QCM 2010 AIS

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P.T. TOYO KANETSU INDONESIA

BATAM FABRICATION PLANT

JI. Tenggri, Batu Ampar

Batam – Indonesia 29432

Phone : 62(778)-412158, 412159

Fax : 62(778)-412157

E-Mail : [email protected]

QUALITY CONTROL MANUAL FOR THE

SHOP FABRICATION AND FIELD ASSEMBLY

OF

PRESSURE VESSEL & PARTS

IN ACCORDANCE WITH

THE ASME CODE SECTION VIII DIV. 1 AND 2

Manual No. : QM-02

Edition No. : 2

Revision No. : 2

Revision Date : February 15 2009

Control No. :

Holder Name :

Preface I – page 1 of 1

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P.T. TOYO KANETSU INDONESIA Edition No. : 2BATAM FABRICATION PLANT Revision No. : 2QUALITY CONTROL MANUAL Section : Preface

Preface ii – page 1 of 1

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P.T. TOYO KANETSU INDONESIA Edition No. : 2BATAM FABRICATION PLANT Revision No. : 2QUALITY CONTROL MANUAL Preface : iii

02 Table of Contents

Section No. Title Revision Date

Preface Cover page 2 February 15 2010

01 Log of Revision 2 February 15 2010

02 Table of Contents 2 February 15 2010

03 Statement of Policy and Authority 2 February 15 2010

04 Manual Control 2 February 15 2010

Preface iii – page 1 of 1

Company :

PT. TOYO KANETSU INDONESIA

BATAM FABRICATION PLANT

Location

Jl. Tenggiri Batu Ampar BATAM 29432 – Indonesia

Sheet 1 Of 1

QC MANUAL – EDITION No. 2Revision No.

1

Section

LOG OF REVISION

Revision Date

SEE BELOW

Edition No. 1Revision No. 0

Section PageApproved by : Sutarbilan 13-05-2004

QC Manager Approved on File

CommentFirst Issue for Initial Joint Review

Accepted by : Darobi. S 13-05-2004AI Approved on File


Section PageApproved by : Sutarbilan 15-05-2007

QC Manager Approved on File

CommentIssue for First

ASME Renewal Audit

Accepted by : Abidin A.M. 15-05-2007

AI Approved on File


Section Page Approval SignaturePrepared by : 24-01-2008

Comment Accepted by : 24-01-2008

Edition No.Revision No.

Section Page Approval Signature

Comment

Review

Accepted by :

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P.T. TOYO KANETSU INDONESIA Edition No. : 2BATAM FABRICATION PLANT Revision No. : 2QUALITY CONTROL MANUAL Preface : iii

05 Glossary of Terms 2 February 15 2010

06 Organization Chart 2 February 15 2010

1 Organization Authority and Responsibility 2 February 15 2010

2 Drawings, Design Calculations and Specifications 2 February 15 2010

3 Material Control 2 February 15 2010

4 Examination and inspection Program 2 February 15 2010

5 Correction and Nonconformance 2 February 15 2010

6 Welding Control 2 February 15 2010

7 Nondestructive Examination 2 February 15 2010

8 Heat Treatment 2 February 15 2010

9 Calibration of Measuring and Test Equipment 2 February 15 2010

10 Records Retention 2 February 15 2010

11 Field Assembly 2 February 15 2010

12 Authorized Inspector 2 February 15 2010

13 List of Exhibits (Sample Forms) 2 February 15 2010

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03 STATEMENT OF POLICY AND AUTHORITY

The Management of P.T. Toyo Kanetsu Indonesia is totally committed to meet all of the requirementsof the ASME Boiler and Pressure Vessel Code as a minimum. The Quality Control Systemdescribed in this Quality Control manual (here and after maybe called Manual), for shopConstruction and field assembly of ASME Code stamped Pressure vessels and Parts is inaccordance with section VIII Div.1 and Div.2, and may include customer and jurisdiction regulatoryrequirements where the Code item would be installed.

Department heads are responsible for performing the activities as described in this QC Manual.They may delegate the performance of the activity to a qualified individual within their departmentbut they shall remain responsible.

The Quality Control Manager is responsible for the preparation, revision, and issue of this Quality

Control Manual, and for the administration and implementation of the Quality System in the shopand field.

He has the authority, responsibility and organizational freedom to identify Quality Control problems,initiate and provide their solutions, and to verify that resolution of such problems have been correctlyapplied

He has the authority and responsibility, to stop any activities at shop and/or field site, when he findsany non-conformity.

In the event of disagreement between Section managers which cannot be resolved by the QualityControl Manager, the problem shall be brought to me for resolution which is, based on the ASME

Code requirements, this QC Manual and good engineering practice.

This Quality Control Manual is an integral part of the Quality Assurance manual (QM-01). ShouldThere be any conflict arise between this Manual and Quality Assurance manual (QM-01), this QCManual shall take precedence.

Signed : Toru Kiritani

President Director

Date : 15 February 2010

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04 MANUAL CONTROL

04.1 The Quality Control manager will issue copies of the Manual in accordance with the QC Manual

distribution list (Exhibit 0-1) maintained by him. Each manual will bear the same control number on its title page as is shown on the list.

04.2 New Code Edition and/or Addenda are reviewed by the Quality Control Manager and other responsible related personnel to determine the need for revisions to the QC Manual and relatedprocedures within six month of the issue of the Code Edition / addenda. The review isdocumented on Code Review Record Form (Exhibit 0-4). When revisions are required, they arepresented to the Authorized Inspector for his acceptance prior to distribute to the ManualHolder.

04.3 Revisions are indicated on the affected page by a vertical line in the right-hand margin adjacent

to the changed wording.

04.4 Revisions shall be approved by the Quality Control Manager and submitted to the AuthorizedInspector for his review and acceptance prior to issue. Revisions will be made bysection，except for exhibits. The revision shall be documented in the Log of Revision (Exhibit 0-2). For exhibits, the revision shall be highlighted by encompassing the change.

04.5 Revised sections of the Manual are issued by the Quality Control Manager to Manual Holderson the list, together with a revised Table of Contents page showing the latest Revision No. anddate of each section of the Manual, and the dated signatures of the Quality Control Manager and the Authorized Inspector.

04.6 Revised exhibit pages are issued individually with a revised “Listing of Exhibits” page, andrevised table of contents page.

04.7 The QC Manager may develop new editions to the Quality Control Manual every three yearscommensurate with the ASME Joint Review. New edition will be handled and controlled in thesame manner as new revision，except revision highlights or indicators are not required and therevision level of all section and exhibit will revert to zero.

04.8 A current copy of the Quality Control Manual is available for use by the Authorized Inspector atthe shop and at field sites.

04.9 Quality Control Manual will be marked “Controlled" and the QC Manager shall updated theQuality Control Manual distribution list (Exhibit 0-1). “Non-controlled" copies of the QualityControl Manual issued outside the organization are for information only，

04.10 Quality Control Manual will be issued with an appended Document Transmittal Advice (Exhibit 0-3), requiring receipt of acknowledgment

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P.T. TOYO KANETSU INDONESIA Edition. : 2BATAM FABRICATION PLANT Revision No. : 1QUALITY CONTROL MANUAL Section : Preface

0.5 GLOSSARY OF TERM

05.1 Authorized Inspector

An Authorized Inspector shall be an Inspector regularly employed by an ASME accredited Authorized Inspection Agency, i.e. an Insurance company authorized to write Boiler andPressure Vessel Insurance, and registered in a state of USA, or province of Canada. TheInspector shall not be in the employ of P.T. TOYO KANETSU INDONESIA. The Inspector shallbe qualified by a written examination under the rules of any State of United States or Provinceof Canada which has adopted the Code.He/She shall hold a valid National Board Commission with an “A” endorsement.

05.2 Code，，，，

Refers to the ASME Boiler and Pressure Vessel Code Sections IIA, B, C & D, V, VIII Div. 1, Div.2, IX applicable edition and addenda including other standards and publications referencedtherein.

05.3 Specifications

Information provided in addition to that given on drawings by a customer or by the Company asa further instruction to the requirements of ASME Codes or otherwise, of a contract

05.4 Company

refers as P.T.TOYO KANETSU INDONESIA.

05.5 Controlled Manual，，，，

Manual which are numbered, issued and updated with collection number, collection holder andrevisions by Quality Control Manager.

05.6，，Sign Off ，，，

The date signatures, initials, of authorized personnel reflecting completion of actions such asrevisions by Quality Control Manager.

05.7 Hold Point，，，，

An inspection, test, nondestructive examination or fabrication operation that must be witnessedby a specified party prior to subsequent fabrication, operation sequences at the required holdpoint shall not be continued prior to having been examined and released by a specified party.

05.8 Non Conformity

is any condition which does not comply with the applicable rules of the Code, Quality ControlManual, other specified requirement. Nonconformity's must be corrected before the completedcomponent can be considered to comply with the Code.

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5.9 Witness Point

a. An inspection, test, nondestructive examination or fabrication operation that is designated tobe witnessed by a specified party. The specified party must be notified sufficiently in

advance prior to performing the designated operation. If the specified party fails to show upthe operation may proceed, with the consent of the specified party，

5.10 Inspection and Test Plan (ITP)

b. An Inspection and Test Plan is one of quality plan documentation which lists manufacturingoperation, witness points, hold points, and other inspection points in a detailed sequence.

5.11 Fabrication Sequence Sheet

c. Fabrication Sequence Sheet is a project document, which lists fabrication flows of operationactivities in sequences which specify stages of construction of Code item at shop as well as

at the field sites.

5.12 Construction

d. The use of this word in this manual, is refer to an all inclusive term comprising material,design, fabrication, examination, inspection, testing, certification and pressure relief.

5.13 SNT-TC-IA

e. SNT-TC-IA is a Recommended Practice for Personnel Qualification and Certification inNondestructive Examination Methods.

5.14 Review

Verification of the Technical Document.


