u stamp manual

QUALITY CONTROL MANUAL

Issue No. : 01

Chapter No.: A

Page No. : 1 of 1

Rev. : 01

Cover Page Date : 12.02.13

FOR CONSTRUCTION OF

PRESSURE VESSELS AND PARTSIN ACCORDANCE WITH

ASME BOILER AND PRESSURE VESSEL CODESECTION VIII DIVISION 1TO BE STAMPED WITH

ASME CERTIFICATION MARK WITH‘U’DESIGINATOR AT SHOP AND FIELD SITES CONTROLLED FROM SHOP.

RMG Autometers Gas Technologies Limited

Phone : +91-120-2469800E-Mail : [email protected] : www. rmgautometers.co.in

Plant

B 15 Sector 80Noida, Uttar PradeshIndia- 201305

Head office

B 30 Phase 2Noida, Uttar PradeshIndia- 201305

CONTROLLED / UNCONTROLLED

SERIAL NO. :

ISSUED TO :

ISSUED BY : Head Quality ____________ (Signature)ISSUE DATE :

http://www.multimax.co.in/

mailto:[email protected]


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Chapter No.: A

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Cover Page Date : 12.02.13


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Chapter No.: B

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Rev. : 01

TABLE OF CONTENTS Date : 12.02.13

Chapter Number

Title No. of Pages

Revision Status

Revision Date

A Cover Page 1 01 12.02.13

B Table of Contents 1 01 12.02.13

C Statement of Policy and Authority 1 00 30.10.12

D Glossary and Abbreviations 3 01 12.02.13

01 Administration of Quality Control Manual 3 01 12.02.13

02 Organization and Responsibilities 5 01 12.02.13

03 Drawing, Design Calculation and Specification Control

5 01 12.02.13

04 Material Control 6 01 12.02.13

05 Examination and Inspection Program 4 01 12.02.13

06 Correction of Nonconformities 3 01 12.02.13

07 Welding Control 5 01 12.02.13

08 Non-Destructive Examination 3 01 12.02.13

09 Heat Treatment 3 01 12.02.13

10 Calibration of Measurement and Test Equipment 2 01 12.02.13

11 Retention of Records 1 00 30.10.12

12 Authorized Inspector 2 01 12.02.13

13 Field Site Control 4 01 12.02.13

14 Certification 1 01 12.02.13

15 List of Exhibits 2 00 30.10.12

PREPARED BYHEAD QUALITY

APPROVED BYGM- OPERATIONS

REVIEWED & ACCEPTED BYAUTHORIZED INSPECTOR

SIGNATURE

DATE

NAME Amrit Pal Singh Kuldeep Tyagi Anil Nanda


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DOCUMENT NO.: QCMU-04 Rev. : 00

STATEMENT OF POLICY AND AUTHORITY Date : 30.10.12

2.0 STATEMENT OF QUALITY POLICY AND AUTHORITY

2.1 RMG Autometers Gas Technologies Limited provide reliable and total solutions for regulation and metering of natural gas during transportation and utilization through adherence to Quality management systems based on continual improvement and with focus on the customer’s expectations and involvements.

2.2 GM-Operations has been assigned the responsibility and authority to establish and maintain Quality Control system and to ensure its implementation.

2.3 Head Quality has freedom from the organization side to identify quality problem and initiate, recommend and provide solution on matters relating to Quality and he shall have direct access to the undersigned.

2.4 Head Quality shall have the authority to stop any work which in his opinion is not in accordance with the requirement of the Code and this Manual.

2.5 Any person, whose authority and responsibility are defined in this Manual, may delegate any of his duties to any qualified and when required, certified person reporting to him but cannot delegate his responsibility.

2.6 In case of disagreement between Head Quality and any other RMG Autometers personal on the matters related to the interpretation of the requirements of this Manual, the same shall be brought to the attention of the undersigned for resolution keeping in mind that requirement of Code and Manual shall always prevail.

2.7 The management of RMG Autometers by approving this Quality Control Manual gives its full support to the Quality Control program. It is mandatory that individuals perform their duties assigned as per this Manual.

Date: 30.10.12 Keshav Thirani

Chairman & Managing Director


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GLOSSARY AND ABBREVIATIONS Date : 12.02.13

GLOSSARY OF TERMS:

CodeASME Boiler and Pressure Vessel Code Section VIII Division 1 and Codes and Standards referenced therein.

Certificate of Authorization

A document issued by the ASME that authorizes the use of the ASME Certification Mark with appropriate designator for a specified time and for a specified scope of activity.

Certification Mark An ASME Symbol identifying a product as meeting Code requirements.

Certification Mark Stamp

A metallic stamp issued by the ASME for use in impressing the Certification Mark

Certification Designator

The symbol used in conjunction with the Certification Mark for the scope of activity described in the manufacturer’s Certificate of Authorization.

Data Report Manufacturer’s Data Report/ Manufacturer’s Partial Data Report.

Hold Point A stage of inspection beyond which work shall not proceed until signed off by RMGA-QC/ the AI as satisfactory.

Manual This Quality Control Manual.

Material Test Certificates

Material Test Report, Certificate of Compliance or Manufacturer’s Partial Data Report as applicable.

National Board National Board of Boilers and Pressure Vessels Inspectors.

Review PointA stage of inspection for which RMGA-QC shall perform the activity, document the results and offer the records to the AI for review and acceptance.

SNT-TC-1A ASNT Recommended practice for “Personnel Qualification and Certification in Non-Destructive Testing”.

Welder Welder or welding operator.

Witness Point A stage of inspection for which AI shall be notified in advance. However, work may proceed with the AI’s consent if the AI is unable to undertake the inspection. The documents shall be presented to the AI for review during the next visit.

Written PracticeRMGA Written Practice for Training, Qualification and Certification of NDE Personnel.

ABBREVIATIONS


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AI Authorized Inspector

AIA Authorized Inspection Agency

AIS Authorized Inspector Supervisor

ASME American Society of Mechanical Engineers

ASNT American Society for Non-Destructive Testing

ASTM American Society for Testing and Materials

CoC Certificate of Compliance

DCR Design Change Request

HTRR Heat Treatment Request and Report

ITP Inspection and Test Plan

MDMT Minimum Design Metal Temperature

MAEWP Maximum Allowable External Working Pressure

MAWP Maximum Allowable Working Pressure

MDR Manufacturer’s Data Report

MPDR Manufacturer’s Partial Data Report

RMGA RMG Autometers Gas Technologies Limited

MIRR Material Inspection Request and Report

NCR Nonconformity Report

NDE Non-Destructive Examination

PQR Welding Procedure Qualification Record


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PWHT Post Weld Heat Treatment

QC Quality Control

QCS Quality Control System

GRN Goods Receipt Note

TDC Technical Delivery Conditions

WPS Welding Procedure Specification

WOPQ Welding Operator Performance Qualification Record

WPQ Welder Performance Qualification Record


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ADMINISTRATION OF QUALITY CONTROL MANUAL Date : 12.02.13

1.0 SCOPE

This Chapter describes the system and procedures for administration of the Quality Control Manual.

1.1 QUALITY CONTROL SYSTEM

The Quality Control system detailed in this Quality Control Manual encompasses all aspects of work for the construction of pressure vessels and parts thereof in accordance with ASME Boiler and Pressure Vessel Code Section VIII Division 1 at shop and field assembly at sites controlled by the shop.

1.2 QUALITY CONTROL MANUAL

1.2.1 Head Quality shall prepare and GM-Operations shall approve this Quality Control Manual.

1.2.2 The Manual shall have a Cover Page, Table of Contents, individual chapters, List of Exhibits and sample forms used in various stages of construction of pressure vessels and parts thereof.

1.2.3 After obtaining the approval of GM-Operations, Head Quality shall submit the Manual to the AI for his review and acceptance prior to implementation. The approval of GM-Operations and acceptance of the AI shall be indicated by their signatures on Table of Contents page. The previous revision of the Manual shall govern until the AI sign-off new revision with date.

1.2.4 Head Quality shall distribute only controlled copies of the Manual within the RMGA organization. Each controlled copy shall be identified with its unique serial number on the Cover Page. Head Quality shall obtain acknowledgement of recipients on ‘QC Manual Distribution List’ (Exhibit No. 1-1).

1.2.5 Head Quality shall issue a controlled copy of the Manual to the AI. A controlled copy of the Manual shall also be issued to the AI at site wherever applicable.

1.2.6 Head Quality may issue uncontrolled copies of the Manual to personnel outside the organization through “Document Transmittal” (Exhibit No. 1-2). Such uncontrolled copies shall be current at the time of issue, but may not be updated subsequently.

1.2.7 Head Quality may decontrol any Manual copy not in use for Code work. Holders of controlled copies shall return the same when requested by Head Quality or when the holder has no more use for it, or when the holder ceases to be an employee of RMGA.


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1.3 REVISIONS TO THE MANUAL

1.3.1 Each Chapter in the Manual shall have a number and shall be independently revision controlled. In case of Exhibits, each Exhibit shall be independently revision controlled.

1.3.2 The Manual shall be revised whenever there is a change in the organization structure or procedures or Code requirements or at the time of ASME Joint Review. Head Quality shall review all such changes and if acceptable, shall revise the concerned Chapter or Exhibit.

1.3.3 All relevant functional heads shall review each Code Edition for any impact on the Quality Control Program and communicate the changes to Head Quality. Head Quality shall review the changes in the Code and revise the Manual, if required with in six months of issue of Code Edition/Addenda so as to ensure that the Manual complies with the latest Code requirements. Any revisions required in the Manual shall be implemented with in six months of issue of Code Edition. All such reviews shall be documented on a copy of ‘Summary of Changes’ pages.

1.3.4 In case of a revision in any Chapter of Manual (except Exhibits), the revision number of the entire Chapter shall be advanced. The latest revised text shall be printed in bold font. The previous revision indicators, if any, shall revert to normal font. The Table of Contents page shall also be revised to indicate the latest revision of each Chapter.

1.3.5 In case of a revision to any Exhibit, revision number on that Exhibit shall be advanced. The changes in the Exhibits shall be indicated by clouding raised area. This marking shall appear only on the sample Exhibits included in the Manual and shall not be available on actual forms in use. The List of Exhibits shall be revised to indicate the latest revision of each Exhibit and the latest revision of the List of Exhibits shall be updated on the Table of Contents page.

1.3.6 The revision status of Manual shall correspond to the revision status of the Table of Contents. The Cover Page shall also indicate the latest revision.

1.3.7 Any revisions to the Manual, after approval by GM-Operations, shall be submitted to the AI for review and acceptance, prior to issuance or implementation.

1.3.8 Whenever the Manual is revised, the revised Chapter / Exhibit, List of Exhibits, Cover Page and Table of Contents shall be distributed to all controlled copy holders. Head Quality shall be responsible for retrieval and destruction of obsolete pages received from all controlled copy holders.


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1.3.9 Head Quality may develop new Issue of the Manual every three years to commensurate with the ASME Joint Review or earlier. New Issues shall be controlled in the same manner as the revisions except that the revision level of all Chapters / Exhibits shall revert to zero and revision indicators are not required. All bold letters shall be made same as other text.

1.3.10 Head Quality shall retain a copy of the previous revisions of Manual for the purpose of future reference duly marked as “OBSELETE” for minimum of three years.

1.3.11 This Manual is issued only in English Language.


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ORGANIZATION AND RESPONSIBILITIES Date : 12.02.13

2.0 SCOPE

This Chapter describes the organization structure and responsibilities of key personnel involved in Code construction.

2.1 RESPONSIBILITIES

Main responsibilities of key personnel are as indicated herein.Responsibilities of other personnel described in the Organization Chart have been included in the various chapters of this Manual

2.1.1 Chairman & Managing Director

i) Long term Strategy.ii) Formulate and approve all policies and objectives in accordance with board

directives.

