Quality Manual 2012 `

Transcription

1 Quaality Man nual `

2 Section : I Page : 1 of 1 Quality Control Manual Title Page Edition : III Revision : 1 Date: 21 / 10 / 2012 Copy No. Controlled Uncontrolled Project Services Company PSC (S.A.E.) Qarit Oraby, Desert Road, Amria, Alexandria, Egypt Phone : Fax : ashraf.elrefaai@psc-eg.com Web :

3 Table of Contents Section : II Page : 1 of 2 Rev. : 2 Date : 20 / 12 / 2012 Table of Contents

4 ++ QUALITY CONTROL MANUAL Table of Contents (11) Table of Contents Section : I1 Page :2of2 Rev. : 2 Date :20/ Action Prepared By Reviewed By Approved By Reviewed and Accepted By Name Ahmed Nabil Mahmoud Allam Mohamed Kandil Ibrahim El-desouky Title Quality Assurance Head Quality Control Manager Managing Director Authorized Inspector C Edition: 111

5 Abbreviations Section : III Page : 1 of 3 Abbreviations

6 Abbreviations (III) Abbreviations Section : III Page : 2 of 3 AI AIA AIS ASME Authorized Inspector Authorized Inspection Agency Authorized Inspector Supervisor American Society of Mechanical Engineers ASTM American Society of Testing and Materials APPROVAL The act of approving, by signing-off on a document after verification that all the requirements have been met. An individual authorised by ASME to carry out a joint review with a ASME DESIGNEE representative of AIA. ASNT The American Society for Non-Destructive Testing. AWS QC1 CERTIFY CMTR Code Company COM Dept. Div. DMD Ed. Eng. FM HT ITP L1 L2 MATERIAL Manual MAEWP MAWP MCM MD MDR Mgr. MPDR MRF MRIF Standard for AWS certification of Welding Inspectors. The Act of verifying and attesting in writing that Documents, process, products, or personnel qualifications comply with specified requirements. Certified - Material Test Report The ASME Boiler &Pressure Vessel Code of Construction SEC I, SEC VIII DIV 1 Code & Standard Edition and / or Addenda's and Reference Sections. ASME B31.1 and NBIC-23 applicable edition and addenda. Project Services Company, PSC (S.A.E.) Construction Manager Department Division Deputy Managing Director Edition Engineer Factory Manager Hydro Test Inspection and Test Plan Level I Level II Material manufactured to an SA, SB or SFA Specification or any other Specification permitted by the applicable construction Code. Quality Control / Quality Manual Maximum Allowable External Working Pressure Maximum Allowable Working Pressure Material Control Manager Managing Director Manufacturer's Data Report Manager Manufacturer's Partial Data Report Material Requisition Form Material Receiving Inspection Form

7 MT MTR N/A NBIC NDE OD Para. PFM PM PO PQR PRH PSC PSM PT PWHT QA QAH QC QCH QCI QCM Rev. RT Sec. SM SPM TOH UT WCRF WCRIF WHM WOPQ WPQ WPS LISL QUALITY CONTROL MANUAL Abbreviations Magnetic Particle Test Material Test Report Not Applicable National Board Inspection Code Non Destructive Examination Operations Director Paragraph Planning Head Production Manager Purchase Order Procedure Qualification Record Purchasing Head Project Services Company PSC ( S.A.E.) Projects Manager Penetrant Test Post Weld Heat Treatment Quality Assurance Quality Assurance Head Quality Control Quality Control Head Quality Control Inspector Quality Control Manager Revision Radiographic Test Section Site Manager Sales and Proposal Manager Technical Office Head Ultrasonic Test Welding Consumable Requisition Form Welding Consumables Receiving Inspection Form Warehouse Manager Welding Operator Performance Qualification Record Welder Performance Qualification Record Welding Procedure Specification Line Inspection Summary List Section : III Page : 3 of 3

8 Scope Section : IV Page : 1 of 2 Scope

9 Scope Section : IV Page : 2 of 2 (IV) Scope II.1 General PSC has kept and maintained a Quality Control System which has been established to provide our custemors with boilers and boiler parts, boiler external piping, pressure vessels and pressure vessel parts (such as: towers and heat exchangers) required to be constructed in accordance with ASME Boiler and Pressure Vessel Code Section I, ASME B31.1, Section VIII Div.1, AWS, API, EN or other governing Codes or Standards (hereafter called Code). The Quality control system has been established to meet the requirements of ASME Code including design, material, fabrication and examination by PSC; and inspection by The Authorized Inspector (AI) for Power Boilers, Power Piping, Pressure Vessels and pressure vessels parts. The Quality control system has been established to cover activities in the shop and field sites. This Manual also is applied to Metallic Repairs and/or Alterations at this Shop and extended for Field Repairs and/or Alterations controlled by this Shop The scope covers the following: - 1. Construction and erection of boiler, boiler parts, pressure vessels, towers and heat exchangers in accordance with Code requirements. 2. Design and fabrication of all pressure vessel accessories, such as ladders, platforms etc. 3. Field erection and testing of boilers and pressure vessels. 4. Design, fabrication, erection, testing and inspection of storage tanks. 5. Repairs, alterations and re-rating of boilers, power piping and pressure vessels to the requirements of NBIC NB23 and relevant construction code/standard 6. Design, fabrication and erection of steel structure, plate works and pressure/non pressure piping.

