U Stamp Manual

QUALITY CONTROL MANUAL
Cover Page
Issue No. : 01
Chapter No.: A
Page No.
: 1 of 1
Rev.
: 01
Date
: 12.02.13
FOR CONSTRUCTION OF
PRESSURE VESSELS AND PARTS
IN ACCORDANCE WITH
ASME BOILER AND PRESSURE VESSEL CODE
SECTION VIII DIVISION 1TO BE STAMPED WITH
ASME CERTIFICATION MARK WITHUDESIGINATOR
AT SHOP AND FIELD SITES CONTROLLED FROM SHOP.
CONTROLLED / UNCONTROLLED
SERIAL NO. :
ISSUED TO :
ISSUED BY :
Head Quality ____________

(Signature)
ISSUE DATE :
RMG
Autometers
Gas Technologies Limited
Phone
E-Mail
Website
Plant
Head office
B 15 Sector 80
Noida, Uttar Pradesh
India- 201305
B 30 Phase 2
Noida, Uttar Pradesh
India- 201305
: +91-120-2469800
: sales@rmgautometers.co.in
: www. rmgautometers.co.in

TABLE OF CONTENTS
Chapter
Number
Title
Issue No. : 01
Chapter No.: B
Page No.
: 1 of 1
Rev.
: 01
Date
No. of
Pages
Revision
Status
: 12.02.13
Revision Date
Cover Page
01
12.02.13
Table of Contents
01
12.02.13
Statement of Policy and Authority
00
30.10.12
Glossary and Abbreviations
01
12.02.13
01
Administration of Quality Control Manual
01
12.02.13
02
Organization and Responsibilities
01
12.02.13
03
01
12.02.13
04
Drawing, Design Calculation and Specification

Control
Material Control
01
12.02.13
05
Examination and Inspection Program
01
12.02.13
06
Correction of Nonconformities
01
12.02.13
07
Welding Control
01
12.02.13
08
Non-Destructive Examination
01
12.02.13
09
Heat Treatment
01
12.02.13
10
Calibration of Measurement and Test Equipment
01
12.02.13
11
Retention of Records
00
30.10.12
12
Authorized Inspector
01
12.02.13
13
Field Site Control
01
12.02.13
14
Certification
01
12.02.13
15
List of Exhibits
00
30.10.12
PREPARED BY
HEAD QUALITY
APPROVED BY
GM- OPERATIONS
REVIEWED & ACCEPTED BY

AUTHORIZED INSPECTOR
Amrit Pal Singh
Kuldeep Tyagi
Anil Nanda
SIGNATURE
DATE
NAME

DOCUMENT NO.: QCMU-04
STATEMENT OF POLICY AND AUTHORITY
Issue No. : 01
Chapter No.: C
Page No.
: 1 of 1
Rev.
: 00
Date
: 30.10.12
2.0
STATEMENT OF QUALITY POLICY AND AUTHORITY
2.1
RMG Autometers Gas Technologies Limited provide reliable and total solutions for regulation
and metering of natural gas during transportation and utilization through adherence to Quality
management systems based on continual improvement and with focus on the customers
expectations and involvements.
2.2
GM-Operations has been assigned the responsibility and authority to establish and maintain
Quality Control system and to ensure its implementation.
2.3
Head Quality has freedom from the organization side to identify quality problem and initiate,
recommend and provide solution on matters relating to Quality and he shall have direct access to
the undersigned.
2.4
Head Quality shall have the authority to stop any work which in his opinion is not in accordance
with the requirement of the Code and this Manual.
2.5
Any person, whose authority and responsibility are defined in this Manual, may delegate any of
his duties to any qualified and when required, certified person reporting to him but cannot
delegate his responsibility.
2.6
In case of disagreement between Head Quality and any other RMG Autometers personal on the
matters related to the interpretation of the requirements of this Manual, the same shall be brought
to the attention of the undersigned for resolution keeping in mind that requirement of Code and
Manual shall always prevail.
2.7
The management of RMG Autometers by approving this Quality Control Manual gives its full
support to the Quality Control program. It is mandatory that individuals perform their duties
assigned as per this Manual.
Date: 30.10.12
Keshav Thirani
Chairman & Managing Director

GLOSSARY AND ABBREVIATIONS
Issue No. : 01
Chapter No.: D
Page No.
: 1 of 3
Rev.
: 01
Date
: 12.02.13
GLOSSARY OF TERMS:
Code
ASME Boiler and Pressure Vessel Code Section VIII Division 1 and Codes and
Standards referenced therein.
Certificate of
Authorization
A document issued by the ASME that authorizes the use of the ASME Certification
Mark with appropriate designator for a specified time and for a specified scope of
activity.
Certification Mark
An ASME Symbol identifying a product as meeting Code requirements.
Certification Mark
Stamp
A metallic stamp issued by the ASME for use in impressing the Certification Mark
Certification
Designator
The symbol used in conjunction with the Certification Mark for the scope of
activity described in the manufacturers Certificate of Authorization.
Data Report
Manufacturers Data Report/ Manufacturers Partial Data Report.
Hold Point
A stage of inspection beyond which work shall not proceed until signed off by
RMGA-QC/ the AI as satisfactory.
Manual
This Quality Control Manual.
Material Test
Certificates
Material Test Report, Certificate of Compliance or Manufacturers Partial Data

Report as applicable.
National Board
National Board of Boilers and Pressure Vessels Inspectors.
Review Point
A stage of inspection for which RMGA-QC shall perform the activity, document
the results and offer the records to the AI for review and acceptance.
SNT-TC-1A
ASNT Recommended practice for Personnel Qualification and Certification in

Non-Destructive Testing.
Welder
Welder or welding operator.
Witness Point
A stage of inspection for which AI shall be notified in advance. However, work

may proceed with the AIs consent if the AI is unable to undertake the inspection.
The documents shall be presented to the AI for review during the next visit.
Written Practice
RMGA Written Practice for Training, Qualification and Certification of NDE

Personnel.
ABBREVIATIONS
AI
Authorized Inspector

AIA
Authorized Inspection Agency
AIS
Authorized Inspector Supervisor
ASME
American Society of Mechanical Engineers
ASNT
American Society for Non-Destructive Testing
ASTM
American Society for Testing and Materials
CoC
Certificate of Compliance
DCR
Design Change Request
HTRR
Heat Treatment Request and Report
ITP
Inspection and Test Plan
MDMT
Minimum Design Metal Temperature
MAEWP
Maximum Allowable External Working Pressure
MAWP
Maximum Allowable Working Pressure
MDR
Manufacturers Data Report
MPDR
Manufacturers Partial Data Report
RMGA
RMG Autometers Gas Technologies Limited
MIRR
Material Inspection Request and Report
NCR
Nonconformity Report
NDE
Non-Destructive Examination
PQR
Welding Procedure Qualification Record
PWHT
Post Weld Heat Treatment
QC
Quality Control
QCS
Quality Control System
Issue No. : 01
Chapter No.: D
Page No.
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Rev.
: 01
Date
: 12.02.13

GRN
Goods Receipt Note
TDC
Technical Delivery Conditions
WPS
Welding Procedure Specification
WOPQ
Welding Operator Performance Qualification Record
WPQ
Welder Performance Qualification Record
Issue No. : 01
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Page No.
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Rev.
: 01
Date
: 12.02.13

ADMINISTRATION OF QUALITY CONTROL MANUAL
1.0
Issue No. : 01
Chapter No.: 01
Page No.
: 1 of 3
Rev.
: 01
Date
: 12.02.13
SCOPE
This Chapter describes the system and procedures for administration of the Quality Control
Manual.
1.1
QUALITY CONTROL SYSTEM

The Quality Control system detailed in this Quality Control Manual encompasses all
aspects of work for the construction of pressure vessels and parts thereof in accordance
with ASME Boiler and Pressure Vessel Code Section VIII Division 1 at shop and field
assembly at sites controlled by the shop.
1.2
1.2.1
Head Quality shall prepare and GM-Operations shall approve this Quality
Control Manual.
1.2.2
The Manual shall have a Cover Page, Table of Contents, individual chapters, List of
Exhibits and sample forms used in various stages of construction of pressure vessels and
parts thereof.
1.2.3
After obtaining the approval of GM-Operations, Head Quality shall submit the Manual to
the AI for his review and acceptance prior to implementation. The approval of GMOperations and acceptance of the AI shall be indicated by their signatures on Table of
Contents page. The previous revision of the Manual shall govern until the AI sign-off
new revision with date.
1.2.4
Head Quality shall distribute only controlled copies of the Manual within the RMGA
organization. Each controlled copy shall be identified with its unique serial number on
the Cover Page. Head Quality shall obtain acknowledgement of recipients on QC
Manual Distribution List (Exhibit No. 1-1).
1.2.5
Head Quality shall issue a controlled copy of the Manual to the AI. A controlled copy of
the Manual shall also be issued to the AI at site wherever applicable.
1.2.6
Head Quality may issue uncontrolled copies of the Manual to personnel outside the
organization through Document Transmittal (Exhibit No. 1-2). Such uncontrolled
copies shall be current at the time of issue, but may not be updated subsequently.
1.2.7
Head Quality may decontrol any Manual copy not in use for Code work. Holders of
controlled copies shall return the same when requested by Head Quality or when the
holder has no more use for it, or when the holder ceases to be an employee of RMGA.
1.3
REVISIONS TO THE MANUAL

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Rev.
: 01
Date
: 12.02.13
1.3.1
Each Chapter in the Manual shall have a number and shall be independently revision
controlled. In case of Exhibits, each Exhibit shall be independently revision controlled.
1.3.2
The Manual shall be revised whenever there is a change in the organization structure or
procedures or Code requirements or at the time of ASME Joint Review. Head Quality
shall review all such changes and if acceptable, shall revise the concerned Chapter or
Exhibit.
1.3.3
All relevant functional heads shall review each Code Edition for any impact on the
Quality Control Program and communicate the changes to Head Quality . Head Quality
shall review the changes in the Code and revise the Manual, if required with in six
months of issue of Code Edition/Addenda so as to ensure that the Manual complies
with the latest Code requirements. Any revisions required in the Manual shall be
implemented with in six months of issue of Code Edition. All such reviews shall be
documented on a copy of Summary of Changes pages.
1.3.4
In case of a revision in any Chapter of Manual (except Exhibits), the revision number
of the entire Chapter shall be advanced. The latest revised text shall be printed in bold
font. The previous revision indicators, if any, shall revert to normal font. The Table of
Contents page shall also be revised to indicate the latest revision of each Chapter.
1.3.5
In case of a revision to any Exhibit, revision number on that Exhibit shall be advanced.
The changes in the Exhibits shall be indicated by clouding raised area. This marking
shall appear only on the sample Exhibits included in the Manual and shall not be
available on actual forms in use. The List of Exhibits shall be revised to indicate the
latest revision of each Exhibit and the latest revision of the List of Exhibits shall be
updated on the Table of Contents page.
1.3.6
The revision status of Manual shall correspond to the revision status of the Table of
Contents. The Cover Page shall also indicate the latest revision.
1.3.7
Any revisions to the Manual, after approval by GM-Operations, shall be submitted to

the AI for review and acceptance, prior to issuance or implementation.
1.3.8
Whenever the Manual is revised, the revised Chapter / Exhibit, List of Exhibits, Cover
Page and Table of Contents shall be distributed to all controlled copy holders. Head
Quality shall be responsible for retrieval and destruction of obsolete pages received
from all controlled copy holders.
1.3.9
Head Quality may develop new Issue of the Manual every three years to commensurate
with the ASME Joint Review or earlier. New Issues shall be controlled in the same
manner as the revisions except that the revision level of all Chapters / Exhibits shall
revert to zero and revision indicators are not required. All bold letters shall be made
same as other text.

1.3.10
1.3.11
Issue No. : 01
Chapter No.: 01
Page No.
: 3 of 3
Rev.
: 01
Date
: 12.02.13
Head Quality shall retain a copy of the previous revisions of Manual for the purpose of
future reference duly marked as OBSELETE for minimum of three years.
This Manual is issued only in English Language.

ORGANIZATION AND RESPONSIBILITIES
2.0
Issue No. : 01
Chapter No.: 02
Page No.
: 1 of 5
Rev.
: 01
Date
: 12.02.13
SCOPE
This Chapter describes the organization structure and responsibilities of key personnel
involved in Code construction.
2.1
RESPONSIBILITIES
Main responsibilities of key personnel are as indicated herein.
Responsibilities of other personnel described in the Organization Chart have been
included in the various chapters of this Manual
2.1.1
i)
ii)
2.1.2
Long term Strategy.