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05.15 ABBREVIATION

TKI : P.T. Toyo Kanetsu Indonesia AI : Authorized Inspector AIA : Authorized inspection Agency AFC : Approved For ConstructionMRL : Material Requisition ListPR : Purchase RequisitionMRC : Material Request CardMRR : Material Receiving ReportMDR : Manufacturer’s Data ReportPQR : Performance Qualification Record

FSS : Fabrication Sequence SheetRFC : Released For ConstructionNCR : Non Conformance ReportNDE : Non Destructive ExaminationPO : Purchase Order QA : Quality AssuranceQC : Quality ControlSC : Sub Contractor SOP : Standard Operating ProcedureITP : Inspection and Test PlanWPS : Welding Procedure SpecificationWPQT : Welder or Welding Operator Performance Qualification Record

RFI : Request for InspectionQ’ty : QuantityNB : National Board of Boiler and Pressure Vessel Inspector MAWP : Maximum Allowable Working PressureMAEWP : Maximum Allowable External Working PressureMDMT : Minimum Design Metal Temperature


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06. ORGANIZATION CHART


SHOP ORGANIZATION CHART

Preface vii – page 1 of 2

COMMAND LINE

COMUNICATION LINE

SHOP ORGANIZATION

PRESIDENT DIRECTOR

PLANT MANAGER

QUALITY CONTROLMANAGER

QUALITY CONTROLENGINEER

NDE LEVEL IIINDE LEVEL IINDE LEVEL I

TESTING HOUSE

QUALITY CONTROLINSPECTOR

ENGINEERINGMANAGER

DESIGN ENGINEER WEIDINGENGINEER

DRAFTER(S)

FABRICATIONMANAGER

FABRICATIONENGINEER

FABRICATIONSUPERVISOR

FITTING

FOREMAN

WELDING

FOREMAN

FITTER (S)WELDER (S)

OPERATOR (S)

PROCUREMENTMANAGER

PROCUREMENTMANAGER

PROCUREMENTENGINEER

MATERIAL

SUPERVISOR

WAREHOUSEKEEPER

ADMINSTRATIONMANAGER

MAINTENACEGROUP

SAFETYGROUP

MARKETINGMANAGER

SUPPORTING SUPPORTING

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FIELD SITE ORGANIZATION CHART

Preface vii – page 2 of 2

QUALITY CONTROLMANAGER

QUALITY CONTROLINSPECTOR

NDE COMPANYLEVEL I & II

FABRICATIONMANAGER

FABRICATIONENGINEER

ASSEMBLYFOREMAN

MATERIALSTORE KEEPER

WELDINGFOREMAN

FITTERS WELDERS

FACILITYSUPERVISOR

SAFETYOFFICER

ADMINISTRATIONSUPERVISOR

Shop

Field

Shop

Field

COMMAND LINE

COMUNICATION LINESHOP ORGANIZATION

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P.T. TOYO KANETSU INDONESIA Edition. : 2BATAM FABRICATION PLANT Revision No. : 1QUALITY CONTROL MANUAL Section : 1

1. ORGANIZATION, AUTHORITY & RESPONSIBILITY

1.0 SCOPE

This section described detailed company's Section Heads and its subordinates reporting，，，，

line, authority and responsibility as reflected in the company “Organization Chart" for shop andfield site(s)operation. The reporting line, authority and responsibility are as follows:

1.1 ORGANIZATION CHART

The organization chart for Shop and Field Site is indicated in Figure 1 “Shop OrganizationChart” and Figure 2 “Filed Organization Chart” respectively.

1.2 PLANT MANAGER，，，，

1.2.1 AUTHORITY

Plant Manager has the authority to implement the company policy and control all the shop andfield activity in accordance with the contractual agreement and specification.

1.2.2 RESPONSIBILITY

1.2.2.1 The Plant Manager is responsible for all plant and fabrication activities and is responsible for ensuring that all quality requirements are met, maintained and improved.

1.2.2.2 Receiving the tender specification from the Marketing Manager, and initiate a Project ContractDesign Review Meeting, to discuss the design program with Engineering, Procurement,Fabrication and QC Manager.

1.2.3 REPORTING

1.2.3.1 Reporting to

The Plant Manager reports to President Director

1.2.3.2 Directly reporting from

，，，，，，，，，，，，，，，(a) Engineering Manager (b) Fabrication Manager (c) QC Manager (d) Administration Manager (e) Procurement Manager

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1.3 QC MANAGER

1.3.1 AUTHORITY

1.3.1.1 The QC Manager has the authority to ensure an independence of the quality function fromthose personnel who have direct responsibility for work being performed.

1.3.1.2 The QC Manager has the authority to stop the work or activity being performed, either at shopor field site if he finds any non-conformity during the Code’s construction.


The specific responsibilities of QC Manager shall include the followings:

- To ensure that the training needs of QC staffs are identified and followed up.- To ensure that all inspection activities are planned and undertaken in timely manner.- To administer NDE Subcontractor and ensuring that all NDE requirements are identified and

met.- To ensure that all materials and fabricated items in accordance with specified requirements.- To liaise with AI, keeping him informed of work progress and notifying him of approaching

inspection points designated by him. Participating in ASME pre-joint and joint review.- To review and ensure that completed “Manufacturer's Data Report" prepared by QC

Engineer is correct prior to sign and date.- Provision for the custody and control of the Code Symbol Stamps to prevent loss or

unauthorized use and to issue Code Symbol Stamp to QC Engineer who will witness thestamp of the name plate in the presence of the AI.

1.3.3 REPORTING


The QC Manager reports to Plant Manager.

1.3.3.2 Directly reporting from，，，，，，，，，，，，，，，

All NDE and QC Personnel for the Shop and Field sites who perform a quality function

1.4 QC ENGINEER

1.4.1 AUTHORITY

The QC Engineer is authorized to carry out QC activities at shop and field sites.


The specific responsibilities of QC Engineer shall include the followings:

- To review contract specification and prepare associated ITP, based on FabricationSequence Sheet，

- Liaise with the Design Engineer in preparing the Welding Map, with regard to NDErequirements and initiate changes / revisions and ensuring timely distribution at shop andfield sites.


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- To monitor fabrication operation to ensure compliance with Codes, procedures andspecifications.

- To monitor ，Quality Control operations based on available Fabrication Sequence Sheet asto ensure compliance with Codes and specifications.

- To maintain Project Non-Conformance and Customer's complains Log and to ensurecorrective action has been properly implemented and timely close-out of Nonconformanceand complaints.

- Prepare the “Manufacturer's Data Report” form.

1.4.3 REPORTING AND COMMUNICATION

1.4.3.1 Reporting

The QC Engineer reports to QC Manager.，，，，

1.4.3.2，Communication

The QC Engineer shall liaise with:

(a) Client(b) Senior NDE (Subcontracted Level III)(c) Fabrication Engineer(s)(d) Design Engineer(s)(e) Procurement Engineer(s)

1.5 QC INSPECTOR(S)


The specific responsibilities of the QC Inspector(s) include the followings:

-，To carry out all inspection activities- To ensure that Non Conformance Reports are initiated as required in，，，，，，，，，，，，，，

accordance with the approved procedures.- To ensure that Fabrication Operations are monitored and comply with specified and

approved measures.- To monitor the operations specified in the Fabrication Sequence Sheet and ITP and sign off

same.- To accompany the material supervisor during the receiving inspection.

1.5.2 REPORTING

The QC Inspector(s) reports to QC Engineer.

1.6 FABRICATION MANAGER


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The specific responsibilities of the Fabrication Manager include the followings:

- To assure that all fabrication activity at shop and field site is performed in accordance withthe drawings, FSS, and this manual.

- To liaise with the Fabrication Engineer & Maintenance Supervisor.- To review fabrication processes, achievement and equipment at shop and field sites

including the vendor facilities.- To interface with the client, as required to ensure that any Fabrication and scheduling

problems are being adequately addressed.- To attend the Project Contract Design Review Meeting.

1.6.2 REPORTING


The Fabrication Manager reports to the Plant Manager.

1.6.2.2 Directly reporting from:

The Fabrication Engineer reports to the Fabrication Manager.

1.7 FABRICATION ENGINEER


The specific responsibilities of the Fabrication Engineer include the followings:

- To prepare “Fabrication Sequence Sheet" which shows detailed action at various stages of fabrication.

- To allocate work and to supervise an operation engaged on the work at shop and field site.- To ensure that work is carried out in accordance with drawings, specifications work

instructions, this QC Manual and the Code to meet the agreed Quality and satisfyrequirements.

- To ensure that required materials are available for the fabrication at specified time.- To ensure no work is carried out on “Non Conforming” 'items until instructed to do so by the

QC Manager.- To ensure that work is carried out in accordance with company’s procedures and Project

Safety Program.- To submit “Fabrication Sequence Sheet” in timely manner to QC Manager to enable him to

prepare the ITP.- To liaise with the Client / Customers Representative in construction with the project

progress.- To prepare purchase requisition based on MRL to purchase material.- Checking the availability of stock material in inventory list and directly at store.

1.7.2 REPORTING

The Fabrication Engineer reports to Fabrication Manager.

1.8 FABRICATION SUPERVISOR


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The specific responsibilities of the Fabrication Supervisor include the followings:

- To closely monitor all activities at various stages of the Code construction and to collectfabrication data.

- To monitor the receiving and the use of material during Code construction. For his activityhe should commit liaison with Fabrication Engineer(s).

- To review and evaluate on routine basis the Code's construction progresses at shop，

- To report to Fabrication Engineer for any deviation that might have impact on Fabricationprogress.

1.8.2 REPORTING

The Fabrication Supervisor reports to Fabrication Engineer.

1.9 ENGINEERING MANAGER

1.9.1 AUTHORITY

The Engineering Manager is authorized to control and guide the Design Engineer and ’WeldingEngineer in order to achieve high productivity and efficiency.


The specific responsibilities of the Engineering Manager shall include the followings:

- To attend the Project Design Review Meeting.- To approve design drawing and calculation and material requisition list, which have been

reviewed and prepared by the Design Engineer.- To liaise with the Fabrication Manager, Procurement Manager and QC Manager in technical

aspects and in estimating the project cost prior to submitting the tender quotation.- To prepare the project Construction Program.


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1.9.3 REPORTING


The Engineering Manager reports to the Plant Manager.

1.9.3.2 Directly reporting from:

The Design Engineer and Welding Engineer report to the Engineering Manager.

1.10 DESIGN ENGINEER

1.10.1 AUTHORITY

Design Engineer is authorized to assist the Engineering Manager to inspect, control and guidethe Drafter / Draftsman in order to achieve higher productivity and efficiency


The specific responsibilities of the Design Engineer shall include the followings:

- To prepare Design Program, Design Drawing and Calculations based on the contractrequirements and the Code/”User’s Design Specification”(for ASME Section VIII Div. 2)To ensure that the “User's Design Specification” and the “Manufacturer's Design Report” hasbeen certified by a Registered Professional Engineer

- To arrange Material Requisition List for production with clear description and specification of material to be used on the project.

- To verify all contract specifications and drawing prepared by draftsmen / drafter.- To initiate any revision of AFC Drawing and detailed drawings and ensure effectiveness

distribution of them to shop and field site in timely manner.- To liaise with Fabrication Manager and Engineering Manager in preparing shop and field

drawings.

1.10.3 REPORTING

The Design Engineer reports to the Engineering Manager.

1.11 WELDING ENGINEER

1.11.1 AUTHORITY

All welding discipline and activities are under his control.


The specific responsibilities of the Design Engineer shall include the followings:

- To prepare material for welder training.

- To evaluate and maintain the quality of performance of welders.- To review client’s project welding specification including implementation of Code，，

requirements and welding qualification.


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- To prepare Welding Procedure Specification and monitor the implementation of WeldingProcedure Specification at shop and field.

- To witness and assists the Welding Qualification Test.- Liaison with Welding Foreman for maintaining the calibration of welding machine and

equipment.

1.11.3 REPORTING

The Welding Engineer reports to the Engineering Manager.

1.12 PROCUREMENNT MANAGER

1.12.1 AUTHORITY，，

The Procurement Manager has the authority

- To approve selected vendor(s) which is/are included in the vendor(s) qualified list.- To disqualify any vendor(s) who is unable to meet the required qualification as specified in

the contractual agreement between the company and its subcontractor / vendor.- To purchase materials / goods in accordance with issued Purchase Requisition.


The specific responsibilities of Procurement Manager shall include the following:

- To ensure that each vendor in it's schedule to supply the purchased material has satisfied the

specified requirements as set forth in the purchase specification including the time and safedelivery of the goods being ordered.

- To select, audit and evaluate the qualification and performance of the vendors from time totime.