10 Manual Control Section : 1 Page : 1 of 3 Rev. : 2 Date : 20 / 12 / 2012 Manual Control

11 Manual Control Section : 1 Page : 2 of 3 Rev. : 2 Date : 20 / 12 / 2012 (1) Manual Control 1.1 This Manual shall be prepared by QAH, who collects the Manual sections prepared by each concerned personal (QCH, TOH & NDE Level III Examiner), reviewed by QCM, whilst the approval of such shall be granted by the Managing Director and reviewed and accepted by the AI of records. The QAH shall issue controlled copies of this approved Manual with transmittal advice in accordance with the list of Manual Holders Log (Exhibit No. (01-01)) maintained by him. 1.2 Each copy of this Manual will bear the same control number on its title page as shown on the List of Manual Holders Log, and the same will be done but on the back of each Manual pages. In case of electronic copies the control number will appear on the title page and it must be protected against changes and printing. 1.3 When new Code Edition or Addenda is issued; it shall be reviewed by the concerned personal (QCH, TOH & NDE Level III Examiner) to determine the need for revisions required to the Quality Control Manual. The QAH shall document this review by his dated initials on a copy of the front page of the Edition/Addenda summary of changes page. This step shall also be recorded in record of Code Edition and Addenda review form (Exhibit (01-02)). 1.4 Revisions of the Manual if needed- shall be prepared and approved the same way as the original and then submitted to the AI of record for his review and acceptance prior to issue. However, revisions will be made by sections except for Exhibits. 1.5 Revisions of the Quality Control Manual are distributed to the List of Manual Holders Log using the Manual Holders Log within six months of Code Edition/Addenda issue date 1.6 Revisions are indicated in the corresponding pages by bold &

12 Section : 1 Page : 3 of 3 Rev. : 2 Date : 20 / 12 / 2012 Manual Control italic font of the revised text. Only the latest revision will be indicated. 1.7 Revised sections and Ehibits of the Manual are issued, distributed and controlled by the QAH in the same manner as stated through Para. 1.1 And 1.2 of this Section. 1.8 Revised Exhibits pages are issued individually with a revised List of Exhibits Exhibit No. (1-03) by QAH. 1.9 QCM may, at his discretion advance the edition level of the Manual at which time all revision status of all sections shall revert to zero. However, exhibits revision numbers shall remain with the same revision status Uncontrolled copies of the Manual may be distributed to parties outside PSC. However, there is no need to distribute a new uncontrolled copies or withdraw the old revisions of the uncontrolled copies when the Manual is updated In case change to the QC Manual are requested by the AI of an AIA other than that of Record, all such changes shall be represented by the Quality Control Manager to the AI of the AIA of Record for his review and acceptance prior to revision of the Manual and its implementation The Quality Control Manual is issued in English Language only. Work Instructions may be issued in both English and Arabic Languages, and in case of conflict between languages, the English text shall govern One master copy of earlier revision of the Manual marked supereeded shall be retained by QAH for minimum 3 years QAH is responsible to insure that revised copies are retuned and destroyed.

13 Statement of Authority and Responsibility Section : 2 Page : 1 of 2 Statement of Authority and Responsibility

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15 Organization Section : 3 Page : 1 of 6 Organization

16 Organization Section : 3 Page : 2 of 6 (3) Organization 3.0 Organization of PSC The Organization Chart of PSC is attached to this Section. 3.1 Managing Director. (MD) MD is the responsible person in PSC for all administrative issues and operations activities within the company scope of works. He is responsible for monitoring the performance of the department s heads and managers, and is responsible to the client for initiating any project and related action, which is outside of head s and manager's responsibilities. MD is responsible for the approval of this QC Manual. His staff consists of : Factory Manager. (FM) He reports directly to MD. He is responsible for managing all activities and operations at PSC Workshop Production Manager. (PM) He reports directly to Factory Manager. He is responsible for production activities according to design instruction, procedures and drawings at PSC Workshop. He will liaise with QCM during production in matters relating to inspection, testing, examinations and Quality Control Purchasing Head. (PRH) He reports directly to MD He is responsible for following up of purchasing all Code materials according to Material Requisition Form (Exhibit No ), upon review by QCM and approval by TOH He is also responsible for the time of material arrival to be suitable with project schedule.

