prepared. Qualification shall be conducted as per the
requirements of WPS, ASME Sec. IX and Construction Code. Welding
Engineer shall witness the welding qualification and shall record actual
ranges of essential and supplementary essential variables used during welding
for inclusion in the PQR.
6.3.2.3 Qualification of the third Party shall be verified by QC Manager prior to
conduct all mechanical tests and non-destructive tests. The testing shall be
done as per the requirements of ASME Sec. IX / Construction Code.
6.3.2.4 Documentation of the Welding Procedures shall be in accordance with ASME
Sec. IX, Article II. The WPS & PQR shall be prepared by the Welding
Engineer and approved by the QC Manager.
6.3.2.5 All WPS / PQR’s shall be made available to the AI for his review. The
completed WPS shall describe all of the essential, non-essential and when
required supplementary essential variables for each welding process used in
WPS. When toughness tests are required, heat treatment condition of base
metal shall be specified on WPS and PQR.
6.3.2.6 Existing PQR’s shall be verified for compliance with governing code edition
requirements (e.g. multiple process welding, location of HAZ impact tests as
per UG-84) before use. Also for Section I fabrication, WPS shall be reviewed
and revised to comply preheat/inter-pass requirement of PW-38 & PWHT
requirement of PW-39. Also Existing PQR's where the heat‐treated
condition is not recorded A supplemental test coupon in the desired
heat‐treated condition may be welded and tested to meet new code
requirements. (ASME Sec. VIII Div. 1) Welding Engineer shall maintain the
list of WPS and PQR.
6.3.2.7 AI May call for and witness the test of welding procedures.
6.3.3 Qualification of Welders and Welding Operators
6.3.3.1 All materials and consumables used for qualification shall have proper
documentation as detailed in Section 3 of this Manual.
6.3.3.2 Welders and welding operators shall be trained to weld as per the process and
applicable essential variables documented in a qualified procedure. The
Welding Engineer shall witness the welding of test coupons by welders /
welding operators. Welding engineer shall assign a welder ID to each welder.
6.3.3.3 Welded test coupons shall be tested by one of the following methods:
1. Mechanical Testing + visual examination
2. Radiography (volumetric examination)
Third Party verified by QC Manager shall conduct mechanical tests /
radiography as per the conditions stated in QW302 of ASME Sec. IX latest
edition.
6.3.3.4 The results of the test shall be documented in a Welder Qualification Test
Record (Exhibit # 23) / Welding Operator Qualification test record (WQTR,
Exhibit#23a) prepared by the Welding Engineer and approved by the QC
Manager.
6.3.3.5 All WQTR’s shall be made available to the AI for his review.

Page 2 of 05
6.3.4. Expiration& Renewal of Qualification of Welders and Welding Operators
6.3.4.1 The performance qualification of a welder or welding operator is affected
when:
1) A performance essential variable changes;
2) When he has not welded with a process during a period of 6 months or
more, his qualifications for the process expire; unless, within the six-
month period, prior to his expiration of qualification;
a) The welder has welded with that process using manual or semiautomatic
welding under the supervision & control of the Company, which will
extend his qualification for an additional six months. The welding operator
has welded with that process using machine or automatic welding, under
the supervision & control of the Company, which will extend his
qualification for an additional six months.
3) When there is a reason to question a welder or welding operator’s ability
to deposit a sound weld that meets the specification or to follow the
variables established in the WPS.
6.3.4.2 Renewal of Qualification:
i) Renewal of qualification affected due to para (2) of 6.3.4.1 may be made
for any process by welding a single test coupon of either pipe or plate, of
any material, thickness or diameter, in any position, and by testing of that
coupon as required by QW-301 & QW-302 of ASME Code Sec. IX. A
successful test renews the original qualification of the welder or welding
operator.
ii) Renewal of qualification revoked due to para (1) & (3) of 6.3.4.1 shall
utilize a test coupon appropriate to the production work. The test coupon
shall be welded and tested as required by QW-301 & QW-302 of ASME
Code Sec. IX. A successful test restores the original qualification of the
welder or welding operator.
6.3.5 Maintenance of Welder and Welding Operator Qualification
The welding Engineer maintains continuity records of all welders and welding
operators by quarterly verification of the last date the welder or welding operator was
used in each process. This is recorded on form exhibit no. 31.
Based on the above welding engineer shall sign continuity of the welder at least every
three months on his continuity record (Exhibit 31).
Welder list is continually updated (at least every six months) for any addition /
deletion of welder and provided to Production Manager for used in assignment of
jobs.
6.3.6 The AI may call for and witness the ability of welder to deposit acceptable welds.
6.3.7 The Welding Engineer shall assign the appropriate qualified welders / welding
operators from the qualified welder List (Exhibit #22) or directly from WQTR.
Alternatively, a Welding Data Sheet (Exhibit # 24) listing the joint Numbers, and
applicable WPS Number and required Welder Qualifications shall be issued for each
work order.

Page 3 of 05
6.3.8 Engagement of Individual Welder/Welding Operator: AIC may engage
individual by contract or agreement for their services as welder/welding
operator at the shop or at field site provided all of the following conditions are
met:
I. All Code construction shall be the responsibility of AIC.
II. All welding shall be performed in accordance with AIC WPS and in accordance
with the requirements of ASME Section IX.
III. All Welders/Welding operators shall be qualified by AIC in accordance with the
requirements of ASME Section IX.
IV. AIC Welding Engineer shall have complete and exclusive administrative
and technical supervision of welder/welding operators,
V. AIC Welding Engineer has authority to assign and remove welder/welding
operator at his discretion without involvement of any other organization.
VI. Acceptance of AI is obtained before using such welders.

6.3.9 Production Welding:

6.3.9.1Use of Qualified Welders / Welding Operators: Production Welding
Supervisor / Welding Foreman / Construction Supervisor shall ensure that
welders / welding operators assigned by the welding engineer are employed
for production welding. QC Inspector / Welding Engineer perform random
checks to verify this.
6.3.9.2Use of Correct WPS: Production welding Supervisor / Construction
Supervisor / Welding Foreman shall instruct the welder / welding operator on
the appropriate WPS to be used, based on the Quality & Welding Plan and
Weld Map. The WPS shall be available to the welder / welding operator at the
welding area.
6.3.9.3 Record of Welders / Welding Operators Employed: A record of welder /
welding operator employed shall be maintained for all pressure retaining
welds & attachment to pressure part welds. This may be done in the following
ways:
• By marking on the Vessel: The welder / welding operator shall mark his
identification and the joint no. adjacent to the weld at intervals of not more
than 3 feet. The marking shall be done by “hard stamping”. For steel plates
less than 6mm and for nonferrous plates less than 13mm hard stamping is
not allowed. Also if required engraving, stenciling or other suitable
method can be employed for marking. If more than one welder involved in
performing a weld seam, both welders shall mark the weld seam with their
identification stamp.
• In the case of tube-to-tube sheet or stud welds it is the responsibility of the
Welding Engineer to maintain a record clearly indicating the area welded
by each welder or welding operator.
• By Maintaining Records: The Welding Foreman / Production Welding
Supervisor shall maintain a record of welders / welding operators
employed on Record of Stage Inspection of Welds (Exhibit 17). The
record shall be made available to the AI.

Page 4 of 05
 6.3.9.4 Tack Welding: Only qualified welders shall make tack welds. Only qualified
WPS shall be used. All tack welds, which are not removed, shall be properly
ground and visually inspected for defects by the QC Engineer / Inspector.
Defective tacks (if any) shall be removed.
6.4 Control of Welding Consumables
6.4.1 Procurement: All welding consumables like electrodes, filler metals, fluxes,
shielding gases, etc. shall be procured as detailed in Section 3.
6.4.2 Storage & Handling: Welding materials shall be stored and handled as so as to
preserve and protect them from damage, exposure to moisture etc. and to maintain
their identification marks so that any possibility of mix-up is eliminated. Damaged
welding materials or welding materials of doubtful identity shall be scrapped. The
issue and return of electrodes, baking and reconditioning of electrodes shall be as per
Work instruction WI-25, based on welding material manufacturer’s recommendations
and store supervisor shall record the readings in the log sheet.
6.4.3 Issue & Use: The Production Supervisor / Construction Supervisor / Welding
Foreman shall prepare and sign Store Consumable Section Request Form
(Exhibit#25) with the correct welding consumables in accordance with the WPS. The
Stores Supervisor shall issue welding consumables only in accordance with properly
signed Store Consumable Section Request Form by the welding engineer. The
Production Welding Supervisor / Construction Supervisor / Welding Foreman shall
closely monitor welding operations to ensure the use of correct welding consumables.
6.5 Equipment Maintenance
6.5.1 All welding cables, cutting torches and other apparatus shall be kept clean and free of
dirt, grease, moisture or any other foreign matter.
6.5.2 Electrode baking and holding ovens shall utilize temperature gauges to ensure
proper temperature control. The temperature gauges shall be calibrated on a
yearly basis using a laboratory-tested thermometer. The QC Inspector shall
check the ovens and verify the readings in a log sheet.

