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P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT JI. Tenggri, Batu Ampar Batam – Indonesia 29432
Phone :
62(778)-412158, 412159
Fax :
62(778)-412157
E-Mail :
[email protected]
QUALITY CONTROL MANUAL FOR THE SHOP FABRICATION AND FIELD ASSEMBLY OF PRESSURE VESSEL & PARTS IN ACCORDANCE WITH THE ASME CODE SECTION VIII DIV. 1 AND 2
Manual No.
: QM-02
Edition No.
:2
Revision No.
:1
Revision Date
: February 15 2010
Control No.
:
Holder Name
:
Preface I – page 1 of 1
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
Edition No. Revision No. Section LOG OF REVISION
Preface ii – page 1 of 1
:2 :1 : Preface
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
Edition No. Revision No. Preface
Company :
Location
PT. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT
Jl. Tenggiri Batu Ampar BATAM 29432 – Indonesia
:2 :1 : iii
Sheet 1 Of 1
Revision No. QC MANUAL – EDITION No. 2
1
Section
Revision Date
REVISION STATUS Edition No. 1 Revision No. 0
SEE BELOW Section
Page Approved by : Sutarbilan 13-05-2004 QC Manager Approved on File
Comment First Issue for Initial Joint Review Edition No. 2 Revision No. 0
Accepted by : Darobi. S 13-05-2004 AI Approved on File Section
Page Approved by : Sutarbilan 15-05-2007 QC Manager Approved on File
Comment Issue for First ASME Renewal Audit Edition No. 2 Revision No. 1
Accepted by : Abidin A.M. 15-05-2007 AI Approved on File Section
Page
Comment Edition No. Revision No.
Section
Page
Comment Review
Approval Signature Prepared by :
24-01-2008
Accepted by :
24-01-2008
Approval Signature Accepted by :
02 Table of Contents Section No.
Revision
Date
Cover page
0
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01
Log of Revision
0
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02
Table of Contents
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February 15 2010
03
Statement of Policy and Authority
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04
Manual Control
0
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Preface
Title
Preface iii – page 1 of 1
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
Edition No. Revision No. Preface
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05
Glossary of Terms
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06
Organization Chart
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1
Organization Authority and Responsibility
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2
Drawings, Design Calculations and Specifications
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3
Material Control
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4
Examination and inspection Program
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5
Correction and Nonconformance
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6
Welding Control
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7
Nondestructive Examination
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8
Heat Treatment
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9
Calibration of Measuring and Test Equipment
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Records Retention
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Field Assembly
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Authorized Inspector
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List of Exhibits (Sample Forms)
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Preface iii – page 1 of 1
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
Edition No. Revision No. Section
:2 :1 : Preface
03 STATEMENT OF POLICY AND AUTHORITY The Management of P.T. Toyo Kanetsu Indonesia is totally committed to meet all of the requirements of the ASME Boiler and Pressure Vessel Code as a minimum. The Quality Control System described in this Quality Control manual (here and after maybe called Manual), for shop Construction and field assembly of ASME Code stamped Pressure vessels and Parts is in accordance with section VIII Div.1 and Div.2, and may include customer and jurisdiction regulatory requirements where the Code item would be installed. Department heads are responsible for performing the activities as described in this QC Manual. They may delegate the performance of the activity to a qualified individual within their department but they shall remain responsible. The Quality Control Manager is responsible for the preparation, revision, and issue of this Quality Control Manual, and for the administration and implementation of the Quality System in the shop and field. He has the authority, responsibility and organizational freedom to identify Quality Control problems, initiate and provide their solutions, and to verify that resolution of such problems have been correctly applied He has the authority and responsibility, to stop any activities at shop and/or field site, when he finds any non-conformity. In the event of disagreement between Section managers which cannot be resolved by the Quality Control Manager, the problem shall be brought to me for resolution which is, based on the ASME Code requirements, this QC Manual and good engineering practice. This Quality Control Manual is an integral part of the Quality Assurance manual (QM-01). Should There be any conflict arise between this Manual and Quality Assurance manual (QM-01), this QC Manual shall take precedence.
Signed :
Toru Kiritani President Director
Date :
15 February 2010
Preface iv – page 1 of 1
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
Edition No. Revision No. Section
:2 :1 : Preface
04
MANUAL CONTROL
04.1
The Quality Control manager will issue copies of the Manual in accordance with the QC Manual distribution list (Exhibit 0-1) maintained by him. Each manual will bear the same control number on its title page as is shown on the list.
04.2
New Code Edition and/or Addenda are reviewed by the Quality Control Manager and other responsible related personnel to determine the need for revisions to the QC Manual and related procedures within six month of the issue of the Code Edition / addenda. The review is documented on Code Review Record Form (Exhibit 0-4). When revisions are required, they are presented to the Authorized Inspector for his acceptance prior to distribute to the Manual Holder.
04.3
Revisions are indicated on the affected page by a vertical line in the right-hand margin adjacent to the changed wording.
04.4
Revisions shall be approved by the Quality Control Manager and submitted to the Authorized Inspector for his review and acceptance prior to issue. Revisions will be made by section，except for exhibits. The revision shall be documented in the Log of Revision (Exhibit 02). For exhibits, the revision shall be highlighted by encompassing the change.
04.5
Revised sections of the Manual are issued by the Quality Control Manager to Manual Holders on the list, together with a revised Table of Contents page showing the latest Revision No. and date of each section of the Manual, and the dated signatures of the Quality Control Manager and the Authorized Inspector.
04.6
Revised exhibit pages are issued individually with a revised “Listing of Exhibits” page, and revised table of contents page.
04.7
The QC Manager may develop new editions to the Quality Control Manual every three years commensurate with the ASME Joint Review. New edition will be handled and controlled in the same manner as new revision，except revision highlights or indicators are not required and the revision level of all section and exhibit will revert to zero.
04.8
A current copy of the Quality Control Manual is available for use by the Authorized Inspector at the shop and at field sites.
04.9
Quality Control Manual will be marked “Controlled" and the QC Manager shall updated the Quality Control Manual distribution list (Exhibit 0-1). “Non-controlled" copies of the Quality Control Manual issued outside the organization are for information only，
04.10
Quality Control Manual will be issued with an appended Document Transmittal Advice (Exhibit 0 -3), requiring receipt of acknowledgment
Preface v – page 1 of 1
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
0.5
GLOSSARY OF TERM
05.1
Authorized Inspector
Edition. : Revision No. : Section :
2 1 Preface
An Authorized Inspector shall be an Inspector regularly employed by an ASME accredited Authorized Inspection Agency, i.e. an Insurance company authorized to write Boiler and Pressure Vessel Insurance, and registered in a state of USA, or province of Canada. The Inspector shall not be in the employ of P.T. TOYO KANETSU INDONESIA. The Inspector shall be qualified by a written examination under the rules of any State of United States or Province of Canada which has adopted the Code. He/She shall hold a valid National Board Commission with an “A” endorsement. 05.2 ，，，，
Code
05.3
Specifications
Refers to the ASME Boiler and Pressure Vessel Code Sections IIA, B, C & D, V, VIII Div. 1, Div. 2, IX applicable edition and addenda including other standards and publications referenced therein.
Information provided in addition to that given on drawings by a customer or by the Company as a further instruction to the requirements of ASME Codes or otherwise, of a contract 05.4
Company refers as P.T.TOYO KANETSU INDONESIA.
05.5 ，，，，
Controlled Manual Manual which are numbered, issued and updated with collection number, collection holder and revisions by Quality Control Manager.
05.6，，Sign Off ，，， The date signatures, initials, of authorized personnel reflecting completion of actions such as revisions by Quality Control Manager. 05.7 ，，，，
Hold Point
05.8
Non Conformity
An inspection, test, nondestructive examination or fabrication operation that must be witnessed by a specified party prior to subsequent fabrication, operation sequences at the required hold point shall not be continued prior to having been examined and released by a specified party.
is any condition which does not comply with the applicable rules of the Code, Quality Control Manual, other specified requirement. Nonconformity's must be corrected before the completed component can be considered to comply with the Code.