17 Section : 3 Page : 3 of 6 Organization Technical Office Head. (TOH) He Reports directly to MD. He is responsible for the Engineering and Design of Power Boilers, Boiler External Piping, and Pressure Vessels built to ASME Code Section I, B31.1, and Section VIII-Div.1, including approval of drawings to show the details of the construction of the Vessel, calculations, to support the design and specifications to show how these vessels comply with the applicable Code Section. He is responsible to manage Engineering and Design documents' transmission (new issues as well as revised issues) and to arrange with sales department for assigning a job number for each order of a Code item. He is also responsible for all engineering activities related to other Construction Codes and re-rating, alteration and repairs in according to NBIC NB 23. The scope of his responsibility covers both PSC work shop and sites controlled by it Design Engineer The Design Engineer reports directly to the TOH and is responsible for preparation of design drawings, calculations and Material Requisitions of Code items being manufactured by the Company as well as repairs and alternations in according to NBIC NB Material Control Head. (MCH) He reports directly to MD. He provides instructions for material controllers to control the receiving, storage, preservation, issuing, scrap,...etc related to all Code section materials, except welding consumables Warehouse Manager (WHM) He reports directly to MD. He provides instructions for Warehouse Keeper to arrange the work of the warehouse (Receiving, storage, preservation, issuing, scrap,...etc). for all other materials and welding consumables not included in the scope of Material Control Head Planning Head (PFH) He reports directly to MD. He will define for each contract the following a) Fabrication Schedule of assigned work. b) Preparation of Resource Plan (Material - Labourers - Machines) and resources activity location. c) Following-up of all activities. d) Progress Reports (Daily - Weekly - Monthly).

18 Section : 3 Page : 4 of 6 Organization Projects Dept. Manager. (PSM) He reports directly to MD. He is responsible for managing projects coordination, contract administration and cost control activities in both work shop and field sites Construction Manager. (COM) He reports directly to MD. He is responsible for managing project activities and all operations at field sites Site Manager. (SM) He reports directly to Construction Manager and he is responsible for the site activities according to design instructions, procedures and drawings. He will liaise with QCM during Construction in matters relating to Inspection, Testing, Examination and Quality Control. It is the responsibility of Site Manager to ensure that only calibrated and identified equipment is used for Site Work Quality Control Manager. (QCM) The QCM reports directly to MD. He has the responsibility to ensure that all the departments within workshop and field sites at all time comply with the requirements of the applicable ASME Code, National Board Inspection Code, and this Quality Control Manual. In addition, it is the responsibility of the QCM to review the applicable Code Edition after issue for change required by such and to arrange for any necessary revisions to Quality Control system. His further duties include but not limited to the following: a. Ensure of correct preparation, revision, approval and implementation of Quality Control Manual. b. Safe custody and controlled use of ASME Certification mark stamp and National Board R&NB stamps in the work shop, and in site through the QC specialist at site. c. Control and issue of National Board serial numbers for shop and site if registered.

19 Section : 3 Page : 5 of 6 Organization d. Preparation of revisions to Quality Control procedures and submission of the same to the AI for his acceptance prior to inclusion or implementation. e. Review and certification of Manufacturer's Data Reports for Code Items. f. Maintaining contact with the AI and the AIA. g. Resolution of Nonconformities. h. Control of all welding activities related to the Code sections ( WPS, PQR, WPQ and WOPQ). i. Performing the required inspection, examinations and/or tests by himself or through his personnel and signifying completion of the inspections, examination and tests and acceptance of production function by signing or initialing the space provided on the ITP. j. Approval of NDE procedures, and execution of required NDE through qualified and certified personnel. k. He is responsible for the control and acceptance of all subcontracting activities directly associated with the Code Items. l. He has to get assurance through supporting formal documents that the subcontractor of a Code activity such as forming, PWHT, NDE, etc., is qualified, experienced and capable to meet the Code requirements while performing such activity. m. The certified report of the subcontractor for such activity/activities shall be reviewed by the QCM and sign if all Code requirements have been met and the concurrence of the AI shall be obtained. n. Other responsibilities of the QCM are quoted under individual applicable sections of this Manual. o. At his discretion, any of the above duties may be delegated to the appropriate Quality Control Personnel Quality Control Head. (QCH) The Quality Head reports directly to the Quality Control Manager and is responsible for overall activities related to Quality at workshop or filed. His further duties include but not limited to the following: a) Preparation of Code Items ITP and control its implementation after required approvals. b) Preparation and control of all welding activities related to the Code sections (WPS, PQR, WPQ and WOPQ). c) Control the execution of required NDE through qualified and certified personnel in according to the approved NDE procedures. d) Control the execution of required PWHT. e) Control of Hydrostatic tests required by the Code Section.

20 NDE Level III QUALITY CONTROL MANUAL Organization Section : 3 Page : 6 of 6 Appointed NDE level III reports directly to the QC Manager and is responsible for reviewing and approving documents such as written practice, procedures, personnel training and certification, records and certification of demonstrated NDE procedures Quality Assurance Head. (QAH) The QAH reports directly to MD. His further duties include but not limited to the following: f) Preparation, control, and distribution of Quality Control Manual. g) Periodical Calibration of measuring and testing equipment and maintenance of record of the calibration activities. h) Safe keeping of records. i) Other responsibilities of the QAH are quoted under individual applicable sections of this Manual. j) At his discretion, any of the above duties may be delegated to the appropriate Quality Assurance Personnel. k) Following up the implementation of the Quality Control Manual Sales and Proposal Manager (SPM) The SPM reports directly to MD. He is responsible about all marketing, estimation and proposal activities. He shall contact and arrange with QCM for any Quality issues related to ASME certification Mark projects. 3.2 Delegation and Performance of Duties Any Manager or Department Head may delegate any of the duties assigned to him to any of the qualified personnel who reports directly to him. However, the responsibility of such duties cannot be delegated Responsibilities and authorities of personnel shown in the organization chart and not described here have been detailed in various Sections of this Manual (If necessary) Each Person in a supervisory position may carry out the duties of personnel under their supervision provided they are qualified and when required are certified to perform the work.