Page 5 of 05
 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 7, Rev. No.:2
MANUAL Page 1 of 3

7.0 Non-Destructive Examination

7.1 Scope / Purpose: This section covers the requirements for non-destructive examination of
Code work to comply with the ASME Section V and acceptance criteria as specified in the
Construction Code. MT, PT Examination are performed by AIC employed NDE Personnel.
RT is subcontracted. UT Method is not used, NDE is specified in quality & Welding Plan.
7.2 Responsibility: The QC Manager is responsible for appointing and approving NDE
Level III and for ensuring that he fulfills the requirements of the AIC procedure for
qualification and certification of personnel employed for NDE, which is in accordance
with code adopted edition of CP-189 (2016 edition) as amended by Mandatory
Appendix IV of ASME Sec V (Refer Article1, T-120(e) of Sec V) for Sec VIII DIV 1
& 2 Vessels. For Section I code adopted edition of CP-189 is 2006 edition. In
addition to the requirements described in ASME Section V Article1 T120 (e) or (f) for
techniques of computed radiography (CR), digital radiography (DR), phased‐array
ultrasonic (PAUT), Ultrasonic time of flight diffraction (TOFD) or Full Matrix
Capture (FMC) the training, experience, and examination requirements in Article 1,
Mandatory Appendix II requirements shall be included in the employer’s written
practice for each technique as applicable.

7.3 The NDE Level III may be either an AIC employee or an outside agency as defined in AIC
written practice.
The QC Manager / NDE Level III are responsible to ensure that AIC NDE personnel engaged
in Code work are qualified and certified in accordance with AIC's written practice.
In addition to the below, the NDE Level III is responsible for approval of AIC written
practice.
• Review and interpretation of Codes and standards, deciding the acceptance criteria as per
Code requirements and evaluation of results.
• Establishment of NDE procedures; Certification of the procedures to ASME Section V
(T150) if required by Code, and demonstration to the satisfaction of AI (if required).
• Training, testing, qualification and certification of NDE personnel in accordance with
AIC’s Written Practice.
• Evaluation of NDE Personnel performance and updating the validity of their qualifications
as per the requirements specified in the written practice.
• Review of NDE subcontractor’s records (written practice & personal qualification) to meet
code requirements.
7.4 Procedure
7.4.1 Planning of NDE:
7.4.1.1 NDE Procedures: The QC Manager shall review the project documents,
drawings and specifications and identify the required procedures / techniques.
In case existing approved procedures do not meet the specific requirements of
the Work Order, new procedures shall be established by NDE Level III and
certified by QC Manager. The effectiveness, functionality and compliance to
Code requirements of the new procedures shall be demonstrated to AI (if
required). Refer procedure AIC-ASME / PT / 01 for PT, AIC-ASME / MT /
01 for MT and AIC-ASME / VT / 01 for VT.
Page 1 of 3
 7.4.1.2 Personnel Qualification: The Level III shall check the availability of NDE
personnel qualified in accordance with AIC procedure for qualification and
certification of personnel employed for NDE. A record of personnel
qualification, including certification of the annual eye examinations, shall be
maintained and made available to the AI.
7.4.1.3 Equipment Availability: The Level III shall check the availability of the
equipment required as per the applicable procedure.
7.4.1.4 Subcontracting: The Level III shall assist QC Manager for finalizing
the subcontracting plan of NDE operations including evaluation and
selection of subcontractors.
7.4.2 Performance of NDE (Including Visual Examination) by AIC:
7.4.2.1 When a stage at which NDE is to be done as per Quality & Welding Plan is
reached, the Production Supervisor / Construction Supervisor shall inform the
QC Engineer / Inspector.
7.4.2.2 The QC Engineer / Inspector shall arrange NDE after completion of visual
testing and coordinate with AI for witnessing the same (If required). Level II
shall perform the NDE.
7.4.2.3 NDE Report: NDE Level II shall record the result in NDE Reports (Exhibit #
26&27) and give the same to the QC Engineer / Inspector. In case repair is
required, QC Engineer / Inspector / NDE Level II identify areas to be repaired
by paint marking.
7.4.2.4 In case the NDE result is satisfactory, NDE Level II shall prepare NDE report.
(Exhibit # 26 & 27).
7.4.2.5 Radiography Map: In case of jobs requiring spot radiography, the Spot
location shall be selected by AI and Welding Engineer shall prepare a
Radiography Map (Exhibit # 36) to identify the locations of the radiography
spots on the weld seams.
7.4.2.6 All code required NDE shall be perform by qualified & certified personal
using approved procedure & calibrated equipment. All NDE Equipment shall
be calibrated before use as per section 9. NDE Level II shall verify the NDE
equipment before use.
7.4.3 Performance of NDE by Subcontractor: The following requirements shall
be applicable for NDE performed by a subcontractor:
7.4.3.1 Subcontractor’s written practice and NDE Procedures shall meet the
applicable rules of the Code and shall be reviewed by NDE Level III and
approved by QC Manager.
7.4.3.2 Certification records for all personnel (regardless of level) used for NDE shall
be reviewed by NDE Level III for complying with Code adopted edition of
CP-189 and approved by QC Manager to meet the requirements of their
employer’s(subcontractors) written practices.
7.4.3.3 When the subcontractor uses his own equipment to perform the NDE, he shall
furnish latest equipment calibration records to the QC Manager.
7.4.3.4 Subcontract NDE Procedure shall be satisfactorily demonstrated to AI (if
required) (refer 7.3.5)
7.4.3.5 The Authorized Inspector (AI) can require a demonstration by NDE Personnel
of an NDE examination or NDE procedure for cause.
Page 2 of 3
7.4.4 NDE Reports
7.4.4.1 NDE reports shall be prepared by NDE personnel (Level II) who
performed the NDE evaluation and interpretation. The details of
qualifications of the NDE personnel shall be recorded in the report.
7.4.4.2 All NDE documentation including Radiographic Films shall be made
available to AI for his review as required. QC Engineer shall review all
NDE Reports.
7.4.4.3 Visual examination: QC Engineer / Inspector shall perform visual
inspection. When required by code (B31.1), Visual examination shall
be performed by personal qualified and certified as per visual
examination procedure AIC-ASME / VT / 01.
Vision acuity test (Jager-1 or equivalent) and color vision test shall be
administered annually.

7.4.4.4 Retention: NDE documents and films shall be retained on file for the
retention period as specified in Section 10 of this Manual.

7.4.5 All NDE procedures are submitted to AI for his review and
acceptance. Written procedures for, Liquid penetrant (PT), and
magnetic particle (MT) examination shall be demonstrated to the
satisfaction of AI and certified by QC Manager to meet requirements
of T-150 of section V.
When UT is required, it shall be subcontracted as per 7.3.3.
RT procedure does not require demonstration and achieving the
required density and penetrometer image on technique or product
radiograph is considered as satisfactory demonstration of technique.
7.4.5.1 Nonconformities: Any Deviation observed due to NDT shall
result in an NCR and it shall be handled as per section 5 of
this Quality Control Manual.

Page 3 of 3
 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 8, Rev. No.0
MANUAL Page 1 of 2