1.12.3 Reporting

The Procurement Manager reports to Plant Manager

1.13 PROCUREMENT ENGINEER

1.13.1 AUTHORITY

The Procurement Engineer has the authority to raise “Purchase Requisition".

1.13.2 RESPONSIBILITIES

The specific responsibilities of the Procurement Engineer shall include the following:

- To ensure that the material listed in the Purchase Requisition is correct as well as in thePurchase Order prior to issuing the purchase order to the vendor.

- To ensure that the material received is provided with the proper test certificates and as per Purchase Order.

- Liaison with Material Supervisor with regards to receiving of project material，

1.13.3 REPORTING


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The Procurement Engineer reports to Procurement Manager for the technical aspect to procurematerials.

1.14 MATERIAL SUPERVISOR，，，，

1.14.1 AUTHORITY

Material supervisor is authorized to carry out warehouse/store activities at shop.，，，，

1.14.2 RESPONSIBILITIES，，，，

The specific responsibilities of the Material Supervisor include the following:，，，，

- To ensure that material are checked on receipt for quantity and certification and that anyliaison required with material specification is maintained in accordance with agreed

procedures，- To ensure correct materials are prepared for quality control clearance prior to issuance.- To initiate segregation / quarantined of non-conformance materials and liaise with QC

Inspector for same.

1.14.3 REPORTING

The Material Supervisor reports to the Procurement Engineer and Warehouse and Storekeeper personnel are reporting to him.


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2. DRAWINGS, DESIGN CALCULATIONS AND SPECIFICATIONS

2.0 General

Each order for a Code Constructed item received would be assigned with a job (contract)number by the Marketing Manager, which will be used to identify all documents related to theorder/job.

2.1 Contract Review:

2.1.1 Contract may originate by the Marketing Department. A copy of customer project specification,government regulatory requirements (if any) will be reviewed during Project Contract Designreview meeting by:

2.1.2 The Engineering Manager who is responsible for determining whether the design requirements /data are sufficiently defined.

2.1,3 The QC Manager who is responsible for determining whether all Code's requirements (exceptfor design requirements) are adequately defined and could be met during the construction.

2.1.4 The Fabrication Manager who is responsible for determining manufacturing, processing,packaging and handling requirements could be met.

2.1.5 The Procurement Manager who is responsible for determining whether the required materialspecifications are adequately defined, and be supplied within the required time.

2.1.6 The Marketing Department may accept a revision to an order only after he has obtained thewritten instruction by customer.

2.1.7 The Marketing Department shall obtain resolution from the customer for comments made byEngineering Manager, Fabrication Manager and QC Manager.

2.2 Design by the Company:

2.2.1 Upon receiving of an order for a Code item which is to be designed by the Company, thecustomer’s design specification will be reviewed for adequacy by the Design Engineer and QCManager for compliance with applicable Code requirements. Any question found to be resolved

with the customer before the start of Code design work.

2.2.2 Upon approval of the customer's design specification a construction program (Exhibit 2-2) shallbe prepared by Engineering Department incorporating the comments of the FabricationManager. The construction program should list the following information:

，，，，

A. Engineering ActivityB. Procurement ActivityC. Fabrication Activity including NDE ActivitiesD. Project's schedule key dates

2.2.3 Completed design and shop drawings, calculations, material specifications and NDErequirements are prepared by Design Engineer and approved by Engineering Manager.


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2.2.4 Revisions to the above design documents are prepared and approved in the same way asthe originals.

2.2.5 Only materials listed in the ASME Code Section II Part A, B and C or otherwise permitted by theCode shall be used for construction. The Design Engineer shall then assign a draftsman toprepare detailed design drawing, such drawing shall include as minimum the following:

- Material List.- The Applicable Code Section including Edition & Addenda.- Design Pressure /Temperature and MAWP/temperature, MAEWP/temperature when

applicable.- Corrosion Allowance.- Minimum Design Metal Temperature.- NDE Requirements.- Heat Treatment Requirements.

- Hydrostatic / Pneumatic Test Pressure and test position.- Welding details and production test plate (if any).- Fabrication Tolerances.- Impact Test Requirements.- Alloy Verification requirement.- client’s and statutory additional requirement / specification (if any).- Special material testing requirement.- Pressure Relief requirements.- Name Plate Stamping information.

2.2.6 The Engineering Manager is responsible to submit the design drawing to the Al for his review.

Any comments shall be incorporated in the revised drawing for his re-review purposes.

2.3 Computer Aided Designs

2.3.1 When computer-aided design calculations and drawings are used for Company's designedCode items, the Design Engineer is responsible for the input of correct design data and theverification that the correct output has been obtained in the following manner:

，，，，

i) in the event that output do not satisfy the Code requirements a new programshall be used.

ii) All data that are not within the scope of the computer program shall be alternately

(manually) calculated and shall be initiated based on Code requirements.

2.3.2， The Engineering Manager will review new Code edition and/or Addenda to determine if standarddesign nor computer program are affected. Required revisions shall be made within six monthsof the New Edition and Addenda issue date. The revision / review shall be documentedaccordingly.

2.3.3 All revisions are documented on a dated record of change signed by the Engineering Manager

and recorded on each affected document or in computer program documentation.


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2.3.4 Computer-aided drawings and calculation output shall be made available for review andacceptance by AI, The Design Engineer shall verify correctness of computer aided calculationby alternate (manual) calculation on every new edition or addenda. The Design Engineer provides the Al with any alternate calculations to verify computer output.

2.4 Design by Others

2.4.1 When design drawings, calculations and material specifications are provided to theCompany by others, the Engineering Manager or his designee reviews these documentsfor compliance with the Code and user's design requirements on customer specification. Anydiscrepancy is brought to the attention of the design concern for correction to meet the Coderequirements.

2.4.2 When the design documents meet the Code requirements, they are approved by theEngineering Manager who will stamp, initial and date each document with “APPROVED FOR ASME CODE CONSTRUCTION (AFC)".

，，，，

2.4.3 Company shall be responsible for any ASME design activities performed by others.

2.5，， ASME Section VIII Division 2 Vessel

2.5.1 The user shall provide a "User's Design Specification". The User's Design Specification shall bereviewed and certified by a Registered Professional Engineer, registered in one of the state of the USA or province of Canada and experienced in pressure vessel design. User’s DesignSpecification shall meet the requirements in ASME Section VIII Div.2 paragraph 2.2.2.

2.5.2 The certified "User's Design Specification" shall be obtained and reviewed by the Design

Section Manager which shall at least contain the information required by Section VIII Div. 2 part2 Paragraph 2.2.2, as follows :

a) Installation Site, including location, Environmental conditions, and jurisdictional authority (if applicable).b) Vessel identification, vessel number, and service fluid.c) Vessel configuration and controlling dimensions.d) Design conditions.e) Operating conditions.f) Design fatigue life.g) Materials of construction.h) Loads and load cases.

i) Overpressure protection.

2.5.3 Based on requirements of User Design Specification (UDS) the Design Section Manager shallestablish and prepare Manufacturer's Design Report complies with the requirements of ASMESection VIII Division 2 Part 2 Paragraph 2.3.3.1., for the condition set-forth in the certified User's

Design Specification. The Manufacturer's Design Report shall include the following information :


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a) Final as-built drawings.b) The actual material specification used for each component.c) Design calculation and analysis.d) The results of any fatigue analysis.e) Any assumption used by the Manufacturer to perform the vessel design.

. The “Manufacturer’s Design Report” shall be reviewed and certified by one or combination of

methods shown below, in accordance with Annex 2.B.2.1 of ASME Section VIII Division 2.

a. One or more Professional Engineer registered in one or more of states of the United States

of America or the Provinces of Canada and experienced in Pressure Vessel Design.

b. One or more individual(s) experienced in Pressure Vessel design shall certify that the

Manufacturer’s Design Report meets the requirements in paragraph 2.3.3. of ASME Sect.

VIII Division 2.

2.5.4 Over Pressure Protection

1) The user shall be responsible for the design, construction and installation of the

over pressure protection system unless it is delegated to the Manufacturer. This

system shall meet the requirements of Part. 9 of ASME Sect. VIII Div. 2.

2) The type of over pressure protection intended for the vessel shall be documented in

the User’s Design Specification as follows :

a. Type of over pressure protection system.

b. System design

3) The user shall state if jurisdictional acceptance is required prior to operation of the

vessel.

2.5.5 Loads and Load Cases

1) The user shall specify all expected loads and load case combinations as listed in

paragraph 4.1.5.3 of ASME Sect. VIII Div. 2.

2) These loading data may be establish by :

a. Calculation.

b. Experimental methods.

c. Actual experience measurement from similar units.

d. Computer analysis.

e. Published data.

2.5.6 Design Fatigue Life (If any)

1) Cyclic operating conditions and whether or not a fatigue analysis of the vessel as

required shall be determined in accordance with paragraph 4.1.1.4. When a fatigue

analysis is required, provide information in sufficient detail so that an analysis of the

cyclic operation can be carried out in accordance with paragraph 5.5.


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2) When a vessel is designed for cyclic conditions, the number of design cycles per

year and the required vessel design life in years shall be stated.

3) When cyclic operating conditions exist and a fatigue analysis is not required based

on comparable equipment experience, this shall be stated.

2.5.7 Revision

If revision are made to the User’s Design Specification, the Manufacturer’s Design

Report shall be reconciled with amendment of User’s Design Specification. Any

revisions required in Manufacturer’s Design Report and drawings shall be

submitted to the Registered Professional Engineer as described in para 2.6.1.a and

para 2.6.1.b of ASME VII-2 for re-certification purposes.

2.6 Distribution of Drawings, Design Calculations, and Specifications

2.6.1. Distribution of all drawings, design calculations, and specifications are logged and controlledunder Document Control Sheet (Exhibit 2-1) by Design Engineer.

2.6.2. Approved for construction drawings, design calculations, and specifications are distributed byDesign Engineer to QC Manager and discuss the scope of work, Process Control Sheet(Traveler), ITP, etc.

2.6.3 The Fabrication Manager hand carries the Released For Construction documents to the

Fabrication Engineer and Leaders to discuss the scope of work with them.

2.6.4. Field assembly drawings are issued to Fabrication Leader by the Fabrication Manager who willalso review the scope of work with them when delivering the drawings.

2.6.5. The QC Manager is responsible to provide the AI with shop and field drawings, designcalculations and specifications for his review before the start of the construction at the shop andfield sites.

2.6.6. The QC Manager provides copies of the above documents to the QC Inspector, for the use atshop and field.

2.6.7. Revision to shop and field assembly drawings are prepared, approved and distributed in thesame manner as the original.

2.6.8. Obsolete documents are destroyed by document holder in each Section, unless containingnotes that require their retention, in such a case the document holder shall stamp the documentwith "OBSOLETE" stamp and retain them in the job file for information only.


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2.11 Drawing and Document Chart


CLIENT PROCUREMENT ENGINEERING QUALITY CONTROL FABRICATION

CLIENTDESIGNSPECIFICATION

THROUGHMARKETINGMANAGER

APPROVAL(OPTIONAL)

VERIFICATION THROUGHMARKETING

MANAGER

DESIGNCALCULATION

MATERIALSPECIFICATION

NDEREQ'NTWELD/NDTMAP

AFCDRAWINGISSUE

WPS,PQR& WELDERCERTIFICATE

(COPY)

MATERIALREQUESTLIST

TO

MATERIALCONTROLF-CHART

COPY COPY

ORIGINALRETAIN

MAT'LCONTROL SHEET

INSPECTIONANDTESTPLANT

NONCONFORMANCEREPORT

CORRECTIVEACTION

VERIFICATION

AS-BUILTDOC/CERT. DOSSIER

SIGNMDRBYAI

COPY

F A B R I C A T I O N

CUTTINGPLAN

FABRICATION INSTRUC.