Formulate and approve all policies and objectives in accordance with board
directives.
GM- Operations
i) Responsible for overall day to day management of the company.

ii) Ensure that the various targets set by the Chairman & Managing Director are met
successfully.
iii) Approve Quality Control Manual.
iv) Appoint NDE Level III.
v) Certify NDE Level I and Level II personnel jointly with NDE Level III.
2.1.3
Head Quality
i) Prepare and issue Quality Control Manual and its revisions.
ii) Liaise with ASME, National Board (NB), Authorized Inspection Agency (AIA) and
Authorized Inspector (AI).
iii) Maintain certificates of authorization and ensure safe custody and control of ASME
Certification Mark and NB Stamp.
iv) Overall responsibility for in-process and final examination and testing during
construction of Code items.
v) Approve examination stages for each job on ITP and co-ordinate with the AI for
marking of inspection stages.
vi) Coordinate all quality control activities at RMGA shop and at sites controlled by
shop.
vii) Register Data Report with National Board, when required.
viii) Liaise with Site QC Engineer and Site NDE Level-II for all quality, welding and NDE
activities at site.
ix) Approve technical requirement for welding materials.

x)
xi)
xii)
xiii)
xiv)
2.1.4
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Approve WPS, certify PQR and WPQ / WOPQ records.

Approve heat treatment cycle and certify heat treatment.
Approve final disposition of all nonconformities.
Certify Data Reports.
Retain Records.
GM Business Development
i) Generate business as per target fixed by Chairman & Managing Director.
ii) To update and inform to Management for potential market and product requirements
2.1.5
Chief Finance Officer

i) Overall responsibility of finance and accounts.
2.1.6
Incharge-HRD Admin
i) Formulate and implement human resource policies.

ii) Recruit of manpower and provide training when required.
iii) Employee relations, grievances and counseling.
2.1.7
2.1.8
2.1.9
NDE LEVEL III

i)
Approve Written Practice and NDE procedures.
ii)
Train, examine and qualify NDE personnel.
iii)
Certify NDE Level I and Level II personnel jointly along with GM-Operations.
iv)
Demonstrate NDE procedures to the AI prior to use.
v)
Review calibration records for NDE equipment.
vi)
Approval of NDE techniques for examination at site.
NDE LEVEL II
i)
Calibrate NDE equipment.
ii)
Carry out NDE at shop and at site and evaluate test results in accordance with procedures
approved by NDE Level III.
MANAGER FINANCE
i)
Organize dispatch of products to customers.

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2.1.10 MARKETING MANAGER

i)
Develop new customers.
2.1.11 PROJECT COORDINATOR

i)
Internal and external follow up of projects. Coordinate with clients for obtaining
technical clarification from client as required by Head Design, Head Quality,
Head Material.
2.1.12 DRAFTMAN
i)
Chairman
Prepration of drawings
on& Managing
CADDirector
software.
2.1.13 WELDERS
i)
GM Business
Carry out the welding on the job as per applicable WPS and other
Procedures.
GM Operations
Developmen
t
2.1.14 All the functional heads, except NDE Level III, may delegate their duties to their suitably
qualified
lower level designees, but shall remain responsible for their respective functions. A
Marketing Manager or Supervisor may perform the duties assigned to his subordinates provided he is
Manager
qualified to do so.
Manager Finance
Production
Head Design
Project
Head Quality
In-charge
Head
2.1 ORGANIZATION CHART

HRD, Admin
Manager
Coordinator
Materials
of this Manual. List of Manual designations and corresponding designations of key personnel are shown
on page 4 of 4 of this Chapter.
Design
The organization
chart for shop is depicted on Page 3 of 4 of this Chapter. Typical organization structure
Production
Incharge
Engineer site is shown in Chapter 13
for the field
Engineer
Draftman
Welders
Maintenance
NDE Level III
Purchase
Stores Incharge
Engineer
NDE Level II
Welding
Engineer QC
Engineer
Organization Chart
Functional Control
Administrative Control

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MANUAL DESIGNATION
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ORGANIZATION DESIGNATION
GM- Operations
GM- Operations
Head Quality
Head Quality
Production Manager
Production Manager
Head Design
Head Design
Project Coordinator
Project Coordinator
Head Materials
Head Materials
In-charge HRD Admin
In-charge HRD Admin
Production- Engineer
Engineer-Production
Incharge Maintenance
Incharge Maintenance
NDE Level III
NDE Level III
Welding Engineer
Head Quality
Engineer QC
Engineer QC
Design Engineer
Design Engineer
Marketing Manager
Marketing Manager
Purchase Engineer
Purchase Engineer
Stores Incharge
Stores Incharge
NDE Level II
Head Quality
Draftsman
Draftsman
Welder
Welder

DRAWING, DESIGN CALCULATION AND SPECIFICATION CONTROL
Issue No. : 01
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Page No.
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Rev.
: 01
Date
: 12.02.13
3.0 SCOPE
This Chapter describes the system and procedures for preparation, approval, distribution and
revision of design calculations, drawings, and other design documents.
3.1
REVIEW OF CUSTOMER DOCUMENTS
3.1.1
GM-Business Development shall receive customer Purchase Order along with

technical specifications and allocate a unique Internal Order Number (AO 00 series).He shall
then forward the same to Head Design, Quality Control, Purchase for review. GM-Business
Development shall prepare offer sheet in consultation with Head Design.
3.1.2
The Internal order number suffixed with letter AO means ASME Order and two
digit running serial number (01, 02 etc.) shall be used as Manufacturers Serial Number (For
example, U 001).
3.1.3
Head Design shall review information provided by the Customer for to ensure
that all required information including applicable Loading (if any) have been provided to
enable him perform Code calculations verifying compliance with Code requirements including
applicability of loadings as per UG-22 of Code. Any discrepancy/missing information shall be
brought to the notice of customer through GM-Business Development and resolved to comply
with Code requirements. This shall be accomplished prior to acceptance of the order.
3.2
DRAWINGS AND DESIGN CALCULATIONS
3.2.1
Head Design shall prepare the design calculations as per the applicable Edition
and addenda (when applicable) of the Code, and additional customer requirements, if any. All
applicable loadings as per UG22 of the Code shall be considered in the design.
3.2.2
Head Design shall assign a Design Engineer for preparation of drawings.
3.2.3
Either U.S Customary, SI single system of unit shall be used for all aspects of
design. All entries on a Manufactures Data Reports and data for Code required Name
Plate shall be in units consistent with the fabrication drawing for the component using U.S.
customary, S.I. or local Customary units provided they are acceptable to the receiving
Jurisdictions. It is acceptable to show alternate units parenthetically.
3.2.4
Head Design shall be responsible for selection of materials from those covered
under ASME Code Section II Part A or B for which allowable stress values are listed in ASME
Code Section II Part D and shall be further restricted to those permitted by the Code or otherwise
permitted by Code Cases. All applicable cautionary notes given in ASME Section II Part D for
the relevant material shall be evaluated for conformance. All material used in Code job shall
confirmed to be acceptable for use by the construction Code.
3.2.5
When design calculations and/or drawings are provided by customer or any

outside agency, Head Design shall review and approve the same for Code compliance. Any
discrepancy shall be resolved to meet Code requirements.
3.2.6
The fabrication drawings shall contain the following information, as a minimum:
Equipment Name / Tag No., Work Order No. and Manufacturers Serial Number.

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Code of Construction (ASME Code Section VIII Division 1) including Edition.

Applicable Code Cases, if any.
Design Pressure and maximum design temperature.
MAWP and MAEWP (if applicable) at coincident temperature.
MDMT at MAWP.
Applicable loadings as per UG - 22 of Code.
Bill of materials according to the construction Code, including material specification and
grade for each part, thickness, size and quantity.
Geometrical and manufacturing details including dimensional tolerances as per purchase
specification and Code requirements.
Weld details including fillet sizes.
Service restrictions as per UW-2 (Lethal etc.) and corrosion allowance.
Heat Treatment, if any.
Radiography and other NDE as applicable.
Requirements for and/or exemptions from impact testing of material, weld and HAZ.
Requirements for production test plates, if any.
Hydrostatic test pressure, temperature and water quality requirement, if any.
Name plate / stamping detail.
Special requirements, if any.
3.2.7
All drawings and design calculations shall be reviewed for Code compliance and
approved by Head Design.
3.2.8
Design Engineer shall mark the drawings as Issued for Reference and distribute
to Head Quality, Project Coordinator, Head Materials, Production Manager and obtain their
acknowledgement on Documents issue record Sheet (Exhibit No. 3-1). Subcontracted related
work shall also be forwarded to Head Materials with relevant Drawings and TDS.
3.2.9
Issued for Reference drawings shall only be used for preliminary planning
activities or obtaining comments from the recipients. The drawings may also be forwarded to the
customer for comments. The comments shall be incorporated, provided they do not violate any
Code requirements. After incorporation of comments from Customer, Head Quality, Project
Coordinator, Head Materials and Head Design shall issue drawing duly marked as issue for
manufacturing. Head Design shall approves drawings and design calculations.
3.2.10
All revisions to drawings / design documents shall be controlled in the same

manner as the original drawing / documents. Any revisions to drawings and design documents
shall also be approved by Head Design.
3.2.11
The latest changes in the revised drawings shall be highlighted by clouding the
revised matter and marking revision number inside a triangle. A brief description of the revisions
shall also be indicated on the revision table in the drawing.
3.2.12
Revision of each page of design calculations shall be individually controlled.

Revision status of the Index sheet shall be the revision status of the entire document.

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3.2.13
Design Engineer shall issue revised drawings to all the original recipients. The
recipients shall be responsible for destroying the old revision or if retained for reference,
marking them as OBSELETE.
3.2.14
Documents Issue Record Sheet shall indicate the latest revision status of
individual drawings for the relevant Work Order.
3.2.15
Head Design shall submit the drawings and design calculations to the AI for his
review before commencement of fabrication. All subsequent revisions shall also be offered to the
AI for review. Any point raised by the AI shall be resolved. The review by the AI shall not
relieve RMGA from their responsibility for completeness and correctness of design calculations
and drawings and compliance with Code requirements.
3.2.16
As- Built drawings and calculations giving details of actual material used and
final dimensions shall be prepared by Design Engineer and shall be submitted to the AI for his
review after approval of Head Design. As- Built drawings shall be prepared as next revision
of the drawings.
3.3
DRAWING CHANGE REQUEST (DCR)
3.3.1
Any of the concerned departments including Purchase, Production, Quality

Control or Design may request for changes in the drawings to suit construction activities,
material substitutions, etc. on Design Change Request (Exhibit No. 3-2).No material
substitution shall be accepted unless it has been approved by Head Design.
3.3.2
The initiator shall obtain the comments of Head Quality on welding and quality
control requirements on the DCR. The comments shall be reviewed by Head Design and if found
acceptable, the DCR shall be approved by Head Design. DCRs related to Code requirements
shall also be offered to the AI for his review.
3.3.3
Design Engineer shall allocate a unique serial number to each approved DCR and
distribute the same to all the recipients of the concerned drawing as per the distribution list
mentioned in DCR and obtain acknowledgement on the DCR. The recipients shall indicate the
DCR number and date on the appropriate drawing at the relevant area by clouding.
3.3.4
Design Engineer shall mark the DCR number and date on the file copy of the
applicable drawing and ensure that the DCRs are incorporated in the next revision of that
drawing. The number of DCRs against any revision of the drawing shall be limited to five.
3.3.5
Whenever the drawings are revised or any DCR is approved, effect of the same
shall be verified and documented on relevant design calculations by Head Design even if no
changes are required. If required, the design calculations shall be revised to ensure Code
compliance.
3.4
3.4.1
3.4.2
MATERIAL INDENTAND TECHNICAL DELIVERY CONDITIONS (TDC)

Based on approved drawing, design calculations, Code requirements and
customer specifications, Design Engineer shall prepare the Material Indent (Exhibit No. 3-3)
including the Technical Delivery Conditions (Exhibit No. 3-4) for materials. Head Design shall
review and approve the Material Indent and TDC.
Technical Delivery Conditions shall contain the following details as a minimum:

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Material specification and grade, including applicable Edition/Addenda.