Preface vi – page 1 of 3
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
Edition. : Revision No. : Section :
2 1 Preface
05.9
Witness Point ，， An inspection, test, nondestructive examination or fabrication operation that is designated to be witnessed by a specified party. The specified party must be notified sufficiently in advance prior to performing the designated operation. If the specified party fails to show up the operation may proceed, with the consent of the specified party，
05.10
Inspection and Test Plan (ITP) An Inspection and Test Plan is one of quality plan documentation which lists manufacturing operation, witness points, hold points, and other inspection points in a detailed sequence.
05.11
Fabrication Sequence Sheet Fabrication Sequence Sheet is a project document, which lists fabrication flows of operation activities in sequences which specify stages of construction of Code item at shop as well as at the field sites.
05.12
Construction The use of this word in this manual, is refer to an all inclusive term comprising material, design, fabrication, examination, inspection, testing, certification and pressure relief.
05.13
SNT-TC-IA SNT-TC-IA is a Recommended Practice for Personnel Qualification and Certification in Nondestructive Examination Methods.
05.14
Review Verification of the Technical Document.
Preface vi – page 2 of 3
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
05.15
Edition. : Revision No. : Section :
2 1 Preface
ABBREVIATION TKI AI AIA AFC MRL PR MRC MRR MDR PQR FSS RFC NCR NDE PO QA QC SC SOP ITP WPS WPQT RFI Q’ty NB MAWP MAEWP MDMT
: P.T. Toyo Kanetsu Indonesia : Authorized Inspector : Authorized inspection Agency : Approved For Construction : Material Requisition List : Purchase Requisition : Material Request Card : Material Receiving Report : Manufacturer’s Data Report : Performance Qualification Record : Fabrication Sequence Sheet : Released For Construction : Non Conformance Report : Non Destructive Examination : Purchase Order : Quality Assurance : Quality Control : Sub Contractor : Standard Operating Procedure : Inspection and Test Plan : Welding Procedure Specification : Welder or Welding Operator Performance Qualification Record : Request for Inspection : Quantity : National Board of Boiler and Pressure Vessel Inspector : Maximum Allowable Working Pressure : Maximum Allowable External Working Pressure : Minimum Design Metal Temperature
Preface vi – page 3 of 3
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL 06.
Edition. : Revision No. : Section :
2 1 Preface
ORGANIZATION CHART PT. TOYO KANETSU INDONESIA SHOP ORGANIZATION CHART
SUPPORTING
SUPPORTING PRESIDENT DIRECTOR
MARKETING MANAGER
PLANT MANAGER
QUALITY CONTROL MANAGER
QUALITY CONTROL ENGINEER
NDE LEVEL III NDE LEVEL II NDE LEVEL I TESTING HOUSE
QUALITY CONTROL INSPECTOR
ENGINEERING MANAGER
DESIGN ENGINEER
WEIDING ENGINEER
DRAFTER(S)
FABRICATION MANAGER
PROCUREMENT MANAGER
FABRICATION ENGINEER
PROCUREMENT MANAGER
FABRICATION SUPERVISOR
PROCUREMENT ENGINEER
WELDING FOREMAN
FITTING FOREMAN
MATERIAL SUPERVISOR
WELDER (S) OPERATOR (S)
FITTER (S)
WAREHOUSE KEEPER
COMMAND LINE COMUNICATION LINE SHOP ORGANIZATION
Preface vii – page 1 of 2
ADMINSTRATION MANAGER
MAINTENACE GROUP
SAFETY GROUP
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
Edition. : Revision No. : Section :
2 1 Preface
PT. TOYO KANETSU INDONESIA FIELD SITE ORGANIZATION CHART
Shop
QUALITY CONTROL MANAGER
FABRICATION MANAGER
Shop
Field
QUALITY CONTROL INSPECTOR
FABRICATION ENGINEER
Field
NDE COMPANY LEVEL I & II
MATERIAL STORE KEEPER
ASSEMBLY FOREMAN
FITTERS
WELDING FOREMAN
FACILITY SUPERVISOR
WELDERS
SAFETY OFFICER ADMINISTRATION SUPERVISOR
COMMAND LINE COMUNICATION LINE SHOP ORGANIZATION
Preface vii – page 2 of 2
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
Edition. : Revision No. : Section :
1.
ORGANIZATION, AUTHORITY & RESPONSIBILITY
1.0
SCOPE
2 1 1
This section described detailed company's Section Heads and its subordinates reporting，，，， line, authority and responsibility as reflected in the company “Organization Chart" for shop and field site(s)operation. The reporting line, authority and responsibility are as follows: 1.1
ORGANIZATION CHART The organization chart for Shop and Field Site is indicated in Figure 1 “Shop Organization Chart” and Figure 2 “Filed Organization Chart” respectively.
1.2 ，，，， 1.2.1
PLANT MANAGER AUTHORITY Plant Manager has the authority to implement the company policy and control all the shop and field activity in accordance with the contractual agreement and specification.
1.2.2
RESPONSIBILITY
1.2.2.1 The Plant Manager is responsible for all plant and fabrication activities and is responsible for ensuring that all quality requirements are met, maintained and improved. 1.2.2.2 Receiving the tender specification from the Marketing Manager, and initiate a Project Contract Design Review Meeting, to discuss the design program with Engineering, Procurement, Fabrication and QC Manager. 1.2.3
REPORTING
1.2.3.1 Reporting to The Plant Manager reports to President Director 1.2.3.2 Directly reporting from ，，，，，，，，，，，，，，， (a) Engineering Manager (b) Fabrication Manager (c) QC Manager (d) Administration Manager (e) Procurement Manager
Section 1 – page 1 of 8
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
1.3
QC MANAGER
1.3.1
AUTHORITY
Edition. : Revision No. : Section :
2 1 1
1.3.1.1 The QC Manager has the authority to ensure an independence of the quality function from those personnel who have direct responsibility for work being performed. 1.3.1.2 The QC Manager has the authority to stop the work or activity being performed, either at shop or field site if he finds any non-conformity during the Code’s construction. 1.3.2
RESPONSIBILITY The specific responsibilities of QC Manager shall include the followings: -
1.3.3
To ensure that the training needs of QC staffs are identified and followed up. To ensure that all inspection activities are planned and undertaken in timely manner. To administer NDE Subcontractor and ensuring that all NDE requirements are identified and met. To ensure that all materials and fabricated items in accordance with specified requirements. To liaise with AI, keeping him informed of work progress and notifying him of approaching inspection points designated by him. Participating in ASME pre-joint and joint review. To review and ensure that completed “Manufacturer's Data Report" prepared by QC Engineer is correct prior to sign and date. Provision for the custody and control of the Code Symbol Stamps to prevent loss or unauthorized use and to issue Code Symbol Stamp to QC Engineer who will witness the stamp of the name plate in the presence of the AI.
REPORTING
1.3.3.1 Reporting to The QC Manager reports to Plant Manager. 1.3.3.2 Directly reporting from ，，，，，，，，，，，，，，， All NDE and QC Personnel for the Shop and Field sites who perform a quality function 1.4
QC ENGINEER
1.4.1
AUTHORITY The QC Engineer is authorized to carry out QC activities at shop and field sites.
1.4.2
RESPONSIBILITY The specific responsibilities of QC Engineer shall include the followings: -
To review contract specification and prepare associated ITP, based on Fabrication Sequence Sheet， Liaise with the Design Engineer in preparing the Welding Map, with regard to NDE requirements and initiate changes / revisions and ensuring timely distribution at shop and field sites. Section 1 – page 2 of 8
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL 1.4.3
Edition. : Revision No. : Section :
2 1 1
To monitor fabrication operation to ensure compliance with Codes, procedures and specifications. To monitor，Quality Control operations based on available Fabrication Sequence Sheet as to ensure compliance with Codes and specifications. To maintain Project Non-Conformance and Customer's complains Log and to ensure corrective action has been properly implemented and timely close-out of Nonconformance and complaints. Prepare the “Manufacturer's Data Report” form.
REPORTING AND COMMUNICATION
1.4.3.1 Reporting The QC Engineer reports to QC Manager. ，，，， 1.4.3.2，Communication The QC Engineer shall liaise with: (a) (b) (c) (d) (e)
Client Senior NDE (Subcontracted Level III) Fabrication Engineer(s) Design Engineer(s) Procurement Engineer(s)
1.5
QC INSPECTOR(S)
1.5.1
RESPONSIBILITY The specific responsibilities of the QC Inspector(s) include the followings: -，To carry out all inspection activities - To ensure that Non Conformance Reports are initiated as required in，，，，，，，，，，，，，， accordance with the approved procedures. - To ensure that Fabrication Operations are monitored and comply with specified and approved measures. - To monitor the operations specified in the Fabrication Sequence Sheet and ITP and sign off same. - To accompany the material supervisor during the receiving inspection.