2.1.2 GM- Operations

i) Responsible for overall day to day management of the company.ii) Ensure that the various targets set by the Chairman & Managing Director are met

successfully.iii) Approve Quality Control Manual.iv) Appoint NDE Level III.v) Certify NDE Level I and Level II personnel jointly with NDE Level III.

2.1.3 Head Quality

i) Prepare and issue Quality Control Manual and its revisions.ii) Liaise with ASME, National Board (NB), Authorized Inspection Agency (AIA) and

Authorized Inspector (AI).iii) Maintain certificates of authorization and ensure safe custody and control of ASME

Certification Mark and NB Stamp.iv) Overall responsibility for in-process and final examination and testing during

construction of Code items.v) Approve examination stages for each job on ITP and co-ordinate with the AI for

marking of inspection stages.vi) Coordinate all quality control activities at RMGA shop and at sites controlled by

shop.vii) Register Data Report with National Board, when required.


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viii) Liaise with Site QC Engineer and Site NDE Level-II for all quality, welding and NDE activities at site.

ix) Approve technical requirement for welding materials.x) Approve WPS, certify PQR and WPQ / WOPQ records.xi) Approve heat treatment cycle and certify heat treatment.xii) Approve final disposition of all nonconformities.xiii) Certify Data Reports.xiv) Retain Records.

2.1.4 GM Business Development

i) Generate business as per target fixed by Chairman & Managing Director.ii) To update and inform to Management for potential market and product requirements

2.1.5 Chief Finance Officer

i) Overall responsibility of finance and accounts.

2.1.6 Incharge-HRD Admin

i) Formulate and implement human resource policies.ii) Recruit of manpower and provide training when required.iii) Employee relations, grievances and counseling.

2.1.7 NDE LEVEL III

i) Approve Written Practice and NDE procedures.

ii) Train, examine and qualify NDE personnel.

iii) Certify NDE Level I and Level II personnel jointly along with GM-Operations.

iv) Demonstrate NDE procedures to the AI prior to use.

v) Review calibration records for NDE equipment.

vi) Approval of NDE techniques for examination at site.

2.1.8 NDE LEVEL II

i) Calibrate NDE equipment.

ii) Carry out NDE at shop and at site and evaluate test results in accordance with procedures approved by NDE Level III.


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2.1.9 MANAGER FINANCE

i) Organize dispatch of products to customers.

2.1.10 MARKETING MANAGER

i) Develop new customers.

2.1.11 PROJECT COORDINATOR

i) Internal and external follow up of projects. Coordinate with clients for obtaining technical clarification from client as required by Head Design, Head Quality, Head Material.

2.1.12 DRAFTMAN

i) Prepration of drawings on CAD software.

2.1.13 WELDERS

i) Carry out the welding on the job as per applicable WPS and other Procedures.

2.1.14 All the functional heads, except NDE Level III, may delegate their duties to their suitably qualified lower level designees, but shall remain responsible for their respective functions. A Manager or Supervisor may perform the duties assigned to his subordinates provided he is qualified to do so.

2.1 ORGANIZATION CHART of this Manual. List of Manual designations and corresponding designations of key personnel are shown

on page 4 of 4 of this Chapter.The organization chart for shop is depicted on Page 3 of 4 of this Chapter. Typical organization structure for the field site is shown in Chapter 13


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Organization Chart

Chairman & Managing Director

GM Operations

Welding

Engineer

Head Design

Chief Finance Officer

NDE Level II

Design

Engineer

Manager Finance

Production

Engineer

Stores InchargePurchase

Engineer

Incharge

Maintenance

NDE Level IIIWelders

Functional Control Administrative Control

Engineer QC

Marketing Manager

GM Business

Development

Production

Manager

Head

Materials

Project

Coordinator

In-charge

HRD, Admin

Head Quality

Draftman


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MANUAL DESIGNATION ORGANIZATION DESIGNATION


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Chairman & Managing Director Chairman & Managing Director

GM- Operations GM- Operations

Head Quality Head Quality

Production Manager Production Manager

Head Design Head Design

GM Business Development GM Business Development

Project Coordinator Project Coordinator

Head Materials Head Materials

Chief Finance Officer Chief Finance Officer

In-charge HRD Admin In-charge HRD Admin

Production- Engineer Engineer-Production

Incharge Maintenance Incharge Maintenance

NDE Level III NDE Level III

Welding Engineer Head Quality

Engineer QC Engineer QC

Design Engineer Design Engineer

Marketing Manager Marketing Manager

Purchase Engineer Purchase Engineer

Stores Incharge Stores Incharge

NDE Level II Head Quality

Draftsman Draftsman

Welder Welder


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DRAWING, DESIGN CALCULATION AND SPECIFICATION CONTROL Date : 12.02.13

3.0 SCOPE

This Chapter describes the system and procedures for preparation, approval, distribution and revision of design calculations, drawings, and other design documents.

3.1 REVIEW OF CUSTOMER DOCUMENTS

3.1.1 GM-Business Development shall receive customer Purchase Order along with technical specifications and allocate a unique Internal Order Number (AO 00 series).He shall then forward the same to Head Design, Quality Control, Purchase for review. GM-Business Development shall prepare offer sheet in consultation with Head Design.

3.1.2 The Internal order number suffixed with letter ‘AO’ means ASME Order and two digit running serial number (01, 02 etc.) shall be used as Manufacturer’s Serial Number (For example, U 001).

3.1.3 Head Design shall review information provided by the Customer for to ensure that all required information including applicable Loading (if any) have been provided to enable him perform Code calculations verifying compliance with Code requirements including applicability of loadings as per UG-22 of Code. Any discrepancy/missing information shall be brought to the notice of customer through GM-Business Development and resolved to comply with Code requirements. This shall be accomplished prior to acceptance of the order.

3.2 DRAWINGS AND DESIGN CALCULATIONS

3.2.1 Head Design shall prepare the design calculations as per the applicable Edition and addenda (when applicable) of the Code, and additional customer requirements, if any. All applicable loadings as per UG–22 of the Code shall be considered in the design.

3.2.2 Head Design shall assign a Design Engineer for preparation of drawings.

3.2.3 Either U.S Customary, SI single system of unit shall be used for all aspects of design. All entries on a Manufacture’s Data Reports and data for Code required Name Plate shall be in units consistent with the fabrication drawing for the component using U.S. customary, S.I. or local Customary units provided they are acceptable to the receiving Jurisdictions. It is acceptable to show alternate units parenthetically.

3.2.4 Head Design shall be responsible for selection of materials from those covered under ASME Code Section II Part A or B for which allowable stress values are listed in ASME Code Section II Part D and shall be further restricted to those permitted by the Code or otherwise permitted by Code Cases. All applicable cautionary notes given in ASME Section II Part D for the relevant material shall be evaluated for conformance. All material used in Code job shall confirmed to be acceptable for use by the construction Code.

3.2.5 When design calculations and/or drawings are provided by customer or any outside agency, Head Design shall review and approve the same for Code compliance. Any discrepancy shall be resolved to meet Code requirements.


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3.2.6 The fabrication drawings shall contain the following information, as a minimum:

Equipment Name / Tag No., Work Order No. and Manufacturer’s Serial Number. Code of Construction (ASME Code Section VIII Division 1) including Edition. Applicable Code Cases, if any. Design Pressure and maximum design temperature. MAWP and MAEWP (if applicable) at coincident temperature. MDMT at MAWP. Applicable loadings as per UG - 22 of Code. Bill of materials according to the construction Code, including material specification and

grade for each part, thickness, size and quantity. Geometrical and manufacturing details including dimensional tolerances as per purchase

specification and Code requirements. Weld details including fillet sizes. Service restrictions as per UW-2 (Lethal etc.) and corrosion allowance. Heat Treatment, if any. Radiography and other NDE as applicable. Requirements for and/or exemptions from impact testing of material, weld and HAZ. Requirements for production test plates, if any. Hydrostatic test pressure, temperature and water quality requirement, if any. Name plate / stamping detail. Special requirements, if any.

3.2.7 All drawings and design calculations shall be reviewed for Code compliance and approved by Head Design.

3.2.8 Design Engineer shall mark the drawings as “Issued for Reference” and distribute to Head Quality, Project Coordinator, Head Materials, Production Manager and obtain their acknowledgement on “Documents issue record Sheet” (Exhibit No. 3-1). Subcontracted related work shall also be forwarded to Head Materials with relevant Drawings and TDS.

3.2.9 “Issued for Reference” drawings shall only be used for preliminary planning activities or obtaining comments from the recipients. The drawings may also be forwarded to the customer for comments. The comments shall be incorporated, provided they do not violate any Code requirements. After incorporation of comments from Customer, Head Quality, Project Coordinator, Head Materials and Head Design shall issue drawing duly marked as issue for manufacturing. Head Design shall approves drawings and design calculations.

3.2.10 All revisions to drawings / design documents shall be controlled in the same manner as the original drawing / documents. Any revisions to drawings and design documents shall also be approved by Head Design.


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3.2.11 The latest changes in the revised drawings shall be highlighted by clouding the revised matter and marking revision number inside a triangle. A brief description of the revisions shall also be indicated on the revision table in the drawing.

3.2.12 Revision of each page of design calculations shall be individually controlled. Revision status of the Index sheet shall be the revision status of the entire document.

3.2.13 Design Engineer shall issue revised drawings to all the original recipients. The recipients shall be responsible for destroying the old revision or if retained for reference, marking them as “OBSELETE”.

3.2.14 Documents Issue Record Sheet shall indicate the latest revision status of individual drawings for the relevant Work Order.

3.2.15 Head Design shall submit the drawings and design calculations to the AI for his review before commencement of fabrication. All subsequent revisions shall also be offered to the AI for review. Any point raised by the AI shall be resolved. The review by the AI shall not relieve RMGA from their responsibility for completeness and correctness of design calculations and drawings and compliance with Code requirements.

3.2.16 ‘As- Built’ drawings and calculations giving details of actual material used and final dimensions shall be prepared by Design Engineer and shall be submitted to the AI for his review after approval of Head Design. ‘As- Built’ drawings shall be prepared as next revision of the drawings.

3.3 DRAWING CHANGE REQUEST (DCR)

3.3.1 Any of the concerned departments including Purchase, Production, Quality Control or Design may request for changes in the drawings to suit construction activities, material substitutions, etc. on “Design Change Request” (Exhibit No. 3-2).No material substitution shall be accepted unless it has been approved by Head Design.

3.3.2 The initiator shall obtain the comments of Head Quality on welding and quality control requirements on the DCR. The comments shall be reviewed by Head Design and if found acceptable, the DCR shall be approved by Head Design. DCRs related to Code requirements shall also be offered to the AI for his review.

3.3.3 Design Engineer shall allocate a unique serial number to each approved DCR and distribute the same to all the recipients of the concerned drawing as per the distribution list mentioned in DCR and obtain acknowledgement on the DCR. The recipients shall indicate the DCR number and date on the appropriate drawing at the relevant area by clouding.

3.3.4 Design Engineer shall mark the DCR number and date on the file copy of the applicable drawing and ensure that the DCRs are incorporated in the next revision of that drawing. The number of DCRs against any revision of the drawing shall be limited to five.

3.3.5 Whenever the drawings are revised or any DCR is approved, effect of the same shall be verified and documented on relevant design calculations by Head Design even if no


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changes are required. If required, the design calculations shall be revised to ensure Code compliance.

3.4 MATERIAL INDENTAND TECHNICAL DELIVERY CONDITIONS (TDC)

3.4.1 Based on approved drawing, design calculations, Code requirements and customer specifications, Design Engineer shall prepare the “Material Indent” (Exhibit No. 3-3) including the “Technical Delivery Conditions” (Exhibit No. 3-4) for materials. Head Design shall review and approve the Material Indent and TDC.