Other applicable specifications and standards.
Ordering information as per relevant specification.
Supplementary requirements, as applicable.
Requirement of Material Test Report (MTR), Manufacturers Partial Data Reports,
Certificate of Compliance (CoC), if applicable.
Marking requirements.
Requirement of inspection.
3.4.3
Design Engineer shall distribute the Material Indent and TDC to Purchase
Engineer and Project Coordinator, Production Manager through Document Transmittal(Exhibit
1-2). A copy of TDC shall also be issued to Head Quality.
3.4.4
Whenever the drawings are revised or a DCR is approved, Design Engineer shall
review the applicable Material Indent and TDC and revise the same, if required. Revised
Material Indent and TDC shall be approved by Head Design and distributed as above.
3.5
SOFTWARE CONTROL
3.5.1
If any computer software/program is used for design calculations, Head Design

shall verify the computer software/program by parallel Manual calculations and verification of
output prior to its first use.
3.5.2
The software / programs shall be based on Code formula. Where specific rules are
not given in Code, the software / programs shall be based on appropriate formula from other
national or International Standards acceptable to the Authorized Inspector.
3.5.3
Head Design shall review the software/ programs to ensure compliance with the
applicable Edition of Code and document the same.
3.5.4
Upon issuance of new Code Edition/Addenda, Head Design shall verify

software program prior to first use for compliance to requirements of new
Editions/Addenda of the Code.
3.5.5
Whenever software version is changed Head Design shall verify output of the
software program by parallel set of manual calculation for compliance to applicable
Edition/addenda.
3.5.6
Head Design shall verify the input parameters/ data used for all design
calculations.
3.5.7
Head Design shall maintain the records of verification and make the same
available to the AI for review.

MATERIAL CONTROL
Issue No. : 01
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Rev.
: 01
Date
: 12.02.13
4.0 SCOPE:
This Chapter describes the system and procedures for procurement, receipt, identification,
receiving inspection, storage and issue of materials used in Code construction. Welding materials
shall be controlled as described in Chapter No. 07 (Welding Control).
4.1
4.1.1
4.1.2
VERIFICATION OF STOCK MATERIAL

Purchase Engineer shall forward the Material Indent to Stores Incharge for
checking the availability of the required material in stock.
Stores Incharge shall check availability of the required material in stock.
4.1.3
If the required material is available in stock, Stores Incharge shall offer the
available material for examination to Engineer QC through Material Inspection Request and
report( Exhibit No. 4-1) .
4.1.4
Engineer QC shall carry out visual and dimensional examination including

thickness check, verify the markings available on material, correlate the markings with the
relevant material test certificates and review the material test certificates against the requirements
of applicable drawings, TDC and material specification and prepare Material Inspection
Request and report (Exhibit No. 4-1) .
4.1.5
If additional testing is required to meet the requirements of TDC and drawings,

Engineer QC shall arrange for the tests using calibrated test equipment and review the results of
additional tests prior to accepting such material.
4.1.6
For the material test certificates indicating Edition/Addenda of the ASME

material specification different from that specified on the drawing and TDC, Engineer QC shall
verify all requirements like chemical and mechanical properties, heat treatment, marking,
certification requirements, etc. against the requirement of applicable Edition of the material
specification before recertification and acceptance. In case any material is available in the stock
of old Edition/Addenda then same will be compared with the new applicable Edition/Addenda.
4.1.7
Material conforming to an ASTM specification as per Guidelines on Acceptable

ASTM Editions Table ED-1 of ASME Code Section II Part A or B may be accepted in lieu of
the corresponding ASME specification after recertification.
4.1.8
For ASTM materials to Editions not listed in Table ED-1 of ASME Section II Part
A or B, Engineer QC shall process a Nonconformity Report as per Chapter No. 06 (Correction of
Nonconformities). He shall verify the material test certificates against the requirements of
applicable Edition of material specification on Material Verification Report (Exhibit No. 4-2).
If acceptable, Engineer QC shall re-certify the material to the required material specification.
4.1.9
Engineer QC shall indicate the results of examination on the MIRR and return to
Purchase Engineer who shall instruct the Stores Incharge to allocate the acceptable material
against the relevant job by marking the Work Order number & part no. as per drawing on the

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material. For accepted material, Engineer QC shall retain a copy of the MIRR along with the
material test certificates and additional test reports, if any in the job file. The material test
certificates for accepted material shall be endorsed as below and signed off by Engineer QC.
Material Test Report Reviewed as per
SpecificationGrade/Class..
of ASME Section II Part
Edition.Addenda
and found acceptable
------------------------------------------------------------Engineer QC
Sign..Date.
4.1.10
If required, Purchase Engineer may raise DCR for use of alternate / substitute
material. Head Design shall review the DCR. No substitution of material shall be permitted
without the approval of Head Design and the concurrence of the AI.
4.1.11
Stores Incharge shall comment on the Material Indent for material available in
stock and accepted through MIRR and forward the Material Indent to Head Materials for
procurement of unavailable material. Store Incharge shall also indicate on material indent,
material which are either not in stock or available in stock but not acceptable for job based
on which purchase order shall be issued by the Head Materials.
4.2
PROCUREMENT
4.2.1
Head Materials shall order materials based on the final Material Indent
requirement by releasing Purchase Order (Exhibit No. 4-3) to approved suppliers. The PO
shall be traceable to the Work Order Number, unless for stock. PO shall contain all the technical
information from the Material Indent and shall refer to the applicable TDC. GM- Operations
shall approve the Purchase Order. The Head Materials shall be responsible for the correctness
and completeness of Purchase Orders.
4.2.2
Preformed / prefabricated welded components, to be incorporated in the final job

shall be purchased from a shop having the Certificate of Authorization for applying ASME
Certification Mark with U designator. Such items shall be procured along with Manufacturers
Partial Data Report (MPDR) as required by the Code. Engineer QC shall verify the Certification
Mark on such components and offer the components to the AI for inspection prior to use.
Standard pressure parts, as defined in UG-11 of ASME Code Section VIII Division 1, shall be
exempt from this requirement.
4.2.3
No substitution of material or changes in technical requirements specified in

Material Indent and TDC shall be permitted without the approval of Head Design on DCR. Any
changes to a PO shall be communicated by issuing an amended PO.
4.2.4
Copies of Purchase Order including amendments, if any, shall be forwarded to

Head Quality and Stores Incharge.

MATERIAL CONTROL
4.2.5
4.3
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Head Materials shall forward material test certificates received from the material
supplier to Head Quality.
RECEIPT, EXAMINATION AND STORAGE
4.3.1
Upon receipt of material, Stores Incharge shall correlate the items with the PO,
check the quantity and physical condition and prepare Goods Receipt Note-GRN (Exhibit No.
4-4).Stores Incharge shall mark the GRN number on all accepted material.
4.3.2
Stores Incharge shall offer the material to Engineer QC for examination through
GRN and also forward any material test certificates received with delivery documents. Incoming
materials awaiting examination shall be kept in a separate identified area.
4.3.3
Engineer QC shall carry out the examination on incoming materials as per clause
4.1.4 to 4.1.9 above against the requirements of PO, applicable drawings, material specification
and TDC. Engineer QC shall document the results on GRN and return a copy of the GRN to
Stores Incharge. For components received with MPDR, Engineer QC shall verify the
Certification Mark on components and offer the components to the AI for inspection prior to use.
4.3.4
Engineer QC shall retain the material test certificates and GRN on file.
4.3.5
Stores Incharge shall ensure that only material accepted by Engineer QC is taken
into stock.
4.3.6
Nonconforming materials shall be dealt with in accordance with Chapter No. 06

(Correction of Nonconformities). Engineer QC shall arrange to identify such items with yellow
paint/Card/Hold Exhibit No. ( 4-5).
4.3.7
Engineer QC shall carry out re-examination of the material, after resolution of the
nonconformity and advise the acceptance / rejection on the GRN to Stores Incharge. Engineer
QC shall arrange to remove the HOLD on the acceptable material.
4.3.8
Material not complying to PO, drawing or TDC requirements shall be rejected.

Engineer QC shall arrange to identify such material by marking REJECT by red paint/Card
Exhibit No.( 4-6). Stores Incharge shall segregate the rejected material in order to prevent mixup with the accepted materials and arrange for disposal of rejected material.
4.3.9
If further material testing is required at receiving inspection or during

manufacturing operations, the Engineer QC shall arrange for the required testing and
accept/reject the material accordingly.
4.3.10
4.4
Stores Incharge shall ensure proper marking, handling and storage of materials.
FREE ISSUE MATERIAL BY CUSTOMER

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4.4.1
For materials supplied as free issue by Customer, Head Quality shall obtain the
material test certificates from the customer through GM Business Development.
4.4.2
Materials Receipt examination shall be carried out as per clause 4.3 above against
the requirements of approved drawings and TDC.
4.4.3
Any discrepancies shall be brought to the notice of the customer and resolved to
meet the Code requirements.
4.4.4
Store Incharge shall maintain material issue details for customer supplied material
separately.
4.5
SUB-CONTRACTING FORMING / FABRICATION
4.5.1
Forming of components such as shell, head, etc., may be sub-contracted to

vendors approved by Head Quality/GM-Operations. Where the subcontractor is not a holder of
ASME Certificate of Authorization for application of Certification Mark with U designator,
welding shall be excluded from the scope of the subcontractor.
4.5.2
Purchase Engineer shall forward the request for subcontracting to Head Materials
along with applicable drawing and TDC approved by Head Design. The TDC shall include the
requirements for subcontractors certification for the formed part according to Clause UG-79 of
Code, including the method of forming (hot or cold) and heat treatment, whether or not
performed by the sub-contractor. Heat-Treatment if any, performed by forming subcontractor
shall be reported.
4.5.3
Head Materials shall prepare and process the PO as described above, referring to
and including the applicable TDC, drawing etc.
4.5.4
Engineer QC shall examine the items after receipt at RMGA shop as per the
procedure outlined above.
4.6
4.6.1
4.6.2
4.6.3
ISSUE OF MATERIAL
Based on the approved drawings, Production Manager/Engineer shall prepare
Material Issue Slip (Exhibit No. 4-7) detailing the Work Order No., part no., size & quantity
and forward to Store Incharge for issue of material from the Stores. For plates, sheets etc.,
Production Manager/Engineer shall enclose cutting list/plan along with Material Issue Slip.
Stores Incharge shall ensure that only accepted material is issued on job.
Production Engineer shall arrange to mark the Work Order Number and part
number on each part, in addition to the required material markings and offer the material for
acceptance to Engineer QC through Inspection Request and Report (Exhibit No. 4-8).

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4.6.4
Engineer QC shall carry out visual and dimensional examination including

thickness check, verify the markings available on material, correlate the markings with the
relevant material test certificates and review the material test certificates against the requirements
of applicable drawings, TDC and material specification.
4.6.5
Engineer QC shall prepare Material Attestation Report (Exhibit No. 4-9) for all
pressure parts and non-pressure parts directly welded to pressure parts.
4.6.6
Engineer QC shall offer the Material Attestation Report along with applicable
material test certificates to the AI to enable him to verify that it represents the material and meets
the requirements of the material specification. Acceptance of material by the AI shall be signified
by his signature and date on the Material Attestation Report.
4.7
MATERIAL TRACEABILITY
4.7.1
Production Manager/Engineer shall be responsible for maintaining traceability of

material identification on all pressure parts and non-pressure parts directly welded to pressure
parts, throughout fabrication.
4.7.2
If the material is to be subjected to operations during which identification

markings will be partially or completely cut, or the material is to be divided into two or more
parts, Production Engineer shall arrange for accurate transfer of identification marks, prior to
cutting, to a location where the markings shall be visible on the completed vessel. In addition to
the markings required as per Code, the parts shall also be identified with Work Order number and
part number.
4.7.3
Hard stamping shall not be used on vessels constructed on ferrous material less
than 6 mm thickness or of non-ferrous plates less than 13 mm thickness, or when the service
conditions prohibit. In such cases, marking transfer may be done by etching, engraving, paint
marking etc., and traceability records of all material used shall be maintained by the Engineer
QC.
4.7.4
Alternatively, the materials may be identified with unique Coded marking

traceable to original required materials marking as per procedure for Coded marking, approved
by Head Quality & acceptable to the AI. Such Coded marking transfers shall be recorded on
Material Attestation Report for the part.
4.7.5
Production Engineer shall offer the transferred markings to Engineer QC for

verification, prior to cutting through Inspection Request and Report. If acceptable, Engineer QC
shall put his stamp adjacent to the transferred markings.
4.7.6
Production Manager shall ensure that no material without proper identification is

used for fabrication of Code items.
4.7.7
Engineer QC shall ensure that only acceptable material is used in Code

construction.