1.5.2
REPORTING The QC Inspector(s) reports to QC Engineer.
1.6
FABRICATION MANAGER Section 1 – page 3 of 8
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL 1.6.1
Edition. : Revision No. : Section :
2 1 1
RESPONSIBILITY The specific responsibilities of the Fabrication Manager include the followings: -
1.6.2
To assure that all fabrication activity at shop and field site is performed in accordance with the drawings, FSS, and this manual. To liaise with the Fabrication Engineer & Maintenance Supervisor. To review fabrication processes, achievement and equipment at shop and field sites including the vendor facilities. To interface with the client, as required to ensure that any Fabrication and scheduling problems are being adequately addressed. To attend the Project Contract Design Review Meeting.
REPORTING
1.6.2.1 Reporting to The Fabrication Manager reports to the Plant Manager. 1.6.2.2 Directly reporting from: The Fabrication Engineer reports to the Fabrication Manager. 1.7
FABRICATION ENGINEER
1.7.1
RESPONSIBILITY The specific responsibilities of the Fabrication Engineer include the followings: -
1.7.2
To prepare “Fabrication Sequence Sheet" which shows detailed action at various stages of fabrication. To allocate work and to supervise an operation engaged on the work at shop and field site. To ensure that work is carried out in accordance with drawings, specifications work instructions, this QC Manual and the Code to meet the agreed Quality and satisfy requirements. To ensure that required materials are available for the fabrication at specified time. To ensure no work is carried out on “Non Conforming” 'items until instructed to do so by the QC Manager. To ensure that work is carried out in accordance with company’s procedures and Project Safety Program. To submit “Fabrication Sequence Sheet” in timely manner to QC Manager to enable him to prepare the ITP. To liaise with the Client / Customers Representative in construction with the project progress. To prepare purchase requisition based on MRL to purchase material. Checking the availability of stock material in inventory list and directly at store.
REPORTING The Fabrication Engineer reports to Fabrication Manager.
1.8
FABRICATION SUPERVISOR Section 1 – page 4 of 8
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL 1.8.1
Edition. : Revision No. : Section :
2 1 1
RESPONSIBILITY The specific responsibilities of the Fabrication Supervisor include the followings: -
1.8.2
To closely monitor all activities at various stages of the Code construction and to collect fabrication data. To monitor the receiving and the use of material during Code construction. For his activity he should commit liaison with Fabrication Engineer(s). To review and evaluate on routine basis the Code's construction progresses at shop， To report to Fabrication Engineer for any deviation that might have impact on Fabrication progress.
REPORTING The Fabrication Supervisor reports to Fabrication Engineer.
1.9
ENGINEERING MANAGER
1.9.1
AUTHORITY The Engineering Manager is authorized to control and guide the Design Engineer and ’Welding Engineer in order to achieve high productivity and efficiency.
1.9.2
RESPONSIBILITY The specific responsibilities of the Engineering Manager shall include the followings: - To attend the Project Design Review Meeting. - To approve design drawing and calculation and material requisition list, which have been reviewed and prepared by the Design Engineer. - To liaise with the Fabrication Manager, Procurement Manager and QC Manager in technical aspects and in estimating the project cost prior to submitting the tender quotation. - To prepare the project Construction Program.
Section 1 – page 5 of 8
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
1.9.3
Edition. : Revision No. : Section :
2 1 1
REPORTING
1.9.3.1 Reporting to The Engineering Manager reports to the Plant Manager. 1.9.3.2 Directly reporting from: The Design Engineer and Welding Engineer report to the Engineering Manager. 1.10
DESIGN ENGINEER
1.10.1
AUTHORITY Design Engineer is authorized to assist the Engineering Manager to inspect, control and guide the Drafter / Draftsman in order to achieve higher productivity and efficiency
1.10.2
RESPONSIBILITY The specific responsibilities of the Design Engineer shall include the followings: - To prepare Design Program, Design Drawing and Calculations based on the contract requirements and the Code/”User’s Design Specification”(for ASME Section VIII Div. 2) To ensure that the “User's Design Specification” and the “Manufacturer's Design Report” has been certified by a Registered Professional Engineer - To arrange Material Requisition List for production with clear description and specification of material to be used on the project. - To verify all contract specifications and drawing prepared by draftsmen / drafter. - To initiate any revision of AFC Drawing and detailed drawings and ensure effectiveness distribution of them to shop and field site in timely manner. - To liaise with Fabrication Manager and Engineering Manager in preparing shop and field drawings.
1.10.3
REPORTING The Design Engineer reports to the Engineering Manager.
1.11
WELDING ENGINEER
1.11.1
AUTHORITY All welding discipline and activities are under his control.
1.11.2
RESPONSIBILITY The specific responsibilities of the Design Engineer shall include the followings: - To prepare material for welder training. - To evaluate and maintain the quality of performance of welders. - To review client’s project welding specification including implementation of Code，， requirements and welding qualification. Section 1 – page 6 of 8
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
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- To prepare Welding Procedure Specification and monitor the implementation of Welding Procedure Specification at shop and field. - To witness and assists the Welding Qualification Test. - Liaison with Welding Foreman for maintaining the calibration of welding machine and equipment. 1.11.3
REPORTING The Welding Engineer reports to the Engineering Manager.
1.12
PROCUREMENNT MANAGER
1.12.1 ，，
AUTHORITY The Procurement Manager has the authority - To approve selected vendor(s) which is/are included in the vendor(s) qualified list. - To disqualify any vendor(s) who is unable to meet the required qualification as specified in the contractual agreement between the company and its subcontractor / vendor. - To purchase materials / goods in accordance with issued Purchase Requisition.
1.12.2
RESPONSIBILITY The specific responsibilities of Procurement Manager shall include the following: - To ensure that each vendor in it's schedule to supply the purchased material has satisfied the specified requirements as set forth in the purchase specification including the time and safe delivery of the goods being ordered. - To select, audit and evaluate the qualification and performance of the vendors from time to time.
1.12.3
Reporting The Procurement Manager reports to Plant Manager
1.13
PROCUREMENT ENGINEER
1.13.1
AUTHORITY The Procurement Engineer has the authority to raise “Purchase Requisition".
1.13.2
RESPONSIBILITIES The specific responsibilities of the Procurement Engineer shall include the following: - To ensure that the material listed in the Purchase Requisition is correct as well as in the Purchase Order prior to issuing the purchase order to the vendor. - To ensure that the material received is provided with the proper test certificates and as per Purchase Order. - Liaison with Material Supervisor with regards to receiving of project material，
1.13.3
REPORTING Section 1 – page 7 of 8
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
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2 1 1
The Procurement Engineer reports to Procurement Manager for the technical aspect to procure materials. 1.14 ，，，， 1.14.1 ，，，， 1.14.2 ，，，，
1.14.3
MATERIAL SUPERVISOR AUTHORITY Material supervisor is authorized to carry out warehouse/store activities at shop. RESPONSIBILITIES ，，，， The specific responsibilities of the Material Supervisor include the following: - To ensure that material are checked on receipt for quantity and certification and that any liaison required with material specification is maintained in accordance with agreed procedures， - To ensure correct materials are prepared for quality control clearance prior to issuance. - To initiate segregation / quarantined of non-conformance materials and liaise with QC Inspector for same. REPORTING The Material Supervisor reports to the Procurement Engineer and Warehouse and Storekeeper personnel are reporting to him.
Section 1 – page 8 of 8
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
Edition. : Revision No. : Section :
2.
DRAWINGS, DESIGN CALCULATIONS AND SPECIFICATIONS
2.0
General
2 1 2
Each order for a Code Constructed item received would be assigned with a job (contract) number by the Marketing Manager, which will be used to identify all documents related to the order/job. 2.1
Contract Review:
2.1.1
Contract may originate by the Marketing Department. A copy of customer project specification, government regulatory requirements (if any) will be reviewed during Project Contract Design review meeting by:
2.1.2
The Engineering Manager who is responsible for determining whether the design requirements / data are sufficiently defined.