3.4.2 Technical Delivery Conditions shall contain the following details as a minimum:

Material specification and grade, including applicable Edition/Addenda. Other applicable specifications and standards. Ordering information as per relevant specification. Supplementary requirements, as applicable. Requirement of Material Test Report (MTR), Manufacturer’s Partial Data Reports,

Certificate of Compliance (CoC), if applicable. Marking requirements. Requirement of inspection.

3.4.3 Design Engineer shall distribute the Material Indent and TDC to Purchase Engineer and Project Coordinator, Production Manager through “Document Transmittal”(Exhibit 1-2). A copy of TDC shall also be issued to Head Quality.

3.4.4 Whenever the drawings are revised or a DCR is approved, Design Engineer shall review the applicable Material Indent and TDC and revise the same, if required. Revised Material Indent and TDC shall be approved by Head Design and distributed as above.

3.5 SOFTWARE CONTROL

3.5.1 If any computer software/program is used for design calculations, Head Design shall verify the computer software/program by parallel Manual calculations and verification of output prior to its first use.

3.5.2 The software / programs shall be based on Code formula. Where specific rules are not given in Code, the software / programs shall be based on appropriate formula from other national or International Standards acceptable to the Authorized Inspector.

3.5.3 Head Design shall review the software/ programs to ensure compliance with the applicable Edition of Code and document the same.

3.5.4 Upon issuance of new Code Edition/Addenda, Head Design shall verify software program prior to first use for compliance to requirements of new Editions/Addenda of the Code.

3.5.5 Whenever software version is changed Head Design shall verify output of the software program by parallel set of manual calculation for compliance to applicable Edition/addenda.


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3.5.6 Head Design shall verify the input parameters/ data used for all design calculations.

3.5.7 Head Design shall maintain the records of verification and make the same available to the AI for review.


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MATERIAL CONTROL Date : 12.02.13

4.0 SCOPE :

This Chapter describes the system and procedures for procurement, receipt, identification, receiving inspection, storage and issue of materials used in Code construction. Welding materials shall be controlled as described in Chapter No. 07 (Welding Control).

4.1 VERIFICATION OF STOCK MATERIAL

4.1.1 Purchase Engineer shall forward the Material Indent to Stores Incharge for checking the availability of the required material in stock.

4.1.2 Stores Incharge shall check availability of the required material in stock.

4.1.3 If the required material is available in stock, Stores Incharge shall offer the available material for examination to Engineer QC through “Material Inspection Request and report”( Exhibit No. 4-1) .

4.1.4 Engineer QC shall carry out visual and dimensional examination including thickness check, verify the markings available on material, correlate the markings with the relevant material test certificates and review the material test certificates against the requirements of applicable drawings, TDC and material specification and prepare “Material Inspection Request and report” (Exhibit No. 4-1) .

4.1.5 If additional testing is required to meet the requirements of TDC and drawings, Engineer QC shall arrange for the tests using calibrated test equipment and review the results of additional tests prior to accepting such material.

4.1.6 For the material test certificates indicating Edition/Addenda of the ASME material specification different from that specified on the drawing and TDC, Engineer QC shall verify all requirements like chemical and mechanical properties, heat treatment, marking, certification requirements, etc. against the requirement of applicable Edition of the material specification before recertification and acceptance. In case any material is available in the stock of old Edition/Addenda then same will be compared with the new applicable Edition/Addenda.

4.1.7 Material conforming to an ASTM specification as per ‘Guidelines on Acceptable ASTM Editions – Table ED-1’ of ASME Code Section II Part A or B may be accepted in lieu of the corresponding ASME specification after recertification.

4.1.8 For ASTM materials to Editions not listed in Table ED-1 of ASME Section II Part A or B, Engineer QC shall process a Nonconformity Report as per Chapter No. 06 (Correction of Nonconformities). He shall verify the material test certificates against the requirements of applicable Edition of material specification on “Material Verification Report” (Exhibit No. 4-2). If acceptable, Engineer QC shall re-certify the material to the required material specification.


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4.1.9 Engineer QC shall indicate the results of examination on the MIRR and return to Purchase Engineer who shall instruct the Stores Incharge to allocate the acceptable material against the relevant job by marking the Work Order number & part no. as per drawing on the material. For accepted material, Engineer QC shall retain a copy of the MIRR along with the material test certificates and additional test reports, if any in the job file. The material test certificates for accepted material shall be endorsed as below and signed off by Engineer QC.

Material Test Report Reviewed as perSpecification………………Grade/Class……………..of ASME Section II Part………………………………Edition…………….Addenda…………………………and found acceptable-------------------------------------------------------------Engineer QC Sign……..Date…….

4.1.10 If required, Purchase Engineer may raise DCR for use of alternate / substitute material. Head Design shall review the DCR. No substitution of material shall be permitted without the approval of Head Design and the concurrence of the AI.

4.1.11 Stores Incharge shall comment on the Material Indent for material available in stock and accepted through MIRR and forward the Material Indent to Head Materials for procurement of unavailable material. Store Incharge shall also indicate on material indent, material which are either not in stock or available in stock but not acceptable for job based on which purchase order shall be issued by the Head Materials.

4.2 PROCUREMENT

4.2.1 Head Materials shall order materials based on the final Material Indent requirement by releasing “Purchase Order” (Exhibit No. 4-3) to approved suppliers. The PO shall be traceable to the Work Order Number, unless for stock. PO shall contain all the technical information from the Material Indent and shall refer to the applicable TDC. GM- Operations shall approve the Purchase Order. The Head Materials shall be responsible for the correctness and completeness of Purchase Orders.

4.2.2 Preformed / prefabricated welded components, to be incorporated in the final job shall be purchased from a shop having the Certificate of Authorization for applying ASME Certification Mark with ‘U’ designator. Such items shall be procured along with Manufacturer’s Partial Data Report (MPDR) as required by the Code. Engineer QC shall verify the Certification Mark on such components and offer the components to the AI for inspection prior to use. Standard pressure parts, as defined in UG-11 of ASME Code Section VIII Division 1, shall be exempt from this requirement.


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4.2.3 No substitution of material or changes in technical requirements specified in Material Indent and TDC shall be permitted without the approval of Head Design on DCR. Any changes to a PO shall be communicated by issuing an amended PO.

4.2.4 Copies of Purchase Order including amendments, if any, shall be forwarded to Head Quality and Stores Incharge.

4.2.5 Head Materials shall forward material test certificates received from the material supplier to Head Quality.

4.3 RECEIPT, EXAMINATION AND STORAGE

4.3.1 Upon receipt of material, Stores Incharge shall correlate the items with the PO, check the quantity and physical condition and prepare “Goods Receipt Note-GRN” (Exhibit No. 4-4).Stores Incharge shall mark the GRN number on all accepted material.

4.3.2 Stores Incharge shall offer the material to Engineer QC for examination through GRN and also forward any material test certificates received with delivery documents. Incoming materials awaiting examination shall be kept in a separate identified area.

4.3.3 Engineer QC shall carry out the examination on incoming materials as per clause 4.1.4 to 4.1.9 above against the requirements of PO, applicable drawings, material specification and TDC. Engineer QC shall document the results on GRN and return a copy of the GRN to Stores Incharge. For components received with MPDR, Engineer QC shall verify the Certification Mark on components and offer the components to the AI for inspection prior to use.

4.3.4 Engineer QC shall retain the material test certificates and GRN on file.

4.3.5 Stores Incharge shall ensure that only material accepted by Engineer QC is taken into stock.

4.3.6 Nonconforming materials shall be dealt with in accordance with Chapter No. 06 (Correction of Nonconformities). Engineer QC shall arrange to identify such items with yellow paint/Card/Hold “Exhibit No”. ( 4-5).

4.3.7 Engineer QC shall carry out re-examination of the material, after resolution of the nonconformity and advise the acceptance / rejection on the GRN to Stores Incharge. Engineer QC shall arrange to remove the ‘HOLD’ on the acceptable material.

4.3.8 Material not complying to PO, drawing or TDC requirements shall be rejected. Engineer QC shall arrange to identify such material by marking ‘REJECT” by red paint/Card Exhibit No.”( 4-6)”. Stores Incharge shall segregate the rejected material in order to prevent mix-up with the accepted materials and arrange for disposal of rejected material.


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4.3.9 If further material testing is required at receiving inspection or during manufacturing operations, the Engineer QC shall arrange for the required testing and accept/reject the material accordingly.

4.3.10 Stores Incharge shall ensure proper marking, handling and storage of materials.

4.4 FREE ISSUE MATERIAL BY CUSTOMER

4.4.1 For materials supplied as free issue by Customer, Head Quality shall obtain the material test certificates from the customer through GM Business Development.

4.4.2 Materials Receipt examination shall be carried out as per clause 4.3 above against the requirements of approved drawings and TDC.

4.4.3 Any discrepancies shall be brought to the notice of the customer and resolved to meet the Code requirements.

4.4.4 Store Incharge shall maintain material issue details for customer supplied material separately.

4.5 SUB-CONTRACTING FORMING / FABRICATION

4.5.1 Forming of components such as shell, head, etc., may be sub-contracted to vendors approved by Head Quality/GM-Operations. Where the subcontractor is not a holder of ASME Certificate of Authorization for application of Certification Mark with ‘U’ designator, welding shall be excluded from the scope of the subcontractor.

4.5.2 Purchase Engineer shall forward the request for subcontracting to Head Materials along with applicable drawing and TDC approved by Head Design. The TDC shall include the requirements for subcontractor’s certification for the formed part according to Clause UG-79 of Code, including the method of forming (hot or cold) and heat treatment, whether or not performed by the sub-contractor. Heat-Treatment if any, performed by forming subcontractor shall be reported.

4.5.3 Head Materials shall prepare and process the PO as described above, referring to and including the applicable TDC, drawing etc.

4.5.4 Engineer QC shall examine the items after receipt at RMGA shop as per the procedure outlined above.

4.6 ISSUE OF MATERIAL


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4.6.1 Based on the approved drawings, Production Manager/Engineer shall prepare “Material Issue Slip” (Exhibit No. 4-7) detailing the Work Order No., part no., size & quantity and forward to Store Incharge for issue of material from the Stores. For plates, sheets etc., Production Manager/Engineer shall enclose cutting list/plan along with Material Issue Slip.

4.6.2 Stores Incharge shall ensure that only accepted material is issued on job.

4.6.3 Production Engineer shall arrange to mark the Work Order Number and part number on each part, in addition to the required material markings and offer the material for acceptance to Engineer QC through “Inspection Request and Report” (Exhibit No. 4-8).

4.6.4 Engineer QC shall carry out visual and dimensional examination including thickness check, verify the markings available on material, correlate the markings with the relevant material test certificates and review the material test certificates against the requirements of applicable drawings, TDC and material specification.

4.6.5 Engineer QC shall prepare “Material Attestation Report” (Exhibit No. 4-9) for all pressure parts and non-pressure parts directly welded to pressure parts.

4.6.6 Engineer QC shall offer the Material Attestation Report along with applicable material test certificates to the AI to enable him to verify that it represents the material and meets the requirements of the material specification. Acceptance of material by the AI shall be signified by his signature and date on the Material Attestation Report.

4.7 MATERIAL TRACEABILITY

4.7.1 Production Manager/Engineer shall be responsible for maintaining traceability of material identification on all pressure parts and non-pressure parts directly welded to pressure parts, throughout fabrication.

4.7.2 If the material is to be subjected to operations during which identification markings will be partially or completely cut, or the material is to be divided into two or more parts, Production Engineer shall arrange for accurate transfer of identification marks, prior to cutting, to a location where the markings shall be visible on the completed vessel. In addition to the markings required as per Code, the parts shall also be identified with Work Order number and part number.