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EXAMINATION AND INSPECTION PROGRAM
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5.0 SCOPE
This Chapter describes the systems and procedures for examination, inspection, testing and Code
stamping of pressure vessels and parts, preparation and certification of Data Reports and control
of ASME Certification Mark and National Board stamps.
5.1
INSPECTION AND TEST PLAN AND INSPECTION DATABOOK
5.1.1
Based on approved drawings, applicable Code Edition, Addenda and additional customers
requirements, Engineer QC shall prepare Inspection and Test Plan (Exhibit No. 5-1) describing
stages and extent of examinations, inspections and tests, their acceptance standards and reference
documents.
5.1.2
ITP shall specifically indicate all examination, inspection and test activities required to be
completed prior to setting up of closure of the vessel, particularly when entry to completed vessel
is not provided. Internal visual inspection before setting up of closure joint shall be identified as
a Hold point for RMGA Engineer-QC and the AI.
5.1.3
Head Quality shall approve the Inspection and Test Plan and offer to the AI along with approved
drawings for his review and marking Hold, Witness and Review stages of Inspection, before
commencement of fabrication. All inspection stages Hold/ Witness/Review shall be Hold
points for RMGA Engineer-QC and work shall not proceed unless so authorized by RMGA
Engineer-QC.
5.1.4
Engineer QC shall distribute copies of approved Inspection and Test Plan to Head Design,
Production Manager and Project Coordinator, Head Materials as a controlled document using
Document Transmittal (Exhibit No. 1-2).
5.1.5
Engineer QC shall prepare the Inspection Data Book (Exhibit No. 5-2) including Weld Joint
Inspection Check List (Exhibit No. 5-3) based on approved drawings and ITP, accurately
transferring the inspection stages from the ITP. The Inspection Data Book shall be approved by
Head Quality and submitted to the AI for verification of transfer of the inspection stages.
5.1.6
In case of any revisions to the applicable drawings, Engineer QC shall review the ITP and
Inspection Data Book for any change and revise the same, if required. This review shall be
documented on the Cover page of respective documents, even if no changes are required.
5.1.7
Head Quality shall review and approve the revised ITP and Inspection Data Book. All revisions
to ITP or Inspection Data Book shall be offered to the AI for review and acceptance. Copies of
revised ITP shall be forwarded to all the original recipients.
5.2
5.2.1
IN-PROCESS EXAMINATION AND INSPECTION

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

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5.2.2
Production Engineer shall offer the job to Engineer QC at stages as per the
approved ITP, through Inspection Request and Report. Engineer QC shall carry out all
examinations and tests as per drawings, ITP and approved procedures and document the results
on Inspection Request and Report as well as Inspection Data Book.
5.2.3
Engineer QC shall keep the AI informed about the progress of the job and offer
the same to the AI at the stipulated stages. The clearance of the stage by RMGA Engineer-QC
/the AI shall be documented with their signatures and date in Inspection Data Book.
5.2.4
For Formed heads. Engineer QC shall carry out the visual and dimensional
examination including profile check with template, prepare Dished End Inspection
Report(Exhibit No.5-9).
5.2.5
Rolled Shell shall be visually inspected and dimensionally checked including

profile with a template as per requirements of UG-80 and inspection details recorded on Rolled
shell inspection report (Exhibit No.5-10).
5.2.6
Engineer QC shall inform the results of examination, inspection or tests to

Production Engineer by returning the duplicate copy of Inspection Request and Report, duly
signed. No further operation shall be carried out until all the previous Hold points of RMGA
Engineer-QC or AI as applicable, have been cleared.
5.2.7
Any nonconformity noted shall be processed in accordance with Chapter No. 06

(Correction of Nonconformities).
5.2.8
All Welding shall be carried out as per Chapter No. 07 (Welding Control).
5.2.9
All NDE shall be carried out at the required stages as per Chapter No. 08 (NonDestructive Examination). Engineer QC shall carry out visual examination of items / welds prior
to offering for NDE.
5.2.10
After completion of fabrication, Production Engineer shall offer the job to

Engineer QC for obtaining the clearance for heat treatment or pressure test, as applicable.
5.3
FINAL INSPECTION AND TEST
5.3.1
Engineer QC shall verify that all fabrication, examination, inspection and tests
have been completed and all previous stages have been accepted/signed off by RMGA EngineerQC /AI. He shall visually examine and dimensionally check of the items, record the results in the
Final Dimension Report (Exhibit No. 5-4) and offer the item to the AI prior to releasing the
vessel for heat treatment or pressure test (as applicable).
5.3.2
At this stage, Engineer QC shall also ensure that all NDE has been satisfactory
completed and all nonconformities have been satisfactorily closed out, including the final review
by the AI.
5.3.3
All heat treatment shall be carried out as per Chapter No. 09 (Heat Treatment
Control). Production test coupons, if applicable, shall be subjected to same heat treatment
(including soaking temperature, holding time and cooling rates), as the Code item.

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5.3.4
Engineer QC shall arrange for the required mechanical tests on production test
coupons, wherever applicable, using calibrated test equipment at a laboratory.
5.3.5
All examinations, inspections and tests for Code compliance shall be carried out
using equipment calibrated as per Chapter No. 10 (Calibration of Measurement and Test
Equipment).
5.3.6
Engineer QC shall maintain records of all examinations, inspection and tests and
offer the records to the AI, when requested.
5.3.7
Engineer QC shall ensure that all required examinations, inspections and tests
have been completed, prior to releasing the item for pressure test.
5.3.8
Production Engineer shall arrange to carry out pressure test in accordance with
approved drawings/ITP and procedure approved by Head Quality.
5.3.9
Engineer QC shall witness the pressure test, record the results in Pressure Test
Report (Exhibit No. 5-5) and if acceptable, offer the pressure test to the AI for his inspection.
5.3.10
Whenever pneumatic test is permitted to be conducted in lieu of hydrostatic test,

Engineer QC shall ensure that all the requirements of Clause UW-50 of Code are complied with.
5.4
CODE STAMPING AND CERTIFICATION OF DATA REPORTS
5.4.1
Head Quality shall be responsible for safe custody and control of the ASME
Certification Mark and National Board Stamp to prevent their loss or any unauthorized use.
5.4.2
Upon completion of the pressure test, Head Quality shall verify that all the
specified requirements have been met and all inspection stages as stipulated in Inspection and
Test Plan have been accepted by the AI prior to obtaining the AIs concurrence to apply the
ASME Certification Mark and if applicable, National Board Stamp.
5.4.3
Head Quality shall verify the vessel stamping / Name Plate (Exhibit No. 5-6) as
per approved drawing and ensure that the Name Plate is attached to correct vessel / item by a
method acceptable as per Code. Head Quality shall arrange for affixing the ASME Certification
Mark and if applicable, National Board stamp, with the prior concurrence of the AI and in his
presence. The U designator shall be stamped or etched directly below the ASME Certification
Mark.
5.4.4
The details of As-Built drawings of parts dimensions and materials used shall
be furnished by Engineer QC to Design Engineer to enable him prepare the As-built drawing.
As-Built drawings shall be prepared as next revision of the drawings. Head Design shall
approve the As-built drawings and design calculations and offer to the AI for review.
5.4.5
Engineer QC shall prepare the Manufacturers Data Report. Head Quality shall
verify the MDR for correctness and completeness, certify the same and submit to the AI along
with As-built drawings for his review and signature.
5.4.6
Head Quality shall distribute copies of the Manufacturers Data Report duly
signed by the AI to:

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The user or his designated agent

The appropriate enforcement authority in the jurisdiction in which the vessel is to be
installed, where required by law,
The AI.
MPDR shall be forwarded in duplicate, to the Manufacturer of the completed vessel or to the
user or his designated agent for replacement or repair parts and one copy shall be given to the
AI.
5.4.7
Retention of Data Reports (MDR/MPDR) and other records shall be as per

Chapter No.11 (Retention of Records).
5.4.8
Head Quality shall maintain a Log of ASME Code Stamp Jobs (Exhibit No. 57) with details of all Code items constructed by RMGA.
5.5
REGISTRATION OF DATA REPORTS WITH NATIONAL BOARD
5.5.1
When required, Manufacturers Data Reports shall be registered with National

Board.
5.5.2
Head Quality shall assign National Board number after the pressure test or at the
time of Name plate / equipment stamping, when no shop pressure test is to be conducted.
5.5.3
National Board numbers shall begin with 1 and shall be in sequential increment
order without any skips or gaps of unused numbers, or duplication of numbers. No prefixes /
suffixes, either alphabetical or numerical, shall be used with the National Board number. The
National Board number shall be incorporated on the Name Plate adjacent to the National Board
Stamp.
5.5.4
Head Quality shall maintain a Log of National Board Numbers Issued (Exhibit
No. 5-8) detailing the National Board No., date assigned, Work Order Number, Manufacturers
Serial Number, type of equipment, customer name, location of installation (if known), date of
signing of MDR by the AI and date of forwarding the MDR to National Board for registration.
5.5.5
Head Quality shall forward the original MDR to National Board within 60 days of
signing of the MDR by the AI.

CORRECTION OF NONCONFORMITIES
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6.0 SCOPE
This Chapter describes procedure for resolving nonconformities observed during any stage of
construction.
6.1
DEFINITION
6.1.1
Nonconformity is any condition, which does not comply with the applicable
rules of the Code, this Manual, drawings or any other specified requirements. Nonconformities
must be corrected before the completed item can be considered to comply with the Code.
Examples of nonconformities include, but are not limited to:
Materials and parts having deviation from specified requirement.

Repair of defects in material.
Un-calibrated equipment used in measurement or test.
6.2
REPORTING AND IDENTIFICATION
6.2.1
Any RMGA personnel observing nonconformity shall report the same to Head
Quality/Engineer QC. Engineer QC shall verify the same, prepare a Nonconformity Report
(Exhibit No. 6-1) and allocate a unique number to each NCR. Nonconformities observed by
others shall be verified by Engineer QC to enable him prepare the Nonconformity report.
6.2.2
The NCR number shall be indicated in the Inspection Data Book/Material Attestation
Report/Inspection Reports, as applicable. Head Quality shall maintain a List of NCR
(Exhibit No. 6-2) giving NCR No. in continuation and listing all the NCRs issued for Code
items.
6.2.3
The nonconforming item or activity shall not be allowed to process further until the
nonconformity has been satisfactorily resolved. Engineer QC shall identify nonconforming
items by marking HOLD by yellow paint/Card.
6.2.4
All applicable NCRs shall be satisfactory resolved including final review by the AI prior to
release for heat treatment or prior to pressure test of the Code item.
6.3
PROPOSAL AND FINAL RULING
6.3.1
The functional head responsible for the area / activity where nonconformity has been detected
shall propose a corrective action on the NCR. The NCR shall be forwarded to Head Quality
and Head Design for their comments on the proposed corrective action.
6.3.2
Based on the above comments, Head Quality shall provide a ruling for nonconformity
resolution and offer to the AI for review of proposal.
6.4
AI REVIEW
6.4.1
Head Quality shall keep the AI informed of all nonconformities including proposal for Use
As-Is / Repair / Reject.

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6.4.2
Head Quality shall obtain the AIs concurrence on the proposed resolution prior to
implementing corrective action for all nonconformities related to Code or Manual
requirements.
6.5
USE-AS-IS DISPOSITION
6.5.1
Use-As-Is disposition is permitted only for nonconformities not violating requirements of the
Code or this Manual. Head Design shall provide technical justification for the basis of
acceptance for such cases. Engineer QC shall remove the Hold tag and work may proceed
further.
6.6
REPAIR DISPOSITION
6.6.1
When the resolution involves repair, Engineer QC shall send the copy of NCR to the concerned
functional heads and allow the work to proceed on the item / activity in accordance with ruling
on the NCR.
6.6.2
If necessary, a supplementary ITP and a supplementary Inspection Data book shall be prepared
as described in Chapter No. 05 (Examination & Inspection Program).
6.6.3
The concerned functional head shall be responsible for corrective action as per ruling on the
NCR. Repair welding, if required, shall be performed in accordance with Chapter No. 07
(Welding Control).
6.6.4
Engineer QC shall arrange for re-inspection of the job after rectification and shall indicate the
results of re-inspection on the NCR. The supplementary ITP and Inspection Data Book, if any,
shall be followed during re-inspection after rectification as per NCR.
6.6.5
Repairs to welds resulting from visual or non-destructive examination do not require any NCR
to be raised. Such repairs shall be carried out by qualified welders using qualified WPS as per
Weld Plan reviewed by the AI. However, NCR shall be raised for repair to welds after PWHT
or pressure test and Head Quality shall obtain the owners/users concurrence prior to
performing such repairs. As per requirements of UCS-56 of ASME Sec-V111 shall be
complied with.
6.6.6
For any repairs of defects in material, NCR shall be raised and the AIs concurrence shall be
obtained for proposed method and extent of repair before starting the work.
6.7
REJECT DISPOSITION
6.7.1
When the nonconforming item is rejected following an NCR, Engineer QC shall attach Reject
tag on the item. Production Manager shall ensure the removal of the rejected items from the
fabrication area to a separate area marked for rejected items and Stores Incharge shall arrange
for disposal of the rejected item.
6.8
RECORDS
6.8.1
In case the proposed resolution of nonconformities requires revision of drawings, it shall be

done as per Chapter No. 03 (Drawings, Design Calculation and Specification Control).