FABRICATION SPECS.

FAB. SEQUENCESHEET

BARCHART/S - CURVESCHEDULE

DISPOSITION

FINALI NSPECTION

HYDROSTATICTEST

PACKING& SHIPPING

ABBREVIATION :AFCDRAWING: Approvedfor Construction Drawing

NOTES:1) All theaboveconstruction documentsshall be submitted to AI

to for hisreview2) All version will behandled asper initial squence

COPY

COPY

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3.0 MATERIAL CONTROL

3.1 Requisitions

3.1.1 AII Material Requisition List (Exhibit 3-1)for Code material, including welding material areprepared from approved material specifications by the Design Engineer which list all Coderequirements. These shall include the material specification type or grade selected from theapplicable Code Section II parts A, B and C, use for Code's construction and purchasepurposes.

3.1.2 Completed Material Requisitions List are reviewed for Code compliance by the QC Engineer who would make any required corrections approves by initial and date the MRL and returns it tothe Design Engineer.

3.1.3 The Fabrication Engineer is responsible for checking the availability of stock materials inMaterial Inventory List (Exhibit3-9) and directly at store. In the case where material is not

available, he shall identify in MRL and Purchase requisition (Exhibit 3-2) shall be raised. Thecompleted Purchase Requisition (PR) is then submitted to Procurement Manager for Procurement Purposes (See 3.3).

3.1.4 When additional requirements for further treatment, examination and test of material is a Coderequirements, then that information shall be included in both the MRL and PR and would also bereflected in the PO (Exhibit 3.3).

3.1.5 The Procurement Manager will make a selection of the vendor(s) based on Vendor's QualifiedList. The selected vendor will then be issued a P/O accompanied with the Purchase Requisition(PR). Copy of un-priced P/O win be sent to QC Department, Fabrication Section and MaterialSupervisor for their Receiving Inspection purposes.

3.1,6 Additional Code material (if any)，requested by the Field Fabrication Engineer requisitioned bythe Fabrication Manager as described above. It is the company policy that No procurement of material for pressure parts will be procured at field sites.

3.2 Additional Requirements for Section VIII Division 2

3.2.1 Design Engineer shall clearly explain to the Purchasing Engineer that while preparing MRL, heshall ensure that material ordered is in compliance with the requirements of Section VIII Division2 Part 3 Paragraph 3.2.6. The Material Manufacturer shall provide a statement that thematerials comply with Section VIII Div. 2 Part 3 requirements. The mill certificate shall includethe numerical result of all required tests.

3.2.2 Upon receiving, material shall be inspected for Code compliance with the part 3 specialrequirements for any treatment, test or examination specified therein and compared against thematerial Manufacturer's certified report results. In the event that conflict found between thematerial spec. and the special requirements, an NCR shall be raised.

3.2.3 For Section VIII Div.2 Pressure Vessel material used for construction of pressure vessel partsshall be limited to those material specifications shown the allowable design stress in Annex 3A.Furthermore for vessel subject to fatigue further restrictions applies in that the material is limitedto that for which fatigue curves are provided.

3.3 Purchase Orders


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3.3.1 The Procurement Manager issues the Purchace Order (Exhibit 3-3) accompanied with the PR toselected vendors. P.O. copies are processed in the company procurement system anddistributed as follows:

Purchase Order Distribution Chart

Copy P.O. Distribution Purpose

Original vendor Vendor use / Retention

2nd Batam Accounting Record for Settlement

3rd Procurement &

AdministrationDepartment

File

1st Batam/Jakarta Accounting For cross checking against incomingmaterial，Corresponding DeliveryOrder, Invoice, acknowledgementfrom vendor and material delivery toshop and field site.

4th Fabrication Section Record retention.

5th QC Section For material receiving inspection.

6th Material Supervisor For material receiving inspection.

3.3.2 For material to be sent to a field site, the Fabrication Manager and QC Manager ，，，，

respectively forwards a hard copy of the un-priced Purchase Order to the Fabrication Engineer and QC Inspector at field site.

3.3.3 Changes to Purchase Orders will be prepared, reviewed and approved from revised requisitionsin the same way as the originals.

3.4 Receiving Inspection:，，，，

3.4.I All Code materials which has been received at the shop or field site shall be placed in a，，，，，，

segregated “Quarantine” area pending Quality Control receiving inspection.

3.4.2 The QC Inspector accompanied by the Material Supervisor and using the QC copy of ，，，，，，，，

the Purchase Order with the attached PR, examines all Code items for dimensions, marking,physical, specification/heat number, condition and quantity against mill test certificates and/or certificate of compliance or Partial Manufacturer’s Data Reports.


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3.4.3 Marking such as heat number, material specification, type or grade are recorded on the MaterialReceiving Report (Exhibit 3-4) by the Material Supervisor. If the QC Inspector found that the

marking is acceptable, he marks the material with the applicable job number, signs and datesthe Material Receiving Report and Material Mill/Test Certificate and forwards them to the QCManager.

3.4.4 For all Code material, for which the material specification requires Material Test Report and/or Certificate of Compliance, the QC Engineer shall check the Material Test Reports on chemicaland physical properties, and other test and examination results and to compare with theapplicable specification requirements of the Code. lf the original marking on the material foundcoincide with that on material test report and/or Certificate of Compliance, the QC Engineer shall check the Material Test Report on chemical and physical properties, and other test andexamination results and to compare with the applicable specification requirements of the Code.lf the original marking on the material found to coincide with that on material test report and on

the Material Receiving Report via-a-vis: material specification, grade/type, dimension, testrequirements and heat treatment, the QC Engineer shall record his acceptance in the Mill/TestCertificate and Certificate of Compliance as well as in the Material Receiving Report.

3.4.5 When acceptable, the QC Engineer signs and dates the Material Mill / Test Certificate and/or Certificate of Compliance and informs Fabrication Manager to release the material to the shopor field site.

3.4.6 Material which does not meet the Purchase Request, Purchase Order and Code requirements istagged with a “HOLD” Tag (Exhibit 3-5), and Held in the “Quarantine” area and should becontrolled as described in Section 5.

3,4.7 Before cutting Code material into two or more pieces, the entire material marking is transferredby the layout man ， and inspected by the QC Inspector. In some cases, a coded marking,traceable to the Material Test Report or material specification, as applicable and acceptable tothe Authorized Inspector, may be used. All identification markings on high tensile steel usinghard stamp shall be embossed by low stress hard stamp. All material of alloy steel or carbonsteel less than 1/4” (6mm) shall not be hard stamped. For identification purposes an alternativemeans to be sought i.e. by using suitable paint mark and shall be traceable on the MaterialControl Sheet (Exhibit 3-11) which was prepared based on the Cutting Plan (Exhibit 3-10).Material Certification shall be recorded in the “Material Identification and Traceability Report"(Exhibit 3-6) by the QC Inspector.

For section VIII Div. 2 vessel, where service conditions prohibit die stamping on the

material surface, all material traceability shall be recorded on a MaterialIdentification and Traceability Report.

3.5 Field Site Receiving Inspection of Code Pressure Retaining Parts and Piping

3.5.1 Code pressure parts and piping are unloaded in the assigned lay-down area andexamined by the Materia1 Supervisor and QC Inspector for damage, Code stamping andidentification marking to provide traceability to the Manufacturer's assembly drawings and partialMDRs.

3.5.2 The QC Inspector shall record the manufacturer’s identification marking in Material Identificationand Traceability Report Form (Exhibit 3-6).

3.5.3 The applicable Partial Manufacturer's Data Report and Material Mill Test Reports for material shipped loose which has not been included on a Data Report must be received and


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verified against the stamped part or material traceability marking before the item could bereleased by the QC Inspector for assembling / erection.


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3.5.4 Items for which full documentation has not been received, but which are Code Stamped or marked as a required by the material specification, shall be put on “hold" and not permitted to

be installed, The Al is kept informed of their status. NCR shall be issued for this effect.

3.5.5 Sub assemblies and raw materials that do not meet all Codes and customers requirements areconsidered nonconformity and shall be corrected or removed as described in Section 5 of thisManual.

3.6 Customer Supplied Material

3.6.1 All Code materials supplied by the customer’s or his agent is received and inspected bythe QC Inspector as described in paragraph 3.4 and 3.5 above. Except a material requisition isused ln lieu of a purchase requisition.

3.6.2 Nonconforming material is controlled as described in Section 5 of this Manual.

3.7 Substitution Material:

3.7.1 Substitution of material shall be approval by the Design Engineer, the drawings, designcalculation and other applicable document shall be reviewed as per paragraph 3.1. The Al shallbe advised of the substitution for his review and acceptance. Should the AI accepts previousdrawings, calculation, welding qualification and other related documents which has beenaffected by this substitution shall be reviewed for the require revision and re-qualification test.

3.8 Coded marks for structure steel material attached to pressure retaining parts.

，，，， All structural steel material to be attached by means of welding to any pressure retaining partsshall be identified as follows. Code marks i.e.

No. Material ldentification

1. P-N0,1 P1

2. P-N0.2 P2

3. P-No.X PX

3.9 Vendor Supplied Pressure Retaining parts

3.9.1 When the Company decides to use a subcontractor for fabrication of Code parts, the DesignEngineer prepares the requisition which shall detailed an applicable Code and contractrequirements, specified Quality Control requirements shall be identified by Quality ControlSection.

3.9.2 For supplied parts that involve fabrication welding, the vendor must hold an appropriate ASMECode Stamp Authorization.

3.9.3 For parts which is limited to forming, cutting, machining and drilling type operation, thesubcontract does not necessarily hold an ASME Certification, but the company shall be

responsible for verification of the correctness of work by inspection during receiving inspection.

3.10 Material Records


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3.10.1 Material Mill Test Reports and Material Identification and Traceability Report are submitted tothe AI for review before being placed in the file.

3.10.2 All records referenced in these sections are available for review by the AI and are filedin the QC Job file at shop or field site.

3.11 Issue of Material (Shop and Field Site)

3.11.1 Material shall be issued to the workshop or field site from the store or “Quarantine” area uponreceipt of a Material Request Card (Exhibit 3-7) issued by the Fabrication Supervisor induplicate approved by Fabrication Engineer.

3.11.2 Upon delivery of material(s), the Material Request Card shall be completed by the storekeeper,the stock card shall be adjusted accordingly and the duplicate copy of the Material RequestCard returned to the recipient with the issued material.

3.11.3 The original copy of the Material Request Card shall be retained by the store and filed centrallyby its number.

3.11.4 The storekeeper shall ensure that the material is issued to the correct size, dimension,schedule, specifications and quantity. In the case where the materials are to be cut by thestorekeeper, the QC Inspector shall verify the transfer of heat number and material specificationand grade against the original mark stamping.

3.12 Returning of Surplus Material

The storekeeper shall ensure that all surplus materials are returned to the store, correctlyidentified, following cutting with the Material Return Slip (Exhibit 3-8) being used. The MaterialReturn Slip shall be raised by the Fabrication Engineer and shall be given a unique sequentialnumber with a copy field in a central file with the Fabrication Section and the original filed by thestore. The Material Return Slip shall always bear the Material Request Card number againstwhich the materials where originally issued.