8.0 Heat Treatment

8.1. Scope / Purpose
This Section covers the requirements for heat treatment of pressure vessels, vessel parts,
piping, etc. to comply with Code requirements.
8.2. Responsibility
The Welding Engineer is responsible for preparation of heat treatment procedure (PWHT-F-01
for PWHT by furnace and PWHT-L-02 for Localized PWHT), Heat Treatment control sheet
(Exhibit #28).
The QC Manager is responsible for subcontracting all heat treatment operations, review and
approval of heat treatment procedure and Heat Treatment control sheet.
8.3. Procedure
8.3.1 The heat treatment requirements shall be indicated on the drawings in accordance with
Code.
8.3.2 The Welding Engineer shall prepare the Heat Treatment Control sheet (Exhibit #28).
This shall be in accordance with the requirements of the approved drawings. This Heat
Treatment Control sheet shall include the following information / details:
• Placement and support of the job on the furnace bed.
• Location and number of thermocouples.
• Loading / unloading temperature.
• Method of attachment of thermocouples.
• Method of removal of thermocouple attachment material.
• Heating / cooling rates, holding temperature, holding time with maximum /
minimum values as applicable.
8.3.3 The Production Supervisor shall check that all the operations (e.g. welding, NDE, repairs
if any etc.) required to be completed prior to heat treatment has been carried out. The QC
Engineer / Inspector shall verify the above and release the job for heat treatment by
signing off the record of stage inspection of welds (Exhibit # 17).
8.3.4 Subcontracted Heat Treatments: The subcontractor’s heat treatment facilities shall be
surveyed and approved by the QC Manager. The survey shall include checking for
availability of calibrated instruments. Subcontracted heat treatment shall be done as per
AIC’s Heat Treatment Control sheet and procedures (PWHT-F-01 for PWHT by furnace
and PWHT-L-02 for Localized PWHT) or subcontractor procedure approved by QC
Manager.
The subcontractor shall load the job on the furnace bed with adequate supports to
prevent distortion and attach thermocouples as detailed in the Heat Treatment Control
sheet. He shall offer the loading for inspection to AIC’s QC Engineer / Inspector. The
QC Engineer / Inspector shall inspect the loading, location and placement of
thermocouples on the job and check for compliance with Heat Treatment Control sheet.
The QC Engineer / Inspector shall also check the validity of calibration of instruments.
8.3.5 After completion of heat treatment, (for code items heat-treated in shop as well as for
subcontracted) visual inspection shall be carried out on the code item to ensure that the
code item is free from distortion and damage and the identification marking has been
maintained.
Page 1 of 02
8.3.6 NDE shall be conducted on the code item after Heat Treatment, as per Quality and
Welding Plan.
8.3.7 The Welding Engineer shall review the actual heat treatment chart and sign the same
after acceptance of heat treatment.
8.3.8 Production test coupon: when required and indicated in the Quality & Welding Plan
shall be given the same heat treatment as the code item that it represents.
8.3.9 Documentation: When the heat treatment of the Code item is carried out the results of
the same are recorded on actual heat treatment charts, which must contain at least the
following information;
a) The Date on which the heat treatment is carried out.
b) Name of the heat treatment operator, signature and date.
c) Speed of the charts (if applicable)
d) Description of the item heat treated
e) Rate of Heating (ROH)
f) Rate of cooling (ROC)
g) Holding Temperature
h) Holding / soaking time
i) Starting Time
j) End Time
k) Total Cycle Time
l) Recorder Number
The record shall be made available to AI for his review. The documentation shall be
retained on file under the Work Order for the retention period as specified in Section 10
of this Manual.
8.3.10 Cold Formed Parts: When heat treatment is required for the cold form parts in
accordance with code requirements the technical delivery conditions for the purchase
shall specify these requirements. The parts supplier’s certificates shall clearly state if
heat treatment has been carried out.
A copy of the heat treatment chart for the cold formed parts after review by QC
engineers shall be submitted to the AI for the review and acceptance.
8.3.11 Special Heat Treatment:
For any localized heat treatment or heat treatment of long item with overlap or heat
treatment by internal firing or heat treatment at field site, the welding engineer shall
establish specific procedure with detailed instructions for carrying out such special heat
treatment and get the same accepted by the AI before use.

8.3.12 Nonconformities: for Any Deviations from these requirements shall result in an NCR.
NCR’s shall be handled per Section 5 of this Quality Control Manual.

Page 2 of 2
 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 9, Rev. No.:1
MANUAL Page 1 of 3

9.0 Calibration of Examination, Measurement and Test Equipment (CEMTE)

9.1 Scope
This Section covers the requirements for calibration of measuring and test equipment (including
subcontractor’s instruments) used in fulfillment of the applicable Code requirements.
9.2 Responsibility
The QA-HSE Manager / QC Manager is responsible for ensuring that calibration of examination,
measuring and test equipment used for inspection/examination testing and heat treatment are
maintained in valid condition.
9.3 Procedure
9.3.1 A unique identifying number shall be assigned to each measuring / test/examination
equipment. A tag / sticker shall be affixed on each equipment marking the identification
number and calibration status with due date.
9.3.2 Calibration method, frequency, acceptance criteria shall be established as per the code
applicable procedures, standards or work instructions.
9.3.3 QC Engineer shall maintain an Instrument Calibration Status Record (Exhibit#29)
documenting the calibration status. The register shall contain the following information:
• Description / Manufacturer
• Serial No.
• Location
• Calibration date
• Validity date
Entries in this Record shall be made only after verifying that the calibration meets the
stated acceptance criteria.
9.3.4 Pressure gauges used for pressure testing shall be calibrated against a dead weight tester or
by comparison with a calibrated master gauge.
9.3.5 All Mechanical tests shall be conducted in outside approved Laboratories, using calibrated
equipment. The QA-HSE Manager and QC Manager shall verify the calibration of the
used equipment.
9.3.6 Instruments / equipment which are defective and unserviceable shall be removed, marked
“REJECTED” and recorded (Exhibit # 29).
9.3.7 Calibration records of the equipment / instrument including those of the subcontractors
who performed NDE, PWHT and shall be made available for review to the Authorized
Inspector / Customer.
9.3.8 When any instrument / equipment is found out of calibration/damaged, the QC Inspector
shall remove it from the work area and arrange for its calibration or replacement.

Page 1 of 03
9.3.9 Any Code item checked with an instrument not having valid calibration/damaged shall be
considered non-conforming until it is re-checked with a calibrated instrument. In the event
of discrepant instrument found, they shall be treated as a nonconformance and NCR shall
be raised. QA-HSE Manager/QC Manager shall access the extent to which the discrepancy
could affect the performance/compliance with items of code requirements.
9.3.10 Calibration Frequency: The calibration frequency shall be as per Table-1.

Page 2 of 03
 Equipment Calibration Acceptance criteria Calibration Calibrated
SR Used for
description Frequency standard by

01 Pressure 6 months or when +1 % of full scale Dead Weight

Pressure test Subcontract
Gauges error is suspected range Tester
+ 0.4 % full scale for
02 Current, Voltage AC voltage, current, Manufacturing
Clamp Meter 1 Year Subcontract
measurement resistant and Std.
capacitance

03 Every time before Capability to carry ASME V Article

AC Yoke MT (NDE) AIC
use the 4.5 kg weight 7

04 Temp. Gauges + 5 0C up to 200 o C,

Electrode Ovens 1 Year Thermometer Subcontract
(Electrode Ovens) + 10 o C above 200o C

Thermometer Calibration &

05 Master
(Subcontractor Measure Impact 6months + 1 oC Subcontract
thermometer
equipment) Test Material temp.
Densitometer ASME Sec. V Calibrated film
06 (Subcontractor RT film density 90days paragraph T-262.1, + strip, ASME Sec Subcontract
equipment) 0.05 V - T-262
Charpy Impact
National Std.
7 M/C
Impact Test 1 Year ASTM E-23 ASTM A370 Subcontract
(Subcontractor
ASTM E23
equipment)
National Std.
08 Step Wedge Calibration of 1 Year from ASME Sec. V
ASME Sec V – Subcontract
Calibration Film Densitometer opening date paragraph T-262.2
T262
09 Dimensional
Vernier caliper 1 Year least count National Std. AIC
checks
10 Micrometer To check thickness 1 Year least count National Std. AIC

11 Light Intensity Manufacturers

Light Meter 1 Year + 2% of reading Subcontract
Measurement Std.
+ 0.1mm (up to
12 Ultrasonic Manufacturers
To check thickness 1 Year 60mm), + 0.5 mm ( Subcontract
Thickness gauge Std.
above
National Institute
13 Dimensional 3 months or when
Measuring Tape + 1mm of reading of Standards and AIC
checks error is suspected
Technology
Tensile Test
National Std.
14 Machine
Tensile test 1 Year ASTM E-4 ASTM A370 Subcontract
(Subcontractor
ASTM E4
equipment)

Page 3 of 03
 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 10, Rev. No.: 2
MANUAL Page 1 of 3