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22 Design, Calculations, Drawings and Specifications Section : 4 Page : 1 of 8 Date : 21 / 1/ / 2012 Design, Calculations, Drawings and Specifications

23 Design, Calculations, Drawings and Specifications Section : 4 Page : 2 of 8 Date : 21 / 1/ / 2012 (4) Design, Calculations, Drawings and Specifications 4.1 General Each order received for a Code item is assigned a job or work order number by the Sales and Proposal Manager, which is used to identify documents related to the order. 4.2 Design by PSC For Code items, to be designed by PSC, the TOH and Quality Control Manger review the Customer s Design Specifications for Code compliance and adequacy of data. Any deficiencies are reconciled with the Customer to enable proper design work to start and continue accordingly After Their approval to Customer s Design Specifications, the TOH shall assign a Design Engineer(s) to prepare the Design Calculation Sheets, Drawings; Material Requisition forms (Exhibit No. (04-01) and if required, Material Technical Delivery Specifications (Exhibit No. (04-03) The applicable Code Edition and addenda used in design for Code items according to Sections I and VIII Div. 1 shall be the applicable Code Edition and addenda on time of contract The Design Calculations, Drawings, and Material Requisition are submitted to TOH for his review and approval Any disapproved documents are returned to the Design Engineer for correction and re-submittal. Final approval is shown by the dated signature of TOH on the documents. QCM reviews all design documents to assure compliance with the Code requirements and his review shall appear on all design documents by signature and date Revisions to the above design documents are prepared and approved in the same way as the first issue (Rev.0) Preparation of detailed documents will be done by Design Engineer and designee, as per detail in the following paragraph 4.4.

24 Design, Calculations, Drawings and Specifications 4.3 Design by Others Section : 4 Page : 3 of 8 Date : 21 / 1/ / When design drawings, calculations and material specifications are provided to PSC by others. The Design Engineer reviews these documents for compliance with the Code and User's design requirements; TOH approves the Design Engineer's reviewed documentation by signature and date on the original drawing and calculations. Any discrepancies are brought to the attention of the design concern for correction to meet Code requirements. Customer drawings shall be issued and controlled as PSC drawings as per Para below When the design documents (Calculation, drawings, MRF,..etc.) meet Code requirements, they are approved by the TOH and forwarded to QCM who will review all design documents to assure compliance with the Code requirements and his review shall appear on all design documents by signature and date In case of parts where PSC workshop is not responsible for the design, and the design is prepared and approved by ASME Certificate Holder Client or other ASME Certificate Holder that assigned by the Client, no design review shall be performed by PSC, but review of drawings for adequacy of data, review of customer material requisition or P.O or Material Technical Delivery Specification by PSC Design Engineer and approved by TOH; then submitted to the QCM for his review and consideration. In such case MPDR shall indicate the Design responsibility. 4.4 Preparation of Shop/Field Drawings and Calculations Calculations In case of Design by PSC The Design Engineer is responsible for the preparation of calculations, drawings and for issuing of Material Requisition Form (04-01) In case of Design by OTHERS In addition to the responsibilities of the Design Engineers mentioned per paragraph above, and in case that the MRF is not submitted by the Customer, the Design Engineer is responsible to review the engineering documents, prepare the MRF and submit all to TOH for his approval. After TOH review and approval, the same documents will be submitted to the QCM for his review and then to the AI for his review and comments if any.

25 Design, Calculations, Drawings and Specifications Section : 4 Page : 4 of 8 Date : 21 / 1/ / In both cases For both cases above, calculation Sheets shall be consecutively numbered and formulas identified as to the applicable Code paragraph. Calculations shall identify and consider all loading required for user s design requirements and for applicable ASME Code Construction Section Drawings The detailed drawings shall include, but not limited to, details of welded and bolted joints, Non Destructive Examination, Post Weld Heat Treatment, material specifications type, class or grade, dimensions together with tolerances, Impact test requirement and/or exemption, hydrostatic or pneumatic tests, applicable Code Section Edition and Addenda, design data including MAWP and Design Pressure at coincident temperature and minimum design metal temperature. Drawings shall also indicate certification Mark details and location Revisions to the above documents are prepared and approved in the same way as the first issue. 4.5 Distribution of Design Calculations, Material Specifications, Shop and Field Assembly Drawings Design Engineer files the original of all drawings, calculations, material specifications and other documents in its job files and logs them by job number After approval, all documents are forwarded to TOH Copies of approved drawings are distributed according to the Distribution list form (Exhibit No.(04-02)) by TOH, recipient shall sign and date the Distribution List Form as acknowledgment of receipt of documents listed TOH is responsible for providing AI at shop and/or field, with all design calculations, drawings, material specifications and any other documents deemed necessary for his review and acceptance Revisions to shop and field assembly drawings are prepared, approved and distributed in the same manner as the originals (First issued).