4.7.3 Hard stamping shall not be used on vessels constructed on ferrous material less than 6 mm thickness or of non-ferrous plates less than 13 mm thickness, or when the service conditions prohibit. In such cases, marking transfer may be done by etching, engraving, paint marking etc., and traceability records of all material used shall be maintained by the Engineer QC.


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4.7.4 Alternatively, the materials may be identified with unique Coded marking traceable to original required materials marking as per procedure for Coded marking, approved by Head Quality & acceptable to the AI. Such Coded marking transfers shall be recorded on “Material Attestation Report” for the part.

4.7.5 Production Engineer shall offer the transferred markings to Engineer QC for verification, prior to cutting through Inspection Request and Report. If acceptable, Engineer QC shall put his stamp adjacent to the transferred markings.

4.7.6 Production Manager shall ensure that no material without proper identification is used for fabrication of Code items.

4.7.7 Engineer QC shall ensure that only acceptable material is used in Code construction.


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EXAMINATION AND INSPECTION PROGRAM Date : 12.02.13

5.0 SCOPE

This Chapter describes the systems and procedures for examination, inspection, testing and Code stamping of pressure vessels and parts, preparation and certification of Data Reports and control of ASME Certification Mark and National Board stamps.

5.1 INSPECTION AND TEST PLAN AND INSPECTION DATABOOK

5.1.1 Based on approved drawings, applicable Code Edition, Addenda and additional customer’s requirements, Engineer QC shall prepare “Inspection and Test Plan” (Exhibit No. 5-1) describing stages and extent of examinations, inspections and tests, their acceptance standards and reference documents.

5.1.2 ITP shall specifically indicate all examination, inspection and test activities required to be completed prior to setting up of closure of the vessel, particularly when entry to completed vessel is not provided. Internal visual inspection before setting up of closure joint shall be identified as a Hold point for RMGA Engineer-QC and the AI.

5.1.3 Head Quality shall approve the Inspection and Test Plan and offer to the AI along with approved drawings for his review and marking Hold, Witness and Review stages of Inspection, before commencement of fabrication. All inspection stages Hold/ Witness/Review shall be Hold points for RMGA Engineer-QC and work shall not proceed unless so authorized by RMGA Engineer-QC.

5.1.4 Engineer QC shall distribute copies of approved Inspection and Test Plan to Head Design, Production Manager and Project Coordinator, Head Materials as a controlled document using “Document Transmittal” (Exhibit No. 1-2).

5.1.5 Engineer QC shall prepare the “Inspection Data Book” (Exhibit No. 5-2) including “Weld Joint Inspection Check List” (Exhibit No. 5-3) based on approved drawings and ITP, accurately transferring the inspection stages from the ITP. The Inspection Data Book shall be approved by Head Quality and submitted to the AI for verification of transfer of the inspection stages.

5.1.6 In case of any revisions to the applicable drawings, Engineer QC shall review the ITP and Inspection Data Book for any change and revise the same, if required. This review shall be documented on the Cover page of respective documents, even if no changes are required.

5.1.7 Head Quality shall review and approve the revised ITP and Inspection Data Book. All revisions to ITP or Inspection Data Book shall be offered to the AI for review and acceptance. Copies of revised ITP shall be forwarded to all the original recipients.

5.2 IN-PROCESS EXAMINATION AND INSPECTION

5.2.1 Production Manager/Engineer shall arrange to draw material from Stores against Material “Issue Slip” (Exhibit No. 4-7) and arrange for material identification as per Chapter No. 04 (Material Control). Only identified materials shall be issued for fabrication. In case any additional tests are required on materials or at any stage during manufacturing, Engineer QC shall arrange for the same.


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5.2.2 Production Engineer shall offer the job to Engineer QC at stages as per the approved ITP, through Inspection Request and Report. Engineer QC shall carry out all examinations and tests as per drawings, ITP and approved procedures and document the results on Inspection Request and Report as well as Inspection Data Book.

5.2.3 Engineer QC shall keep the AI informed about the progress of the job and offer the same to the AI at the stipulated stages. The clearance of the stage by RMGA Engineer-QC /the AI shall be documented with their signatures and date in Inspection Data Book.

5.2.4 For Formed heads. Engineer QC shall carry out the visual and dimensional examination including profile check with template, prepare “Dished End Inspection Report”(Exhibit No.5-9).

5.2.5 Rolled Shell shall be visually inspected and dimensionally checked including profile with a template as per requirements of UG-80 and inspection details recorded on “Rolled shell inspection report” ”(Exhibit No.5-10).

5.2.6 Engineer QC shall inform the results of examination, inspection or tests to Production Engineer by returning the duplicate copy of Inspection Request and Report, duly signed. No further operation shall be carried out until all the previous Hold points of RMGA Engineer-QC or AI as applicable, have been cleared.

5.2.7 Any nonconformity noted shall be processed in accordance with Chapter No. 06 (Correction of Nonconformities).

5.2.8 All Welding shall be carried out as per Chapter No. 07 (Welding Control).

5.2.9 All NDE shall be carried out at the required stages as per Chapter No. 08 (Non-Destructive Examination). Engineer QC shall carry out visual examination of items / welds prior to offering for NDE.

5.2.10 After completion of fabrication, Production Engineer shall offer the job to Engineer QC for obtaining the clearance for heat treatment or pressure test, as applicable.

5.3 FINAL INSPECTION AND TEST

5.3.1 Engineer QC shall verify that all fabrication, examination, inspection and tests have been completed and all previous stages have been accepted/signed off by RMGA Engineer-QC /AI. He shall visually examine and dimensionally check of the items, record the results in the “Final Dimension Report” (Exhibit No. 5-4) and offer the item to the AI prior to releasing the vessel for heat treatment or pressure test (as applicable).

5.3.2 At this stage, Engineer QC shall also ensure that all NDE has been satisfactory completed and all nonconformities have been satisfactorily closed out, including the final review by the AI.

5.3.3 All heat treatment shall be carried out as per Chapter No. 09 (Heat Treatment Control). Production test coupons, if applicable, shall be subjected to same heat treatment (including soaking temperature, holding time and cooling rates), as the Code item.


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5.3.4 Engineer QC shall arrange for the required mechanical tests on production test coupons, wherever applicable, using calibrated test equipment at a laboratory.

5.3.5 All examinations, inspections and tests for Code compliance shall be carried out using equipment calibrated as per Chapter No. 10 (Calibration of Measurement and Test Equipment).

5.3.6 Engineer QC shall maintain records of all examinations, inspection and tests and offer the records to the AI, when requested.

5.3.7 Engineer QC shall ensure that all required examinations, inspections and tests have been completed, prior to releasing the item for pressure test.

5.3.8 Production Engineer shall arrange to carry out pressure test in accordance with approved drawings/ITP and procedure approved by Head Quality.

5.3.9 Engineer QC shall witness the pressure test, record the results in “Pressure Test Report” (Exhibit No. 5-5) and if acceptable, offer the pressure test to the AI for his inspection.

5.3.10 Whenever pneumatic test is permitted to be conducted in lieu of hydrostatic test, Engineer QC shall ensure that all the requirements of Clause UW-50 of Code are complied with.

5.4 CODE STAMPING AND CERTIFICATION OF DATA REPORTS

5.4.1 Head Quality shall be responsible for safe custody and control of the ASME Certification Mark and National Board Stamp to prevent their loss or any unauthorized use.

5.4.2 Upon completion of the pressure test, Head Quality shall verify that all the specified requirements have been met and all inspection stages as stipulated in Inspection and Test Plan have been accepted by the AI prior to obtaining the AI’s concurrence to apply the ASME Certification Mark and if applicable, National Board Stamp.

5.4.3 Head Quality shall verify the vessel stamping / “Name Plate” (Exhibit No. 5-6) as per approved drawing and ensure that the Name Plate is attached to correct vessel / item by a method acceptable as per Code. Head Quality shall arrange for affixing the ASME Certification Mark and if applicable, National Board stamp, with the prior concurrence of the AI and in his presence. The ‘U’ designator shall be stamped or etched directly below the ASME Certification Mark.

5.4.4 The details of “As-Built” drawings of parts dimensions and materials used shall be furnished by Engineer QC to Design Engineer to enable him prepare the “As-built” drawing. “As-Built” drawings shall be prepared as next revision of the drawings. Head Design shall approve the “As-built” drawings and design calculations and offer to the AI for review.

5.4.5 Engineer QC shall prepare the Manufacturer’s Data Report. Head Quality shall verify the MDR for correctness and completeness, certify the same and submit to the AI along with “As-built” drawings for his review and signature.

5.4.6 Head Quality shall distribute copies of the Manufacturer’s Data Report duly signed by the AI to:


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The user or his designated agent The appropriate enforcement authority in the jurisdiction in which the vessel is to be

installed, where required by law, The AI.

MPDR shall be forwarded in duplicate, to the Manufacturer of the completed vessel or to the user or his designated agent for replacement or repair parts and one copy shall be given to the AI.

5.4.7 Retention of Data Reports (MDR/MPDR) and other records shall be as per Chapter No.11 (Retention of Records).

5.4.8 Head Quality shall maintain a ‘Log of ASME Code Stamp Jobs’ (Exhibit No. 5-7) with details of all Code items constructed by RMGA.

5.5 REGISTRATION OF DATA REPORTS WITH NATIONAL BOARD

5.5.1 When required, Manufacturer’s Data Reports shall be registered with National Board.

5.5.2 Head Quality shall assign National Board number after the pressure test or at the time of Name plate / equipment stamping, when no shop pressure test is to be conducted.

5.5.3 National Board numbers shall begin with “1” and shall be in sequential increment order without any skips or gaps of unused numbers, or duplication of numbers. No prefixes / suffixes, either alphabetical or numerical, shall be used with the National Board number. The National Board number shall be incorporated on the Name Plate adjacent to the National Board Stamp.

5.5.4 Head Quality shall maintain a “Log of National Board Numbers Issued” (Exhibit No. 5-8) detailing the National Board No., date assigned, Work Order Number, Manufacturer’s Serial Number, type of equipment, customer name, location of installation (if known), date of signing of MDR by the AI and date of forwarding the MDR to National Board for registration.

5.5.5 Head Quality shall forward the original MDR to National Board within 60 days of signing of the MDR by the AI.


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CORRECTION OF NONCONFORMITIES Date : 12.02.13

6.0 SCOPE

This Chapter describes procedure for resolving nonconformities observed during any stage of construction.

6.1 DEFINITION

6.1.1 Nonconformity is any condition, which does not comply with the applicable rules of the Code, this Manual, drawings or any other specified requirements. Nonconformities must be corrected before the completed item can be considered to comply with the Code. Examples of nonconformities include, but are not limited to:

Materials and parts having deviation from specified requirement. Repair of defects in material. Un-calibrated equipment used in measurement or test.

6.2 REPORTING AND IDENTIFICATION

6.2.1 Any RMGA personnel observing nonconformity shall report the same to Head Quality/Engineer QC. Engineer QC shall verify the same, prepare a “Nonconformity Report” (Exhibit No. 6-1) and allocate a unique number to each NCR. Nonconformities observed by others shall be verified by Engineer QC to enable him prepare the Nonconformity report.

6.2.2 The NCR number shall be indicated in the Inspection Data Book/Material Attestation Report/Inspection Reports, as applicable. Head Quality shall maintain a ‘List of NCR’ (Exhibit No. 6-2) giving NCR No. in continuation and listing all the NCRs issued for Code items.

6.2.3 The nonconforming item or activity shall not be allowed to process further until the nonconformity has been satisfactorily resolved. Engineer QC shall identify nonconforming items by marking “HOLD” by yellow paint/Card.

6.2.4 All applicable NCRs shall be satisfactory resolved including final review by the AI prior to release for heat treatment or prior to pressure test of the Code item.