10.0 Records Retention

10.1. Scope / Purpose
This Section covers the requirements for retention of relevant QC documents, Data reports
and engineering documents for Code compliance.
10.2. Responsibility
The QC Manager is responsible for all the required Code documentation including retention
and retrieval.
The QC Manager is responsible for retention and retrieval of all design documents like As-
Built drawings (Dimensional), calculations, customer documents, customer specifications,
Manufacturers Data Reports, Engineering Change Requests, etc.
QC Manager shall maintain a record of code items manufactured (registered and not
registered with NB). This list shall include vessel serial number descriptions date of
hydrostatic test & date of certification. These details for Code Items not registered with NB
shall be recorded on Log of Non NB Registered code items (Exhibit # 37a).
10.3. Procedure
10.3.1.1. Data Book: Upon completion of a work order, QC Engineer shall prepare a data
book. He retains the original data book and distributes copies as per contract
requirements. One copy shall be made available for review to AI. All data books
shall be properly indexed for identification and stored appropriately for ready
retrieval when required.
10.3.2. Retention:
(a) The radiographic films shall be retained until the MDR’s are signed by the AI,
except for Section I Power Boilers and PP items where, it shall be retained for at
least 5 years.
(b) The documents outlined below shall be maintained for a period of at least 3 years
for ASME VIII Div. 1 and 5 years for ASME section I & B31.1:
(1) Manufacturer’s Partial Data Reports (MPDR) & manufacturer’s data reports
(MDR).
(2) Manufacturing drawing
(3) Design calculations, including any applicable Proof Test Reports
(4) Pressure part Documentation and certification
(5) Material Test Certificate
(6) Welding Procedures Specifications and Procedure Qualification Records
(7) Welders & Welding Operator Qualification Records and their continuity
(8) Repair procedure and repair records
(9) Quality & Weld Plan
(10) Heat treatment records and test results or test coupon “if any required”
(11) Post weld heat treatment chart and instruction sheet
(12) Nonconformance report and dispositions
(13) Result of production test plates, if applicable
Page 1 of 3
 (14) Picture or Tracing of nameplate or stamping
(15) All NDE reports stating the result of inspection, code required NDE
examination and testing including MT, PT, RT & UT as applicable.
(16) NDE Procedures and demonstration record
(17) Material repair procedures & reports (if any)
(18) Dimensional drawings of the as-built condition
(19) Hydrostatic/ pneumatic test reports

10.3.3. Disposal: After the completion of retention period, the documents may be disposed
of and a record may be maintained of the disposal.
10.4. Manufacturer’s Data Report (MDR)
10.4.1. Distribution of MDR:
For Section VIII Div. 1 items the Manufacture shall furnish a copy of the
Manufacturer’s Data Report:
a. User;
b. Upon request, to the Inspector;
c. Submit a copy to the appropriate enforcement authority in the jurisdiction in
which the vessel will be installed, when required by law;
d. Keep a copy of the Manufacturer’s Data Report on file in a safe repository for at
least 3 years.
The vessel may be registered and the Data Reports are filed with the National Board
of Boilers and Pressure Vessel Inspectors, 1055 Crupper Avenue, Columbus, Ohio
43229, USA.
Records shall be made available to AIS during annual audit and to ASME designee
during ASME Joint review.
QC Engineer shall prepare the MDR; QC manager shall review & certify the MDR.
10.4.2 For Section I items the Manufacture shall furnish a copy of the Manufacturers
Data Report:
a. Purchaser;
b. Authorized Inspection Agency;
c. State, Municipal or provincial authority at the place of installation.
d. Keep a copy of the Manufacturer’s Data Report on file in a safe repository
for at least 5 years.
e. The Vessel may be registered and the Data Reports filed with the National
Board of Boilers and Pressure Vessel Inspectors
The Completed date reports for the assembly shall be forwarded to the boiler
manufacturer or engineering contractor responsible for providing Master
Data Reports. A copy shall be provided to the Authorized Inspector (AI)
upon request and a copy retained for at least 5 years.

Page 2 of 3
 Originals of all P-4 & P-4A forms shall be sent to the responsible boiler
manufacturer or engineering contractor. BEP certified on Form P‐4A/P‐4
shall be retained for a minimum period of 5 years.

10.4.3 For parts, partial data reports in duplicate are provided to purchaser and a
copy to AI.
10.5 Certification Mark Stamping
10.5.1 The QC Manager has the custody and control of the ASME Certification Mark
Stamps. The required Stamp will be issued for use only when all fabrication,
examinations and inspections are completed, and the Authorized Inspector (AI)
has authorized to be Certification Mark Stamping.
10.5.2 For Boiler, Boiler components Certification Mark shall be stamped with “S”
Designator as shown the Exhibit 18 as required ASME Section I PG-106 and PG-
111. For ASME Section I components the marking as shown in Exhibit 18 shall
be directly stamped on the item unless otherwise permitted by the Code.
10.5.3 For Section VIII Div. 1 vessels the Certification Mark with “U” Designator shall
be stamped on a plate as shown in Exhibit 18, which is permanently attached to
the vessel as required by ASME section VIII, Division I, UG-118 & UG-119.
10.5.4 In case of heat exchanger, a supplemental tag or marking shall be supplied on the
heat exchanger to caution the user if there are any restrictions on the design,
testing or operation of the heat exchanger. The marking shall meet the
requirement of UG-118 or UG-119, except that height of the characters for the
caution notice required by UHX-19.2.2 shall be at least 1/8” or 3mm high.
10.5.5 For ASME B31.1 power piping items the Certification Mark shall be marked as
shown in the Exhibit 18 as required by PG-109 of ASME Section I.
10.5.6 The Design Engineer (Subcontract) shall prepare the information provided.
10.5.7 The Manufacturer’s serial Numbers shall be controlled and issued consecutively
by QA-HSE Manager.
10.5.8 If Stamping the Certification Mark on the Nameplate after attachment to the
vessel is not possible, it may be applied, with the prior concurrence of the
Authorized Inspector (AI), after Completion of all fabrication and examination,
and immediately before the hydrostatic or pneumatic test, and the Nameplate
attached to the vessel.
10.5.9 Any nonconformance found which cannot be corrected shall require immediate
removal of the Nameplate and Certification Mark. The QC Manager shall ensure
that the name plate with correct marking is affixed to the correct plate.
10.5.10 Removable parts shall be permanently marked in a manner to identify them with
vessel or chamber of which they form parts such as removable boots, Heat
exchangers channels etc. Certification marks shall not be applied to such items.

Page 3 of 3
 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 11, Rev. No.:1
MANUAL Page 1 of 2

11.0 Authorized Inspector

11.1 Scope
This Section covers the requirements of inspection and certification to be performed by
the Authorized Inspector for Code construction.
11.2 Definition
The AI is the Inspector as defined by the Code, who is regularly employed by the
AIA of Record and who holds a valid National Board commission “AI”. The AIS
is the person who holds National Board commission with “B” endorsement and
designated as such by the AIA of Record. Inspector for Repair & alteration work
is defined in NBIC and he shall have “R” Endorsement on his National Board
Commission Card.
11.3 Contract
AIC shall at all times have an agreement with an ASME and NB accredited authorized
inspection agency meeting requirements of ASME QAI-1 (latest edition) and NB-369
AIC enters into a Contract with an ASME accredited Authorized Inspection Agency
(AIA), for carrying out Inspection and certification of all Code work. This AIA is
identified as the AIA of record. Only AIA of record will be utilized by AIC at its shop
and all field location.
11.4 Procedure
11.4.1 The QC Manager keeps the AI informed about new contracts for manufacture of
Code items.
11.4.2 AI’s Hold, Witness, Review Points: The QC Engineer shall interact with the
AI to identify AI’s Hold, Witness, Review points and incorporate them in the
Quality & Welding Plan (see par. 4.3.1).
11.4.3 Manual Copy: The QA-HSE Manager shall issue a controlled copy of this
Manual to the AI at shop & Field Site. The AI reviews and accepts all revisions
to this Manual prior to distribution to Manual Holders.
11.4.4 Free Access: AIC shall allow and ensure free access to AI / AIS and ASME
Designee to:
• Engineering, QC and other offices for perusal and review of all documents,
calculations, procedures, specifications, test results, quality control records
and other relevant documents.
• All parts of the shops, field installations, suppliers, material manufacturers,
subcontractors and testing laboratories where Code work is being performed.
11.4.5 Inspection by AI: The QC Engineer / Inspector shall keep AI informed
regarding the progress of work. AI shall be given advance information about
various Witness / Hold points. The QC Engineer / Inspector shall ensure that all
the inspections are carried out by AI at appropriate stages as per Quality &
Welding Plan and are accepted before proceeding to the next stage.

11.4.6 Non Conformances: All Code non-conformances and corrective actions shall
be submitted to AI for his review and acceptance.

Page 1 of 2
11.4.7 Documentation: The QC Manager shall submit the final data book with
completed Manufacturer's Data Report to the AI for his review and signature.
The AI signs the Manufacturer's Data Report and Authorize to apply the
Certification Mark Stamp when he has satisfied himself that all Code
requirements have been complied with.
11.4.8 Audits: The QA-HSE Manager and QC Manager shall provide all necessary
assistance to the AI / AIS during monitoring of the systems & the annual audits
required by the ASME and QAI-1 “Latest edition”.
11.4.9 QA-HSE Manager shall inform ASME/NB for any change/cancellation of
agreement with AIA.