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6.8.2
Head Quality shall be responsible for ensuring completion of resolution, final disposition of
NCR, removal of Hold tag and submitting the NCR for the AIs review.
6.8.3
Head Quality shall maintain all NCRs on file and shall make the same available to the AI when
required.

WELDING CONTROL
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7.0 SCOPE
This Chapter describes the qualification of welding procedure and performance qualifications,
welding consumable control and welding process control.
All welding shall comply with the requirements of applicable Edition of ASME Section IX with
additional requirements of the Code, as applicable.
7.1
QUALIFICATION OF WELDING PROCEDURES
7.1.1
Head Quality shall prepare Welding Procedure Specification (WPS) in accordance

with ASME Section IX, applicable requirements of Code and additional customer requirements,
if any. WPS shall include all essential, non-essential and where applicable, supplementary
essential variables, including their allowable ranges as per ASME Section IX Code. Head
Quality shall review and approve the WPS.
7.1.2
Head Quality shall conduct procedure qualification test under his supervision and
record all the variables used during welding of test coupon.
7.1.3
Head Quality shall arrange for NDE and heat treatment on the coupon, if required,
supervise the preparation of test specimen, arrange for mechanical tests using calibrated test
equipment in accordance with ASME Section IX, Code and additional customer requirements, if
any and evaluate the test results for acceptance.
7.1.4
Head Quality shall prepare the Procedure Qualification Record (PQR) recording
the welding parameters used and the test results. Head Quality shall review and certify the PQR
as per ASME Section IX.
7.1.5
WPS shall be revised in case of any changes in the non-essential variables. In case
of any changes in the essential or where applicable, supplementary essential variables, a new
WPS shall be prepared and qualified.
7.1.6
Head Quality shall provide the WPS and supporting PQR to the AI for review.
The AI may ask for re-qualification of any welding procedure and / or for witnessing of any tests.
7.2
QUALIFICATION OF WELDERS
7.2.1
Head Quality is also responsible for training, qualification and certification of

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

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7.2.3
Head Quality shall evaluate the test results for acceptance and prepare the Welder
Performance Qualification Record (WPQ) / Welding Operator Performance Qualification Record
(WOPQ) recording the welders name, identification number, actual variables used, range
qualified and test results. Head Quality shall certify the WPQ/WOPQ as per ASME Section IX.
7.2.4
Head Quality shall assign a unique welder identification number to each welder
and maintain a record for the same in a register. This number shall not be repeated or reused even
if the concerned welder leaves employment.
7.2.5
Head Quality shall maintain Welder Continuity Record (Exhibit No. 7-1) to
monitor continuity of qualification of each welder, recording the welding performed by the
welder in each qualified welding process at least once in each quarter.
7.2.6
Welders or welding operators shall be re-qualified under any of the following

conditions:
a) If there is a change in any essential variable as per ASME Section IX.
b) When a welder or welding operator has not welded with a process during a period of six
months or more, all his qualifications for that process shall expire unless, within six month
period, prior to his expiration of qualification
i. The welder has welded with that process using Manual or Semiautomatic
welding.
ii. The welding operator has welded with that process using Machine or
Automatic welding.
c) When there is a specific reason to question his ability to make welds that meet the
specification. In such a case, the qualifications that support the welding he is doing shall be
revoked. All other qualifications not questioned shall remain in effect.
7.2.7
The AI, Head Quality may ask for re-qualification of any welder or welding
operator.
7.2.8
Head Quality shall prepare List of Qualified Welders (Exhibit No. 7-2) listing
the range of qualification for each welder. This list shall be updated every three months based on
the Welder Continuity Record. Head Quality shall review and approve the list.
7.2.9
Additional revisions to the list may be made during the intermediate period to
inform the addition / deletion of welders. However, the validity of any such intermediate list
shall be maintained same as the previous list.
7.2.10
Head Quality shall issue a copy of the List of Qualified Welders to Production
Manager.
7.3
WELDING CONSUMABLE CONTROL

WELDING CONTROL
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7.3.1
All welding consumables shall meet the requirement of applicable SFA/AWS

classification as per ASME Section II Part C and any additional customer / Work Order
requirements. Alternatively, welding consumables shall meet specific WPS requirements.
7.3.2
Welding Engineer shall prepare Indent for Welding Consumables (Exhibit No.
7-3) along with Technical Delivery Conditions for Welding Consumables (Exhibit No. 7-4),
mentioning all technical requirements for procurement of welding consumables based on
drawings, Code and additional customer requirements, if any. The TDC for Welding
Consumables shall include respective SFA specification, AWS classification number, approved
brand names, furnishing required Batch Test certification reports and marking details. Head
Quality shall approve the Indent and TDC for Welding Consumables and forward to Head
Materials for procurement as per Chapter No. 04 (Material Control).
7.3.3
Upon receipt of welding consumables, Store Incharge shall correlate the items
with the PO, check the quantity and physical condition and prepare GRN. Store Incharge shall
mark the GRN number on all packages / boxes of welding materials.
7.3.4
Stores Incharge shall offer the material to Engineer QC for examination through
GRN along with batch test certificates received with delivery documents.
7.3.5
Engineer QC shall verify batch number and marking on the consumable boxes
and on the consumables, review the batch test certificate against the requirements and also verify
physical condition of electrode boxes for any damage.
7.3.6
Engineer QC shall document the acceptance / rejection on the GRN and get it
approved by Head Quality and forward a copy of the GRN to Stores Incharge. Engineer QC shall
retain the batch test certificates and GRN on file.
7.3.7
Stores Incharge shall store the accepted welding consumables inside the electrode
cabin. Any rejected consumables shall be affixed with the Reject tag and kept in the designated
area for the rejected items for disposal.
7.3.8
Before use, welding consumables shall be dried as per Procedure for Storage,
Drying and Issue of Welding Consumables and then transferred and kept in the holding ovens at
specified temperature. Head Quality shall prepare the procedure based on consumable
manufacturers recommendation and/or ASME Section-II Part C and shall approve the same.
7.3.9
Production Engineer shall prepare Welding Consumable Issue Slip (Exhibit No.
7-5) for issue of welding consumables from Stores, based on the applicable WPS. Stores
Incharge shall issue the welding consumables on first-in first-out basis and indicate the batch
number of welding consumables issued on the Welding Consumable Issue Slip.
7.3.10
Production Engineer/Production Manager shall issue only one type of electrode /

filler wire to any welder at one time. A maximum of 30 pieces of electrodes shall be issued to a
welder at one time. Welders shall return any unused electrodes to Production

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Engineer/Production Manager who shall keep the returned electrodes in a separate box and such
electrodes shall be used only for welder training purpose.
7.4
WELDING PROCESS CONTROL
7.4.1
Based on approved drawings and Code requirements, Head Quality shall prepare
and approve Weld Plan (Exhibit No. 7-6), indicating the qualified WPS for welding each weld
joint on the job. Head Quality shall submit the weld plan to AI for review along with applicable
WPS and PQR.
7.4.2
Head Quality shall distribute a copy of the approved Weld Plan to Production
Manager along with applicable WPS(s) using Document Transmittal (Exhibit No. 1-2).
7.4.3
Whenever the applicable drawings are revised, Head Quality shall review the
Weld Plan for any change and revise the same, if required. This review shall be documented on
the Weld Plan even if no changes are required. Revised Weld Plan shall be approved by Head
Quality and offered to the AI for review. Copy of revised Weld Plan shall be distributed to
Production Manager.
7.4.4
Production Manager shall assign the welding job to qualified welders based on the
current list of Qualified Welders and the applicable WPS specified in the approved Weld Plan.
7.4.5
Production Manager shall ensure that all welding is carried out by qualified
welders strictly in accordance with the applicable WPS using approved consumables.
7.4.6
Production Manager shall provide necessary instructions to the welder regarding

welding parameters to be used as per the applicable WPS and ensure that a copy of the WPS is
available to the welder in the work area.
7.4.7
Tack welds used to secure alignment shall either be removed completely when
they have served their purpose or their stopping and starting ends shall be properly prepared by
grinding or other suitable means so that they may be satisfactorily incorporated into the final
weld. Each tack weld shall be visually examined by Engineer QC and if found defective, shall be
completely removed.
7.4.8
Tack welds, whether removed or left in place, shall be made using the WPS
specified for the weld joint in the approved Weld Plan by welders qualified in accordance with
ASME Section IX.
7.4.9
Welding of temporary attachments shall be carried out by using qualified welders

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

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7.4.10
Production Manager shall record the identification number of the welder used for
welding each weld joint, including tack welds, on Shop Welding Record (Exhibit No. 7-7).
7.4.11
Additionally, each welder may stamp his identification number adjacent to the
weld which he makes at interval not exceeding one meter (3 feet) in the steel plates 6mm (1/4
inch) and over in thickness and in non-ferrous plates 13mm (1/2 inch) and over in thickness. Die
stamping shall not be used when service conditions prohibit.
7.4.12
Repairs to welds shall be carried out using qualified welders as per approved
Weld Plan reviewed by the AI. If required, a specific repair procedure shall be prepared by
Welding Engineer and approved by Head Quality and offered to the AI for review. The excavated
area shall be examined by PT to ensure complete removal of defect prior to repair. The repaired
area shall be once again examined by the same NDE method(s) as used for the original weld.
7.4.13
Welding Engineer shall maintain the records of repair on welds, including the
identification number of the welder used, on the Shop Welding Record.
7.4.14
For repair of defects in material, Engineer QC shall raise a NCR and process same
as per Chapter No. 06 (Correction of Nonconformities).
7.4.15
Welding Engineer shall monitor the welding activities on shop at random to verify
whether parameters employed by welders for making production welds confirm to approved
WPS.
7.5
7.5.1
USE OF WELDERS / WELDING OPERATORS BY CONTRACT / AGREEMENT

RMGA may engage individuals by contract or agreement for their services as
welders / welding operators at shop for the construction of pressure vessels or parts thereof
provided all the following conditions are met:
a)
RMGA shall be responsible for all Code items construction.
b)
All welding shall be performed in accordance with WPS qualified by RMGA

in accordance with the requirements of the ASME Section IX.
c)
Head Quality shall be responsible for qualification and certification of all such
welders in accordance with the requirement of the Code.
d)
All welders engaged shall be under complete and exclusive administrative and
technical supervision of Production Manager.
e)
Production Manager shall have full authority to assign or remove welders at

his discretion without involvement of any other organization.
f)
Head Quality shall issue welder identification number to each welder and
shall keep a separate record for identification numbers issued to such welders.

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g)
RMGA shall obtain an acceptance from the Authorized Inspection Agency for
the use of such welders on Code items construction.
h)
RMGA shall be responsible for the Code compliance of the vessel or part
including Certification Mark stamping and providing Manufacturers Data Report forms
properly executed and counter signed by the AI.