6.3 PROPOSAL AND FINAL RULING

6.3.1 The functional head responsible for the area / activity where nonconformity has been detected shall propose a corrective action on the NCR. The NCR shall be forwarded to Head Quality and Head Design for their comments on the proposed corrective action.

6.3.2 Based on the above comments, Head Quality shall provide a ruling for nonconformity resolution and offer to the AI for review of proposal.

6.4 AI REVIEW

6.4.1 Head Quality shall keep the AI informed of all nonconformities including proposal for ‘Use –As-Is’ / Repair / Reject.


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6.4.2 Head Quality shall obtain the AI’s concurrence on the proposed resolution prior to implementing corrective action for all nonconformities related to Code or Manual requirements.

6.5 USE-AS-IS DISPOSITION

6.5.1 ‘Use-As-Is’ disposition is permitted only for nonconformities not violating requirements of the Code or this Manual. Head Design shall provide technical justification for the basis of acceptance for such cases. Engineer QC shall remove the ‘Hold’ tag and work may proceed further.

6.6 REPAIR DISPOSITION

6.6.1 When the resolution involves repair, Engineer QC shall send the copy of NCR to the concerned functional heads and allow the work to proceed on the item / activity in accordance with ruling on the NCR.

6.6.2 If necessary, a supplementary ITP and a supplementary Inspection Data book shall be prepared as described in Chapter No. 05 (Examination & Inspection Program).

6.6.3 The concerned functional head shall be responsible for corrective action as per ruling on the NCR. Repair welding, if required, shall be performed in accordance with Chapter No. 07 (Welding Control).

6.6.4 Engineer QC shall arrange for re-inspection of the job after rectification and shall indicate the results of re-inspection on the NCR. The supplementary ITP and Inspection Data Book, if any, shall be followed during re-inspection after rectification as per NCR.

6.6.5 Repairs to welds resulting from visual or non-destructive examination do not require any NCR to be raised. Such repairs shall be carried out by qualified welders using qualified WPS as per Weld Plan reviewed by the AI. However, NCR shall be raised for repair to welds after PWHT or pressure test and Head Quality shall obtain the owners/users concurrence prior to performing such repairs. As per requirements of UCS-56 of ASME Sec-V111 shall be complied with.

6.6.6 For any repairs of defects in material, NCR shall be raised and the AI’s concurrence shall be obtained for proposed method and extent of repair before starting the work.

6.7 REJECT DISPOSITION

6.7.1 When the nonconforming item is rejected following an NCR, Engineer QC shall attach ‘Reject’ tag on the item. Production Manager shall ensure the removal of the rejected items from the fabrication area to a separate area marked for rejected items and Stores Incharge shall arrange for disposal of the rejected item.

6.8 RECORDS

6.8.1 In case the proposed resolution of nonconformities requires revision of drawings, it shall be done as per Chapter No. 03 (Drawings, Design Calculation and Specification Control).


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6.8.2 Head Quality shall be responsible for ensuring completion of resolution, final disposition of NCR, removal of “Hold” tag and submitting the NCR for the AI’s review.

6.8.3 Head Quality shall maintain all NCRs on file and shall make the same available to the AI when required.


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WELDING CONTROL Date : 12.02.13

7.0 SCOPE

This Chapter describes the qualification of welding procedure and performance qualifications, welding consumable control and welding process control.

All welding shall comply with the requirements of applicable Edition of ASME Section IX with additional requirements of the Code, as applicable.

7.1 QUALIFICATION OF WELDING PROCEDURES

7.1.1 Head Quality shall prepare Welding Procedure Specification (WPS) in accordance with ASME Section IX, applicable requirements of Code and additional customer requirements, if any. WPS shall include all essential, non-essential and where applicable, supplementary essential variables, including their allowable ranges as per ASME Section IX Code. Head Quality shall review and approve the WPS.

7.1.2 Head Quality shall conduct procedure qualification test under his supervision and record all the variables used during welding of test coupon.

7.1.3 Head Quality shall arrange for NDE and heat treatment on the coupon, if required, supervise the preparation of test specimen, arrange for mechanical tests using calibrated test equipment in accordance with ASME Section IX, Code and additional customer requirements, if any and evaluate the test results for acceptance.

7.1.4 Head Quality shall prepare the Procedure Qualification Record (PQR) recording the welding parameters used and the test results. Head Quality shall review and certify the PQR as per ASME Section IX.

7.1.5 WPS shall be revised in case of any changes in the non-essential variables. In case of any changes in the essential or where applicable, supplementary essential variables, a new WPS shall be prepared and qualified.

7.1.6 Head Quality shall provide the WPS and supporting PQR to the AI for review. The AI may ask for re-qualification of any welding procedure and / or for witnessing of any tests.

7.2 QUALIFICATION OF WELDERS

7.2.1 Head Quality is also responsible for training, qualification and certification of welders.

7.2.2 Head Quality shall conduct the welding of performance qualification test coupons in accordance with qualified WPS under his supervision, record the actual parameters used during the test and arrange for testing on the coupon as per ASME Section IX, additional Code and customer requirements. When mechanical tests are required, Head Quality shall supervise the preparation of test specimen and arrange for testing using calibrated test machines.


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7.2.3 Head Quality shall evaluate the test results for acceptance and prepare the Welder Performance Qualification Record (WPQ) / Welding Operator Performance Qualification Record (WOPQ) recording the welder’s name, identification number, actual variables used, range qualified and test results. Head Quality shall certify the WPQ/WOPQ as per ASME Section IX.

7.2.4 Head Quality shall assign a unique welder identification number to each welder and maintain a record for the same in a register. This number shall not be repeated or reused even if the concerned welder leaves employment.

7.2.5 Head Quality shall maintain “Welder Continuity Record” (Exhibit No. 7-1) to monitor continuity of qualification of each welder, recording the welding performed by the welder in each qualified welding process at least once in each quarter.

7.2.6 Welders or welding operators shall be re-qualified under any of the following conditions:

a) If there is a change in any essential variable as per ASME Section IX.b) When a welder or welding operator has not welded with a process during a period of six

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

i. The welder has welded with that process using Manual or Semiautomatic welding.

ii. The welding operator has welded with that process using Machine or Automatic welding.

c) When there is a specific reason to question his ability to make welds that meet the specification. In such a case, the qualifications that support the welding he is doing shall be revoked. All other qualifications not questioned shall remain in effect.

7.2.7 The AI, Head Quality may ask for re-qualification of any welder or welding operator.

7.2.8 Head Quality shall prepare “List of Qualified Welders” (Exhibit No. 7-2) listing the range of qualification for each welder. This list shall be updated every three months based on the Welder Continuity Record. Head Quality shall review and approve the list.

7.2.9 Additional revisions to the list may be made during the intermediate period to inform the addition / deletion of welders. However, the validity of any such intermediate list shall be maintained same as the previous list.

7.2.10 Head Quality shall issue a copy of the List of Qualified Welders to Production Manager.

7.3 WELDING CONSUMABLE CONTROL


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7.3.1 All welding consumables shall meet the requirement of applicable SFA/AWS classification as per ASME Section II Part C and any additional customer / Work Order requirements. Alternatively, welding consumables shall meet specific WPS requirements.

7.3.2 Welding Engineer shall prepare “Indent for Welding Consumables” (Exhibit No. 7-3) along with “Technical Delivery Conditions for Welding Consumables” (Exhibit No. 7-4), mentioning all technical requirements for procurement of welding consumables based on drawings, Code and additional customer requirements, if any. The TDC for Welding Consumables shall include respective SFA specification, AWS classification number, approved brand names, furnishing required Batch Test certification reports and marking details. Head Quality shall approve the Indent and TDC for Welding Consumables and forward to Head Materials for procurement as per Chapter No. 04 (Material Control).

7.3.3 Upon receipt of welding consumables, Store Incharge shall correlate the items with the PO, check the quantity and physical condition and prepare GRN. Store Incharge shall mark the GRN number on all packages / boxes of welding materials.

7.3.4 Stores Incharge shall offer the material to Engineer QC for examination through GRN along with batch test certificates received with delivery documents.

7.3.5 Engineer QC shall verify batch number and marking on the consumable boxes and on the consumables, review the batch test certificate against the requirements and also verify physical condition of electrode boxes for any damage.

7.3.6 Engineer QC shall document the acceptance / rejection on the GRN and get it approved by Head Quality and forward a copy of the GRN to Stores Incharge. Engineer QC shall retain the batch test certificates and GRN on file.

7.3.7 Stores Incharge shall store the accepted welding consumables inside the electrode cabin. Any rejected consumables shall be affixed with the ‘Reject’ tag and kept in the designated area for the rejected items for disposal.

7.3.8 Before use, welding consumables shall be dried as per Procedure for Storage, Drying and Issue of Welding Consumables and then transferred and kept in the holding ovens at specified temperature. Head Quality shall prepare the procedure based on consumable manufacturer’s recommendation and/or ASME Section-II Part C and shall approve the same.

7.3.9 Production Engineer shall prepare “Welding Consumable Issue Slip” (Exhibit No. 7-5) for issue of welding consumables from Stores, based on the applicable WPS. Stores Incharge shall issue the welding consumables on first-in first-out basis and indicate the batch number of welding consumables issued on the Welding Consumable Issue Slip.

7.3.10 Production Engineer/Production Manager shall issue only one type of electrode / filler wire to any welder at one time. A maximum of 30 pieces of electrodes shall be issued to a welder at one time. Welders shall return any unused electrodes to Production


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Engineer/Production Manager who shall keep the returned electrodes in a separate box and such electrodes shall be used only for welder training purpose.

7.4 WELDING PROCESS CONTROL

7.4.1 Based on approved drawings and Code requirements, Head Quality shall prepare and approve “Weld Plan” (Exhibit No. 7-6), indicating the qualified WPS for welding each weld joint on the job. Head Quality shall submit the weld plan to AI for review along with applicable WPS and PQR.

7.4.2 Head Quality shall distribute a copy of the approved Weld Plan to Production Manager along with applicable WPS(s) using “Document Transmittal” (Exhibit No. 1-2).

7.4.3 Whenever the applicable drawings are revised, Head Quality shall review the Weld Plan for any change and revise the same, if required. This review shall be documented on the Weld Plan even if no changes are required. Revised Weld Plan shall be approved by Head Quality and offered to the AI for review. Copy of revised Weld Plan shall be distributed to Production Manager.

7.4.4 Production Manager shall assign the welding job to qualified welders based on the current list of Qualified Welders and the applicable WPS specified in the approved Weld Plan.

7.4.5 Production Manager shall ensure that all welding is carried out by qualified welders strictly in accordance with the applicable WPS using approved consumables.

7.4.6 Production Manager shall provide necessary instructions to the welder regarding welding parameters to be used as per the applicable WPS and ensure that a copy of the WPS is available to the welder in the work area.

7.4.7 Tack welds used to secure alignment shall either be removed completely when they have served their purpose or their stopping and starting ends shall be properly prepared by grinding or other suitable means so that they may be satisfactorily incorporated into the final weld. Each tack weld shall be visually examined by Engineer QC and if found defective, shall be completely removed.

7.4.8 Tack welds, whether removed or left in place, shall be made using the WPS specified for the weld joint in the approved Weld Plan by welders qualified in accordance with ASME Section IX.

7.4.9 Welding of temporary attachments shall be carried out by using qualified welders with approved WPS as per Weld Plan. These attachments shall be removed by cutting out the projection and grinding off the remaining portion attached to the pressure part. PT shall be used to ensure that the ground area is free from any unacceptable indications.


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7.4.10 Production Manager shall record the identification number of the welder used for welding each weld joint, including tack welds, on “Shop Welding Record” (Exhibit No. 7-7).