2.1,3
The QC Manager who is responsible for determining whether all Code's requirements (except for design requirements) are adequately defined and could be met during the construction.
2.1.4
The Fabrication Manager who is responsible for determining manufacturing, processing, packaging and handling requirements could be met.
2.1.5
The Procurement Manager who is responsible for determining whether the required material specifications are adequately defined, and be supplied within the required time.
2.1.6
The Marketing Department may accept a revision to an order only after he has obtained the written instruction by customer.
2.1.7
The Marketing Department shall obtain resolution from the customer for comments made by Engineering Manager, Fabrication Manager and QC Manager.
2.2
Design by the Company:
2.2.1
Upon receiving of an order for a Code item which is to be designed by the Company, the customer’s design specification will be reviewed for adequacy by the Design Engineer and QC Manager for compliance with applicable Code requirements. Any question found to be resolved with the customer before the start of Code design work.
2.2.2
Upon approval of the customer's design specification a construction program (Exhibit 2-2) shall be prepared by Engineering Department incorporating the comments of the Fabrication Manager. The construction program should list the following information:
，，，，
2.2.3
A. Engineering Activity B. Procurement Activity C. Fabrication Activity including NDE Activities D. Project's schedule key dates Completed design and shop drawings, calculations, material specifications and NDE requirements are prepared by Design Engineer and approved by Engineering Manager. Section 2 – page 1 of 6
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
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2 1 2
2.2.4
Revisions to the above design documents are prepared and approved in the same way as the originals.
2.2.5
Only materials listed in the ASME Code Section II Part A, B and C or otherwise permitted by the Code shall be used for construction. The Design Engineer shall then assign a draftsman to prepare detailed design drawing, such drawing shall include as minimum the following: -
Material List. The Applicable Code Section including Edition & Addenda. Design Pressure /Temperature and MAWP/temperature, MAEWP/temperature when applicable. Corrosion Allowance. Minimum Design Metal Temperature. NDE Requirements. Heat Treatment Requirements. Hydrostatic / Pneumatic Test Pressure and test position. Welding details and production test plate (if any). Fabrication Tolerances. Impact Test Requirements. Alloy Verification requirement. client’s and statutory additional requirement / specification (if any). Special material testing requirement. Pressure Relief requirements. Name Plate Stamping information.
2.2.6
The Engineering Manager is responsible to submit the design drawing to the Al for his review. Any comments shall be incorporated in the revised drawing for his re-review purposes.
2.3
Computer Aided Designs
2.3.1
When computer-aided design calculations and drawings are used for Company's designed Code items, the Design Engineer is responsible for the input of correct design data and the verification that the correct output has been obtained in the following manner:
，，，，
i) ii)
in the event that output do not satisfy the Code requirements a new program shall be used. All data that are not within the scope of the computer program shall be alternately (manually) calculated and shall be initiated based on Code requirements.
2.3.2，
The Engineering Manager will review new Code edition and/or Addenda to determine if standard design nor computer program are affected. Required revisions shall be made within six months of the New Edition and Addenda issue date. The revision / review shall be documented accordingly.
2.3.3
All revisions are documented on a dated record of change signed by the Engineering Manager and recorded on each affected document or in computer program documentation. Section 2 – page 2 of 6
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2.3.4
Computer-aided drawings and calculation output shall be made available for review and acceptance by AI, The Design Engineer shall verify correctness of computer aided calculation by alternate (manual) calculation on every new edition or addenda. The Design Engineer provides the Al with any alternate calculations to verify computer output.
2.4
Design by Others
2.4.1
When design drawings, calculations and material specifications are provided to the Company by others, the Engineering Manager or his designee reviews these documents for compliance with the Code and user's design requirements on customer specification. Any discrepancy is brought to the attention of the design concern for correction to meet the Code requirements.
2.4.2
When the design documents meet the Code requirements, they are approved by the Engineering Manager who will stamp, initial and date each document with “APPROVED FOR ASME CODE CONSTRUCTION (AFC)".
，，，， 2.4.3
Company shall be responsible for any ASME design activities performed by others.
2.5，， ASME Section VIII Division 2 Vessel 2.5.1
The user shall provide a "User's Design Specification". The User's Design Specification shall be reviewed and certified by a Registered Professional Engineer, registered in one of the state of the USA or province of Canada and experienced in pressure vessel design. User’s Design Specification shall meet the requirements in ASME Section VIII Div.2 paragraph 2.2.2.
2.5.2
The certified "User's Design Specification" shall be obtained and reviewed by the Design Section Manager which shall at least contain the information required by Section VIII Div. 2 part 2 Paragraph 2.2.2, as follows : a) Installation Site, including location, Environmental conditions, and jurisdictional authority (if applicable). b) Vessel identification, vessel number, and service fluid. c) Vessel configuration and controlling dimensions. d) Design conditions. e) Operating conditions. f) Design fatigue life. g) Materials of construction. h) Loads and load cases. i) Overpressure protection.
2.5.3
Based on requirements of User Design Specification (UDS) the Design Section Manager shall establish and prepare Manufacturer's Design Report complies with the requirements of ASME Section VIII Division 2 Part 2 Paragraph 2.3.3.1., for the condition set-forth in the certified User's Design Specification. The Manufacturer's Design Report shall include the following information : Section 2 – page 3 of 6
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a) Final as-built drawings. b) The actual material specification used for each component. c) Design calculation and analysis. d) The results of any fatigue analysis. e) Any assumption used by the Manufacturer to perform the vessel design. The "Manufacturer's Design Report" shall be reviewed and certified by the Company's Registered Professional Engineer as complying with the requirements, including evidence of his reconciliation of changes to the User's Design Specification. This Professional Engineer shall be other than the Professional Engineer who certifies the ‘User Design Specification’ although both may be employed by or affiliated with the same organization. 2.6
Fatigue Analysis The design requirements for application of the design-by-analysis methodology of this division are described in ASME Section VIII Div.2 Part 5. Detailed design procedures utilizing the results from a stress analysis are provided to evaluate components for plastics collapse, local failure, buckling, and cyclic loading. Supplemental requirements are provided for the analysis of bolts, perforated plates and layered vessels. Procedures are also provided for design using the results from an experimental stress analysis, and for fracture mechanics evaluations
2.7
Loading All loadings shall be referred to ASME Section VIII Div.2 Part 5 Paragraph 5.1.3 shall be considered.
2.8
Revision Any revision in Manufacturer's Design Report and drawings shall be submitted to the RPE for re-certification purposes.
2.9
Over Pressure Protection Any Pressure Vessel within the scope of ASME Section VIII Division 1 and Division 2 shall be provided with protection against over pressure in accordance with the scope's provision and in consultation with the "End User".
2.10
Distribution of Drawings, Design Calculations, and Specifications
2.10.1. Distribution of all drawings, design calculations, and specifications are logged and controlled under Document Control Sheet (Exhibit 2-1) by Design Engineer. 2.10.2. Approved for construction drawings, design calculations, and specifications are distributed by Design Engineer to QC Manager and discuss the scope of work, Process Control Sheet (Traveler), ITP, etc. 2.10.3. The Fabrication Manager hand carries the Released For Construction documents to the Fabrication Engineer and Leaders to discuss the scope of work with them. 2.10.4. Field assembly drawings are issued to Fabrication Leader by the Fabrication Manager who will also review the scope of work with them when delivering the drawings. Section 2 – page 4 of 6
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2.10.5. The QC Manager is responsible to provide the AI with shop and field drawings, design calculations and specifications for his review before the start of the construction at the shop and field sites. 2.10.6. The QC Manager provides copies of the above documents to the QC Inspector, for the use at shop and field. 2.10.7. Revision to shop and field assembly drawings are prepared, approved and distributed in the same manner as the original. 2.10.8. Obsolete documents are destroyed by document holder in each Section, unless containing notes that require their retention, in such a case the document holder shall stamp the document with "OBSOLETE" stamp and retain them in the job file for information only.