Page 2 of 2
 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 12, Rev. No.: 0
MANUAL Page 1 of 4

12.0 Field Fabrication & Assembly for Boilers, Pressure Vessels & Piping
12.1 Scope / Purpose
This section covers the requirements for Code compliance of fieldwork.
12.2 Responsibility
The Head of Projects / Construction Manager is responsible for all field operations.
12.3 Procedure
12.3.1. All the relevant quality control systems covered in this Manual shall be applicable
to field / Site(s) operations.
12.3.2. Document Control and Distribution
12.3.2.1. The drawings for field construction shall be prepared, reviewed and
approved in the same manner as drawings for shop work (as covered in
Section 2 of this Manual).
12.3.2.2. The drawings shall be distributed to the field site(s) using Document
Transmittal, with purpose of issue (e.g. “For Construction”) clearly
mentioned on the drawings and on the transmittal.
12.3.2.3. Revisions to the field drawings shall be distributed and controlled in the
same manner as revisions to shop drawings (as covered in Section 2 of
this Manual). All obsolete drawings shall be removed and destroyed or
stamped "Superseded" and kept aside. Field Supervisor shall ensure that
only the latest valid revisions to drawings are used for construction.
12.3.2.4. The QC Manager shall assign the field quality control work to a separate
Field QC Engineer / Inspector who shall ensure compliance with all
requirements.
12.3.2.5. The Field QC Engineer / Inspector shall provide the AI with all
drawings, calculations and material specifications and site installation
procedures (if any) for his review and acceptance prior to
commencement of fieldwork.
12.3.3. Material Control
12.3.3.1. Purchase Requests (for materials to be procured) and Raw Material
Requisitions (for materials to be issued from stock) for Code materials
excluding welding consumables shall be prepared by the Material
Controller. Purchase Requests (for materials to be procured) and
Material Requisitions (for materials to be issued from stock) for welding
consumables used for Code work shall be prepared by the Welding
Engineer. Materials shall be procured and received in the same manner
as shop material (as detailed in Section 3 of this Manual).
12.3.3.2. All customer supply materials shall be handled as per Section 3 of this
Manual.
12.3.3.3. The Construction Supervisor shall receive materials at the field site and
store them in a “Hold” area till receiving inspection is completed.

Page 1 of 4
 12.3.3.4. All materials shall be received, inspected and identified at AIC shops in
accordance with the requirements of section 3. They shall be processed
and piece-mark identified prior to shipment to the field. The Field QC
Engineer / Inspector shall inspect the materials received at field site and
ensure that they have proper identification and the required documents;
completed Partial Data Reports, material certificates, Delivery Note, etc.
are available.
12.3.4. Quality & Welding Plan: The QC Engineer shall prepare the Quality & Welding
Plan for field fabrication, following the same procedure as for shop fabrication
(covered in Section 4 of this Manual). The QC Engineer shall interact with the AI to
determine AI’s Hold / Review / Witness points and incorporate the same in the
Quality & Welding Plan.
12.3.5. Field Fabrication: The Construction Supervisor shall ensure that all operations are
performed and offered for inspection as per the Quality & Welding Plan and are
inspected and cleared by field QC Engineer / Inspector / AI at appropriate stages.
Further work shall be done only after clearance by Field QC Engineer / Inspector /
AI.
12.3.6. Field Inspection: All field inspections shall be carried out as per the Quality &
Welding Plan. The field QC Engineer / Inspector shall coordinate with the AI and
arrange for his inspection at the required points as per the Quality & Welding Plan.
The Field QC Engineer / Inspector shall prepare appropriate inspection reports (as
detailed in section 4 of this manual), which shall be signed off by AI as required.
12.3.7. Correction of Non-Conformances: All non-conformances shall be processed as
detailed in Section 5 of this Manual. The field QC Engineer / Inspector shall
maintain all records of non-conformances and corrective actions. A copy of all such
reports shall be forwarded to the QC Manager for his records.
12.3.8. Welding Control: All welding on Code work shall be performed using welding
procedures; welders and welding operators qualified in accordance with ASME Sec.
IX, as detailed in Section 6 of this Manual. The Welding Engineer shall qualify
welding procedures / welders / welding operators for fieldwork. Copies of all WPS,
PQR and WQTR for fieldwork shall be available with the Field QC Engineer /
Inspector. These shall be made available to the AI for his review. All welding
consumables shall be stored and handled as per Section 6 of these manual and
AIC’s procedures. Additionally, the Field Supervisor shall ensure that the welding
process is protected from dirt, dust, wind etc.
12.3.9. Non-Destructive Examination: All field NDE shall be done in accordance with
Section 7 of this Manual. QC Manager shall ensure that all field NDE personnel are
properly qualified to their employer’s procedure and have a current eye examination
to meet the Code requirements. NDE shall be performed by NDE Level II as per
approved procedures, witnessed by AI if required per approved Quality & Welding
Plan. All NDE reports shall be prepared by the NDE Level II, reviewed by QC
Engineer and shall be made available to the AI.
12.3.9.1. Post-weld Heat Treatment: Field PWHT shall be carried out as per
Section 8 of this Manual. The field QC Engineer / Inspector shall
monitor the PWHT operation and keep AI informed. Documentation for
field PWHT shall be done as specified in Section 8 of this Manual.

Page 2 of 4
12.3.10. Calibration of Test Equipment: All measurement and test equipment used for
inspection and testing at field shall be calibrated in the manner as described in
Section 9 of this Manual. The field QC Engineer / Inspector shall ensure the
compliance to the above and maintain calibration records for review by AI, as
required.
12.3.11. Stamping & Certification for Boiler Assembly:
12.3.11.1 The responsibility for stamping of the boiler with Code required “S”
stamping lies with the boiler manufacturer or the engineering contractor.
The boiler manufacturer shall be providing P-3 Master Data Report or
the engineering contractor shall be providing P-3A Master Data Report
including all associated partial data reports.
12.3.11.2. If company is responsible for field assembly and certification as per PG-
106.7 & PG-107.2 of ASME Code Sec 1. QC Manager shall certify the
field assembly portion of Master Data Report and present it to the AI for
his signatures along with all examination and inspection records and
partial data reports.
12.3.11.3 When engineering contractor provides the metallic master stamping
name plate with S stamp, QC Manager is responsible to affix it to the
boiler at the location specified in PG 111.13 and on authorization and in
presence of AI.
12.3.11.4 Company in addition shall provide assembler’s name plate (Exhibit 18)
with “A” symbol stamp and affix it near the Master Name Plate.
Stamping & fixing of name plate shall be done in presence of AI.
12.3.11.5 In case the company is responsible for partial field assembly, the
certification and stamping shall be as per PG-107.2.3(b) on form P-3
(without marking it as Master).
12.3.11.6 The completed data reports for the assembly shall be forwarded to the
boiler manufacturer or engineering contractor responsible for providing
Master Data Reports. A copy shall be provided to the AI upon request
and a copy retained for at least 5 years as per Section I.
12.3.12. Stamping & Certification for Boiler External Piping:
12.3.12.1. Shop fabricated piping spools are received by the company with
appropriate S or PP stamp markings and Form P-4A duly certified for
shop construction and inspection. Such spools are field assembled by the
company.
12.3.12.2. On Satisfactory completion of assembly and hydro test, QC Manager
shall certify the field assembly part of these P-4A forms and present it to
the AI for his signatures for field assembly inspection. The field test
pressure shall be indicated on P-4A forms.
12.3.12.3 When company is responsible for field fabrication of piping spools, QC
Manager shall prepare and certify P-4A for field fabrication and present
it to AI for his signatures. Such spools fabricated at field shall be applied
with PP stamp in accordance with PG 109.2 in presence of AI.
12.3.12.4 When company has responsibility to field fabricate parts of boilers such
as water walls, super heater and economizer headers (when design is
provided by others). Such parts shall be stamped as per PG-106.8 and
certified on P-4 forms (Refer PG-109.3b)
Page 3 of 4
 12.3.12.5 Originals of all P-4 & P-4A forms shall be sent to the responsible boiler
manufacturer or engineering contractor. A copy shall be retained for at
least 5 years as per Section I.
12.3.13. For field assembly work on the pressure vessel, field QC Engineer shall sign the
field assembly portion of data report and submit to AI at site for his signatures and
Authorization to apply code stamp.
12.3.14. All Code Stamping at field shall be carried out in presence of AI at site.