3.13 Inventory Material

The Shop QC Inspector shall re-inspect any material inventory to be use on a Code project for compliance with project and Code requirements. This inspection shall be documented usingMRR (Exhibit 3-4). (Correction)

3.14 Material Control Chart


GENDMAT'LSPVFabENGHN

: Material:: Supervisor: Fabrication: Engineering: Heat Number

FABRICATION PROCESS

Mat'l SPV. FabEng

MarkMat'l with Job#. HN&Grade

Material ReturnSlip(Exh3-8)

- Store

- Store

Material Supervisor

IssueMaterial

Check/ApprovedMat'l Request Card

FabricationEngineer Material Request Voucher(Exh3-7)

FabricationEngineer

IssuedMat'l Request Card

- Fabrication- QualityControl

Material ReceivingReport(Exh3-4)

YES

QC. Insp. +Mat'l SPV

MarkMat'l with Job#. HN& Grade

YES

REJECTSCRAP/RETURNTOVENDOR

(Exh3-5)

ACCEPTABLE

NO

RESOLUTION


CheckMat'lAsper PO& PR

ACCEPTABLENO


Check Mat'lAsper PO&PR

Material Supervisor

RECEIVEM AT'LPLACEDONQUARANTINEAREA

VENDOR

Pack& ShipM aterial

Invoice

DeliveryOrder

ShippingList

PurchaseOrder(Exh3-3)

Procurement Mng

CheckPurchaseOrder

Fabrication PurchaseRequest(Exh3-2)ISSUE

PurchaseRequest

YES

NO

AVAILABLE

Material Requisition List(Exh3-1)

Fab. Eng- Mt'l SPVCHECKMRL

AGAINSTINVENTORY

DESIGN ENGINEERING

ISSUEMAT'LREQUISITIONLIST

YES

NOAVAILABLE

QC

CHECKMRL

PROJECTDATA INPUTDESIGNENG.

DESIGNCalculationMaterialSpecification

WeldingMapAFCDrawing

- Engineering- QualityControl- Fabrication- Store

- Pro curement- Fabrication

* XeroxCopy, Unprice:- Store - Procurement - 3rdcopy- Material Supervisor - BTM Acct. - 2ndcopy- QCManager - JKTAcct . - 1st copy- FabricationManager - Vendor - ORIGINAL

Distribution:- Procurement manager- Accounting- Store

START

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4. EXAMINATION AND INSPECTION PROGRAM

4.1 Shop Fabrication

4.1.1 Fabrication of Code items are controlled by using Inspection and Test Plan ITP (Exhibit 4-1) ， prepared by QC Engineer based on the AFC Drawings, which shall lists the sequence of fabrication, examination and inspection operations in the spaces provided.

4.1.2 Fabrication Manager & QC Manager reviews the ITP and AFC drawings with the AI to designate

of their inspection points. If found necessary by request, the client could also be involved.

4.1.3 The ITP contains columns for initial and date by QC Inspector and the AI on those inspections

they accept.

4.1.4 No work shall proceed unless the ITP has been signed by QC Inspector and AI for their agreed

designated holds points.

4.1.5 Revision to the ITP shall be handled in the same manners as original. Editorial change to be

made by QC Engineer, who initial and date the change. ITP shall be maintained by QC Engineer

until job / project is completed and put on the QC job file, after Code item is completed then be

kept in QC in the related job's file. When AFC drawings are revised the ITP shall be reviewed by

QC Engineer for any change and if no change is required the review shall be documented on theconstruction sheet of the ITP by QC Engineer.

4.1.6 The QC Manager or his designee has the responsibility to notify the AI in sufficiently in advance

for his designated inspection and hold points.

4.1.7 The QC Manager or his designee has the authority to stop or hold the work partially or entirely if

he found any Non Compliance during the Code item Construction.

4.1.8 For Asme Sect.VIII Div. 2 , the ITP shall include the requirement of table 7.A.1

4.2. STAGE EXAMINATION & INSPECTION

Production Manager shall be responsible for fabrication as per the drawings. At the appropriate stages

identified on the ITP, he shall offer the stage to QC Manager for examination.

Shell plates and edges of heads and other components are gas-cut/machined/ground to the required edge

preparation. Edges are examined visually or by PT or MT when required by ITP. Adjoining edges of shell

plates are shaped to a proper curvature by preliminary rolling or forming in order to avoid objectionable flat


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spots and peaking at the weld joints. Rolled shells are checked for out of roundness, shape and diameter to meet

the tolerance requirements. Re-rolling is permissible to achieve the required dimensions.

Dimensions of shell and head shall meet the Code required tolerances. When external pressure condition is

applicable, the maximum plus or minus deviation from the true circular form is verified using the template as

per Code requirements (UG80, UG81).

Components shall be fitted, aligned and retained in position during welding using bars, jacks, clamps or tack

welds or other means. These temporary attachments are removed when they have served their purpose in a

manner so that it does not cause damage to the materials.

Completed joints are examined to ensure that they do not exceed the tolerance requirement of code for

alignment and weld reinforcements and that the weld surfaces are acceptable.

During stage examination, QC Manager shall be responsible for

a) Verifying identification and traceability of all materials used in fabrication

b) examination of material before fabrication to ensure correct specifications and correct thickness &

dimensions

c) examination of weld edges and parts after fit-up to ensure they have been properly fitted and that

the joining surfaces re cleaned and within alignment tolerances

d) examination during and after welding and at other stages identified on ITP

He shall signify acceptance for all the stages on ITP and offer to AI in accordance with his inspection point for

his acceptance and signatures on ITP

4.3 Field Assembly

4.3.1 Field assembly of Code items controlled by the shop organization.

4.3.2 The Field Inspection & Test Plan with assembly drawings is reviewed and accepted bythe QC Manager for Code and Quality control requirements, which he may add if hefound deemed necessary to do so.

4.3.3 The Field Inspection & Test Plan and assembly drawings are then sent to the Field QCInspector, who will then review the Inspection & Test Plan with the AI to designate their inspection points, prior the start of Code Work.

4.3.4 The QC Inspector and AI initials and date the field Inspection & Test Plan to documenttheir involvement.

4.3.5 The Field Inspection & Test Plan contains the same columns for initials and dates toconfirm completion of each stage of operation by the QC Inspector, prior to theinspection of the AI.

4.4. Final Inspection

4.4.1. When shop or field assembly of a Code item is completed, the QC Inspector performs his finalinspection. He initials and dates the Inspection & Test Plan when the item meets all Code


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requirements.4.4.2. The AI will make his final inspection prior to hydrostatic or pneumatic test required as specified

in the Inspection & Test Plan. For parts for which would not be tested until field assembly iscompleted, he makes his inspection after the fabrication of the component completed.

4.4.3. When a pressure vessel is not provided with an opening or other means of access to inspectinternal surfaces, a hold point for the QC Inspector and AI will be shown on the Inspection & TestPlan to permit internal inspection before starting the final closure weld.

4.4.4. Actual dimensions and the following material markings are recorded during final inspection by theQC Inspector :

• the heat number for all material

• the material specification, type or grade for all materials.

• Manufacturer / Sub contractor Identification marking on sub assemblies without welding

4.4.5. This tabulation of material Identification and Traceability (Exhibit 3-6) is also provided, identifyingeach piece with it’s corresponding drawing item, and traceable to the Mill Test Reports. This isthen sent to the Design Engineer for preparation of the As-Built Drawing and Manufacturer’s DataReport.

4.5，， Hydrostatic Test

4.5.1 Code required hydrostatic tests are witnessed by the QC inspector and AI, following

shop / field preliminary test to determine the structural integrity or repair of any leakage

is required.

4.5.2 The QC Manager will make sure that the AI has been notified sufficiently in advance of

each test so that he could witness the test.

4.5.3 The test pressure is applied, under close supervision of QC Inspector

4.5.4 When the test meets Code Requirements and is accepted by the QC Inspector and AI,

they will initial and date the Inspection & Test Plan in the space provided.

4.5.5 Upon completion of the test, the Inspection & Test Plan and other supporting documents

are returned to the QC Manager for review and filing as described in Section 10 of this

Manual.

4.5.6 All pressure and temperature gauge used in the test shall be in calibrated status and in

good condition. The serial number of the test gauge shall be recorded in the

hydrostatic test report form.

4.5.7 It is recommended that the metal temperature during the test to be maintained at least

30oF (17oC) above the minimum design metal temperature, but need not exceed 1200F

(480C).

).

4.6，， Pneumatic Test

4.6.1. Pneumatic and proof tests are conducted by the Shop or Field Prod. Eng. Using a written

instruction prepared by the QC Engineer which includes minimum test temperature, testpressure, wall temperature, holding time, pressure increments, dial range of gauges andother special requirements applicable to the type of test.


3

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4.6.2. For ASME Section VIII Division 1 : pneumatic test pressure shall be at least equal to 1.1times the maximum allowable working pressure to be stamped on the vessel multipliedby the lowest ratio of the stress value S for the test temp of the vessel to the stress

value S for the design Temperature.

For ASME Section VIII Division 2 : The pneumatic test pressure shall be at least 1.15 times the MAWP

to be stamped on the vessel name plate multiplied by the lowest ratio of the stress value “S T” for the test

temperature of the vessel to that the stress value “S” for the design temperature for the material in

construction.

4.6.3. The requirements on sub-para. 4.4.1 through sub para. 4.4.5 shall also apply to pneumatic and

proof tests, which are fully documented on the test report. The QC Inspector and the AI sign and

date this report when they satisfy themselves that the test meets Code requirements in all respect.4.6.4. On welded pressure vessels to be pneumatically tested, the full length of the following welds

shall be examined for the purpose of detecting cracks :

(a) all welds around openings ;

(b) all attachment welds, including welds attaching non-pressure parts to pressure parts, having a

throat thickness greater than ¼ in. (6 mm)

4.7 Test Gauges

4.7.1 At least one directly connected calibrated indicating test gauge located at highest point of the

Vessel and visible to the operator controlling the pressure and having a dial graduated over arange of about double the intended maximum test pressure but not less than 11/2 nor more than4 times that pressure shall be used for all types of test.

4.7.2 An additional indicating gauge may be necessary to allow the pressure to be visible to the

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

4.8 Code Stamping and Data Report

4.7.1 The QC Manager has custody and control of the Code Symbol Stamps and NB symbol stamp toprevent loss or unauthorized use of same. He shall issue the required stamp for use at the shop

or field site when field assembly is completed.

4.7.2 The Code stamping is applied directly to the vessel or part or on a name plate to bepermanently attached to a vessel or when direct stamping is not permitted, from data shown onthe drawing. It is verified as correct by the the QC Inspector before he initials and dates the ITP.

4.7.3 Stamping of Code symbol stamp on the Name plate (Exhibit 4 - 3a, b) after fitted to the vessel isprevented, it may be applied prior to attached, in the presence of the AI after completion of theconstruction, but prior to hydrostatic and pneumatic test. Any non conformance found which cannot be corrected, the name plate shall immediately be removed consequently the Code symbolstamp defaced.