26 Design, Calculations, Drawings and Specifications Section : 4 Page : 5 of 8 Date : 21 / 1/ / Superseded documents to be returned back by recipient to the TOH to destroy the same unless containing notes which require their retention. In this case the documents are marked-up on the document table with "For Information Only". Destroying of documents will be confirmed against signature on Distribution List Form by the concerned recipient(s) Computer Aided Design. When computer programs are used to prepare ASME Code calculations the program output shall be identified with a program name, number and version. Each program application/module shall be verified prior to use. A verification report shall be prepared by Design Engineer and approved by TOH. The Verification Report shall 1. Identify scope or application for which the program is verified. 2. Identify the hardware used. 3. Include comparison of the program output either by: a- Hand calculations. b- Test results. c- Another verified computer program. ASME Code Edition shall be reviewed by TOH for possible changes to the program. Revised programs shall identify the reason for the change. When calculations are produced using the program, Design Engineer shall ensure that the program is suitable for the required application and that all applications to be utilized have been verified. All program printout will be identified with the program name/number and version. When calculations are sub-contracted to an organization which uses computer programs, Design Engineer or TOH shall review and accept the program verification report of the sub-contractor. If not available, the TOH shall prepare verification report for the subcontractor's computer program 4.6 Units Either US customary, SI units or local customary units, may be used to demonstrate compliance with all Code requirements A single system of units shall be used for all aspects of design except where unfeasible or impractical.

27 Design, Calculations, Drawings and Specifications Section : 4 Page : 6 of 8 Date : 21 / 1/ / When components are manufactured for different locations where local customary units are different than those used for the general design, the local units may be used for the design and documentations of that component (Please refer to Para ) below For any single equation, all variables shall be expressed in a single system of units When separate equations are provided for US customary and SI Units, there equations must be executed using variables in the units associated with the specific equation. Data expressed in other units shall be converted to US customary or SI units for use in these equations. The results obtained from execution of these equations may be converted to other units Production, measurements and test equipment, drawings, WPSs and other fabrication documents may be in US customary units or SI Units Any conversion necessary between different units for verification of Code compliance and to ensure that dimensional consistency is maintained, shall be in accordance with the following: Conversion factors shall be accurate to at least four significant figures The results of conversions of unit shall be expressed to a minimum of three significant figures Conversion factors between US customary units and SI Units may be found in non-mandatory appendix, guidance for the use of US customary and SI Units in the ASME Code Whenever local customary units are used the manufacturer shall provide the source of the conversion factors which shall be subject to verification and acceptance by the AI All entries on a Manufacturer's Data Report and data for Code required nameplate marking shall be in units consistent with the fabrication drawings for the component using US customary units, SI Units, or local customary units, it is acceptable to show alternate unit parenthetically.

28 Design, Calculations, Drawings and Specifications 4.7 Additional requirements of ASME Code Sec.I Section : 4 Page : 7 of 8 Date : 21 / 1/ / 2012 When the pressure parts of a forced-flow steam generator according to Section I, with no fixed steam and waterline are designed for different pressure levels, as permitted by PG 21.2 in Section I, the owner shall provide or cause to provide a boiler pressure system design diagram, certified by a Professional Engineer experienced in the mechanical design of power plants, which supplies the following information:- a) The relative location of the various pressure parts, within the scope of Code section, shall be defined with respect to the path of water-steam flow. b) A line showing the expected maximum sustained pressure, as described by PG 21.2 in Section I, indicating the expected variation in pressure along the path of water-steam flow. c) The maximum allowable working pressure of the various pressure parts. d) The location and set pressure of the overpressure protection devices. e) Copy of this diagram shall be attached to the Master Data Report. For an isolable or separately fired superheater which discharges steam directly to a process stream, the required stop valve and safety valves may be omitted when, flow and pressure calculations demonstrating that the superheater will not be overpressurized under any steam flow. TOH shall assure that the pressure system design diagram or the calculations are certified by a Professional Engineer experienced in the mechanical design of power plants. TOH shall make the same documents available to the Authorized Inspector for review. 4.8 Subcontracting design: a) Design work may be subcontracted to an experienced individual or organization evaluated by the TOH b) TOH shall be responsible to provide suitable information to the design subcontractor and shall review and approve the design documents prepared by subcontractor.

29 Section : 4 Page : 8 of 8 Date : 21 / 1/ / 2012 Design, Calculations, Drawings and Specifications c) The responsibility of the design work carried out by the subcontractor shall always remain with the company PSC. 4.9 Change of drawings In case the drawing has revised, Design Engineer shall review any effect of the change on the calculations and sign off the cover page as an evidence of review.