Page 4 of 4
 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 13, Rev. No.:2
MANUAL Page 1 of 10

Repairs & Alterations

13.0 General
13.0.1 This section is applicable for repairs and alterations to be earned out on Boilers,
Pressure Vessels, Piping and Heat Exchangers at the shop and field sites controlled
from the shop.
13.0.2 Currently scope of this manual includes repair/alteration to items constructed
as per: BPV Code Section I, VIII Div.1 and B31.1. Also repair/alteration can be
carried out on other non ASME vessels including those generally designed to
ASME Code sections but without Code Certification Marks.
13.0.3 The repairs and alternations shall be performed in accordance with the National
Board Inspection Code(NBIC) and the applicable Jurisdictional requirements, if
any. Edition of NBIC mandatory on the date of contract shall be used.
13.0.4 Before initiating any repairs (including routine repairs) or alterations, prior
authorization of Authorized inspector (AI) shall be obtained with sufficient
information so that Authorized Inspector (AI) can determine if repair or alteration
methods are acceptable.
13.0.5 Subcontracted activities are identified in the applicable sections of this manual
and those sections have been referenced in this system. Company shall take full
responsibilities for the work carried out by subcontractors.
13.1 Definitions
13.1.1 “Repair" is defined as the work carried out to restore pressure retaining Items,
components and system to a safe and satisfactory operating condition such that
existing design requirements are met.
13.1.2 "Alteration” is defined as any change in the item described on the original
Manufacturer's Data Report or similar other document or drawing, which affects
the pressure containing capabilities of the pressure retaining item. Non-physical
changes such as an increase in the maximum allowable Working pressure (internal
or external) or design temperature shall be considered an alteration. A reduction in
MDMT such that additional Mechanical Tests are required shall also be considered
an alteration.
13.1.3 “Re-rating’' means the alterations involving changes in the MAWP, design
temperature or reduction in MDMT of the equipment The Re-rating shall be
applicable only if 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 re-rated condition.
13.1.4 “Routine Repairs" are repairs for which the requirements for in-process
involvement by the Inspector and stamping by the “R" Certificate holder may be
waived as determined appropriate by the Jurisdiction and the Inspector. All other
applicable requirements of Code shall be met Prior to performing routine repairs,
the “R” Certificate Holder should determine that routine repairs are acceptable to
Page 1 of 10
 the Jurisdiction where the pressure-retaining Item is installed.
13.1.5 “Authorized Inspector” are personnel’s as defined in NBIC holding “AI” or “IS”
commission and “R” endorsement for inspection during metallic repair or
alteration of code item and regularly employed by AIA accredited by NB that
assumes responsibility of personnel’s actions.
13.1.6 “Authorized Inspection Agency” is an entity accredited by National Board in
accordance with NB-369 and with whom the AIC has agreement to provide
inspection services.
“Repair Inspector (RI)” is an individual in the employment of Authorized Inspection
Agency holding valid and current National Board Commission with “R”
Endorsement. The term “AI” used in this section of manual means Repair
Inspector (RI) for the purpose of Repair and Alteration activities. The RI making
the acceptance inspection shall be the same Inspector who authorized the repair
or alteration. Where this is not possible or practicable, another Inspector may
perform the acceptance inspection; however, in all cases, the RI who performs
the acceptance inspection shall be an employee of the same organization as the
RI who authorized the repair or alteration.
13.2 Statement of Authority and Responsibility
13.2.1 The authority of control of this manual and implementation of Quality Control
System is vested with QC Manager, as described in Section 3 of this manual.

13.3 Manual Control

13.3.1 The preparation, revision and issue of this Quality Control Manual shall be the
responsibility of QA-HSE Manager. The system has been detailed in Section 4 of
this Quality Control Manual.

13.4 Organization
13.4.1 The Organization Chart for carrying out repair and alteration at shop and field sites
controlled from shop shall be as shown in Section 1 of this manual and the Quality
Control responsibilities are as detailed in this manual.

13.5 Construction Standards

13.5.1 When original equipment is constructed to the ASME Code, repairs and alterations
shall conform in so far as possible to the section and edition of the ASME Code
most appropriate to the work performed.
13.5.2 When the original equipment is not constructed to the ASME Code, repairs and
alterations shall conform in so far 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 may be used provided
prior concurrence of the Authorized Inspector (AI) obtained. When applicable prior
concurrence of Jurisdiction and Owner shall also be obtained for use of standards
Page 2 of 10
 other than that original construction standard. Refer 1.2 of NBIC Part 3 for other
requirements.
13.6 Drawings, Design and Specifications
13.6.1 On receiving the order for carrying out Repairs or Alteration, it shall be the
responsibility of Design Engineer (Subcontract) to identify and confirm whether
the required work is categorized as repair or routine repair or Alteration or rerating
in accordance with the requirements of NBIC.
13.6.2 Design Engineer (Subcontract) 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 vessel
data report, drawings, and 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), Design Engineer (Subcontract) shall arrange a copy from the
National Board by providing the necessary information like Name of the
manufacturer, vessel serial number, year make and NB number.
13.6.3 The system of preparation of design calculations shall be as explained in 2.3.3 of
this manual the design calculations for repair or alteration shall be based on the
original construction standard or as otherwise specified in 13.5 above. Reference
for design shall be based on manufacturer's data report 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.
13.6.4 Drawings for alterations (and when required for repairs) shall be approved by the
QA-HSE Manager. In addition to the applicable details given in 2.3.3.1 of this QC
Manual, the drawings shall also indicate the original construction code,
construction Code used for repairs/alterations, applicable National Board
Inspection Code and name plate stamping details. Distribution and revision to the
drawings shall be controlled in the manner described in Section 2 of this manual.
13.6.5 Design Engineer (Subcontract) is also responsible for verifying the identification of
the existing materials from the original data reports, original drawings and other
such documents. Material specification for the existing material and material to be
installed shall be clearly indicated on the drawings
13.6.6 When any material or part is to be replaced during repairs or alteration, TDC for
material shall be prepared by Design Engineer (Subcontract) and approved by QC
Manager as described in Section 2 of this manual.
13.6.7 Design Engineer (Subcontract) is responsible for selection of units based on the
requirements of the clients, units used for the original item and the original
construction Code. However, one system of units shall be used throughout the
repair or alteration process.
13.6.8 All design documents shall be submitted to the Authorized Inspector (AI) for his
review before proceeding further with repairs or alterations.

Page 3 of 10
13.7 Materials & Replacement Parts

13.7.1 Consideration shall be given to the condition of existing material especially in the
weld preparation area. If the existing material cannot be verified by the Design
Engineer (Subcontract) QC Manager shall arrange to perform sufficient chemical
& mechanical tests to identify the material and its properties.
13.7.2 The use of stock material, procurement, inspection, storage, issuance and
Identification of material shall be as described in Section 3 of this QC Manual,
13.7.3 All materials used in making repair or alteration shall conform in so far as possible
to the requirements of original construction standards or as specified in 13.5 above.
35.7.4 The relevant material test certificate or certificate of compliance shall be obtained
and submitted to the Authorized Inspector (AI) for his review and acceptance.
13.7.5 Carbon or alloy steels having carbon content more than 0.35% shall not be used for
item requires welding.
13.7.6 When ASME is the original code of construction, replacement parts subjected to
Internal or external pressure which require welding and inspection by Authorized
Inspector (AI) shall be fabricated, inspected and documented as per ASME Code as
parts. PDR is not required for parts fabricated by the "R” Certificate holder that
will be used on pressure retaining items being repaired or altered by the same “R”
certificate holder.
13.7.7 A PDR shall be provided if the parts will be installed by other company during
repair.
13.7.8 Replacement parts shall be hydro test as per the original code of construction if not,
concurrence from owner shall be obtained and reason the replacement part was not
tested shall be documented on R-form.
13.7.9 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 stamp holder and documented on Form R-3 of NBIC.

13.8 Repair & Alteration Method

13.8.1 For all repairs or alteration work, prior to start of the activities, QC Manager shall
prepare and approve a detailed procedure describing the projected scope of work.
The procedure shall as a minimum include repair or alteration methodology,
applicable welding procedure specifications, proposed NDT methods and their
extent, material, preheat and post weld heat treatment requirements and
documentation requirements. Any other special requirements of the NBIC,
Construction Code and Owners shall also be included.
13.8.2 Based on this procedure and other applicable drawings and documents, QC
Engineer shall prepare Quality & Welding Plan detailing the stages of operations,
reference documents and procedures, format of record. QC Manager shall approve
the Quality & Welding Plan.
Page 4 of 10
 13.8.3 QC Engineer/ Inspector shall present the following to the Authorized Inspector
(AI) for his review and acceptance and to enable him to indicate his inspection
points on Quality & Welding Plan:
I. Approved design calculations, drawings, materials specifications.
II. Copy of original manufacturer's data report.
III. Quality & Welding Plan.
IV. Repair or Alteration procedure detailing projected scope of work.
V. Applicable WPS, PQR and Welder Qualification test records.
VI. Proposed NDE and Heat treatment and applicable procedures.

13.8.4 The examination and tests required during repair shall be in accordance with the
original construction standard. However, if impossible or impractical, alternative
methods as permitted by NB-23 and acceptable to the Authorized Inspector (AI)
and the owner may be used.
13.8.5 The Authorized Inspector (AI) shall have access to make such Inspections of
vessels he deems necessary in order to ensure that Inspections can be performed,
and to accept the repair and alterations after final inspection.
13.8.6 Alteration by encapsulation shall be performed as per para 3.4.3 of NBIC part 3.