NON-DESTRUCTIVE EXAMINATION
Issue No. : 01
Chapter No.: 08
Page No.
: 1 of 3
Rev.
: 01
Date
: 12.02.13
8.0 SCOPE
This Chapter covers requirements for training, qualification and certification of NDE personnel,
approval of NDE procedures and NDE on materials and welds.
All NDE shall be carried out as per requirements of ASME Section V and applicable Code
Sections.
8.1
CERTIFICATION OF NDE PERSONNEL
8.1.1
GM-Operations shall prepare and Head Quality maintains RMGA Written

Practice for Training, Qualification and Certification of NDE Personnel in accordance with SNTTC-1A, Edition/Addenda as referred in the applicable Code. The Written Practice shall cover
Radiography, Ultrasonic, Magnetic Particle and Liquid Penetrant examination methods.
8.1.2
GM-Operations shall appoint and certify NDE level III in accordance with
RMGA Written Practice by virtue of his educational and professional qualifications, valid ASNT
certificate documented experience, examination, demonstrated ability and achievements. The
appointment shall be renewed once in three years subject to the period for which the ASNT
qualification of NDE Level III is valid.
8.1.3
GM-Operations shall prepare written practice and NDE Level III shall review and
approve for acceptance by AI.
8.1.4
NDE Level III shall train, examine and qualify NDE Level I and II personnel, in
accordance with RMGA Written Practice. GM-Operations shall certify NDE Level I and II
personnel jointly along with NDE Level III.
8.1.5
Near vision and color vision examination including check for shades of grey for
all certified NDE personnel shall be performed once in a year.
8.1.6
NDE personnel shall be recertified in accordance with the Written Practice once
in every five years.
8.1.7
Head Quality shall maintain a list of certified NDE Personnel along with all
supporting documentation as per RMGA Written Practice.
8.2
8.2.1
NDE PROCEDURES
GM-Operations shall prepare and NDE Level III shall approve NDE Procedures
in accordance with the requirements of the ASME Section V and referencing Code Section
detailing the equipment to be used, method of calibration, requisite qualification of personnel,
and evaluation and acceptance standards as a minimum. NDE Level III shall arrange to
demonstrate the procedures in accordance with Article T-150 of ASME Code Section V, to the
satisfaction of the AI. He shall also update NDE procedures as and when required by new
Edition Addenda of the Code. GM-Operations and NDE Level III shall certify the procedures in
accordance with Article T-150 of ASME Section V.

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8.2.2
NDE procedures shall be revised, whenever there is any change in essential or

non-essential variables as defined in ASME Section V. NDE procedures shall be re-demonstrated
to AI, whenever there is a change in essential variables.
8.2.3
The present design and fabrications of pressure vessels or parts do not require
NDE other than RT and PT. If other NDE methods are required in future for Code acceptance of
items, the procedure shall be demonstrated by the NDE Level III to the satisfaction of the AI,
prior to use. NDE Level III shall also arrange for qualification of NDE personnel as per RMGA
Written Practice for those additional methods.
8.3
PERFORMING NDE ON JOB
8.3.1
Head Design shall specify the extent of NDE on the drawings. Head Quality shall
transfer the NDE requirements in to ITP and Inspection Data Book.
8.3.2
At appropriate stage as per Inspection and Test plan, Production Engineer shall
offer the job for required NDE to Engineer QC through Inspection Request and Report. He shall
ensure that all previous stages have been completed before raising NDE request.
8.3.3
Engineer QC shall carry out visual examination of items / welds prior to offering
for NDE.
8.3.4
NDE Level I/Level II shall perform calibration of equipment, carry out NDE in
accordance with the approved procedure and record the examination data in the relevant NDE
report. Level I must receive written guidance from NDE Level II or Level III.
8.3.5
NDE Level II or Level III shall evaluate and interpret the results against
requirements of Code and record the results on NDE report. The results of the examination shall
be informed to Production Manager. If any unacceptable indication is observed, Production
Engineer shall carry out necessary repair and re-offer for NDE. RMGA NDE II Level III or
Level shall complete the interpretation and evaluation before presenting the radiographs and/or
NDE reports to the AI for review.
8.3.6
All NDE shall be carried out before PWHT, unless specifically mentioned in ITP/
drawings.
8.3.7
For spot radiography, the spots shall be selected by the AI, or alternatively by
Head Quality with prior permission of the AI. If he is not available.
8.3.8
NDE equipment shall be calibrated as per Chapter No. 10 (Calibration of

Measurement and Test Equipment).
8.3.9
Head Quality shall make available NDE Procedures, NDE reports, radiography
films and personnel qualification records to the AI for review. The AI may require requalification of any NDE personnel, procedure or examination for a cause.
8.4
8.4.1
SUB-CONTRACTING OF NDE
If any NDE is required to be subcontracted, the following shall be ensured:

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8.4.2
RMGA NDE level III and GM-Operations shall review and approve the Written
Practice and personnel qualification records of the sub-contractor in accordance with the
requirements of SNT-TC-1A, Edition/ Addenda as referenced in the applicable Code. This
review shall be documented. If required, RMGA NDE Level-III shall conduct additional specific
examination as per RMGA NDE Written Practice.
8.4.3
RMGA NDE Level III and GM-Operations shall review and approve subcontractors facilities prior to undertaking any Code related NDE work.
8.4.4
All NDE shall be carried out as per RMGA procedures approved by NDE Level
III and demonstrated to the AI.
8.4.5
NDE level III shall verify the calibration of NDE equipment to be used by subcontractor.
8.4.6
Copies of above records shall be maintained by Head Quality and made available
to the AI for review.

HEAT TREATMENT
Issue No. : 01
Chapter No.: 09
Page No.
: 1 of 3
Rev.
: 01
Date
: 12.02.13
9.0 SCOPE
This Chapter covers the requirements for heat treatment of Code items.
9.1
HEAT TREATMENT REQUIREMENT AND PROCEDURE
9.1.1
Head Design shall specify the heat treatment requirements for fabricated and formed items /
components on the drawings based on Code and additional customer requirements if any.
9.1.2
Head Quality shall approve Heat Treatment Procedure based on the applicable Code
requirements and submit to the AI for his review. The procedure shall include details of heat
treatment furnace, heat treatment techniques, equipment to be used, method of attachment of
thermocouples on the job and reporting requirements, as a minimum. A copy of the approved
procedure shall be issued to Production Manager.
9.1.3
Engineer QC shall arrange for calibration of thermocouples and time-temperature recorders as

per Chapter No. 10 (Calibration of Measurement and Test Equipment) with Incharge
Maintenance. Incharge Maintenance shall maintain the furnace and auxiliary facilities in the
conditions suitable for proper heat-treatment.
9.2
HEAT TREATMENT ON JOB
9.2.1
At the appropriate stage as per ITP and drawings, Production Engineer shall offer the vessel or
part to Engineer QC, for Visual and dimension examination prior to heat treatment through Heat
Treatment Request and Report (Exhibit No. 9-1). Engineer QC shall ensure that all NDE has
been satisfactorily completed and all NCR satisfactorily resolved.
9.2.2
Engineer QC shall verify that all the previous stages as per ITP, including welding of all
attachments, examination, inspection, NDE and other tests as per approved drawings/ITP have
been completed. Engineer QC shall visually examine and dimensionally check the item and if
found satisfactory, offer the item to the AI for inspection prior to releasing for heat treatment by
signing off on the HTRR.
9.2.3
Production Manager shall forward the HTRR to Head Quality for indicating the details of items
to be heat treated in one charge, method of placement of the job in furnace, number, location and
method of attachment of thermocouples capable of reading actual job temperature and the heat
treatment cycle to be followed including the permissible tolerance limits.
9.2.4
In case a combination of items is to be heat treated in one charge, Head Quality shall take into
consideration the materials, applicable WPS and governing thickness for each item to ensure
compliance with Code requirements.
9.2.5
Head Quality shall forward a copy of HTRR to Production Manager with the details of required
heat treatment cycle.

HEAT TREATMENT
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9.2.6
Production Engineer shall arrange for loading of items in the furnace and attachment of
thermocouples as per approved procedure and HTRR.
9.2.7
The item shall be adequately supported so as to ensure uniform heating/cooling from all sides
and to avoid any direct impingement of flame. The thermocouples shall be secured on the item to
be heat treated without having any air gap. Welding Engineer shall ensure that applicable WPS as
per approved Weld Plan is used for attachment welds.
9.2.8
Engineer QC shall witness the loading of items and attachment of thermocouples as per heat
treatment procedure and HTRR and sign off the time temperature graph prior to start of heat
treatment. Engineer QC shall also verify placement of test coupons, if applicable, prior to start of
heat treatment cycle.
9.2.9
Engineer QC shall arrange for mechanical testing of test coupons, wherever applicable, using
calibrated test equipment.
9.2.10 Production Engineer shall ensure that heat treatment is performed in accordance with the
approved procedure and HTRR.
9.3
REPORTING
9.3.1
On completion of heat treatment, Production Engineer shall hand over the time-temperature
graph to Head Quality, who shall review the time-temperature graph and if found satisfactory he
shall approve the same ands offer the same to the AI for his review.
9.3.2
Any nonconformity observed shall be processed in accordance with Chapter No. 06 (Correction
of Nonconformities).
9.4
9.4.1
SUB-CONTRACTING OF HEAT TREATMENT

In case sub-contractors facilities are to be utilized for heat treatment of Code items, the
following shall be ensured:
a)
Head Quality shall review and approve subcontractors equipment/ facilities, including
the calibration records of thermocouples and time-temperature recorders. This review shall
be documented.
b)
Production Engineer shall offer the items to Engineer QC, for examination and
releasing the item for heat treatment as above.
c)
Purchase Engineer shall forward the request for subcontracting heat treatment to Head
Materials, who shall process the purchase order for heat treatment enclosing the approved
Heat Treatment procedure and HTRR.
d)
Production Engineer shall ensure that any attachment welds for thermocouple locations
are made by RMGA as per approved WPS, prior to sending the item to subcontractor.

HEAT TREATMENT
Issue No. : 01
Chapter No.: 09
Page No.
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Rev.
: 01
Date
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Thermocouple may be attached with capacitor discharge welding method. A WPS shall
be prepared as per section IX when energy output is greater than 125 watt/second. WPS
shall contain combination of material to be joined and technique of application.
e)
Engineer QC shall witness loading of the item at subcontractors works along with test
coupons (if applicable), confirm attachment of required number of thermocouples on the job
at stipulated locations and verify the calibration status of thermocouples and timetemperature recorder. The heat treatment Furnace Operator and Engineer QC shall sign off
the time-temperature graph prior to commencement of heat treatment.
f)
Engineer QC shall ensure that the item is adequately supported so as to ensure uniform
heating/cooling from all sides and there is no direct impingement of flame on the job.
g)
9.5
9.5.1
Heat treatment shall be carried out strictly as per approved procedure and HTRR.
h)
After completion of the heat treatment cycle, Head Quality shall review and approve the
time-temperature graph and submit to the AI for review.
i)
Engineer QC shall visually examine the item on receipt at RMGA shop after heat
treatment to check for any damage or distortion and verify identification markings.
RECORDS
Head Quality shall offer all records pertaining to heat treatment i.e. Heat
Treatment Procedure, HTRR, time-temperature graph and calibration records, including those for
sub-contracted heat treatment, to the AI for review.

CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT
10.0
Issue No. : 01
Chapter No.: 10
Page No.
: 1 of 2
Rev.
: 01
Date
: 12.02.13
SCOPE
This Chapter describes the systems and procedures for calibration of examination,
measurement and test equipment used in fulfillment of applicable Code requirements.
10.1
RESPONSIBILITIES
10.1.1
Head Quality shall specify the required accuracy and frequency for calibration for all
measurement and test equipment.
10.1.2
Engineer QC shall review all the calibration reports and verify that the calibration results
comply with specified requirements.
10.1.3
Engineer QC shall ensure that only calibrated measurement and test equipment are used during
Code construction at shop.
10.1.4
Site Incharge shall ensure that only calibrated measurement and test equipment are used during
field assembly at site.
10.2
CALIBRATION STANDARDS
10.2.1
Head Quality shall ensure that all calibrations, whether carried out in house or outside, are
done using master instrument traceable to National / International standards. Where no such
standards exist, the equipment manufacturers recommendations shall be followed and the
basis shall be documented.
10.2.2
Head Quality shall ensure that mechanical tests, when required, are carried out using calibrated
test equipment. For impact tests, the impact testing machine shall be calibrated annually and
temperature measurement apparatus shall be calibrated every six months as per SA370 with
reference to ASTM E23.
10.3
IDENTIFICATION
10.3.1
Engineer QC shall identify all measurement and test equipment under the calibration program
with a unique identification number which shall be permanently marked on the equipment.
10.3.2
Engineer QC shall prepare a List of Measurement and Test Equipment (Exhibit No. 10-1)
indicating the RMGA identification number, instrument type, make & range, required accuracy,
frequency, calibration certificate no., date of calibration and next calibration due date.
10.3.3
Engineer QC shall ensure that each measurement and test equipment is affixed with a
calibration sticker indicating the identification number, date of last calibration and due date for
next calibration.
10.3.4
In case of small instruments on which the calibration sticker cannot be affixed, it may be
pasted on the box or container of the instrument.

CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT
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Chapter No.: 10
Page No.
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Date
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10.3.5
Engineer QC shall ensure that any measurement and test equipment not identified with
calibration sticker is not used during any examination, inspection or testing of the Code items.
10.4
PERFORMING CALIBRATION
10.4.1
Engineer QC shall ensure the calibration of all measurement and test equipment on receipt and
at frequency stipulated on the List of Measurement and Test Equipment by Head Quality and
shall be responsible for recalling the measurement or test equipment for re-calibration, prior to
the due date for re-calibration.
10.4.2
Engineer QC shall arrange for calibration of pressure gauges used during hydrostatic or
pneumatic pressure test once in every six months or earlier, if any error is suspected. Pressure
gauge shall be subject to validation after every pressure test.
10.4.3
Incharge Maintenance shall be responsible for calibration of thermocouples and measuring

instruments on welding machines / electrode ovens once in a year or earlier, if there is any
reason to doubt their accuracy. Time temperature recorders shall be calibrated once in six
months or earlier, if there is any reason to doubt their accuracy.
10.4.4
NDE Level II shall perform calibration of NDE equipment in accordance with procedures
approved by NDE Level III. NDE Level III shall review and approve the results of calibration.
10.4.5
Any measurement and test equipment shall be re-calibrated when repaired or when there is any
reason to doubt its accuracy.
10.5
NONCONFORMANCE / REJECTION
10.5.1
In case any measurement or test equipment is observed to be damaged or out of calibration,

same shall be affixed with HOLD tag. Head Quality shall ensure that such equipment is not
used before re-calibration irrespective of its calibration status. If any equipment cannot be
repaired and calibrated, it shall be marked with REJECT tag and returned to Stores Incharge
for disposal.
10.5.2
The identification number of measurement and test equipment used shall be recorded on
the relevant examination /inspection/NDE/test reports.
10.5.3
In case any measurement or test equipment is observed to be out of permissible limits at the
time of recalibration, Engineer QC shall raise NCR and process as per Chapter No. 06
(Correction of Non-conformities. Head Quality shall evaluate all the previous records where
the particular instrument was used to establish the acceptance of previous measurements.

RETENTION OF RECORDS
11.0
Issue No. : 01
Chapter No.: 11
Page No.
: 1 of 1
Rev.
: 00
Date
: 30.10.12
SCOPE
This Chapter describes the requirements for retention of records for Code items.
11.1
RETENTION
11.1.1
Head Quality shall retain the following documents for a minimum period of three years from
the date of signing of the Data Report by the AI:
a)
b)
c)
d)
e)
Manufacturers Partial Data Reports/ Manufacturers Data Reports.

Manufacturing drawings.
Design calculations, including any applicable Proof Test Reports.
Material Test Reports and/or material certifications.
Welding Procedure Specifications and Procedure Qualification
Records.
f)
g)
h)
i)
j)
k)
l)
m)
n)
Welders Qualification Records.

RT Reports.
Repair procedures and records.
Process control sheets.
Heat Treatment records and test results.
Post welds heat treatment records.
Nonconformances and Dispositions.
Hydrostatic test records.
Pressure parts documentation and certification.
11.1.2
Head Design shall retain as-built drawings, design calculations and proof test reports for a
minimum period of three years from the date of signing of the MDR by the AI.
11.1.3
Head Quality shall retain a complete set of radiographs for the Code item till the MDR is
signed by the AI.
11.1.4
A longer retention period than specified above may be followed, if required by the contract or
statutory regulations.
11.1.5
The retained records shall be stored and maintained to protect from damage, loss or any
deterioration during retention period and shall be easily retrievable. No document/ record shall
be removed from retention area without prior authorization from the controlling authority.
11.2
RECORD SUBMISSION
11.2.1
Head Quality shall provide copies of records for submission to the customer through GM
Business Development. All records shall be made available to the AI, AIS and ASME Review
Team on request.
11.3
DISPOSAL

RETENTION OF RECORDS
11.3.1
Issue No. : 01
Chapter No.: 11
Page No.
: 2 of 1
Rev.
: 00
Date
: 30.10.12
Head Quality shall arrange for disposal of records at the end of retention period by any suitable
means.

12.0
Issue No. : 01
Chapter No.: 12
Page No.
: 1 of 2
Rev.
: 01
Date
: 12.02.13
SCOPE
This Chapter covers the relationship of AI and AIS with RMGA during the construction of Code
items.
AUTHORIZED INSPECTOR:
a)Authorized Inspector shall be in regular employment by an ASME accredited Authorized
Inspection Agency i.e the inspection organization of a State or municipality of the United
States, a Canadian province, or an insurance company authorized to write boiler and
pressure vessel insurance.
The Authorized Inspector shall not be in the employment of the Manufacturer. All
Authorized Inspectors shall have been qualified by a written examination under the rules of
any State of the United States or province of Canada which has adopted the Code.
12.1 INSPECTION AGREEMENT
12.1.1 RMGA shall have in force at all times an inspection contract or agreement with an ASME
accredited Authorized Inspection Agency (AIA), as defined in Code, for providing the services
of AI and AIS to carry out inspection as per Code requirement. Head Quality shall inform ASME
whenever the agreement is cancelled or changed to another AIA.
12.1.2 Head Quality shall have overall responsibility for co-ordination with the AI and AIS for all Code
related inspection activities.
12.2 AIA OF RECORD
12.2.1 LR Insurance Inc., identified as AIA of record, shall perform all required inspection at the shop
and field site locations controlled from shop, for the type of work listed in the scope of ASME
certificate of Authorization.
12.2.2 In case of a situation where the purchaser requests another AIA to perform inspection in the
shop or field site on its projects or Code job, the request shall be in writing, for example on the
purchase order.
12.2.3 If LR Insurance Inc. cannot provide coverage for inspection at a specific field site, necessitating
the use of another AIA, this should also be documented suitably.
12.2.4 In case of 12.2.2 or 12.2.3 above, the following shall be ensured:
a. All AIAs performing inspections shall follow the system laid down in the QC Manual
accepted by the AIA of record.
b. All AIAs performing inspections shall have a contract or agreement with RMGA for the
specific Code work.

Issue No. : 01
Chapter No.: 12
Page No.
: 2 of 2
Rev.
: 01
Date
: 12.02.13
c. The AIA of Record i.e. LR Insurance Inc., shall review and accept all changes to the QC
Manual.
d. Each AI shall be provided with a controlled copy of the QC Manual.
e. AIA of Record shall be informed by RMGA in writing whenever they use Second
Agency for performing Code inspection as required by the purchaser in the P.O.
12.3 FREE ACCESS
12.3.1 RMGA shall provide free access to the AI and AIS at all times to all parts of the shop that
concern the construction of the vessel or part and to the site of field erected vessels, during the
period of construction, assembly and testing of Code items.
12.3.2 When requested, RMGA shall also provide free access to AI and AIS to such parts of all plants
that are concerned with the supply or manufacturing of the material for the vessel.
12.3.3 RMGA shall also provide for the AI and AIS to have free access to all drawings, design
calculations, specifications, procedures, ITP, Inspection Data Book, Weld Joint Inspection
Checklist, weld plan, proof test reports, other examinations and test records, repair procedures,
test certificates or any other related documents, as required by them to perform their duties in
accordance with the Code.
12.4 QUALITY CONTROL MANUAL
12.4.1 Head Quality shall submit a copy of Manual and any revisions to the Manual, to the AI for his
review and acceptance, prior to implementation.
12.4.2 Head Quality shall issue a controlled copy of the Manual to the AI at Shop. A controlled copy of
the Manual shall also be issued to the AI at field site, if applicable.
12.5 MONITORING OF QC SYSTEM / AIS AUDITS
12.5.1 The AI shall have the freedom to monitor RMGA Quality Control System at regular intervals as
required by Code.
12.5.2 AIS shall have the freedom to audit the AI activity periodically as required.
12.5.3 Head Quality shall provide all assistance to the AI during monitoring of quality control system
and to the AIS during the audit.
Issue No. : 01
Chapter No.: 13
Page No.
: 5of 5
Rev.
: 01
FIELD SITE CONTROL
Date
13.0
: 12.02.13
SCOPE
This Chapter covers controls required during field assembly at sites controlled by the shop to
ensure compliance with the requirements of Code and this Manual.
13.1
ORGANIZATION AND RESPONSIBILITY
13.1.1
The organization structure for assembly at field sites controlled from shop is
indicated on Page 4 of this Chapter. Responsibilities of key personnel at site are defined in this
Chapter, in addition to those detailed in Chapter No. 02 (Organization and Responsibilities).
13.1.2
Site Incharge shall have overall responsibility for all fabrication, assembly,
examination and test activities at field site as per requirements of Code, approved drawings, ITP,
approved Weld Plan and approved procedures.
13.1.3
Head Quality shall have overall responsibility for all quality control activities at
site.
13.1.4
Site QC Engineer and NDE Level II at site shall report functionally to Head
Quality and administratively to Site Incharge.
13.1.5
Site QC Engineer shall liaise with the AI at site and inform him about progress of
site activities and approaching inspection stages.
13.1.6
Site QC Engineer and NDE Level II will be nominated at the time of field site
control.
13.2
QC SYSTEM AT SITE
13.2.1
Head Quality shall audit the QC system at site for compliance with Code and this
Manual. Head Quality shall provide all assistance to the AI at site for monitoring the QC System
at site.
13.2.2
Head Quality shall issue controlled copies of Manual to Site Incharge, Site QC
Engineer and to the AI at site.
13.3
SITE PROCESS CONTROL
13.3.1
Whenever site work is involved, Head Design shall define the extent of shop
fabrication and site assembly on the drawings. If required, Design Engineer shall prepare and
Head Design shall approve separate drawings for site assembly and submit to the AI at site for
review as per Chapter No. 03 (Drawing, Design Calculation and Specification Control).
13.3.2
All drawings including their revisions shall be marked as Issued for

Manufacturing and issued to Site Incharge, Head Quality and Site QC Engineer through
Documents Issue Record Sheet The recipients shall either destroy the old revision or if
retained, mark them as OBSELETE.
13.3.3
Site Engineer shall receive materials, components, welding consumables and

equipment from shop along with packing slip and reports and verify the physical condition for
any damage.
Issue No. : 01
Chapter No.: 13
Page No.
: 5of 5
Rev.
: 01
FIELD SITE CONTROL
Date
: 12.02.13
13.3.4
Site QC Engineer shall examine the materials, parts and components received at
site from the shop and verify that all quality control documents for previously completed stages,
including MDR (if applicable) duly certified by Head Quality up to Certificate of Shop
Compliance and endorsed by the AI at shop up to Certificate of Shop Inspection, have been
provided.
13.3.5
Site QC Engineer shall examine the materials and welding consumables received
directly at site as per Chapter No. 04 (Material Control) and Chapter No. 07 (Welding Control)
respectively. If found acceptable, Site Store Incharge shall arrange to store the material in preassigned area.
13.3.6
For components received with MPDR, Site QC Engineer shall verify the ASME
Certification Mark on components and offer the components to the AI at site for inspection prior
to use.
13.3.7
Engineer QC shall prepare and Head Quality shall approve ITP for site activities
and submit to the AI at site, through Site QC Engineer, for marking of inspection stages. Copies
of approved ITP shall be issued to Site Incharge and Site QC Engineer.
13.3.8
Based on the approved ITP and drawings, Site QC Engineer shall prepare the
Inspection Data Book, obtain the approval of Head Quality and submit to the AI at site for
verification of accurate transfer of inspection stages.
13.3.9
Any revisions to the ITP and Inspection Data Book shall be controlled as per
Chapter No. 05 (Examination and Inspection Program).
13.3.10
Site QC Engineer shall conduct the required examination and tests as per
approved ITP and maintain all examination and test records as detailed in Chapter No. 05
(Examination and Inspection Program).
13.3.11
Site QC Engineer shall liaise with the AI at site and keep him informed about
progress of site activities and approaching inspection stages.
13.3.12
Site QC Engineer shall inform any nonconformity observed at site to Head