30 Material Control Section : 5 Page : 1 of 7 Material Control

31 Material Control Section : 5 Page : 2 of 7 (5) Material Control 5.1 Requisitions Design Engineer prepares the Material Requisition Form (Exhibit (04-01)) for all material except welding material which is prepared by the QCH, who uses Welding Consumables Requisition Form WCRF (Exhibit (05-01)) Design Engineer is responsible to prepare, in accordance with the applicable documents and the Code requirements, The Material Requisition Form that are then approved by the TOH and reviewed by QCM The Material Requisition Form shall include as a minimum, all Code requirements; this includes material specification, type/grade, permitted by the applicable construction Code Section and of that specification given in Section II, marking and material test report requirements, and any additional requirements of the Code Section, such as UG-79, UCS-79 when cold formed, special testing, and charpy impact tests at minimum design metal temperature is required and grain size and the supplementary requirements of the design if any, and any other instructions to the supplier. However, when required, a Technical Delivery Specification Exhibit No.(04-03) may be made giving information required and this document shall be referenced in the MRF with its revision number Selection of materials according to ASME B31.1 which is based on their inherent properties to: Listed materials. Materials meeting the requirements of Para shall be acceptable materials to use in Boiler External Piping Completed Material Requisition Forms (MRF) are to be signed and dated by Design Engineer and forwarded to TOH for approval then to be forwarded to QCM for review, and, finally submitted to the Material Control Head who verify the material available at store to deduct it from the quantity required to be purchased for each item then to be forwarded to Purchasing Head.

32 Material Control Section : 5 Page : 3 of For stock material one copy of MRF is distributed by Material Control Head to the QCH Completed WCRF Exhibit No. (05-01) is to be signed and dated by the QCH who will forward it to QCM to approve; then to Warehouse Manager who verify the material available at the store to deduct it from the quantity required to be purchased for each item then to be forwarded to Purchasing Head For stock material one copy of WCRF is distributed by Warehouse Manager to the QCH. 5.2 Purchase Orders For all Code material that must be ordered, Purchasing Head, prepares the Purchase Order (Exhibit (05-02)) and attaches a copy of the approved MRF, and submit this to one of the selected vendors. However, purchase of welding consumable will be conducted with the same way and in according to the final WCRF The requirements for certification Marking and Partial Data Reports shall be included either in the Purchase Order (Exhibit (05-02)) or reference the attached MRF when purchasing Parts that required ASME Certification Mark Which shall be ordered on the Manufacturer who has ASME authorization for application of required ASME stamp Upon receiving the subject documents from Design Engineer, TOH then transmits a copy from MRF, to QCM for use during receiving inspection For material to be sent to a Field Site, copy of the Purchase Orders or MRF and WCRF shall be sent to the Site QC Engineer Changes to Purchase Order will be prepared, reviewed and approved from revised MRF or WCRF in the same way as the Initial /Original issue Substitution of Material is not permitted without the prior approval of Design Engineer. Revision of design documents including MRF is to be issued and submitted to the AI for review. The AI shall be informed on a substitution by Design Engineer.

33 Material Control Section : 5 Page : 4 of Material Receiving Inspection All Code Materials received at the shop or site are placed in the material inspection storage area arranged by the Material Control Head. This area is a part of the main storage area which subdivided into three main areas; Material Inspection Area, Accepted Material Area and Hold Material Area The Material Control Head makes a preliminary receiving of the incoming materials comparing the coming packing list against the actual incoming materials to detect any discrepancy may be occurred on the Material Receiving Report (MRR) (exhibit (05-05)); then submit a copy to the QCH to execute the required inspection The Quality Control Eng., using his copy of the Material Specification, MRR Exhibit (05-05) and MRF, examines all Code Materials, except welding materials, for dimensions, marking, condition and quantity. The result of inspection shall be recorded on Material Receiving Inspection Form MRIF-(exhibit (05-03)).The Quality Control Engineer shall record the measuring instruction used during incoming material inspection on the MRIF report The Quality Control Engineer reviews the Material Certificate, Chemical Analysis and Physical Properties and other test results, against those listed in the applicable Material Specifications when Material test Report / Certificate is required. He shall also verify the marking required by the material specification and the Material Requisition Form MRF. The material marking should be verified against the mill test certificate When acceptable, the Quality Control Eng. signs and dates the MRIF and the Material Certificate or the Material test report MRIF should be forwarded to the QCH for approval by signature and date; then a copy is forwarded to Material Control Head to release the materials to the work shop or site The Material Control Head will notify the concerned shop and site Material Control Eng., the Site Manager or the Production Manager of all materials released, by sending to them a copy of the approved MRIF.