4.7.4 After completion of a shop fabrication of Code item, the QA Engineer prepares the

Manufacturer's Data Report based on the final records and submits it for review by QCManager, who certifies it by sign and date in ink.


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4.7.5 After completion of the field assembly of a Code item, the QC Manager prepares and certifiesthe Certificate of field assembly portion of the Manufacturer's Data Report.

4.7.6 The completed Manufacturer's Data Report, together with final records is then presented to the

AI for his review. When he accepts that all Code requirements have been met, the AI wouldallow and verify the application of the Code Symbol Stamp or the stamping on the pressurevessel or parts and sign and date the Manufacturer's Data Report.

4.7.7. All records shall return to the QC Manager for retention as described in Section 10 in thisManual (Record Retention).

4.8 Non Conformities All non conformities occurred during fabrication or field assembly are controlled and correctedas described in Section 5 in this Manual, prior to signing of the Manufacturer's Data Report andstamping of the name plate.

4.9 Examination and Inspection Documentation

All drawings, design calculation, material test reports or certificate of compliance, examinations

reports and test report/record including the fabrication records shall be made available for the AI

and collected for inclusion in the job file.

4.10 Distribution of Manufacturers Data Reports (MDR)

For Code item a copy of the MDR shall be furnished to :

- Client/Owner/User or their designated Agent;

- Upon request to AI

- Jurisdictional Authorities at the place of installation when required by law

- Keep a copy of the MDR on file in a safe custody for at least 5 years

- In addition to above, data reports may be registered with National Board.

For Parts, Partial Data Reports shall be furnished in duplicate to the manufacturer of the

complete vessel. A copy shall be retained for 5 years.

4.11 National Board

If required by client or if the final location is U.S.A. or Canada the MDR shall be registered with

the National Board of Boiler and Pressure Vessel Inspectors. The National Board serial numbers

shall be controlled and issued by the QC Engineer. The National Board serial numbers shall be

issued in a progressive numerical order from 1 without Skips or gaps of unused numbers or

duplication of numbers. The NB numbers are assigned on completion of pressure test or when

the pressure test is not completed at the shop the NB numbers are assigned at the time of

certification of data reports. The QC Engineer shall maintain a Log of NB Numbers / NB Log

(Exhibit 10-1) of National Board serial numbers issued, showing National Board serial number,description of the item stamped, customer and location, date MDR certified and the date of


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dispatch of MDR to the National Board for registration. The data reports requiring registration

shall bear signature, NB commission number and endorsements of the AI. The data reports which

are not registered with National Board shall bear signature, State/province commission number of

the AI and not his NB commission number. When items are registered with the National Board,

the QC Engineer shall send the original MDR with applicable attachments to the National Board

within 60 days of certification. The data reports shall be sent to: NATIONAL BOARD OF

BOILERS & PRESSURE VESSEL INSPECTORS 1055, CRUPPER AVENUE, COLUMBUS,

OHIO 43229, USA


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5. CORRECTION OF NONCONFORMITIES

5.1 Identification of Non Conformities:

5.1.1 Nonconformity is any condition which does not comply with the applicable rules of the Code, QCManual or other specified requirements. Nonconformities must be corrected before thecompleted component can be considered to comply with the Code.

5.1.2 It is the duty of all Company employees to report any nonconformity to their superior, who winimmediately notify the QC Inspector for further action.

5.1.3 As soon as a nonconforming condition is reported to the QC Inspector, he will inspect the item,and if verified as nonconformity, he will identify it by tagging or marking “HOLD” (Exhibit 3-5)and preparing a Nonconformance Report (Exhibit 5-1). lf practicable, the nonconforming item ismoved to a segregated “HOLD" area otherwise then shall be so identify to prevent any activity

being performed.

5.1.4 The Nonconformance Report shall contain suggested disposition for correction of the condition.NCR is signed and dated by the QC Inspector and forwarded to the QC Manager for review andacceptance. All concurrence is to be sought,

5.1.5 In the event that disposition or solution made by QC Manager would cause disagreementamong Managers then the QC Manager shall seek advice from the Plant Manager for resolution. All resolution shall meet Code requirements.

5.2 Correction of Nonconformities:

5.2.1 USE-AS-IS: A1l disposition for “USE-AS-IS”, the QC Manager shall liaise with the EngineeringManager, for technical justification and to obtain approval. Any required revisions to drawings ，

calculations and procurement documentation pertaining to the “USE-AS-IS” are made asdescribed in this Manual. All of this action shall be with the concurrence of the AI.

5.2.2 REPAIR / REWORK: All dispositions requiring repair or rework may be carried out usingCompany Standard Operating Procedures, or with special procedures approved by the QCManager, the Engineering Manager and accepted by the AI.For repairs to base metal and weldment, the proposed disposition is submitted to the AI for hisacceptance of the method and extent of repair, examination and test and for his designation of required inspection points.

5.2.3 SCRAP / RETURN TO VENDOR: This disposition requires the QC Inspector to verify anddocument on the Nonconformance Report that the item has been removed from the work areaand tagged or clearly marked with “REJECTED" sticker (Exhibit 3-5) and hold in segregatedarea to prevent inadvertent use before disposal on return to vendor.

5.3，， Verification of Correction

5.3.1 The Q.C Inspector re-inspects the items after completion of dispositions described in 5.2.1 and5.2.2. when he is satisfied himself that the item meets the Code requirements, the QC Inspector and Al will sign and date of the Nonconformance Report and remove the “HOLD" sticker or marking, to permit the item to return to the next operation sequence as reflected in theFabrication Sequence Sheet.

5.4 Records

Section 5– page 1 of 2

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6 Welding Control

6.1 General :

6.1.1 All welding on Code work is performed using Welding Procedure Specifications (WPS) andcompetent welders and welding operators qualified in accordance with applicable clauses of ASME Code Section IX, related Code Section, QC Manual and other specifications.

6.2 Welding Procedure Specification:

6.2.1 WPSs are written by the Welding Engineer to include all variables required for the process by ASME Code Section Ix and the intended range of production welding. The required test weldsare made under his supervision. Preparation and testing of the required test specimens isperformed to meet with Section IX requirements by the qualified testing laboratory, whose report

of the test results is reviewed by the Welding Engineer. If acceptable, he prepares and certifiesthe Procedure Qualification Record (PQR).

6.2.2 Copies of the qualified WPS are provided to the Shop and Field Fabrication Manager for the useon production place. The Welding Engineer maintains copies of the WPS and PQR packages inthe project job file.

6.2.3 WPSs and PQRs are submitted to the Al for his review, and are made available at any time,upon request.

6.2.4 WPSs are revised whenever there is a change in a non essential variable, a new WPS isprepared and qualified whenever an essential or supplementary essential variable is to be

changed or none of the existing qualified PQRs could support the required WPS.

6.2.5 At the AI’s discretion he may request re-qualification of a WPS at any time if he has specifiedreason to question the WPS for a defined welding job.

6.3 Qualification of Welders and Welding Operators:

6.3.1 All welders and welding operators involved in Code welding shall be qualified with the applicable ASME Section IX and the Code Section used for construction, under the supervision of theShop or Field Fabrication Manager. A qualified testing laboratory prepares testing of therequired specimens, or radiography of the weld test coupon. Their report of the test is reviewedby the Welding Engineer and if it meets the Code requirements the Welding Engineer prepares

and certifies the Welder / Welding Operator Qualification Test Record (WPQR) and put theWelders name in the Welder/Operator Register.

6,3.2 A WPQR is also required for the welder who weld the test coupon used to qualify a WPS or tore-qualify him, based on the performance essential variables used.

6.3.3 Copies of the WPQR and its register are sent to the Shop and Field Fabrication Manager for their involvement in Code welding. The Original WPQRs are retained in the Welding Engineer file.

6.3.4， WPQRs are available for review by the Al at shop or field site at any time he requests，

6.3.5 All Qualified Welder/Welding Operators are recorded in the Master Approved Welders/WeldingOperators Register (Exhibit 6-1).

6.4 Expiration and Renewal of Qualification

Section 6 page 1 of 4

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Expiration of QualificationThe perform and qualification of a welder or operator shall be affected when one of the followingoccurs;

a. A performance essential variable changes.b. When he has not welded with a process during a period of 6 month or more, his

qualifications for that process shall expire; unless, within the 6 month period, prior to hisexpiration of qualification

c. When there is a specific reason to question his ability to make welds that meet thespecification, the qualifications that support the welding he is doing shall be revoked. Allother qualification not questioned remain in effect.

6.5 Maintain of Qualified welder and Welding Operator Qualification

6.5. 1 Each qualified welder shall be listed in the Monthly Record Welder Log (Exhibit 6-2) maintainedby the Welding Engineer from the monthly data provided by the Shop or Field Fabrication

Engineer. The log indicates the last date each month on which each welder and weldingoperator has welded in each process for which he is qualified.

6.5.2 The Welding Engineer determines from the log (Exhibit 6-2) when a welder qualification is aboutto expire, so as to ensure that he could performs production welding, or re-qualification isrequired.

，，，，

6.6，， Production Welding

6.6.1 The Shop or Field Fabrication Engineer verifies that each welder is qualified to weld and isresponsible for instructing the welder in the correct use of the WPS listed on the FabricationSequence Sheet for each weld he may perform.

6.6.2 Each qualified welder shall be given a unique symbol stamped No. with which to identify eachone metre weld he makes. When stamping is precluded due to material thickness and materialspecification or customer restriction, the weld shall be identified by paint marking andtransferred to a welding map which would indicate the welders that performed each weld.

AII Section VIII Division 2 Code items shall be provided with the above mentioned weldmap system.

6.6,3 When radiographic examination is a requirement, the welder's identification marking shall bevisible on the radiograph accompanying with the other identification required by Code andclient’s specification (if any).

6.7 Tack Welds

6.7.1 Tacks weld whether left in place or completely removed, are made by qualified welders using aqualified WPS.

6.7.2 If left in place, the ends of each tack weld are ground to ensure complete fusion into the finalweld and the welder's symbol is marked on the Code item and recorded on the weld mapaccordingly.

6.7.3 After preparation, each tack weld is visually examined by the QC Inspector, and if found

defective it shall be removed completely.

6.8 Welding Material


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，，，，

6.8.1 All welding material is purchased and received as described in Section 3 of this Manual.

6.8.2 Welding material is stocked in a dry storage space and issued to welders by Warehouse

Keeper.

6.8.3 It is advisable that Low Hydrogen coated electrodes be received in hermetically sealedcontainers. When container cover is opened or broken, the electrodes are to be placed ina holding oven maintained at the temperature recommended by the electrode manufacturer,before issue to welders.

6.8.4 Welding materials shall be stocked at dry storage space (humidity controlled) and identified byits specified AWS specification and classification. The storekeeper will provide “Daily WeldingConsumable Report” (Exhibit 6-3) to record the issuance and returning control of weldingmaterial.

6.8.5 Low Hydrogen covered electrodes should be issued only in a quantity sufficient to complete theweld or for a period not to exceed four (4) hours.

6.8.6 Unconsumed Low Hydrogen covered coated electrodes returned to storage are examined for condition, cleanliness and identification before return to a segregated storage for reconditionspurposes. Damaged, unidentified or wet electrodes are to be scrapped/discarded immediatelywith the concurrence of store keeper.