Quality, through NCR for resolution as per Chapter No. 06 (Correction of Nonconformities).
Site QC Engineer shall verify the implementation of corrective action and offer the NCR to the
AI at site for review of proposed corrective action and final disposition.
13.3.13
Head Quality shall approve Weld Plan and submit to the AI at site for review
along with applicable WPS and supporting PQR, through Site QC Engineer. Site QC Engineer
shall issue a copy of approved Weld Plan along with the applicable WPS and List of Qualified
Welders to Site Incharge.
13.3.14
Site QC Engineer shall supervise any welding procedure qualification or welder /

welding operator performance qualification at site as per Chapter No. 07 (Welding Control).
Site QC Engineer shall prepare the WPS, PQR and WPQ/WOPQ records and forward to Head
Quality for approval of WPS and certification of PQR and WPQ/WOPQ.
Issue No. : 01
Chapter No.: 13
Page No.
: 5of 5
Rev.
: 01
FIELD SITE CONTROL
Date
: 12.02.13
13.3.15
Site Engineer shall arrange to carry out all welding at site as per Chapter No. 07
(Welding Control).
13.3.16
Site Incharge shall have full authority to assign or remove any welder at any time.
Welders at site shall be under direct administrative and technical control of Site Incharge.
13.3.17
RMGA may engage individuals by contract or agreement for their services as

welders or welding operators at site, provided all the conditions as per Clause 7.5 of Chapter
No. 07 (Welding Control) are met. For this purpose, the responsibilities of Production Manager
and Head Quality shall be carried out by Site Incharge and Site QC Engineer respectively.
13.3.18
NDE Level III shall be responsible for approving NDE procedures to be

employed at site and their demonstration to the AI at site, if required. NDE Level III shall
review calibration of NDE equipment to be used at site.
13.3.19
NDE Level II at site shall carry out all required NDE in accordance with approved
procedures as per Chapter No. 08 (Non-Destructive Examination).
13.3.20
On completion of fabrication and assembly, Site QC Engineer shall ensure that all
stipulated examination, inspection, NDE and other tests have been satisfactorily completed. He
shall carry out visual and dimensional examination and offer the job to the AI at site for
inspection prior to releasing the job for heat treatment or pressure test, as applicable. He shall
also verify that all NCR have been satisfactorily resolved and closed.
13.3.21
When heat treatment is required, Site Engineer shall arrange to carry out the same
as per Chapter No. 09 (Heat Treatment) in accordance with approved heat treatment procedure
and HTRR approved by Head Quality.
13.3.22
Site Incharge shall ensure that pressure test is conducted as per drawings,
approved procedure and Code requirements using calibrated pressure gauges. Site QC
Engineer shall witness the pressure test and if acceptable, offer to the AI at site for witnessing.
13.3.23
Site QC Engineer shall ensure that all measurement and test equipment to be used
at site is calibrated as per Chapter No. 10 (Calibration of Measurement and Test Equipment).
13.4
EQUIPMENT/NAME PLATE STAMPING AND DATA REPORTS
13.4.1
On satisfactory completion of assembly, examination and tests, Site QC Engineer shall verify
the correctness of nameplate / stamping details, ensure that the nameplate is attached to correct
vessel, offer to the AI at site for verification and obtain his concurrence for applying
Certification Mark and if applicable, NB Stamp.
13.4.2
Head Quality shall assign the National Board number, when required, on completion of the
pressure test.
13.4.3
Head Quality or his authorized designee shall carry the Certification Mark Stamp and if
applicable, NB stamp to the site. Head Quality shall be responsible through Site QC Engineer
for application of Certification Mark Stamp and if applicable, NB Stamp on the item / name
plate in the presence of the AI at site. The U designator shall be stamped or etched directly
below the ASME Certification Mark.
Issue No. : 01
Chapter No.: 13
Page No.
: 5of 5
Rev.
: 01
FIELD SITE CONTROL
Date
: 12.02.13
13.4.4
Head Quality shall arrange for retrieval of the Code Symbol stamp / Certification Mark Stamp
and NB stamps after use at field site.
13.4.5
Head Quality shall complete and certify the Certificate of Field Assembly Compliance on the
Data Report and offer to the AI at site for his review and signature through Site QC Engineer.
Head Quality shall arrange to distribute the Data Reports as per Chapter No. 05 (Examination
and Inspection Program).
13.4.6
Field Site assembly of the vessel may also be carried out by others as permitted in Para
U-3 of the Code and as detailed below:a) The Manufacturer of the vessel completes the vessel in the field, completes the form U-1
or U-1A Manufacturers Data Report, and stamps the vessel.
b) The Manufacturers of parts of a vessel to be completed in the field by some other party
stamps these parts in accordance with Code rules and supplies the Form U-2 or U-2A
Manufacturers Partial Data Report to the other party. The other party must hold a valid
U Certificate of Authorization, makes the final assembly, required NDE, final pressure test;
complete the form U-1 or U-1 A Manufacturers Data Report ; and stamp the vessel.
c) The field portion of the work is completed by a holder of a valid U certificate of
Authorization other the vessel manufacturer. The certificate holder performing the field
work is required to supply a Form U-2 or U-2A Manufacturers Partial Data Report
covering the portion of the work completed by his organization (including data on the
pressure test if conducted by the certificate holder performing the field work) to the
Manufacturer responsible for the Code vessel. The vessel manufacturer applies his
certification mark with the U Designator in the presence of a representative from his
inspection agency and completes the form U-1 or U-1A Manufacturers Data Reports with
his Authorised Inspector.
13.5
RECORD RETENTION
13.5.1
All records shall be retained at RMGA shop as per Chapter No. 11 (Retention of Records).
Issue No. : 01
Chapter No.: 13
Page No.
: 5of 5
Rev.
: 01
FIELD SITE CONTROL
Date
ORGANIZATION STRUCTURE FOR FIELD SITE

GM Operations
Head Quality
NDE LEVEL III

At RMGA Works
At Field Site
SITE INCHARGE
SITE QC
ENGINEER
SITE STORE
INCHARGE
SITE ENGINEER
WELDERS
NDE
LEVEL II
: 12.02.13
Issue No. : 01
Chapter No.: 13
Page No.
: 5of 5
Rev.
: 01
FIELD SITE CONTROL
Date
: 12.02.13
Functional control
Administrative control
14.1.1(a) At present methods other than written signature are not being used in RMGA for indicating
certifications, authorizations, and approvals.
(b)Whenever other methods (Electronic Signature, Approval, Authorizations) are employed, controls
and safeguards shall be provided and described to ensure the integrity of the certification, authorization,
and approval. QC Manual shall be revised to include this requirement. Integrity of the system shall be
demonstrated to the AI prior to implementation.

LIST OF EXHIBITS
Exhibit
Number
Title
Issue No. : 01
Chapter No.: 15
Page No.
: 1 of 2
Rev.
: 01
Date
: 12.02.13
Form Number
No. of
Pages
Revision
Status
Revision
Date
1-1
QC Manual Distribution List
FU-QC-01
01
00
30.10.12
1-2
Document Transmittal
FU-PP-01
01
00
30.10.12
3-1
Documents Issue Record Sheet
FU-DSG-01
01
00
30.10.12
3-2
Design Change Request
FU-DSG-02
01
00
30.10.12
3-3
Material Indent
FU-DSG-03
01
00
30.10.12
3-4
Technical Delivery Conditions
FU-DSG-04
02
01
30.10.12
4-1
Material Inspection Request and

Report
FU-STR-01
01
00
30.10.12
4-2
Material Verification Report
FU-QC-02
03
00
30.10.12
4-3
Purchase Order
FU-PUR-01
01
00
30.10.12
4-4
Goods Receipt Note
FU-STR-04
01
00
30.10.12
4-5
Hold Tag
FU-STR-02
01
00
30.10.12
4-6
Reject Tag
FU-STR-03
01
00
30.10.12
4-7
Material Issue Slip
FU-PRD-01
01
00
30.10.12
4-8
Inspection Request and Report
FU-PRD-02
01
00
30.10.12
4-9
Material Attestation Report
FU-QC-03
01
00
30.10.12
5-1
Inspection and Test Plan
FU-QC-04
05
00
30.10.12
5-2
Inspection Data Book
FU-QC-05
03
00
30.10.12
5-3
Weld Joint Inspection Checklist
FU-QC-06
01
00
30.10.12
5-4
Final Dimension Report
FU-QC-07
02
00
30.10.12
5-5
Pressure Test Report
FU-QC-08
01
00
30.10.12
5-6
Name Plate
FU-DSG-05
03
00
30.10.12
5-7
Log of National Board Numbers

issued
FU-QC-09
01
00
30.10.12
5-8
Log Of ASME Code Jobs
FU-QC-10
01
00
30.10.12
5-9
Dished End Inspection Report
FU-QC-15
01
00
30.10.12
5-10
Rolled Shell Inspection Report
FU-QC-16
01
00
30.10.12
6-1
Nonconformity Report
FU-QC-11
01
00
30.10.12
6-2
List OF NCR
FU-QC-12
01
00
30.10.12

LIST OF EXHIBITS
Exhibit
Number
Issue No. : 01
Chapter No.: 15
Page No.
: 2 of 2
Rev.
: 01
Date
Title
: 12.02.13
Form Number
No. of
Pages
Revision
Status
Revision
Date
7-1
Welders Continuity Record
FU-WT-01
02
00
30.10.12
7-2
List of Qualified Welders
FU-WT-02
01
00
30.10.12
7-3
Indent for Welding Consumables
FU-WT-03
01
00
30.10.12
7-4
Technical Delivery Conditions for

Welding Consumables
FU-WT-04
01
00
30.10.12
7-5
Welding Consumable Issue Slip
FU-WT-05
01
00
30.10.12
7-6
Weld Plan
FU-WT-06
02
00
30.10.12
7-7
Shop Welding Record
FU-WT-07
01
00
30.10.12
9-1
Heat Treatment Technique and

Report
FU-QC-13
02
00
30.10.12
10-1
List of Measurement and Test

Equipment
FU-QC-14
01
00
30.10.12

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QUALITY CONTROL MANUAL

Head Quality ____________

Gas Technologies Limited

QUALITY CONTROL MANUAL

Statement of Policy and Authority

Glossary and Abbreviations

Administration of Quality Control Manual

Organization and Responsibilities

Drawing, Design Calculation and Specification

Examination and Inspection Program

Calibration of Measurement and Test Equipment

Field Site Control

REVIEWED & ACCEPTED BY

Amrit Pal Singh

QUALITY CONTROL MANUAL

STATEMENT OF POLICY AND AUTHORITY

STATEMENT OF QUALITY POLICY AND AUTHORITY

QUALITY CONTROL MANUAL

An ASME Symbol identifying a product as meeting Code requirements.

Manufacturers Data Report/ Manufacturers Partial Data Report.

This Quality Control Manual.

Material Test Report, Certificate of Compliance or Manufacturers Partial Data

National Board of Boilers and Pressure Vessels Inspectors.

ASNT Recommended practice for Personnel Qualification and Certification in

Welder or welding operator.

A stage of inspection for which AI shall be notified in advance. However, work

RMGA Written Practice for Training, Qualification and Certification of NDE

QUALITY CONTROL MANUAL

Authorized Inspection Agency

Authorized Inspector Supervisor

American Society of Mechanical Engineers

American Society for Non-Destructive Testing

American Society for Testing and Materials

Design Change Request

Heat Treatment Request and Report

Inspection and Test Plan

Minimum Design Metal Temperature

Maximum Allowable External Working Pressure

Maximum Allowable Working Pressure

Manufacturers Data Report

Manufacturers Partial Data Report

RMG Autometers Gas Technologies Limited

Material Inspection Request and Report

Welding Procedure Qualification Record

Post Weld Heat Treatment

Quality Control System

QUALITY CONTROL MANUAL

Goods Receipt Note

Technical Delivery Conditions

Welding Procedure Specification

Welding Operator Performance Qualification Record

Welder Performance Qualification Record

QUALITY CONTROL MANUAL

QUALITY CONTROL SYSTEM

QUALITY CONTROL MANUAL

REVISIONS TO THE MANUAL

QUALITY CONTROL MANUAL

Any revisions to the Manual, after approval by GM-Operations, shall be submitted to

QUALITY CONTROL MANUAL

QUALITY CONTROL MANUAL

Long term Strategy.

i) Responsible for overall day to day management of the company.

QUALITY CONTROL MANUAL

Approve WPS, certify PQR and WPQ / WOPQ records.