34 Material Control Section : 5 Page : 5 of Material which does not meet the requirements of Material Requisition Forms, Purchase Orders and applicable ASME Code Section shall be transferred to the "Hold Material Area", and controlled as described in Section 7 of this Manual (Dealing with Correction of Non-conformities) In case of any ASTM materials, the Quality Control Eng. shall review the year of acceptable Edition according to the applicable ASME Code Section, then review all the requirements of the ASTM specification, sign and date Material Test Report (MTR) if acceptable the material shall be recertified to required ASME specification on the Material Test Certificate and material stamped accordingly next to original stamping where ASTM material are not according to acceptable Edition either older or newer then acceptable shall be considered as non conforming and dealt with as per Sec.7 of this Manual dealing with correction of Nonconformities.In case of any deviation or rejection the usual receiving procedure shall be followed Before cutting Material into two or more pieces, the entire material marking is to be transferred by the layout foreman and verified by the Quality Control Eng. a coded marking traceable to the original required material marking and to the Material Certificate or material specification, as required for the product form, may be used to identify each piece. The method and extent of marking shall be acceptable to the AI. The said marking shall be done as a minimum by paint marking and a material map contains heat number, designation, grade, manufacturing name and certification number (if required) shall be used for all Code items for the purpose of maintaining material traceability (Vessels/Tanks Material Map - Exhibit (05-06)) or (Piping Material Map- Exhibit (05-07)) Hard stamp shall not be done on ferrous materials under 6mm and non-ferrous materials under 13mm thickness Permanent attachments welded to pressure parts shall be identified as in Para above Temporary attachments welded to pressure parts shall be identified or kept in a container with at least mark with the P- Number of the material. For material, which has no assigned P- Number, a WPS shall be established as described in Section 8 dealing with welding control of this Manual to prove weldability of the material and use of the WPS while welding of the same material

35 Material Control Section : 5 Page : 6 of For receiving inspection of welding materials, the QCH, using his copy of WCRF (Exhibit (05-01)), is responsible for inspection of welding materials using Welding Consumables Receiving Inspection Form (Exhibit (05-04)). 5.4 Receiving Inspection of Code Boiler and Pressure Vessel Parts Code Parts are unloaded in the Inspection Area, and examined by the Quality Control Eng. for damage, ASME Certification Mark and identification marking to provide traceability to Manufacturer's Partial Data Reports and drawings when required Manufacturer's Serial Numbers, piece mark numbers and National Board Numbers; if registered, for each item received are recorded by the Quality Control Eng., who will enter the date of receipt of Manufacturer's Partial Data Reports and name of Manufacturer who certified the Parts, in MRIF The Applicable Manufacturer's Partial Data Report (MPDR) must be received and verified against the Part certification mark by the Quality Control Eng. before the item can be released for installation or further fabrication AI shall be afforded the right to inspect and verify all Parts against the applicable Manufacturer's Partial Data Report prior to use Parts that do not meet Code and Customer Requirements are considered nonconforming and shall be dealt with as described in Section 7 of this Manual. (Dealing with Correction of Nonconformities) 5.5 Customer Supplied Material All Code Material supplied by the Customer or his designee is received and inspected by the Quality Control Eng. as described above; using either a copy of the Customer Purchase Order or MRF approved as stated in Para. 5.1, or packing list with the client Technical Delivery Specification or MRF or P.O. reviewed and accepted as per Section 4 of this Manual to verify compliance with all Code and customer requirements. (Dealing with Design, Calculations, Drawings and Specifications, Para )of Section 4.

36 Material Control Section : 5 Page : 7 of Stock Material The Quality Control Eng. verifies that stock material purchased to an earlier material specification meets all the requirements of the Code Edition & Addenda for the new contract. The Quality Control Inspector verifies the compliance of the MTR against the applicable material specifications for the new contract, he shall sign and date the Material Test Report/Certificate for recertification when acceptable and inspect the material as per Para. 5.3 above. 5.7 Material Records. All records referenced in this Section are available for the AI review, and are filed in the job file by the Quality Control Eng Warehouse and Material Storage Area. Warehouse Manager and Material Control Eng. guides store Keepers and Material concerning Control Specialist :- 1. Classification of material places inside warehouse. 2. Follow cards for each kind of material. 3. Special conditions of storing for specific materials (Welding Material). 4. Special Material is not mixed with similar product of unknown or dissimilar quality. 5. Contamination inside warehouse and how to minimize such. 5.9 Nonconformities. Quality Control Eng. must report any nonconformity to QCH and QCM to take action and solution as described in Section "7" of this Manual. (Dealing with Correction of Non-conformities) Additional Tests. Any additional tests required during receiving inspection or fabrication shall be sub-contracted to approved laboratory by QCM, relevant report(s) shall be reviewed by QCH and approved by QCM with his dated signature.

37 Examination and Inspection Program Section : 6 Page : 1 of 6 Examination and Inspection Program

38 Section : 6 Page : 2 of 6 Examination and Inspection Program (6) Examination and Inspection Program 6.1 Shop Fabrication: 6.2 Scope: This Section describes the system used to ensure that manufacturing, examination and inspection activities are planned, performed and documented in accordance with established procedures, instructions and drawings. 6.3 Inspection & Test Plan (ITP): Inspection & Test Plan (Exhibit (06-01)) is established to control the examination and inspection program system. It shall be prepared by QCH from the approved shop drawings and shall list the sequence of fabrication, examination and inspection operations for each item in the spaces provided. Approval of this document shall be granted by QCM. It shall be presented to the AI for his review and designation of inspection points and, if required, the client acceptance prior to release for fabrication For each inspection and test point, the plan shall indicate the applicable procedure, which details the characteristics to be inspected, inspection technique and acceptance criteria The ITP shall be the master document for controlling and documenting the status of operations in PSC workshop and include the inspection points, in addition to the following: a) Lists the fabrication, examination and inspection operations in sequence. b) Identifies applicable drawings c) Identifies procedures and instructions for example: Inspection & NDE procedure, welding procedure, and specifications for each operation. d) Provide space for indicating inspection points. e) Provide space for sign-off inspection points. f) When completed and signed off, document the fabrication history of the product.