6.9 Production Test Plates

6.9.1 Where production test plates are required by Code it shall be prepared in accordance with aprocedure prepared by the Design Engineer and Welding Engineer and listed on the Fabrication

Sequence Sheet and ITP, which shall includes:

- Number, identification, specification and grade, attached location and dimensions of requiredcoupon ;

- Preheat temperature and PWHT requirements;- Acceptance criteria of tension bend and impact tests and other test and examination as

required ;- Retest requirements ;

6.9.2 The Welding Supervisor supervises the welding of test coupons, which are prepared and testedby a qualified testing house whose test report is reviewed by the Welding Engineer. The Al shallbe notified in advance prior to the test who may witness the test if he desires to do so.

6.9.3 Test results are to be submitted for review by the AI.

6.10 Welding Records，，，

All fabrication/production weld records mentioned in this section are to be made available for review by the Al prior to be retained in the QC Engineer and Fabrication Engineer job file.


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SECTION 7

7 NON-DESTRUCTIVE EXAMINATION

7.0 General

7.0.1 All NDE required by the Code is specified on ITP and drawing, and is performed by a qualifiedand certified NDE in-house/ subcontractor personnel. Written Practice for NDE personnel andspecified NDE procedures shall be reviewed by QC Manager for Code compliance andapproved by the NDE Level III.

7.0.2 All NDE method specified on ITP, drawing/weld map shall be performed by NDE Personnel whoare qualification and certification in accordance with Company’s Written Practice prepared inaccordance with SNT-TC-1A Current Code accepted Edition & Addenda.

7.1 NDE Level III and Written Practice

Company used services of out side individual as NDE level III who is appointed by Director byissuing Letter of Appointment.

7.1.1 The appointment of company level III base on the following:

7.1.1.1 Qualification and certification in accordance with Company’s written practice.

7.1.1.2 Valid endorsement on his ASNT Level III certificate for RT, UT, MT, PT method.

7.1.1.3 Experience in providing level III services to others Manufacture.

7.1.1.4 Experience in developing NDE procedure & monitoring NDE activities includingevaluation of result to ASME Code requirement.

7.1.2 The Level III shall be responsible for :

7.1.2.1 Establishing, maintaining and approving company’s written practice for training,

qualification and certification of NDE personnel based on SNT-TC-1A, accepted byCode Edition and Addenda.

7.1.2.2 Training, examination, qualification and periodic technical evaluation of company NDE

personnel.

7.1.2.3 Approving company NDE procedure for RT, UT, MT, PT.

7.1.2.4 Demonstration, qualification and certification of NDE procedures.

7.1.2.5 Monitoring and control of NDE sub-contractor.


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7.2 NDE Personnel

7.2.1 The QC Manager, shall review and approve all subcontractor NDE personnel used on Code

NDE have the training, experience, qualifications and are certified for the methods as describedin the SNT-TC-1A and applicable ASME Edition and Addenda requirements, in accordance withtheir Company's Written Practice and the applicable Code Sections.

7.2.2 NDE Personnel Register (Exhibit 7-1) are available for review by the AI, who may request re-qualification if he has specific reason to question the NDE personnel’s ability to perform theNDE examination.

7.2.3 Copies of the following NDE personnel qualification records for all NDE Personnel performingCode NDE are kept on file by the QC Manager, and made available for review by the AI and bythe NDE Level III upon request:

a) Name of certified individualb) Level of certification and NDE method.c) Educational background and experience of certified individuals.d) Statement indicating satisfactory completion of training in accordance with Employer’s

Written Practice.e) Result of the vision examinationf) Current examination copy (ies) or evidence of successful completion of examinations.g) Other suitable evidence of satisfactory qualifications, when such qualifications are used in

lieu of the specific examination.h) Composite grade(s) or suitable evidence of grades.i) Signature of Level III that verified qualifications of candidate for certification

j) Dates of Certification and/or re-certification in each method qualified and the dates of assignments to NDE.

k) Certification expiration date.l) Signature of Company's QC Manager.

7.3 Sub- Contractor of NDE

Sub contractor shall provide following documents for review and verification:

7.3.1 Their written practice meeting with SNT-TC-1A requirement.

7.3.2 Personnel & certificate records.

7.3.3 Calibration record of NDE instruments. All above document shall be verified by company or Level III. Copies of this document shall be kept for record & review by Authorized Inspector. QCManager shall be responsible to verify that all sub-con NDE personnel qualified and certified inaccordance with their employer written practice. Sub contractor can use either company NDEprocedure or alternatively their own procedure provided the same are approved by companyNDE Level III. Evaluation of test result shall be carried out by sub-contractor or company

certified and qualified NDE Level II.

7.4 NDE Reports


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7.4.1 All reports of NDE, including RT film, are reviewed and accepted by the NDE Level II beforesubmittal to the AI for his review. For Code NDE performed at a field site, the QC Inspector may

perform the review.

7.4.2 NDE reports, including RT film for full and partial Code RT, are filed by the QC Manager for retention as described in Section 10 of this Manual.

7.5 Additional NDE RequirementBefore completion of pneumatic tests permitted by ASME Code Section VIII Division 1, the fulllength of the following welds are examined by MT or PT, whichever is applicable, for thepurpose of detecting possible cracks.

7.5.1 All welds around openings

7.5.2 All attachment welds, including welds attaching non-pressure parts to pressure parts, having athroat thickness greater than ¼" or 6 mm.

7.6 Requirement for Section VIII Div.2 All Type 1 joint shall be 100% Radio graphed. Permitted types of welds and requiredexamination shall be in accordance with table 7.2 of ASME Section VIII Division 2.

7.6.1. Offset (Joggle) Joint Welds are prohibited

7.6.2. Unless specifically exempted, all welds shall be NDE examined as required as per table 7.2.

7.6.3. For examination of Chromium Alloy cladding or lining shall refer to 7.4.8.1 and 7.4.8.2.

7.6.4. In accordance with table 7.2 after final edge preparation, cut edges shall be examined inaccordance with section V article 7 for MT or article 6 for PT


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8 HEAT TREATMENT

8.1 Heat Treatment (HT) shall be conducted at the shop and field site by the subcontractor, HeatTreatment (HT) Procedures shall be prepared by the Design Engineer to meet the requirements

of the applicable Code. The QC Manager shall review the Heat Treatment Instruction and signand date them to indicate his approval. The Al concurrence is to be sought.

8.2 The Fabrication Engineer is responsible for heat treatment and to indicate on the HeatTreatment Furnace Chart the following information:

，，，，

a) The vessels and parts to be heat treated by job number, drawing number and componentidentification mark.

b) The number of the Heat Treatment Procedure with revision status and date，

c) The date of heat treatment (commencing and ending date and time)d) The sketch of placement location of all calibrated thermocouples and Chart speed.e) Chart shall be signed and dated by the QC Engineer prior commencing and at the

completion of heat treatment.f) PWHT Procedure number used for heat treatment.

8.3 The QC Inspector shall sign and date the Heat Treatment furnace chart when he is satisfied thatthe heat treatment has been carried out in accordance with the applicable procedure and theCode.

8.4 All PWHT records are to be submitted to the Al for his review and are retained in the QCEngineer job file.

8.5 QC Inspector shall monitor all heat treatment operation whether done in house or atsubcontractor’s facilities and shall inspect the heat treated items for identification and damage.

8.6 QC Inspector shall verify that all heat treatment is performed using calibrated equipment.


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9 CALIBRATION OF MESUREMENT AND TEST EQUIPMENT

9.1 General

9. 1.1 All measurement, examination and test equipment used in fulfillment of relevant Coderequirements shall be calibrated in accordance with this section and written specified calibrationprocedures approved by the QC Manager or by the NDE Level III,

9.2 Calibration Procedure

9.2.1 The QC Manager is responsible for identifying all measurement, examination and testequipment or it’s container with a equipment serial number and shop ID number.

9.2.2 The QC Manager is responsible for maintaining equipment in calibration, unless out of serviceand clearly marked “NOT CALIBRATED- DO NOT USE”.

9.2.3 Calibration may be performed by the qualified in-house personnel in the shop or testinghouse/laboratory which provides certified records of calibration and has suitable standardswhose accuracy is traceable to the National Standards.

9.2.4 The frequency of calibration is as determined from the manufacturer’s recommendations or fromcompany experience with the instrument accuracy，

9.2.5 Pressure gauges used for hydrostatic, pneumatic or proof testing are calibrated against a dead-weight tester or calibrated master/standard gauge at least once in every 6 months period.

9.2.6 Dead-weight tester or master/standard gauges are re-calibrated at a frequency of three years or

as per recommendation of the gauges manufacturer, whichever is the lesser.

9.3 Calibration Records :

9.3.1 Each calibrated instrument is listed in Measuring Equipment List (Exhibit 9-1) maintained by theQC Engineer in the calibration file.

9.3.2 All equipment is identified with a calibration sticker which records the item serial number or shopidentification mark, date of last calibration, initials of a person who performed the calibration anddue date for the next calibration.

9.3.3 The QC Engineer makes calibration records, including those of subcontractors who performNDE, Heat Treatment and mechanical testing machine, available for review.

9.4 Discrepant Equipment

9.4.1 When instruments are found out of calibration or damaged, the QC Engineer tags the item with “REJECTED“ and “NOT TO BE USED” stickers and subsequently removes it from the work areaand arranges for calibration or replacement.

9.4.2 All Code items checked with such discrepant instruments are nonconforming until the QCEngineer has verified that they meet all Code requirements, or they are re-tested with accurateinstruments/standard gauges.

9.4.3 Traceability is provided from “Tool Room” issue records or by recorded serial numbers of


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instruments used in examination and test.

9.4.4 After removal of a calibrated instrument or pressure temperature gauges from a shop or fieldsite it shall be immediately calibrated so as to verify that the gauges was in calibration status

when last used at the shop or field site.


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10 RECORD RETENTION

10.1 The QC Engineer collects all records described in this Manual at the completion of the job and

reviews them for completeness, correctness and Code compliance before prepare theManufacturer’s Data Report. The Manufacturer’s Data Book completed shall be send to the QCSection Manager for review and approval.

10.2 Manufacturer's Data Reports, after certification in ink by the QC Section Manager and signed bythe AI, are filed with the costumer or his designated Agent, purchaser, pressure vesselmanufacturer, jurisdiction and AI as required by the Code.

10.3 Partial Data Report shall be issued in duplicate to the customer and a copy to AI on request.

10.4 Records shall be maintained as specified below. For ASME Section VIII Div.1 items and parts

1) Radiographs films: Until Data Report signed by the Authorized Inspector.2) Data reports: Five years or retained by the National Board if registered.3) The following record shall be maintained for a period of at least 3 years :

• Manufacturer’s partial Data Report• Manufacturing drawings• Design calculations• Material Test and report and/or material certifications• Welding Procedure Specification and Procedure Qualification Record• Welder Qualification Records• RT and UT reports

• Inspection and Test Plan• Heat Treatment record and test results• Post weld heat treatment records• Nonconformance’s and dispositions• Hydrostatic test record

For ASME Section VIII Division 2, The Manufacturer shall maintain a file for three (3) years after stamping of the vessel and furnish to the user and, upon request, to the inspector the reportsand records shown below.

a. User’s Design Specificationb. Manufacturer’s Design Report

c. Manufacturer’s Data Reportd. Manufacturer’s Construction Record and Partial Data Reportse. Tabulated list of all material used for fabrication with Material Certification and Material Test

Reports and a record of any repairs along with the repair procedures.f. Fabrication information including all heat treatment requirements, forming and rolling

procedure when prepared, an inspection and test plan identifying all inspection pointsrequired by the user and signed inspection report.

g. List of any subcontracted services or parts, if applicable.h. WPS, PQR, weld map and welder or welding operator qualification test results.i. Record of all heat treatments including post weld heat treatment. j. Results of production test plate, if applicable.k. NDE Procedures, records of procedure qualification and records of personnel

demonstration.

l. All reports stating the results of inspection, nondestructive examination and testing


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including radiographic examination, ultrasonic examination, magnetic particle examination,liquid dye penetrant examination, and hardness test.

m. All non-conformance reports including resolution and a detailed description of any repairsincluding repair procedures, a sketch, photo or drawing indicating the location and size of

the repaired area.n. Charts or other records of required hydrostatic, pneumatic, or other test. Test logs shall

include the test date, testing fluid, duration of the test, temperature of the test fluid, and testpressure.

o. Dimensional drawings of the as-built condition.