13.9 Welding, NDE and Heat Treatment

13.9.1 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 6 of this manual.
13.9.2 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
Authorized Inspector (AI) for his review and acceptance before carrying out
welding work.
13.9.3 Standard WPS shown in 2.3 of the NBIC can be used without supporting PQR for
repairs or for performance qualification. Such WPS shall be documented and
certified by QC Manager for use. When required, owner's or jurisdiction's
acceptance will be obtained for use of standard WPS.
13.9.4 NDE requirements including technique, extent of coverage, procedures, and
personnel qualification and acceptance criteria shall be in accordance with original
construction code. 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 Authorized Inspector (AI) and owner or
jurisdiction as applicable may be used.

Page 5 of 10
 13.9.5 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 applicable Edition of SNT-TC-1A or CP-189 may be used.
13.9.6 Other NDE controls shall be as per Section 7 of this manual.
13.9.7 Preheat temperature requirements shall be as specified in the applicable WPS.
Reference can also be made to Table 2.5.1 of NBIC for recommended minimum
preheat temperatures.
13.9.8 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 8 of this
QC Manual. Local PWHT that is not specified by the original construction code
may be performed as per NBIC with prior acceptance of the Authorized Inspector
(AI) and when required by the owner and Jurisdiction.

13.9.9 Under certain conditions, when PWHT in accordance with original construction
standard is not advisable or impractical, alternative methods of PWHT or special
welding methods as described in 2.5.3, Part 3 of NBIC and acceptable to
Authorized Inspector (AI) may be used. Such WPS shall not be used while
performing for routine repairs. QC Manager shall obtain and document
competent technical advice before use of alternative welding methods where
PWHT is non practicable.
13.9.10 Alternative welding methods without PWHT is not permitted for routine repairs.

13.10 Examination and Tests

13.10.1 All examination and tests required during and after repairs or alterations shall be
identified on the Repair procedure and Quality & Welding Plan.
13.10.2 Requirements for the pressure tests including test medium, test pressure, holding
time, and temperature limits etc. shall be specified in the repair procedure.
13.10.3 All pressure tests shall be witnessed by the QC Engineer and shall be offered to
Authorized Inspector (AI)
13.10.4 The extent of pressure testing shall be as acceptable to the Authorized Inspector
(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.
13.10.5 The Test Pressure shall be the minimum required to verify the leak tightness
integrity of the repair and shall not exceed the maximum liquid test pressure of
the original code of construction. The metal temperature during Pressure Test
shall not be less than 16°C (60°F) or more than 49°C (120°F). Test pressure shall
be held for minimum of 10 minutes prior to the examination. Where the test
pressure exceeds the MAWP of the item, the test pressure shall be reduced to the
MAWP for close examination by the inspector. In addition to the above,
requirements as per Section 4.4.1 & 4.4.2 of NBIC part 3 shall be fulfilled while
performing hydro test for repairs and alterations.
Page 6 of 10
 13.10.6 When pressure test is not practicable the QC Manager shall obtain the acceptance
of Authorized Inspector (AI) and the owner/user for carrying out alternative test as
described in Section 4 of Part 3 of NBIC. This acceptance shall be obtained and
recorded before performing any alternative examination or testing.
13.10.7 If the pressure test is waived in Re‐rating, it shall be documented on form R‐2
with the statement under Remark “pressure test Waived in accordance with
NBIC Part‐3 Para 3.4.1(d)

13.11 Non-Conformities
13.11.1 Any non-conformity noticed during execution of repairs or alterations shall be
handled in accordance with the Section 5 of this Quality Control Manual.
13.12 Calibration
13.12.1 All equipment’s and gauges used for inspection and examination during repair and
alterations shall be maintained and calibrated in accordance with Section 9 of this
Quality Control Manual.
13.13 Acceptance and Inspection of Repair or Alteration
13.13.1 Repair or Alteration shall be carried out as per the procedure accepted by
Authorized Inspector (AI) and all the stages identified in the Quality & Welding
Plan shall be offered to him in accordance with his designated inspection points.
13.13.2 Before acceptance of any repair or alteration, the Authorized Inspector (AI) shall
be afforded right to satisfy himself that all the functions deemed necessary and in
compliance with the requirements of the NBIC, have been performed.

13.14 Name Plate and Stamping

13.14.1 The “R” symbol stamp is at all times the property of National Board and shall be
promptly returned on demand. In case the agreement with Authorized Inspection
Agency has been discontinued or the certificate of authorization has expired and no
new certificate has been issued, the “R” symbol stamp shall be immediately
returned to the National Board.
13.14.2 The QC Manager shall be responsible of the custody and use of the “R" symbol
stamp. The custody of the “R” symbol stamp may be temporarily transferred to the
site QC Engineer, when it is required to be used on field sites. Under no
circumstances the “R" stamp shall be given or loaned to any other organization
13.14.3 The “R” symbol stamp shall always be applied on authorization by Authorized
Inspector (AI) and in his presence.
13.14.4 For Repair, Alteration. Re-rate, or any part certified in accordance with National
Board Forms R-1, R-2, and R-3 shall be stamped with "R’ symbol as shown in the
Exhibit 18.

Page 7 of 10
 13.14.5 Stamping and/or name plate for repair/alteration/re-rating/parts fabricated by
welding shall be adjacent to the original manufacturer stamping or name plate and
shall be as shown in Exhibit 18.
13.14.6 When repair or alterations requires removal of the part of the item bearing the
original code stamping; the Authorized inspector (AI), subject to approval of the
owner, shall witness the making of facsimile copy of old stamping and transfer
such stamping on the new part When the stamping is on the Name Plate the
Authorized Inspector (AI) shall witness transfer of the Name Plate to the new part
13.14.7 Re-stamping or replacement of original ASME Code symbol stamp shall only be
performed when re-stamping is permitted by the original Code of construction and
any relocation of the stamping or the name plate shall be as indicated on the
relevant forms in accordance with NBIC.
13.15 Form “R” Reports & Distribution
13.15.1 QC Manager shall ensure that the repair or alteration has been completed in
accordance with the procedure and the system described above. He shall verify
correctness and completeness of all documents including acceptance of Authorized
Inspector (AI) for all stages.

13.15.2 The repairs shall be recorded on form R-1 (Report for Repairs). When required,
description of the relocation of Code Stamping or Name Plate shall also be
reported on form R-1. Reports of the replacement parts (Form R-3 or
manufacturer’s partial data reports) shall also be a part of the completed form R- 1.
Additional data can be recorded on form R-4 and attached to the form R-1.
13.15.3 Alterations or Re-rating shall be documented on Form R-2. When required,
description of the relocation of Code Stamping or Name Plate shall also be
reported on from R-2. Reports of the replacement parts (Form R-3 or
manufacturer’s partial data reports) and copy of the original manufacturer’s data
report (when available) or copy of the report required by other Codes shall also be
a part of the completed form R-2, Additional data can be recorded on from R-4 and
attached to the form R-2.
13.15.4 The relevant R1, R2, R3 or R4 Form shall be prepared and certified by QC
Manager before submitting the same to Authorized Inspector (AI) along with all
relevant documents for his review QA-HSE Manager shall also certify the design
certificate section of Form R-2.
13.15.5 On review and endorsement by Authorized Inspector (AI), the report forms shall be
distributed by QC Manager as follows:
I. Completed R-1 form along with attachments shall be distributed to the
owner/user, Authorized Inspector (AI), Jurisdiction (when required) and the
Authorized Inspection Agency responsible for the in-service inspection of
pressure retaining item (when applicable).
II. Completed R-2 form along with attachments shall be distributed to the
owner/user, Authorized Inspector (AI), Jurisdiction (when required), the
Authorized Inspection Agency responsible for the in-service inspection of
pressure retaining item (when applicable) and the R certificate holder
responsible for design (when applicable).
Page 8 of 10
13.16 National Board Registration

13.16.1 When the repairs or alteration forms are required to be registered with National
Board the R form number shall be referenced on the applicable Repair/Alteration
reports (Forms R1 & R2). R form numbers will start from R-1 and will be in
sequence without any skips and gaps. NB stamp shall not be applied on the R
stamp name plates.
13.16.2 A sequential log of all the R reports (Exhibit # 37b) issued shall be maintained by
QC Manager indicating Unique Serial number, R form number (only when
registered), description of equipment, owner, date repairs certified, and date R form
sent to National Board for registration within 30 days from the date of certification.
13.16.3 Form R-1 along with attachments shall be registered with National Board when
required by the owner or Jurisdiction.
13.16.4 If the original vessel is registered with National Board, Form R-2 along with
attachments shall be registered with National Board.
13.16.5 If the original vessel is not registered with National Board, Form R-2 along with
attachments shall be registered with National Board when required by the owner or
Jurisdiction.