Section 2 – page 5 of 6
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Drawing and Document Chart
CLIENT
PROCUREMENT
QUALITY CONTROL
ENGINEERING
CLIENT DESIGN SPECIFICATION THROUGH MARKETING MANAGER
FABRICATION
COPY
VERIFICATION
COPY
DESIGN CALCULATION MATERIAL SPECIFICATION
COPY
NDE REQ'NT WELD/NDT MAP
APPROVAL (OPTIONAL) THROUGH MARKETING MANAGER
AFC DRAWING ISSUE
COPY
COPY
MAT'L CONTROL SHEET INSPECTION AND TEST PLANT
MATERIAL REQUEST LIST
FABRICATION
ORIGINAL RETAIN WPS , PQR & WELDER CERTIFICATE (COPY)
CUTTING PLAN FABRICATION INSTRUC. FABRICATION SPECS. FAB. SEQUENCE SHEET BAR CHART/S - CURVE SCHEDULE
TO
MATERIAL CONTROL F-CHART NON CONFORMANCE REPORT
CORRECTIVE ACTION
VERIFICATION
AS-BUILT DOC / CERT. DOSSIER
ABBREVIATION : AFC DRAWING : Approved for Construction Drawing
SIGN MDR BY AI
NOTES : 1) All the above construction documents shall be submitted to AI to for his review 2) All version will be handled as per initial squence
DISPOSITION
FINAL INSPECTION
HYDROSTATIC TEST
PACKING & SHIPPING
Section 2 – page 6 of 6
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3.0
MATERIAL CONTROL
3.1
Requisitions
3.1.1
AII Material Requisition List (Exhibit 3-1)for Code material, including welding material are prepared from approved material specifications by the Design Engineer which list all Code requirements. These shall include the material specification type or grade selected from the applicable Code Section II parts A, B and C, use for Code's construction and purchase purposes.
3.1.2
Completed Material Requisitions List are reviewed for Code compliance by the QC Engineer who would make any required corrections approves by initial and date the MRL and returns it to the Design Engineer.
3.1.3
The Fabrication Engineer is responsible for checking the availability of stock materials in Material Inventory List (Exhibit3-9) and directly at store. In the case where material is not available, he shall identify in MRL and Purchase requisition (Exhibit 3-2) shall be raised. The completed Purchase Requisition (PR) is then submitted to Procurement Manager for Procurement Purposes (See 3.3).
3.1.4
When additional requirements for further treatment, examination and test of material is a Code requirements, then that information shall be included in both the MRL and PR and would also be reflected in the PO (Exhibit 3.3).
3.1.5
The Procurement Manager will make a selection of the vendor(s) based on Vendor's Qualified List. The selected vendor will then be issued a P/O accompanied with the Purchase Requisition (PR). Copy of un-priced P/O win be sent to QC Department, Fabrication Section and Material Supervisor for their Receiving Inspection purposes.
3.1,6
Additional Code material (if any)，requested by the Field Fabrication Engineer requisitioned by the Fabrication Manager as described above. It is the company policy that No procurement of material for pressure parts will be procured at field sites.
3.2
Additional Requirements for Section VIII Division 2
3.2.1
Design Engineer shall clearly explain to the Purchasing Engineer that while preparing MRL, he shall ensure that material ordered is in compliance with the requirements of Section VIII Division 2 Part 3 Paragraph 3.2.6. The Material Manufacturer shall provide a statement that the materials comply with Section VIII Div. 2 Part 3 requirements. The mill certificate shall include the numerical result of all required tests.
3.2.2
Upon receiving, material shall be inspected for Code compliance with the part 3 special requirements for any treatment, test or examination specified therein and compared against the material Manufacturer's certified report results. In the event that conflict found between the material spec. and the special requirements, an NCR shall be raised.
3.2.3
For Section VIII Div.2 Pressure Vessel material used for construction of pressure vessel parts shall be limited to those material specifications shown the allowable design stress in Annex 3A. Furthermore for vessel subject to fatigue further restrictions applies in that the material is limited to that for which fatigue curves are provided.
3.3
Purchase Orders Section 3 – page 1 of 6
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The Procurement Manager issues the P.O. (Exhibit 3-3) accompanied with the PR to selected vendors. P.O. copies are processed in the company procurement system and distributed as follows: Purchase Order Distribution Chart Copy P.O.
Distribution
Purpose
Original
vendor
Vendor use / Retention
2nd
Batam Accounting
Record for Settlement
3rd
File
1st
Procurement & Administration Department Batam/Jakarta Accounting
4th
Fabrication Section
Record retention.
5th
QC Section
For material receiving inspection.
6th
Material Supervisor
For material receiving inspection.
For cross checking against incoming material，Corresponding Delivery Order, Invoice, acknowledgement from vendor and material delivery to shop and field site.
3.3.2
For material to be sent to a field site, the Fabrication Manager and QC Manager，，，， respectively forwards a hard copy of the un-priced Purchase Order to the Fabrication Engineer and QC Inspector at field site.
3.3.3
Changes to Purchase Orders will be prepared, reviewed and approved from revised requisitions in the same way as the originals.
3.4 ，，，， 3.4.I
Receiving Inspection:
3.4.2
The QC Inspector accompanied by the Material Supervisor and using the QC copy of，，，，，，，， the Purchase Order with the attached PR, examines all Code items for dimensions, marking, physical, specification/heat number, condition and quantity against mill test certificates and/or certificate of compliance or Partial Manufacturer’s Data Reports.
All Code materials which has been received at the shop or field site shall be placed in a，，，，，， segregated “Quarantine” area pending Quality Control receiving inspection.
Section 3 – page 2 of 6
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3.4.3
Marking such as heat number, material specification, type or grade are recorded on the Material Receiving Report (Exhibit 3-4) by the Material Supervisor. If the QC Inspector found that the marking is acceptable, he marks the material with the applicable job number, signs and dates the Material Receiving Report and Material Mill/Test Certificate and forwards them to the QC Manager.
3.4.4
For all Code material, for which the material specification requires Material Test Report and/or Certificate of Compliance, the QC Engineer shall check the Material Test Reports on chemical and physical properties, and other test and examination results and to compare with the applicable specification requirements of the Code. lf the original marking on the material found coincide with that on material test report and/or Certificate of Compliance, the QC Engineer shall check the Material Test Report on chemical and physical properties, and other test and examination results and to compare with the applicable specification requirements of the Code. lf the original marking on the material found to coincide with that on material test report and on the Material Receiving Report via-a-vis: material specification, grade/type, dimension, test requirements and heat treatment, the QC Engineer shall record his acceptance in the Mill/Test Certificate and Certificate of Compliance as well as in the Material Receiving Report.
3.4.5
When acceptable, the QC Engineer signs and dates the Material Mill / Test Certificate and/or Certificate of Compliance and informs Fabrication Manager to release the material to the shop or field site.
3.4.6
Material which does not meet the Purchase Request, Purchase Order and Code requirements is tagged with a “HOLD” Tag (Exhibit 3-5), and Held in the “Quarantine” area and should be controlled as described in Section 5.
3,4.7
Before cutting Code material into two or more pieces, the entire material marking is transferred by the layout man ， and inspected by the QC Inspector. In some cases, a coded marking, traceable to the Material Test Report or material specification, as applicable and acceptable to the Authorized Inspector, may be used. All identification markings on high tensile steel using hard stamp shall be embossed by low stress hard stamp. All material of alloy steel or carbon steel less than 1/4” (6mm) shall not be hard stamped. For identification purposes an alternative means to be sought i.e. by using suitable paint mark and shall be traceable on the Material Control Sheet (Exhibit 3-11) which was prepared based on the Cutting Plan (Exhibit 3-10). Material Certification shall be recorded in the “Material Identification and Traceability Report" (Exhibit 3-6) by the QC Inspector.
3.5
Field Site Receiving Inspection of Code Pressure Retaining Parts and Piping
3.5.1
Code pressure parts and piping are unloaded in the assigned lay-down area and examined by the Materia1 Supervisor and QC Inspector for damage, Code stamping and identification marking to provide traceability to the Manufacturer's assembly drawings and partial MDRs.
3.5.2
The QC Inspector shall record the manufacturer’s identification marking in Material Identification and Traceability Report Form (Exhibit 3-6).
3.5.3
The applicable Partial Manufacturer's Data Report and Material Mill Test Reports for material shipped loose which has not been included on a Data Report must be received and verified against the stamped part or material traceability marking before the item could be released by the QC Inspector for assembling / erection.