7.4.11 Additionally, each welder may stamp his identification number adjacent to the weld which he makes at interval not exceeding one meter (3 feet) in the steel plates 6mm (1/4 inch) and over in thickness and in non-ferrous plates 13mm (1/2 inch) and over in thickness. Die stamping shall not be used when service conditions prohibit.

7.4.12 Repairs to welds shall be carried out using qualified welders as per approved Weld Plan reviewed by the AI. If required, a specific repair procedure shall be prepared by Welding Engineer and approved by Head Quality and offered to the AI for review. The excavated area shall be examined by PT to ensure complete removal of defect prior to repair. The repaired area shall be once again examined by the same NDE method(s) as used for the original weld.

7.4.13 Welding Engineer shall maintain the records of repair on welds, including the identification number of the welder used, on the Shop Welding Record.

7.4.14 For repair of defects in material, Engineer QC shall raise a NCR and process same as per Chapter No. 06 (Correction of Nonconformities).

7.4.15 Welding Engineer shall monitor the welding activities on shop at random to verify whether parameters employed by welders for making production welds confirm to approved WPS.

7.5 USE OF WELDERS / WELDING OPERATORS BY CONTRACT / AGREEMENT

7.5.1 RMGA may engage individuals by contract or agreement for their services as welders / welding operators at shop for the construction of pressure vessels or parts thereof provided all the following conditions are met:

a) RMGA shall be responsible for all Code items construction.

b) All welding shall be performed in accordance with WPS qualified by RMGA in accordance with the requirements of the ASME Section IX.

c) Head Quality shall be responsible for qualification and certification of all such welders in accordance with the requirement of the Code.

d) All welders engaged shall be under complete and exclusive administrative and technical supervision of Production Manager.

e) Production Manager shall have full authority to assign or remove welders at his discretion without involvement of any other organization.


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f) Head Quality shall issue welder identification number to each welder and shall keep a separate record for identification numbers issued to such welders.

g) RMGA shall obtain an acceptance from the Authorized Inspection Agency for the use of such welders on Code items construction.

h) RMGA shall be responsible for the Code compliance of the vessel or part including Certification Mark stamping and providing Manufacturer’s Data Report forms properly executed and counter signed by the AI.


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NON-DESTRUCTIVE EXAMINATION Date : 12.02.13

8.0 SCOPE

This Chapter covers requirements for training, qualification and certification of NDE personnel, approval of NDE procedures and NDE on materials and welds.

All NDE shall be carried out as per requirements of ASME Section V and applicable Code Sections.

8.1 CERTIFICATION OF NDE PERSONNEL

8.1.1 GM-Operations shall prepare and Head Quality maintains RMGA Written Practice for Training, Qualification and Certification of NDE Personnel in accordance with SNT-TC-1A, Edition/Addenda as referred in the applicable Code. The Written Practice shall cover Radiography, Ultrasonic, Magnetic Particle and Liquid Penetrant examination methods.

8.1.2 GM-Operations shall appoint and certify NDE level III in accordance with RMGA Written Practice by virtue of his educational and professional qualifications, valid ASNT certificate documented experience, examination, demonstrated ability and achievements. The appointment shall be renewed once in three years subject to the period for which the ASNT qualification of NDE Level III is valid.

8.1.3 GM-Operations shall prepare written practice and NDE Level III shall review and approve for acceptance by AI.

8.1.4 NDE Level III shall train, examine and qualify NDE Level I and II personnel, in accordance with RMGA Written Practice. GM-Operations shall certify NDE Level I and II personnel jointly along with NDE Level III.

8.1.5 Near vision and color vision examination including check for shades of grey for all certified NDE personnel shall be performed once in a year.

8.1.6 NDE personnel shall be recertified in accordance with the Written Practice once in every five years.

8.1.7 Head Quality shall maintain a list of certified NDE Personnel along with all supporting documentation as per RMGA Written Practice.

8.2 NDE PROCEDURES

8.2.1 GM-Operations shall prepare and NDE Level III shall approve NDE Procedures in accordance with the requirements of the ASME Section V and referencing Code Section detailing the equipment to be used, method of calibration, requisite qualification of personnel, and evaluation and acceptance standards as a minimum. NDE Level III shall arrange to demonstrate the procedures in accordance with Article T-150 of ASME Code Section V, to the satisfaction of the AI. He shall also update NDE procedures as and when required by new Edition Addenda of the Code. GM-Operations and NDE Level III shall certify the procedures in accordance with Article T-150 of ASME Section V.


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8.2.2 NDE procedures shall be revised, whenever there is any change in essential or non-essential variables as defined in ASME Section V. NDE procedures shall be re-demonstrated to AI, whenever there is a change in essential variables.

8.2.3 The present design and fabrications of pressure vessels or parts do not require NDE other than RT and PT. If other NDE methods are required in future for Code acceptance of items, the procedure shall be demonstrated by the NDE Level III to the satisfaction of the AI, prior to use. NDE Level III shall also arrange for qualification of NDE personnel as per RMGA Written Practice for those additional methods.

8.3 PERFORMING NDE ON JOB

8.3.1 Head Design shall specify the extent of NDE on the drawings. Head Quality shall transfer the NDE requirements in to ITP and Inspection Data Book.

8.3.2 At appropriate stage as per Inspection and Test plan, Production Engineer shall offer the job for required NDE to Engineer QC through Inspection Request and Report. He shall ensure that all previous stages have been completed before raising NDE request.

8.3.3 Engineer QC shall carry out visual examination of items / welds prior to offering for NDE.

8.3.4 NDE Level I/Level II shall perform calibration of equipment, carry out NDE in accordance with the approved procedure and record the examination data in the relevant NDE report. Level I must receive written guidance from NDE Level II or Level III.

8.3.5 NDE Level II or Level III shall evaluate and interpret the results against requirements of Code and record the results on NDE report. The results of the examination shall be informed to Production Manager. If any unacceptable indication is observed, Production Engineer shall carry out necessary repair and re-offer for NDE. RMGA NDE II Level III or Level shall complete the interpretation and evaluation before presenting the radiographs and/or NDE reports to the AI for review.

8.3.6 All NDE shall be carried out before PWHT, unless specifically mentioned in ITP/ drawings.

8.3.7 For spot radiography, the spots shall be selected by the AI, or alternatively by Head Quality with prior permission of the AI. If he is not available.

8.3.8 NDE equipment shall be calibrated as per Chapter No. 10 (Calibration of Measurement and Test Equipment).

8.3.9 Head Quality shall make available NDE Procedures, NDE reports, radiography films and personnel qualification records to the AI for review. The AI may require re-qualification of any NDE personnel, procedure or examination for a cause.

8.4 SUB-CONTRACTING OF NDE

8.4.1 If any NDE is required to be subcontracted, the following shall be ensured:


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8.4.2 RMGA NDE level III and GM-Operations shall review and approve the Written Practice and personnel qualification records of the sub-contractor in accordance with the requirements of SNT-TC-1A, Edition/ Addenda as referenced in the applicable Code. This review shall be documented. If required, RMGA NDE Level-III shall conduct additional specific examination as per RMGA NDE Written Practice.

8.4.3 RMGA NDE Level III and GM-Operations shall review and approve sub-contractors facilities prior to undertaking any Code related NDE work.

8.4.4 All NDE shall be carried out as per RMGA procedures approved by NDE Level III and demonstrated to the AI.

8.4.5 NDE level III shall verify the calibration of NDE equipment to be used by sub-contractor.

8.4.6 Copies of above records shall be maintained by Head Quality and made available to the AI for review.


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HEAT TREATMENT Date : 12.02.13

9.0 SCOPE

This Chapter covers the requirements for heat treatment of Code items.

9.1 HEAT TREATMENT REQUIREMENT AND PROCEDURE

9.1.1 Head Design shall specify the heat treatment requirements for fabricated and formed items / components on the drawings based on Code and additional customer requirements if any.

9.1.2 Head Quality shall approve Heat Treatment Procedure based on the applicable Code requirements and submit to the AI for his review. The procedure shall include details of heat treatment furnace, heat treatment techniques, equipment to be used, method of attachment of thermocouples on the job and reporting requirements, as a minimum. A copy of the approved procedure shall be issued to Production Manager.

9.1.3 Engineer QC shall arrange for calibration of thermocouples and time-temperature recorders as per Chapter No. 10 (Calibration of Measurement and Test Equipment) with Incharge Maintenance. Incharge Maintenance shall maintain the furnace and auxiliary facilities in the conditions suitable for proper heat-treatment.

9.2 HEAT TREATMENT ON JOB

9.2.1 At the appropriate stage as per ITP and drawings, Production Engineer shall offer the vessel or part to Engineer QC, for Visual and dimension examination prior to heat treatment through “Heat Treatment Request and Report” (Exhibit No. 9-1). Engineer QC shall ensure that all NDE has been satisfactorily completed and all NCR satisfactorily resolved.

9.2.2 Engineer QC shall verify that all the previous stages as per ITP, including welding of all attachments, examination, inspection, NDE and other tests as per approved drawings/ITP have been completed. Engineer QC shall visually examine and dimensionally check the item and if found satisfactory, offer the item to the AI for inspection prior to releasing for heat treatment by signing off on the HTRR.

9.2.3 Production Manager shall forward the HTRR to Head Quality for indicating the details of items to be heat treated in one charge, method of placement of the job in furnace, number, location and method of attachment of thermocouples capable of reading actual job temperature and the heat treatment cycle to be followed including the permissible tolerance limits.

9.2.4 In case a combination of items is to be heat treated in one charge, Head Quality shall take into consideration the materials, applicable WPS and governing thickness for each item to ensure compliance with Code requirements.

9.2.5 Head Quality shall forward a copy of HTRR to Production Manager with the details of required heat treatment cycle.


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9.2.6 Production Engineer shall arrange for loading of items in the furnace and attachment of thermocouples as per approved procedure and HTRR.

9.2.7 The item shall be adequately supported so as to ensure uniform heating/cooling from all sides and to avoid any direct impingement of flame. The thermocouples shall be secured on the item to be heat treated without having any air gap. Welding Engineer shall ensure that applicable WPS as per approved Weld Plan is used for attachment welds.

9.2.8 Engineer QC shall witness the loading of items and attachment of thermocouples as per heat treatment procedure and HTRR and sign off the time temperature graph prior to start of heat treatment. Engineer QC shall also verify placement of test coupons, if applicable, prior to start of heat treatment cycle.

9.2.9 Engineer QC shall arrange for mechanical testing of test coupons, wherever applicable, using calibrated test equipment.

9.2.10 Production Engineer shall ensure that heat treatment is performed in accordance with the approved procedure and HTRR.

9.3 REPORTING

9.3.1 On completion of heat treatment, Production Engineer shall hand over the time-temperature graph to Head Quality, who shall review the time-temperature graph and if found satisfactory he shall approve the same ands offer the same to the AI for his review.

9.3.2 Any nonconformity observed shall be processed in accordance with Chapter No. 06 (Correction of Nonconformities).

9.4 SUB-CONTRACTING OF HEAT TREATMENT

9.4.1 In case sub-contractor’s facilities are to be utilized for heat treatment of Code items, the following shall be ensured:

a) Head Quality shall review and approve subcontractor’s equipment/ facilities, including the calibration records of thermocouples and time-temperature recorders. This review shall be documented.

b) Production Engineer shall offer the items to Engineer QC, for examination and releasing the item for heat treatment as above.

c) Purchase Engineer shall forward the request for subcontracting heat treatment to Head Materials, who shall process the purchase order for heat treatment enclosing the approved Heat Treatment procedure and HTRR.

d) Production Engineer shall ensure that any attachment welds for thermocouple locations are made by RMGA as per approved WPS, prior to sending the item to subcontractor.