13.17 Records Retention

13.17.1 For those “R” reports are not registered with National Board; QC Manager shall
retain a copy of the “R” form along with all the relevant attachments / records for
a minimum period of 5 years (refer table 1.5.1 of NBIC part 3).

13.17.2 Records may represent any information used to further substantiate the statements
used to describe the scope of work completed to a Pressure Retaining Item (PRI),
and documented on a form “R” report.
13.17.3 Below records for Repairs / Alterations work shall be maintained.
➢ Repair/Alteration plan/ procedure.
➢ Drawings, Design calculation, Sketches, Photographs as applicable
➢ Data Reports and Marking Details of original equipment’s
➢ Material Test certificate and related records
➢ WPS/PQR used
➢ WQTR & Process Continuity Records of Welder and Welding Operators
➢ NDE Reports (PT/MT & Volumetric Examination reports)

➢ heat treatment records

➢ Examination & Test Records, Quality & Welding Plan and Pressure Test
Report
Page 9 of 10
 ➢ “R” Forms (R2, R1) and attachments including partial data reports for
replacement items
13.17.5 Form “R” report with Report of Fitness for Service Assessment Form (NB403)
FFSA:
➢ When the method of repair described in NBIC part 3, 3.3.4.8 is used
the records retention shall be for the duration described on the Fitness

➢ For Service Assessment Form (FFSA), form required by the repair

method and as described in NBIC Part 2, Section 4.4.

➢ The record retention period is limited to the FFSA results described on

line 8 of the report of Fitness for Service Assessment Form (NB-403).

13.17.6 Continuity Records

Continuity records for welder, bonder or cementing technician shall be

maintained as described in Section 6 of this Quality Control Manual.

13.17.7 Administrative Records

Records supporting completed administrative reviews or audits of procedures

or process required by this Quality Manual System or in continuation with the
applicable part of the NBIC Part 3, supplementary section as it applies to the
identified scope listed on the “R” certificate of Authorization.

Page 10 of 10
 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 14, Rev. No.: 2
MANUAL Page 1 of 3

14.0 Abbreviations and Definitions

14.1 Abbreviations
AI Authorized Inspector
AIA ASME Accredited Authorized Inspection Agency
AIC Arabian International Company
AIS Authorized Inspector Supervisor
ANSI American National Standard Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing & Materials
AWS American Welding Society
BOM Bill of Materials
IFC Issued for Construction
MAWP Maximum Allowable Working Pressure (internal & external)
MDMT Minimum Design Metal Temperature
MRN Material Return Note
MTC Material Test Certificate
MT Magnetic Particle Examination
NB/NBBI National Board of Boiler and Pressure Vessel Inspectors
NBIC National Board Inspection Code (ANSI/NB 23)
NCR Non-Conformance Report
NDE Non-Destructive Examination
PO Purchase Order
PQR Procedure Qualification Record
PWHT Post Weld Heat Treatment
RMR Raw Material Requisition
PT Liquid Penetrant Examination
RT Radiographic Examination
UT Ultrasonic Examination
VT Visual Examination
EMTE Examination, Measuring & Testing Equipment
WIR Weld Inspection Report
WQTR Welder Qualification Test Record
WPS Welding Procedure Specification
TDC Technical Delivery Condition
Page 1 of 3
 QA Quality Assurance
QC Quality Control
MPDR Manufacturer’s Partial Data Report
MDR Manufacturer’s Data Report
PRT Fabrication of Part without Design Responsibility
FFSA Fitness for Service Assessment
PDR Partial Data Report
CTDC Consumable Technical Delivery Condition
PR Purchase Request
MR Material Requisition
GRN Goods Receipt Note
14.2 Definitions
Code is the American Society of Mechanical Engineers (ASME) Boiler and Pressure
Vessel Code, Section I and Section VIII, Division 1, and all its referenced documents,
including ASME B31.1, Power Piping.
Coded Marking is a unique number that is assigned by AIC to an item and is used in lieu
of the original required markings to maintain material traceability during construction.
The ID number is traceable to the original identification and the documentation for the
item.
Construction is an all-inclusive term comprising design, materials, fabrication,
examination, testing, inspection and certification required during the manufacture and
installation of pressure vessels or power piping.
Contract Documents Are User's Specifications, calculations, drawings and Purchase
Orders supplied to AIC by the Customer as part of a Contract.
Controlled Copy of a document is a copy over whose distribution the issuing department
exercises control. The issuing department ensures the distribution of revised document to
recipients of Controlled Copies so that inadvertent use of superseded versions is avoided.
Customer is the organization which enters into a Contract with AIC to construct a Code
vessel or part. In Code terminology, this could be the User or his Agent or another Vessel
Manufacturer.
Drawing / Calculations are drawings, sketches or calculations which are prepared by
Engineering to illustrate the structural requirements to be followed in the fabrication and
construction of an item. These drawings are issued to the Draftsman for use in the
preparation of Detail and Erection Drawings.
Monitor means random check, by a direct or indirect inspection, that there is conformance
of the item or activity.
National Board is a designation for the National Board of Boiler and Pressure Vessel
Inspectors.
Pressure Part is a vessel part, which is subject to stressing due to pressure.
Uncontrolled Copy of a document is a copy over whose distribution control need not be
exercised.

page 2 of 3
Welding Supervisor - Personnel directly employed by the company and designated as
welding supervisor responsible for supervision activities during qualification of welding
procedure and welder/welding operator as per company’s written procedure. For aic,
Welding Engineer has been designated as Welding Supervisor.

Page 3 of 3
 Document No: ASME – 001
ASME - QUALITY CONTROL Issue No.:02
Section 15, Rev. No.: 2
MANUAL Page 1 of 2

15.0 List of Exhibits

Exhibit No. Title Format No. Revision No. Date
1 Controlled Copy Distribution Record FORM-QL-28 0 29-09-2015
2 Document Transmittal FORM-GEN-01TRN 0 29-09-2015
3 Technical Delivery Condition FORM-PUR-06 0 29-09-2015
3a Consumable Technical Delivery Condition FORM-ENG-01 0 29-09-2015
4 Engineering Change Request FORM-ENG-05 0 29-09-2015
5 Purchase Request FORM-PUR-05 0 29-09-2015
6 Dummy Purchase Order FORM-ENG-08 0 29-09-2015
7 Purchase Order FORM-PUR-07 0 29-09-2015
8 Goods Receipt Note FORM-PRD-01 0 29-09-2015
9 Raw Material Inspection Report FORM-QL-26 0 29-09-2015
10 Raw Material Requisition FORM-PRD-02 0 29-09-2015
11 Raw Material Return slip FORM-PROD-09 0 29-09-2015
12 Quality & Welding Plan FORM-QL-02 0 29-09-2015
13 Weld Map FORM-QL-03 1 16-01-2019
14 Hydrostatic/ Pressure Test Report FORM-QL-24 0 29-09-2015
15 Pneumatic / Leak Test Report FORM-/QL-27 0 29-09-2015
16 Material Traceability Report FORM-QL-15 0 29-09-2015
17 Record of Stage Inspection of Welds FORM-QL-14 0 29-09-2015
18 Code Name Plates (9 sheets) FORM-QL-29 2 31-03-2020
19 Non Conformance Report FORM-QL-07 0 29-09-2015
20 Welding Procedure Specification FORM-QL-10 0 29-09-2015
21 Procedure Qualification Record FORM-QL-21 0 29-09-2015
22 Qualified Welder List FORM-QL-23 0 29-09-2015
23 Welder Qualification Test Record FORM-QL-22a 0 29-09-2015
23a Welder Operator Qualification Report FORM-QL-22b 0 29-09-2015
24 Welding Data Sheet FORM-WG-01 0 29-09-2015
25 Store Consumable Section Request Form FORM-QL-25 0 29-09-2015
26 Liquid Penetrant Examination report FORM-QL-06DP 0 29-09-2015
27 Magnetic Particle Examination Report FORM-QL-05MT 0 29-09-2015
28 Heat Treatment Control Sheet FORM- QL-12 0 29-09-2015
29 Instrument Calibration status record FORM-QF-C01 0 29-09-2015
30 Document Control Record FORM-QL-04 0 23-03-2016
31 Welder continuity records FORM-QL-30 0 23-03-2016
32 In process Inspection Report FORM-QL-31 0 31-10-2018
33 Material Requisition FORM-QL-32 0 31-10-2018

Page 1 of 2
34 Final Dimension Report FORM-QL-33 0 31-10-2018
35 Final Visual Report FORM-QL-34 0 31-10-2018
36 Radiography Map FORM-QL-35 0 31-10-2018
37 Log of NB Registered Code Items FORM-QL-36 0 31-10-2018
37a Log of Non NB Registered Code Items FORM-QL-37 0 31-10-2018
37b Log of “R” Reports FORM-QL-38 0 31-10-2018

Page 2 of 2