Section 3 – page 3 of 6
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3.5.4
Items for which full documentation has not been received, but which are Code Stamped or marked as a required by the material specification, shall be put on “hold" and not permitted to be installed, The Al is kept informed of their status. NCR shall be issued for this effect.
3.5.5
Sub assemblies and raw materials that do not meet all Codes and customers requirements are considered nonconformity and shall be corrected or removed as described in Section 5 of this Manual.
3.6
Customer Supplied Material
3.6.1
All Code materials supplied by the customer’s or his agent is received and inspected by the QC Inspector as described in paragraph 3.4 and 3.5 above. Except a material requisition is used ln lieu of a purchase requisition.
3.6.2
Nonconforming material is controlled as described in Section 5 of this Manual.
3.7
Substitution Material:
3.7.1
Substitution of material shall be approval by the Design Engineer, the drawings, design calculation and other applicable document shall be reviewed as per paragraph 3.1. The Al shall be advised of the substitution for his review and acceptance. Should the AI accepts previous drawings, calculation, welding qualification and other related documents which has been affected by this substitution shall be reviewed for the require revision and re-qualification test.
3.8 ，，，，
Coded marks for structure steel material attached to pressure retaining parts. All structural steel material to be attached by means of welding to any pressure retaining parts shall be identified as follows. Code marks i.e. No.
Material
ldentification
1.
P-N0,1
P1
2.
P-N0.2
P2
3.
P-No.X
PX
3.9
Vendor Supplied Pressure Retaining parts
3.9.1
When the Company decides to use a subcontractor for fabrication of Code parts, the Design Engineer prepares the requisition which shall detailed an applicable Code and contract requirements, specified Quality Control requirements shall be identified by Quality Control Section.
3.9.2
For supplied parts that involve fabrication welding, the vendor must hold an appropriate ASME Code Stamp Authorization.
3.9.3
For parts which is limited to forming, cutting, machining and drilling type operation, the subcontract does not necessarily hold an ASME Certification, but the company shall be responsible for verification of the correctness of work by inspection during receiving inspection.
3.10
Material Records Section 3 – page 4 of 6
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3.10.1
Material Mill Test Reports and Material Identification and Traceability Report are submitted to the AI for review before being placed in the file.
3.10.2
All records referenced in these sections are available for review by the AI and are filed in the QC Job file at shop or field site.
3.11
Issue of Material (Shop and Field Site)
3.11.1
Material shall be issued to the workshop or field site from the store or “Quarantine” area upon receipt of a Material Request Card (Exhibit 3-7) issued by the Fabrication Supervisor in duplicate approved by Fabrication Engineer. START
PROJECT DATA INPUT DESIGN ENG.
3.11.2
Upon delivery of material(s), the Material Request Card shall be completed by the storekeeper, the stock card shall be adjusted accordingly and the duplicate copy of the Material Request Card returned to the recipient with the issued material. DESIGN Calculation Material Specification Welding Map AFC Drawing
DESIGN ENGINEERING ISSUE MAT'L REQUISITION LIST
QC CHECK MRL
Material Requisition List (Exh 3-1)
- Engineering - Quality Control - Fabrication - Store
Fab. Eng - Mt'l SPV NO
CHECK MRL AGAINST INVENTORY
3.11.3
AVAILABLE
YES
The original copy of the Material Request Card shall be retained by the store and filed centrally by its number. YES
AVAILABLE
NO
Fabrication ISSUE Purchase Request
3.11.4
Purchase Request (Exh 3-2)
- Procurement - Fabrication
The storekeeper shall ensure that the material is issued to the correct size, dimension, schedule, specifications and quantity. In the case where the materials are to be cut by the storekeeper, the QC Inspector shall verify the transfer of heat number and material specification and grade against the original mark stamping. Procurement Mng Check Purchase Order
VENDOR
Pack & Ship Material
Purchase Order (Exh 3-3)
* Xerox Copy, Unprice : - Store - Material Supervisor - QC Manager - Fabrication Manager
- Procurement - BTM Acct. - JKT Acct. - Vendor
- 3rd copy - 2nd copy - 1st copy - ORIGINAL
Shipping List
Delivery Order Invoice
Distribution : - Procurement manager - Accounting - Store
Material Supervisor
RECEIVE MAT'L PLACED ON QUARANTINE AREA
QC. Insp. +Mat'l SPV Check Mat'l As per PO & PR
3.12
Returning of Surplus Material
QC. Insp. +Mat'l SPV Check Mat'l As per PO & PR
NO
ACCEPTABLE
The storekeeper shall ensure that all surplus materials are returned to the store, correctly identified, following cutting with the Material Return Slip (Exhibit 3-8) being used. The Material Return Slip shall be raised by the Fabrication Engineer and shall be given a unique sequential number with a copy field in a central file with the Fabrication Section and the original filed by the store. The Material Return Slip shall always bear the Material Request Card number against which the materials where originally issued. YES
RESOLUTION
ACCEPTABLE
YES
NO REJECT SCRAP/RETURN TO VENDOR (Exh 3-5)
QC. Insp. +Mat'l SPV Mark Mat'l with Job#. HN & Grade
Material Receiving Report (Exh 3-4)
- Fabrication - Quality Control
Material Request Voucher (Exh 3-7)
- Store
Fabrication Engineer Issued Mat'l Request Card
Fabrication Engineer Check/Approved Mat'l Request Card
Material Supervisor Issue Material
LEGEND MAT'L SPV Fab ENG HN
: : : : :
3.13
Material: Supervisor Fabrication Engineering Heat Number
3.14
Inventory Material Mat'l SPV . Fab Eng Mark Mat'l with Job#. HN & Grade
Material Return Slip (Exh 3-8)
- Store
FABRICATION PROCESS
The Shop QC Inspector shall re-inspect any material inventory to be use on a Code project for compliance with project and Code requirements. This inspection shall be documented using MRR (Exhibit 3-4). (Correction)
Material Control Chart Section 3 – page 5 of 6
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4.
EXAMINATION AND INSPECTION PROGRAM
4.1
Shop Fabrication
4.1.1
Fabrication of Code items are controlled by using Inspection and Test Plan ITP (Exhibit 41) ， prepared by QC Engineer based on the AFC Drawings, which shall lists the sequence of fabrication, examination and inspection operations in the spaces provided.
4.1.2
Fabrication Manager & QC Manager reviews the ITP and AFC drawings with the AI to designate of their inspection points. If found necessary by request, the client could also be involved.
4.1.3
The ITP contains columns for initial and date by QC Inspector and the AI on those inspections they accept.
4.1.4
No work shall proceed unless the ITP has been signed by QC Inspector and AI for their agreed designated holds points.
4.1.5
Revision to the ITP shall be handled in the same manners as original. Editorial change to be made by QC Engineer, who initial and date the change. ITP shall be maintained by QC Engineer until job / project is completed and put on the QC job file, after Code item is completed then be kept in QC in the related job's file. When AFC drawings are revised the ITP shall be reviewed by QC Engineer for any change and if no change is required the review shall be documented on the construction sheet of the ITP by QC Engineer.
4.1.6
The QC Manager or his designee has the responsibility to notify the AI in sufficiently in advance for his designated inspection and hold points.
4.1.7
The QC Manager or his designee has the authority to stop or hold the work partially or entirely if he found any Non Compliance during the Code item Construction.
4.2
Final Inspection
4.2.1
When shop fabrication or field assembly of a Code item is completed, the QC Inspector performs his final inspection. He initials and dates the ITP when the item meets all Code requirements.
4.2.2
The AI would make his final inspection prior the hydrostatic or pneumatic test required by the Code. For parts not tested until field assembly is completed, he would make his inspection after fabrication of the part is completed.
4.2.3
When a pressure vessel is not provided with an opening or other means of access to inspect internal surfaces, an inspection point for the QC Inspector and AI shall be shown on the ITP as hold point to permit internal inspection before commencing setting of the final closure weld or bolted joint. Section 4 – page 1 of 5
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4.2.4，
The Material Traceability Inspection / MTI (Exhibit 3 - 6) provided in the tabulation materials, identifying each piece of materials used for the construction and location. This MTI shall be distributed to QC Manager for preparation of the Manufacturer's Data Report.