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Thermocouple may be attached with capacitor discharge welding method. A WPS shall be prepared as per section IX when energy output is greater than 125 watt/second. WPS shall contain combination of material to be joined and technique of application.

e) Engineer QC shall witness loading of the item at subcontractor’s works along with test coupons (if applicable), confirm attachment of required number of thermocouples on the job at stipulated locations and verify the calibration status of thermocouples and time-temperature recorder. The heat treatment Furnace Operator and Engineer QC shall sign off the time-temperature graph prior to commencement of heat treatment.

f) Engineer QC shall ensure that the item is adequately supported so as to ensure uniform heating/cooling from all sides and there is no direct impingement of flame on the job.

g) Heat treatment shall be carried out strictly as per approved procedure and HTRR.

h) After completion of the heat treatment cycle, Head Quality shall review and approve the time-temperature graph and submit to the AI for review.

i) Engineer QC shall visually examine the item on receipt at RMGA shop after heat treatment to check for any damage or distortion and verify identification markings.

9.5 RECORDS

9.5.1 Head Quality shall offer all records pertaining to heat treatment i.e. Heat Treatment Procedure, HTRR, time-temperature graph and calibration records, including those for sub-contracted heat treatment, to the AI for review.


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CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT Date : 12.02.13

10.0 SCOPE

This Chapter describes the systems and procedures for calibration of examination, measurement and test equipment used in fulfillment of applicable Code requirements.

10.1 RESPONSIBILITIES

10.1.1 Head Quality shall specify the required accuracy and frequency for calibration for all measurement and test equipment.

10.1.2 Engineer QC shall review all the calibration reports and verify that the calibration results comply with specified requirements.

10.1.3 Engineer QC shall ensure that only calibrated measurement and test equipment are used during Code construction at shop.

10.1.4 Site Incharge shall ensure that only calibrated measurement and test equipment are used during field assembly at site.

10.2 CALIBRATION STANDARDS

10.2.1 Head Quality shall ensure that all calibrations, whether carried out in house or outside, are done using master instrument traceable to National / International standards. Where no such standards exist, the equipment manufacturer’s recommendations shall be followed and the basis shall be documented.

10.2.2 Head Quality shall ensure that mechanical tests, when required, are carried out using calibrated test equipment. For impact tests, the impact testing machine shall be calibrated annually and temperature measurement apparatus shall be calibrated every six months as per SA370 with reference to ASTM E23.

10.3 IDENTIFICATION

10.3.1 Engineer QC shall identify all measurement and test equipment under the calibration program with a unique identification number which shall be permanently marked on the equipment.

10.3.2 Engineer QC shall prepare a “List of Measurement and Test Equipment” (Exhibit No. 10-1) indicating the RMGA identification number, instrument type, make & range, required accuracy, frequency, calibration certificate no., date of calibration and next calibration due date.

10.3.3 Engineer QC shall ensure that each measurement and test equipment is affixed with a calibration sticker indicating the identification number, date of last calibration and due date for next calibration.

10.3.4 In case of small instruments on which the calibration sticker cannot be affixed, it may be pasted on the box or container of the instrument.


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CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT Date : 12.02.13

10.3.5 Engineer QC shall ensure that any measurement and test equipment not identified with calibration sticker is not used during any examination, inspection or testing of the Code items.

10.4 PERFORMING CALIBRATION

10.4.1 Engineer QC shall ensure the calibration of all measurement and test equipment on receipt and at frequency stipulated on the List of Measurement and Test Equipment by Head Quality and shall be responsible for recalling the measurement or test equipment for re-calibration, prior to the due date for re-calibration.

10.4.2 Engineer QC shall arrange for calibration of pressure gauges used during hydrostatic or pneumatic pressure test once in every six months or earlier, if any error is suspected. Pressure gauge shall be subject to validation after every pressure test.

10.4.3 Incharge Maintenance shall be responsible for calibration of thermocouples and measuring instruments on welding machines / electrode ovens once in a year or earlier, if there is any reason to doubt their accuracy. Time temperature recorders shall be calibrated once in six months or earlier, if there is any reason to doubt their accuracy.

10.4.4 NDE Level II shall perform calibration of NDE equipment in accordance with procedures approved by NDE Level III. NDE Level III shall review and approve the results of calibration.

10.4.5 Any measurement and test equipment shall be re-calibrated when repaired or when there is any reason to doubt its accuracy.

10.5 NONCONFORMANCE / REJECTION

10.5.1 In case any measurement or test equipment is observed to be damaged or out of calibration, same shall be affixed with “HOLD” tag. Head Quality shall ensure that such equipment is not used before re-calibration irrespective of its calibration status. If any equipment cannot be repaired and calibrated, it shall be marked with ‘REJECT’ tag and returned to Stores Incharge for disposal.

10.5.2 The identification number of measurement and test equipment used shall be recorded on the relevant examination /inspection/NDE/test reports.

10.5.3 In case any measurement or test equipment is observed to be out of permissible limits at the time of recalibration, Engineer QC shall raise NCR and process as per Chapter No. 06 (Correction of Non-conformities. Head Quality shall evaluate all the previous records where the particular instrument was used to establish the acceptance of previous measurements.


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RETENTION OF RECORDS Date : 30.10.12

11.0 SCOPE

This Chapter describes the requirements for retention of records for Code items.

11.1 RETENTION

11.1.1 Head Quality shall retain the following documents for a minimum period of three years from the date of signing of the Data Report by the AI:

a) Manufacturer’s Partial Data Reports/ Manufacturer’s Data Reports.b) Manufacturing drawings.c) Design calculations, including any applicable Proof Test Reports.d) Material Test Reports and/or material certifications.e) Welding Procedure Specifications and Procedure Qualification

Records.f) Welders Qualification Records. g) RT Reports.h) Repair procedures and records.i) Process control sheets.j) Heat Treatment records and test results.k) Post welds heat treatment records.l) Nonconformances and Dispositions.m) Hydrostatic test records.n) Pressure parts documentation and certification.

11.1.2 Head Design shall retain as-built drawings, design calculations and proof test reports for a minimum period of three years from the date of signing of the MDR by the AI.

11.1.3 Head Quality shall retain a complete set of radiographs for the Code item till the MDR is signed by the AI.

11.1.4 A longer retention period than specified above may be followed, if required by the contract or statutory regulations.

11.1.5 The retained records shall be stored and maintained to protect from damage, loss or any deterioration during retention period and shall be easily retrievable. No document/ record shall be removed from retention area without prior authorization from the controlling authority.

11.2 RECORD SUBMISSION

11.2.1 Head Quality shall provide copies of records for submission to the customer through GM Business Development. All records shall be made available to the AI, AIS and ASME Review Team on request.

11.3 DISPOSAL


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RETENTION OF RECORDS Date : 30.10.12

11.3.1 Head Quality shall arrange for disposal of records at the end of retention period by any suitable means.


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AUTHORIZED INSPECTOR Date : 12.02.13

12.0 SCOPE

This Chapter covers the relationship of AI and AIS with RMGA during the construction of Code items.

AUTHORIZED INSPECTOR:

a)Authorized Inspector shall be in regular employment by an ASME accredited Authorized Inspection Agency i.e the inspection organization of a State or municipality of the United States, a Canadian province, or an insurance company authorized to write boiler and pressure vessel insurance.

The Authorized Inspector shall not be in the employment of the Manufacturer. All Authorized Inspectors shall have been qualified by a written examination under the rules of any State of the United States or province of Canada which has adopted the Code.

12.1 INSPECTION AGREEMENT

12.1.1 RMGA shall have in force at all times an inspection contract or agreement with an ASME accredited Authorized Inspection Agency (AIA), as defined in Code, for providing the services of AI and AIS to carry out inspection as per Code requirement. Head Quality shall inform ASME whenever the agreement is cancelled or changed to another AIA.

12.1.2 Head Quality shall have overall responsibility for co-ordination with the AI and AIS for all Code related inspection activities.

12.2 AIA OF RECORD

12.2.1 LR Insurance Inc., identified as AIA of record, shall perform all required inspection at the shop and field site locations controlled from shop, for the type of work listed in the scope of ASME certificate of Authorization.

12.2.2 In case of a situation where the purchaser requests another AIA to perform inspection in the shop or field site on its projects or Code job, the request shall be in writing, for example on the purchase order.

12.2.3 If LR Insurance Inc. cannot provide coverage for inspection at a specific field site, necessitating the use of another AIA, this should also be documented suitably.

12.2.4 In case of 12.2.2 or 12.2.3 above, the following shall be ensured:

a. All AIAs performing inspections shall follow the system laid down in the QC Manual accepted by the AIA of record.

b. All AIAs performing inspections shall have a contract or agreement with RMGA for the specific Code work.


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AUTHORIZED INSPECTOR Date : 12.02.13

c. The AIA of Record i.e. LR Insurance Inc., shall review and accept all changes to the QC Manual.

d. Each AI shall be provided with a controlled copy of the QC Manual.

e. AIA of Record shall be informed by RMGA in writing whenever they use Second Agency for performing Code inspection as required by the purchaser in the P.O.

12.3 FREE ACCESS

12.3.1 RMGA shall provide free access to the AI and AIS at all times to all parts of the shop that concern the construction of the vessel or part and to the site of field erected vessels, during the period of construction, assembly and testing of Code items.

12.3.2 When requested, RMGA shall also provide free access to AI and AIS to such parts of all plants that are concerned with the supply or manufacturing of the material for the vessel.

12.3.3 RMGA shall also provide for the AI and AIS to have free access to all drawings, design calculations, specifications, procedures, ITP, Inspection Data Book, Weld Joint Inspection Checklist, weld plan, proof test reports, other examinations and test records, repair procedures, test certificates or any other related documents, as required by them to perform their duties in accordance with the Code.

12.4 QUALITY CONTROL MANUAL

12.4.1 Head Quality shall submit a copy of Manual and any revisions to the Manual, to the AI for his review and acceptance, prior to implementation.

12.4.2 Head Quality shall issue a controlled copy of the Manual to the AI at Shop. A controlled copy of the Manual shall also be issued to the AI at field site, if applicable.

12.5 MONITORING OF QC SYSTEM / AIS AUDITS

12.5.1 The AI shall have the freedom to monitor RMGA Quality Control System at regular intervals as required by Code.

12.5.2 AIS shall have the freedom to audit the AI activity periodically as required.

12.5.3 Head Quality shall provide all assistance to the AI during monitoring of quality control system and to the AIS during the audit.


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FIELD SITE CONTROL Date : 12.02.13

13.0 SCOPE

This Chapter covers controls required during field assembly at sites controlled by the shop to ensure compliance with the requirements of Code and this Manual.

13.1 ORGANIZATION AND RESPONSIBILITY

13.1.1 The organization structure for assembly at field sites controlled from shop is indicated on Page 4 of this Chapter. Responsibilities of key personnel at site are defined in this Chapter, in addition to those detailed in Chapter No. 02 (Organization and Responsibilities).

13.1.2 Site Incharge shall have overall responsibility for all fabrication, assembly, examination and test activities at field site as per requirements of Code, approved drawings, ITP, approved Weld Plan and approved procedures.

13.1.3 Head Quality shall have overall responsibility for all quality control activities at site.

13.1.4 Site QC Engineer and NDE Level II at site shall report functionally to Head Quality and administratively to Site Incharge.

13.1.5 Site QC Engineer shall liaise with the AI at site and inform him about progress of site activities and approaching inspection stages.

13.1.6 Site QC Engineer and NDE Level II will be nominated at the time of field site control.

13.2 QC SYSTEM AT SITE

13.2.1 Head Quality shall audit the QC system at site for compliance with Code and this Manual. Head Quality shall provide all assistance to the AI at site for monitoring the QC System at site.