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11 FIELD ASSEMBLY

11.1 Scope

11.1.1 This section describes the procedure used to ensure the proper field assembling of Code itemin accordance with the applicable sections of this Manual and the referenced applicablesections of ASME Section VIII Division 1 & 2.

11.2 Responsibility:

1 1.2.1 The Fabrication Engineer shall retain the responsibility as describes in section 1 of thisManual.

11.3 Drawings, Design Calculations and Specifications:

11.3.1 The Engineering Manager shall be responsible to submit the Drawing to the Quality

Control Manager for review as per section 2.

11.3.2 All “RELEASED FOR ASME CODE CONSTRUCTION” documents are transmitted，，，，，，，，toFabrication Engineer as per Section 2. Documents distributions at site is controlled byDistribution Sheet (Exhibit 2-1).

11.3.3 The revised Drawings and Material List distributed to the Quality Control Manager andFabrication Manager following their review are made and approved by the EngineeringManager and shall be reissued to the Fabrication Engineer.

11.3.4 The QC Manager is responsible to provide the Authorized Inspector with all Drawings,Design Calculations “Owner/User Design Specification”, Manufacturer's Design

Report”, Material List through QC Inspector for his review. The Authorized Inspector shall include his inspection points, initial and date the ITP (Exhibit 4-IA) prior to thestart of the field assembly.

11.3.5 Any question raise by the Al in conjunction with the Drawings or Design Calculationsshall be resolved prior to the start of field assembly.

11.4 Material Control

11.4.1 ， All requisition for the materials including welding consumable shall be prepared as per section 3.1.1, 3.1.2, 3.1.3, 3.1.4 and 3.2.

11.4.2 Purchasing of pressure retaining material shall be performed from the shop only.

11.4.3 All free issued material shall be received and inspected by the Quality ControlInspector for Code Compliance. The Quality Control Inspector shall ensure that anysub assembly part supplied to the field by subcontracted certificate holder shops shallbe provided with Partial Data Report and shall be attached to the final Manufacturer'sData Report.

11.4.4 ， All shop material required for field work shall be field receipt inspected, for shipmentdamage and loss of traceability marking by the field QC inspector with the help of theStore Keeper.

11.5 Field Examination and inspection Program


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11.5.1 Erection or assembling of site fabricated items shall be controlled by the FSS and ITP.The Fabrication Sequence Sheet shall be prepared by the Fabrication Engineer whilstthe ITP prepared by the QC Engineer. Both FSS and ITP along with approved

drawings to be forwarded to the field Fabrication Engineer and QC Inspector. The fieldsite Fabrication Engineer and QC Inspector initial and date their acceptance on the lTP. The QCInspector shall forward the AFC drawing, FSS, ITP and other required document to the AI for hisreview to allow him to designate his inspection points prior o commence with the field siteassembly.

11.5.2 Field test and examination of pressure retaining part shall be performed as per Section 4.3(Examination and Inspection Program). The Quality Control Inspector shall inspect atthe various inspection stages as determined. The Authorized Inspector shall make hisrequired inspection points as indicated on the ITP.

11.6 Control and Correction of Nonconformities

11.6.1 All Nonconformities shall be handled as per section 5.

11.6.2 The Quality Control inspector shall be responsible for maintaining any Nonconformance Report(Exhibit 5-1) and informing the Quality Control Engineer and Manager of any nonconformities for disposition and resolution purposes purpose. The AI concurrence shall be sought.

11.7 Welding Control

11.7.1 Welder not in the employee of the company may be used to construct Code item inaccordance with the applicable code section, provided all of the following conditionsare met.

a) AII Code construction shall be the responsibility of the company.b) An welding shall be performed in accordance with the ’Welding Procedure

Specification ， which have been qualified by the company in accordance with therequirements of Section Ix and the related construction code section.

c) An welders shall be qualified by the company in accordance with the requirements ，， of Section IX.

d) The Welding Engineer has the complete and excusive administrative and technicalsupervision of all Welders and Welding Operators and has the authorization toassign/remove Welders and Welding Operator at his discretion without involvement of anyorganization.

e)，The Welding Engineer shall have evidence that this program has been accepted by the field

A.I.A. which provides the inspection services.f) The originals of the Welder Qualification Test Record are maintained by the Welding

Engineer who shall provide the Authorized Inspector copies of WPS, PQR, Welder Qualification Record of welders or welding operator prior to assigning on Code construction.

g) The Quality Control Inspector shall be responsible for verifying that all the fitters andwelders on field site are qualified and conversant with the displayed WPS.

h) The welding engineer has the authority to assign welder identification symbol on eachqualified welder

11.8 Non Destructive Examination (NDE)

11.8.1 All field NDE shall be performed in accordance with section 7.


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1 1.8.2 A11 report of NDE shall be reviewed and accepted by the Quality Control Inspector ，，，，beforesubmitting to the Authorized Inspector for his review for Code compliance.

11.9 Hydrostatic Testing

11.9.1 Hydrostatic Testing and any additional NDE shall be in accordance with Section 4 and7 respectively.

11.10 Heat Treatment

11.10.1 Approved Heat Treatment procedures shall be issued by the Welding Engineer andforward to the field Site QC Inspector and it shall be performed in accordance withSection 8 of this manual. The field site heat treatment unless otherwise mentionedshould be conducted by using electric resistance element for localized heat treatmentby a subcontractor PWHT firm. The subcontractor heat treatment procedures, facilities,

equipment shall be reviewed and accepted by the QC Manager.

1.11 Calibration of Measurement and Test Equipment

11.11.1 Calibration of Measurement and Test Equipment shall be performed in accordance，，，，，，，withSection 9. The Quality Control Inspector shall be responsible for ensuring that allequipment are calibrated and range is suitable for the intended operation.

11.12 Code Stamping and Data Reports

11.12.1 Upon Completion of the construction of Code item, the Quality Control Manager shallcertify the Manufacturer's Data Report prior to submit to the field Authorized Inspector

for his review, signature and date. The Authorized Inspector shall witness theapplication of the Code Stamp directly to a Code item or to the nameplate attached tothe item.

11.1.2 The Quality Control Engineer shall have total control and custody of the Code SymbolStamp to the Quality Control Inspector, who shall have custody and total control at，，，，neld siteand shall return it to the Quality Control Engineer immediately upon completion of the field sitework.

11.11.3 All records shall be controlled by the Quality control Inspector and returned to the，，，，QualityControl Department for retention as per section 10.


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12 AUTHORIZED INSPECTOR

12.1 The Al is Inspector required by the Code, employed by an ASME Accredited AuthorizedInspection Agency (AIA of record ) with whom the Company has a contract to perform the

inspection services required by the Code.

12.2，，For those contracts which require the use of different AIA other than the AIA of record is a specialrequirement, their services for Code inspection may be provided only after signing a separatecontract for such work with the second AIA.

12.3 The QC Manager arranges for the Al and AIS to have free access to the shop and field sitesinclude the sub-contractor work/shop whenever Code work is being executed and to such partsof all plants that are concerned with the construction and supply of materials for the Code item,when those above inspectors request to do so.

12.4 lf requested by the AI, his inspection points shall be inserted on the ITP for those

operations he may wish to witness or inspect before the work proceeds.

12,5 The QC Manager at the shop, or the QC Inspector at the field site, arc the Companyrepresentative in assisting the AI.

12.6，， The Al shall be provided with access to all drawings, calculations, specifications, procedures.Fabrication Sequence Sheets, repair written proposals, test and examination results, inspectionrecords and any other documents required as to allow him to perform his duties as appropriate,

12.7 All Nonconformance Reports for Code non-conformities and propose disposition and /or resolution are to be submitted to the AI or his review and acceptance.

12.8 The QC Manager or QC Inspector will notify the Al sufficiently in advance of all tests andexaminations so that he could present himself to witness the test.

12.9 The final records, together with the completed ASME Manufacturer's Data Report，，，，signedby the QC Manager or Design Engineer, are submitted to the Al for his authorization to apply theCode Symbol stamp and sign the MDR.

12.10 A current copy of the QC Manual shall be made available for use by the Al at the shop as wellas at the field site.

12.11 The Al will review and accept an changes to the QC Manual which affect the Coderequirements, before they are issued to Manual Holders.

12.12 The QC Manager will assist the AI Supervisor during his required audits, and the AI whilstmonitoring the QC system.


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13 LISTING OF EXHIBITS

Exhibit Title of Form PageNo.

RevisionNo.

Date

0-1 QC Manual Distribution List 3 0 February 15 2010

0-2 Log of Revision 4 0 February 15 2010

0-3 Document Transmittal Advise 5 0 February 15 2010

0-4 Code Review Record 6 0 February 15 2010

2-1 Distribution Sheet 7 0 February 15 2010

2-2 Construction Program 8 0 February 15 2010

3-1 Material Requisition List 9 0 February 15 2010

3-2 Purchase Requisition 10 0 February 15 2010

3-3 Purchase Order Batam 11 0 February 15 2010

3-4 Material/Receiving Report 12 0 February 15 2010

3-5 reject/Hold/Accepted Tag 13 0 February 15 2010

3-6 Material Identification and Traceability Record 14 0 February 15 2010

3-7 Material Request Card 15 0 February 15 2010

3-8 Material Return Slip 16 0 February 15 2010

3-9 Material Inventory List 17 0 February 15 2010

3-10 Cutting Plan 18 0 February 15 2010

3-11 Material Control sheet 19 0 February 15 2010

4-1(A) Inspection and Test Plan 20 0 February 15 2010

4-1(B) Fabrication Sequence Sheet 21 0 February 15 2010

4-2 Name Plate/Stamping Information 22 0 February 15 2010

5-1 Nonconformance Report 23 0 February 15 2010

5-2 Nonconformance Register 24 0 February 15 2010

Exhibit Title of Form Page Revision Date


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No. No.

6-1 Approved Welder/Welding Operator Register 25 0 February 15 2010

6-2 Monthly record Welder Log and Qualification 26 0 February 15 2010

6-3 Daily Welding Consumable Report 27 0 February 15 2010

7-1 NDE Examiner register 28 0 February 15 2010

9-1 Measuring Equipment List 29 0 February 15 2010

10-1 National Board Log 30 0 February 15 2010

Approved by : Date : ______________ QC Manager

Accepted by : Date : ______________ Authorized Inspector

QCM 2010 AIS

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