39 Examination and Inspection Program Section : 6 Page : 3 of When approved shop drawings revised; the QCH shall review the ITP for any required changes and if these drawings revisions not affected the contents of the ITP; this shall be documented on the cover sheet of the ITP and signed and dated by all concerns (QCH, QCM and the AI) The Inspection & Test Plan contains columns for the initials and date of the Quality Control Eng. on the applicable line for those operations he accepts, and for the Authorized Inspector to initial and date in the column provided for him to signify those operations he accepts. 6.4 Hold Points. A Hold Point is an Inspection Point beyond which fabrication shall not proceed until signed off as satisfactory by the Quality Control Eng., client Inspector and/or the Authorized Inspector as designated. 6.5 Witness Point A witness Point is an Inspection Point beyond which fabrication may proceed, provided the Authorized Inspector has been notified on time, and when he is not able to attend, he waives the inspection and is able to review the inspection records at a later date In case the Authorized Inspector has verbally agreed to waive witness point inspection, QCM shall make an entry in the Inspection & Test Plan and provide the Authorized Inspector with documented evidence of the inspection carried out by the Quality Control Eng Review Point. A Review point is an Inspection Point related to documents' review. Fabrication can proceed and such documents will be reviewed by the Authorized Inspector prior to his signature on MDR. 6.7 Monitoring Point. It is a random and unscheduled Inspection Point which would be monitored by the AI and/or Client's Inspector during progress of fabrication.

40 6.8 Final inspection QUALITY CONTROL MANUAL Examination and Inspection Program Section : 6 Page : 4 of During the different stages of fabrication the Production Engineer shall notify the Quality Control Eng. to carry out the required inspection according to ITP, these inspections shall include, but not limited to, preparation, cutting edges, fit up, weld monitoring and NDE tests. These inspections shall be recorded in appropriate form. All MTR or certificates of compliance, examination reports, test records, and other fabrication records shall be available to the AI for review When shop fabrication or field assembly of a Pressure Vessel is completed, the Quality Control Eng. performs his final inspection. He initials and dates the Inspection & Test Plan when the item meets all Code and contractual requirements, the measurement and test equipment used during examination shall be recorded in the relevant reports For parts not tested until field assembly is completed, the AI makes his inspection after fabrication of the part is completed at the shop When a Pressure Vessel is not provided with an opening or other means of access to inspect internal surfaces, a Hold Point for the Quality Control Eng. and the AI shall be shown on the Inspection & Test Plan to permit internal inspection before starting the final closure fit up. 6.9 Pressure Tests QCM shall verify that the AI has been notified sufficiently in advance of each test so that he shall witness them, and complete his inspections; pressure test shall be performed according to a written procedure prepared by the QCH and approved by QCM, the gage identification number shall recorded on the pressure test report by the QC Eng Upon completion of the test and final inspection, the Inspection & Test Plan and supporting documents are returned to QCM for review and filing as described in Section 12 which deals with the Record Retention of this Manual.

41 Section : 6 Page : 5 of 6 Examination and Inspection Program 6.10 TEST GAUGES : One directly connected calibrated indicating test gauge, visible to the operator controlling the pressure, and having a dial graduated over a range of about double the intended maximum test pressure but not less than 1½ nor more than 4 times that pressure for Sec. VIII, div. 1 items, double the test pressure and not less than 1½ the test pressure for Sec. I items, shall be used for all types of test An additional indicating gauge may be necessary to allow the pressure to be visible to the operator at all times during the test, and to prevent excessive pressure being applied Certification Marking and Manufacturer's Data Report The QCM has the responsibility for the safe custody and control of the ASME Certification Mark stamps and National Board NB stamp to prevent loss or unauthorized use QCM shall be responsible to collect all required records and reports and verify that ITP has been completed and signed off to satisfy the requirements of the Code and Customer. The required Certification Mark will be applied, in the presence of the AI, and obtaining the authorization only when all fabrication, examinations and inspections are completed For Section VIII Div.1, the Certification Mark is applied on a Nameplate (Exhibit No.(06-02)) which is permanently attached to the vessel. For Section I items the Certification Marking as shown in (Exhibit No.(06-02)) shall be directly Marked on the item or as otherwise permitted by the Code. TOH shall specify the information required on the Nameplate or Certification Marking on the Code item in the Item drawings Certification Marking details for S and U part items are shown in (Exhibit (06-02)). For boiler external piping the certification marking shall be as per the requirement of PG-109 of Section I,when required to be registered with the National Board, National Board number shall be issued by QCM and stamped on the Name Plate or Code item after authorization of the AI Manufacture DATA REPORT (MDR). Upon Completion of a Code Item QCM shall review the MDR, which had been prepared by the QC Eng. or Head, for correctness and completeness and shall certify the Manufacture Data Report.