13.2.2 Head Quality shall issue controlled copies of Manual to Site Incharge, Site QC Engineer and to the AI at site.

13.3 SITE PROCESS CONTROL

13.3.1 Whenever site work is involved, Head Design shall define the extent of shop fabrication and site assembly on the drawings. If required, Design Engineer shall prepare and Head Design shall approve separate drawings for site assembly and submit to the AI at site for review as per Chapter No. 03 (Drawing, Design Calculation and Specification Control).

13.3.2 All drawings including their revisions shall be marked as “Issued for Manufacturing” and issued to Site Incharge, Head Quality and Site QC Engineer through “Documents Issue Record Sheet” The recipients shall either destroy the old revision or if retained, mark them as ‘OBSELETE’.

13.3.3 Site Engineer shall receive materials, components, welding consumables and equipment from shop along with packing slip and reports and verify the physical condition for any damage.


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13.3.4 Site QC Engineer shall examine the materials, parts and components received at site from the shop and verify that all quality control documents for previously completed stages, including MDR (if applicable) duly certified by Head Quality up to Certificate of Shop Compliance and endorsed by the AI at shop up to Certificate of Shop Inspection, have been provided.

13.3.5 Site QC Engineer shall examine the materials and welding consumables received directly at site as per Chapter No. 04 (Material Control) and Chapter No. 07 (Welding Control) respectively. If found acceptable, Site Store Incharge shall arrange to store the material in pre-assigned area.

13.3.6 For components received with MPDR, Site QC Engineer shall verify the ASME Certification Mark on components and offer the components to the AI at site for inspection prior to use.

13.3.7 Engineer QC shall prepare and Head Quality shall approve ITP for site activities and submit to the AI at site, through Site QC Engineer, for marking of inspection stages. Copies of approved ITP shall be issued to Site Incharge and Site QC Engineer.

13.3.8 Based on the approved ITP and drawings, Site QC Engineer shall prepare the Inspection Data Book, obtain the approval of Head Quality and submit to the AI at site for verification of accurate transfer of inspection stages.

13.3.9 Any revisions to the ITP and Inspection Data Book shall be controlled as per Chapter No. 05 (Examination and Inspection Program).

13.3.10 Site QC Engineer shall conduct the required examination and tests as per approved ITP and maintain all examination and test records as detailed in Chapter No. 05 (Examination and Inspection Program).

13.3.11 Site QC Engineer shall liaise with the AI at site and keep him informed about progress of site activities and approaching inspection stages.

13.3.12 Site QC Engineer shall inform any nonconformity observed at site to Head Quality, through NCR for resolution as per Chapter No. 06 (Correction of Nonconformities). Site QC Engineer shall verify the implementation of corrective action and offer the NCR to the AI at site for review of proposed corrective action and final disposition.

13.3.13 Head Quality shall approve Weld Plan and submit to the AI at site for review along with applicable WPS and supporting PQR, through Site QC Engineer. Site QC Engineer shall issue a copy of approved Weld Plan along with the applicable WPS and List of Qualified Welders to Site Incharge.

13.3.14 Site QC Engineer shall supervise any welding procedure qualification or welder / welding operator performance qualification at site as per Chapter No. 07 (Welding Control). Site QC Engineer shall prepare the WPS, PQR and WPQ/WOPQ records and forward to Head Quality for approval of WPS and certification of PQR and WPQ/WOPQ.


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13.3.15 Site Engineer shall arrange to carry out all welding at site as per Chapter No. 07 (Welding Control).

13.3.16 Site Incharge shall have full authority to assign or remove any welder at any time. Welders at site shall be under direct administrative and technical control of Site Incharge.

13.3.17 RMGA may engage individuals by contract or agreement for their services as welders or welding operators at site, provided all the conditions as per Clause 7.5 of Chapter No. 07 (Welding Control) are met. For this purpose, the responsibilities of Production Manager and Head Quality shall be carried out by Site Incharge and Site QC Engineer respectively.

13.3.18 NDE Level III shall be responsible for approving NDE procedures to be employed at site and their demonstration to the AI at site, if required. NDE Level III shall review calibration of NDE equipment to be used at site.

13.3.19 NDE Level II at site shall carry out all required NDE in accordance with approved procedures as per Chapter No. 08 (Non-Destructive Examination).

13.3.20 On completion of fabrication and assembly, Site QC Engineer shall ensure that all stipulated examination, inspection, NDE and other tests have been satisfactorily completed. He shall carry out visual and dimensional examination and offer the job to the AI at site for inspection prior to releasing the job for heat treatment or pressure test, as applicable. He shall also verify that all NCR have been satisfactorily resolved and closed.

13.3.21 When heat treatment is required, Site Engineer shall arrange to carry out the same as per Chapter No. 09 (Heat Treatment) in accordance with approved heat treatment procedure and HTRR approved by Head Quality.

13.3.22 Site Incharge shall ensure that pressure test is conducted as per drawings, approved procedure and Code requirements using calibrated pressure gauges. Site QC Engineer shall witness the pressure test and if acceptable, offer to the AI at site for witnessing.

13.3.23 Site QC Engineer shall ensure that all measurement and test equipment to be used at site is calibrated as per Chapter No. 10 (Calibration of Measurement and Test Equipment).

13.4 EQUIPMENT/NAME PLATE STAMPING AND DATA REPORTS

13.4.1 On satisfactory completion of assembly, examination and tests, Site QC Engineer shall verify the correctness of nameplate / stamping details, ensure that the nameplate is attached to correct vessel, offer to the AI at site for verification and obtain his concurrence for applying Certification Mark and if applicable, NB Stamp.

13.4.2 Head Quality shall assign the National Board number, when required, on completion of the pressure test.

13.4.3 Head Quality or his authorized designee shall carry the Certification Mark Stamp and if applicable, NB stamp to the site. Head Quality shall be responsible through Site QC Engineer for application of Certification Mark Stamp and if applicable, NB Stamp on the item / name plate in the presence of the AI at site. The ‘U’ designator shall be stamped or etched directly below the ASME Certification Mark.


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13.4.4 Head Quality shall arrange for retrieval of the Code Symbol stamp / Certification Mark Stamp and NB stamps after use at field site.

13.4.5 Head Quality shall complete and certify the Certificate of Field Assembly Compliance on the Data Report and offer to the AI at site for his review and signature through Site QC Engineer. Head Quality shall arrange to distribute the Data Reports as per Chapter No. 05 (Examination and Inspection Program).

13.4.6 Field Site assembly of the vessel may also be carried out by others as permitted in Para U-3 of the Code and as detailed below:-

a) The Manufacturer of the vessel completes the vessel in the field, completes the form U-1 or U-1A Manufacturer’s Data Report, and stamps the vessel.

b) The Manufacturers of parts of a vessel to be completed in the field by some other party stamps these parts in accordance with Code rules and supplies the Form U-2 or U-2A Manufacturer’s Partial Data Report to the other party. The other party must hold a valid U Certificate of Authorization, makes the final assembly, required NDE, final pressure test; complete the form U-1 or U-1 A Manufacturer’s Data Report ; and stamp the vessel.

c) The field portion of the work is completed by a holder of a valid U certificate of Authorization other the vessel manufacturer. The certificate holder performing the field work is required to supply a Form U-2 or U-2A Manufacturer’s Partial Data Report covering the portion of the work completed by his organization (including data on the pressure test if conducted by the certificate holder performing the field work) to the Manufacturer responsible for the Code vessel. The vessel manufacturer applies his certification mark with the U Designator in the presence of a representative from his inspection agency and completes the form U-1 or U-1A Manufacturer’s Data Reports with his Authorised Inspector.

13.5 RECORD RETENTION

13.5.1 All records shall be retained at RMGA shop as per Chapter No. 11 (Retention of Records).


Issue No. : 01

Chapter No.: 13

Page No. : 5of 5



ORGANIZATION STRUCTURE FOR FIELD SITE

At RMGA Works

At Field Site

GM Operations

SITE INCHARGE

SITE ENGINEER

NDE LEVEL III

Head Quality

SITE QC ENGINEER

SITE STORE INCHARGE

NDELEVEL II

WELDERS


Issue No. : 01

Chapter No.: 13

Page No. : 5of 5



Functional control Administrative control

14.1.1(a) At present methods other than written signature are not being used in RMGA for indicating certifications, authorizations, and approvals.

(b)Whenever other methods (Electronic Signature, Approval, Authorizations) are employed, controls and safeguards shall be provided and described to ensure the integrity of the certification, authorization, and approval. QC Manual shall be revised to include this requirement. Integrity of the system shall be demonstrated to the AI prior to implementation.


Issue No. : 01

Chapter No.: 15

Page No. : 1 of 2


LIST OF EXHIBITS Date : 12.02.13

Exhibit Number

TitleForm Number

No. of Pages

Revision Status

Revision Date

1-1 QC Manual Distribution List FU-QC-01 01 00 30.10.12

1-2 Document Transmittal FU-PP-01 01 00 30.10.12

3-1 Documents Issue Record Sheet FU-DSG-01 01 00 30.10.12

3-2 Design Change Request FU-DSG-02 01 00 30.10.12

3-3 Material Indent FU-DSG-03 01 00 30.10.12

3-4 Technical Delivery Conditions FU-DSG-04 02 01 30.10.12

4-1 Material Inspection Request and Report

FU-STR-01 0100 30.10.12

4-2 Material Verification Report FU-QC-02 03 00 30.10.12

4-3 Purchase Order FU-PUR-01 01 00 30.10.12

4-4 Goods Receipt Note FU-STR-04 01 00 30.10.12

4-5 Hold Tag FU-STR-02 01 00 30.10.12

4-6 Reject Tag FU-STR-03 01 00 30.10.12

4-7 Material Issue Slip FU-PRD-01 01 00 30.10.12

4-8 Inspection Request and Report FU-PRD-02 01 00 30.10.12

4-9 Material Attestation Report FU-QC-03 01 00 30.10.12

5-1 Inspection and Test Plan FU-QC-04 05 00 30.10.12

5-2 Inspection Data Book FU-QC-05 03 00 30.10.12

5-3 Weld Joint Inspection Checklist FU-QC-06 01 00 30.10.12

5-4 Final Dimension Report FU-QC-07 02 00 30.10.12

5-5 Pressure Test Report FU-QC-08 01 00 30.10.12

5-6 Name Plate FU-DSG-05 03 00 30.10.12

5-7 Log of National Board Numbers issued

FU-QC-09 0100 30.10.12

5-8 Log Of ASME Code Jobs FU-QC-10 01 00 30.10.12

5-9 Dished End Inspection Report FU-QC-15 01 00 30.10.12

5-10 Rolled Shell Inspection Report FU-QC-16 01 00 30.10.12

6-1 Nonconformity Report FU-QC-11 01 00 30.10.12

6-2 List OF NCR FU-QC-12 01 00 30.10.12


Issue No. : 01

Chapter No.: 15

Page No. : 2 of 2


LIST OF EXHIBITS Date : 12.02.13

Exhibit Number

TitleForm Number

No. of Pages

Revision Status

Revision Date

7-1 Welders Continuity Record FU-WT-01 02 00 30.10.12

7-2 List of Qualified Welders FU-WT-02 01 00 30.10.12

7-3 Indent for Welding Consumables FU-WT-03 01 00 30.10.12

7-4 Technical Delivery Conditions for Welding Consumables

FU-WT-04 0100 30.10.12

7-5 Welding Consumable Issue Slip FU-WT-05 01 00 30.10.12

7-6 Weld Plan FU-WT-06 02 00 30.10.12

7-7 Shop Welding Record FU-WT-07 01 00 30.10.12

9-1 Heat Treatment Technique and Report

FU-QC-13 0200 30.10.12

10-1 List of Measurement and Test Equipment

FU-QC-14 0100 30.10.12

u stamp manual

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quality control manualissue

quality problem

quality control system

quality control program

statement of quality

quality management systems

specification control

management of rmg autometers