4,2.5，
Additional requirement for Section VIII Div. 2 Vessel. Actual dimension and the following material markings shall be recorded during the final inspection by the QC Engineer on the Material Traceability Inspection (Exhibit 3 – 6), i.e. : a) The material specification, type or grade and vessel part sequence number as per AFC drawing. b) The heat number except for standard fitting. This information/data to be submit to the QC Engineer for the preparation of As Built Drawing and MDRs.
4.3
Visual Examination for Section VIII Div.2 All welds for pressure retaining parts shall be visually examined. Personnel performing visual examinations shall pass annual eye test in accordance with paragraph 7.A.2.2 of ASME Section VIII Div.2. The personnel performing visual examination has vision, with correction if necessary, to read a Jaeger type No.1 Standard Chart, at a distance of not less than 300 mm, and capable of distinguishing and differentiating contrast between colors used. Compliance with the requirements shall be demonstrated annually.
4.3.1
When shop or field assembly of a Code item is completed, the QC Inspector performs his final inspection. He initials and dates the ITP when the item meets all Code requirements.
4.3.2
The Al will make his final inspection prior to hydrostatic or pneumatic test required as specified in the ITP. For parts for which would not be tested until field assembly is completed, he makes his inspection after the fabrication of the component is completed.
4.3.3
When a pressure vessel is not provided with an opening or other means of access to inspect internal surfaces, a hold point for the QC Inspector and Al will be shown on the ITP to permit internal inspection before starting the final closure weld.
4.3.4
Additional Requirement for Section VIII Division 2 items. Actual dimensions and the following material markings are recorded during final inspection by the QC Inspector on the QC copy of Material Receiving Report (Exhibit 3-4).
，，，， ，，，，
- the heat number for all material other than standard fittings. - the material specification, type or grade for all materials. The tabulation of material is also provided, identifying each piece with it’s corresponding drawing item and mill test reports. This is then sent to the Design Engineer for preparation of the As-Built Drawing and Manufacturer’s Data Report.
4.4，， Hydrostatic Test 4.4.1
Code required hydrostatic tests to be witnessed by the QC Inspector and AI, to determine the structural integrity or repair of any leakage.
4.4.2
The QC Manager shall verify that the AI has been notified sufficiently prior to each test, in order t Section 4 – page 2 of 5
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hat he witness them and complete his inspection. 4.4.3
The Pressure test as indicated in AFC drawing is applied by the QC Inspector as specified on the ITP note.
4.4.4
When the test meets Code requirement and is accepted by the QC Inspector and AI, they would initial and date the ITP in the space designating the test as their mandatory inspection point. After completion of the final inspection, the ITP and supporting documents shall be returned to the QC Manager for review subsequently file same as described in Section 10 of this Manual (Record Retention).
4.4.5
4.5，， Pneumatic Test 4.5.1
A sound reason shall be made in respect to deviation the Hydrostatic Test and substitute with Pneumatic Test e.g. the internal is prohibited the presence of any water content whilst complete drying process is beyond engineering practice.
4.5.2
Pneumatic test to be witnessed by the shop or field QC Inspector using a written procedure prepared by QC Engineer which includes minimum test temperature, test pressure and holding time, pressure increments, dial range of gauges and other special requirements applicable to the type of test.
4.5.3
Pneumatic test may be carried out when hydrostatic test is impracticable this alternative shall be with concerned of AI. In this case the full length of the following welds shall be examined for the purpose of detecting cracks. a. All weld around openings. b. All attended weld, including weld attaching non pressure parts to pressure parts having a throat thickness grater than 6 mm. The requirement on sub-paragraph 4.4.1 through sub-paragraph 4.4.4 shall also apply to pneumatic test, which are fully documented on test report. The QC Inspector and the AI sign and date this report when the test meets Code requirements.
4.6
Test Gauges
4.6.1
At least one directly connected calibrated indicating test gauge located at highest point of the Vessel and visible to the operator controlling the pressure and having a dial graduated over a range of about double the intended maximum test pressure but not less than 11/2 nor more than 4 times that pressure shall be used for all types of test.
4.6.2
An additional indicating gauge may be necessary to allow the pressure to be visible to the operator at all times during the test and to prevent excessive pressure being applied.
4.7
Code Stamping and Data Report
4.7.1
The QC Manager has custody and control of the Code Symbol Stamps and NB symbol stamp to prevent loss or unauthorized use of same. He shall issue the required stamp for use at the shop or field site when field assembly is completed.
4.7.2
The Code stamping is applied directly to the vessel or part or on a name plate to be permanently attached to a vessel or when direct stamping is not permitted, from data shown on the drawing. It is verified as correct by the the QC Inspector before he initials and dates the ITP. Section 4 – page 3 of 5
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4.7.4
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Stamping of Code symbol stamp on the name plate (Exhibit 4 - 3a, b) after fitted to the vessel is prevented, it may be applied prior to attached, in the presence of the AI after completion of the construction, but prior to hydrostatic and pneumatic test. Any non conformance found which can not be corrected, the name plate shall immediately be removed consequently the Code symbol stamp defaced. After completion of a shop fabrication of Code item, the QA Engineer prepares the Manufacturer's Data Report based on the final records and submits it for review by QC Manager, who certifies it by sign and date in ink.
4.7.5
After completion of the field assembly of a Code item, the QC Manager prepares and certifies the Certificate of field assembly portion of the Manufacturer's Data Report.
4.7.6
The completed Manufacturer's Data Report, together with final records is then presented to the AI for his review. When he accepts that all Code requirements have been met, the AI would allow and verify the application of the Code Symbol Stamp or the stamping on the pressure vessel or parts and sign and date the Manufacturer's Data Report.
4.7.7.
All records shall return to the QC Manager for retention as described in Section 10 in this Manual (Record Retention).
4.8 ，，， 4,8.1
Non Conformities All non conformities occurred during fabrication or field assembly are controlled and corrected as described in Section 5 in this Manual, prior to signing of the Manufacturer's Data Report and stamping of the name plate.
4.9
Examination and Inspection Documentation
4.9.1.
All drawings, design calculation, material test reports or certificate of compliance, examinations reports and test report/record including the fabrication records shall be made available for the AI and collected for inclusion in the job file.
4.10
Distribution of Manufacturers Data Reports (MDR) For Code item a copy of the MDR shall be furnished to:
4.10.1
Client/Owner/User or their designated Agent;
4.10.2
Upon request to AI
4.10.3
Jurisdictional Authorities at the place of installation when required by law
4.10.4
Keep a copy of the MDR on file in a safe custody for at least 5 years
4.10.5
In addition to above, data reports may be registered with National Board. Section 4 – page 4 of 5
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For Parts, Partial Data Reports shall be furnished in duplicate to the manufacturer of the complete vessel. A copy shall be retained for 5 years. 4.11
National Board If required by client or if the final location is U.S.A. or Canada the MDR shall be registered with the National Board of Boiler and Pressure Vessel Inspectors. The National Board serial numbers shall be controlled and issued by the QC Engineer. The National Board serial numbers shall be issued in a progressive numerical order from 1 without Skips or gaps of unused numbers or duplication of numbers. The NB numbers are assigned on completion of pressure test or when the pressure test is not completed at the shop the NB numbers are assigned at the time of certification of data reports. The QC Engineer shall maintain a Log of NB Numbers / NB Log (Exhibit 10-1) of National Board serial numbers issued, showing National Board serial number, description of the item stamped, customer and location, date MDR certified and the date of dispatch of MDR to the National Board for registration. The data reports requiring registration shall bear signature, NB commission number and endorsements of the AI. The data reports which are not registered with National Board shall bear signature, State/province commission number of the AI and not his NB commission number. When items are registered with the National Board, the QC Engineer shall send the original MDR with applicable attachments to the National Board within 60 days of certification. The data reports shall be sent to: NATIONAL BOARD OF BOILERS & PRESSURE VESSEL INSPECTORS 1055, CRUPPER AVENUE, COLUMBUS, OHIO 43229, USA
Section 4 – page 5 of 5
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5.
CORRECTION OF NONCONFORMITIES
5.1
Identification of Non Conformities:
5.1.1
Nonconformity is any condition which does not comply with the applicable rules of the Code, QC Manual or other specified requirements. Nonconformities must be corrected before the completed component can be considered to comply with the Code.
5.1.2
It is the duty of all Company employees to report any nonconformity to their superior, who win immediately notify the QC Inspector for further action.
5.1.3
As soon as a nonconforming condition is reported to the QC Inspector, he will inspect the item, and if verified as nonconformity, he will identify it by tagging or marking “HOLD” (Exhibit 3-5) and preparing a Nonconformance Report (Exhibit 5-1). lf practicable, the nonconforming item is moved to a segregated “HOLD" area otherwise then shall be so identify to prevent any activity being performed.
5.1.4
The Nonconformance Report shall contain suggested disposition for correction of the condition. NCR is signed and dated by the QC Inspector and forwarded to the QC Manager for review and acceptance. All concurrence is to be sought,
5.1.5
In the event that disposition or solution made by QC Manager would cause disagreement among Managers then the QC Manager shall seek advice from the Plant Manager for resolution. All resolution shall meet Code requirements.
5.2
Correction of Nonconformities:
5.2.1
USE-AS-IS: A1l disposition for “USE-AS-IS”, the QC Manager shall liaise with the Engineering Manager, for technical justification and to obtain approval. Any required revisions to drawings ， calculations and procurement documentation pertaining to the “USE-AS-IS” are made as described in this Manual. All of this action shall be with the concurrence of the AI.
5.2.2
REPAIR / REWORK: All dispositions requiring repair or rework may be carried out using Company Standard Operating Procedures, or with special procedures approved by the QC Manager, the Engineering Manager and accepted by the AI. For repairs to base metal and weldment, the proposed disposition is submitted to the AI for his acceptance of the method and extent of repair, examination and test and for his designation of required inspection points.
5.2.3
SCRAP / RETURN TO VENDOR: This disposition requires the QC Inspector to verify and document on the Nonconformance Report that the item has been removed from the work area and tagged or clearly marked with “REJECTED" sticker (Exhibit 3-5) and hold in segregated area to prevent inadvertent use before disposal on return to vendor.
5.3，，
Verification of Correction
5.3.1
The Q.C Inspector re-inspects the items after completion of dispositions described in 5.2.1 and 5.2.2. when he is satisfied himself that the item meets the Code requirements, the QC Inspector and Al will sign and date of the Nonconformance Report and remove the “HOLD" sticker or marking, to permit the item to return to the next operation sequence as reflected in the Fabrication Sequence Sheet.
5.4
Records Section 5– page 1 of 2
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5.4.1
All records of nonconformity and client complaints are made available to the Al for his review. The QC Manager shall maintain an “NCR Register” (Exhibit 5-2).
5.4.2
Completed Nonconformance Reports are returned to the QC Manager for his review and filing in the job file.
Section 5– page 2 of 2
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6
Welding Control
6.1
General :
6.1.1
All welding on Code work is performed using Welding Procedure Specifications (WPS) and competent welders and welding operators qualified in accordance with applicable clauses of ASME Code Section IX, related Code Section, QC Manual and other specifications.
6.2
Welding Procedure Specification:
6.2.1
WPSs are written by the Welding Engineer to include all variables required for the process by ASME Code Section Ix and the intended range of production welding. The required test welds are made under his supervision. Preparation and testing of the required test specimens is performed to meet with Section IX requirements by the qualified testing laboratory, whose report of the test results is reviewed by the Welding Engineer. If acceptable, he prepares and certifies the Procedure Qualification Record (PQR).
6.2.2
Copies of the qualified WPS are provided to the Shop and Field Fabrication Manager for the use on production place. The Welding Engineer maintains copies of the WPS and PQR packages in the project job file.
6.2.3
WPSs and PQRs are submitted to the Al for his review, and are made available at any time, upon request.
6.2.4
WPSs are revised whenever there is a change in a non essential variable, a new WPS is prepared and qualified whenever an essential or supplementary essential variable is to be changed or none of the existing qualified PQRs could support the required WPS.
6.2.5
At the AI’s discretion he may request re-qualification of a WPS at any time if he has specified reason to question the WPS for a defined welding job.
6.3
Qualification of Welders and Welding Operators:
6.3.1
All welders and welding operators involved in Code welding shall be qualified with the applicable ASME Section IX and the Code Section used for construction, under the supervision of the Shop or Field Fabrication Manager. A qualified testing laboratory prepares testing of the required specimens, or radiography of the weld test coupon. Their report of the test is reviewed by the Welding Engineer and if it meets the Code requirements the Welding Engineer prepares and certifies the Welder / Welding Operator Qualification Test Record (WPQR) and put the Welders name in the Welder/Operator Register.
6,3.2
A WPQR is also required for the welder who weld the test coupon used to qualify a WPS or to re-qualify him, based on the performance essential variables used.
6.3.3
Copies of the WPQR and its register are sent to the Shop and Field Fabrication Manager for their involvement in Code welding. The Original WPQRs are retained in the Welding Engineer file.
6.3.4， WPQRs are available for review by the Al at shop or field site at any time he requests， 6.3.5 6.4
All Qualified Welder/Welding Operators are recorded in the Master Approved Welders/Welding Operators Register (Exhibit 6-1). Expiration and Renewal of Qualification Section 6 page 1 of 4
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6.4.1
Expiration of Qualification The perform and qualification of a welder operator shall be affected when one of the following occurs ; a) When he has not welded with a process during a period of 6 month or more, his qualifications for that process shall expire; unless, within the 6 month period, prior to his expiration of qualification 1) The welder has welded with that process using manual or semiautomatic welding, under the supervision and control of the qualifying manufacturer or contractor or participating organization(s) as identified in QW-300.3; that will extend his qualification for an additional 6 months. 2) The Welding Operator has welded with than process using machine or automatic welding, under the supervision and control of the qualifying manufacturer or contractor or participating organization(s) as identified in QW-300.3; that will extend his qualification for an additional 6 months. b) When there is a specific reason to question his ability to make welds that meet the specification, the qualifications that support the welding he is doing shall be revoked. All other qualification not questioned remain in effect.
6.4.2
Renewal of Qualification a) Renewal of Qualification expired under QW-322.1 (a) may be made for any process by welding a single test coupon of either plate or pipe, of any material, thickness or diameter, in any position, and by testing of that coupon as required by QW-301 and QW-302. A successful test renews the welder or welding operator’s previous qualifications for that process for those materials, thicknesses, diameters, positions, and other variables for which he has previously qualified. Providing the requirements of wq-304 and QW-305 are satisfied, renewal of qualification under QW-322.1 (a) may be done on production work. b) Welders and welding operators whose qualifications have been revoked under QW-322.1 (b) above shall requalify. Qualification shall utilize a test coupon appropriate to the planned production work. The coupon shall be welded and tested as required by QW-301 and QW302. Successful test restores the qualification.
6.5
Maintain of Qualified welder and Welding Operator Qualification
6.5. 1
Each qualified welder shall be listed in the Monthly Record Welder Log (Exhibit 6-2) maintained by the Welding Engineer from the monthly data provided by the Shop or Field Fabrication Engineer. The log indicates the last date each month on which each welder and welding operator has welded in each process for which he is qualified.
6.5.2
The Welding Engineer determines from the log (Exhibit 6-2) when a welder qualification is about to expire, so as to ensure that he could performs production welding, or re-qualification is required.
，，，，
Note) - A welder has welded using a manual or semi automatic welding process will maintain his qualification for machine and automatic welding with that process. - A welding operator who has welded with a machine or automatic welding process will maintain his qualification for machine and automatic welding with that process.
6.6，，
Production Welding
6.6.1
The Shop or Field Fabrication Engineer verifies that each welder is qualified to weld and is Section 6 page 2 of 4
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responsible for instructing the welder in the correct use of the WPS listed on the Fabrication Sequence Sheet for each weld he may perform. 6.6.2
Each qualified welder shall be given a unique symbol stamped No. with which to identify each weld he makes. When stamping is precluded due to material thickness and material specification or customer restriction, the weld shall be identified by paint marking and transferred to a welding map which would indicate the welders that performed each weld. AII Section VIII Division 2 Code items shall be provided with the above mentioned weld map system.
6.6,3
When radiographic examination is a requirement, the welder's identification marking shall be visible on the radiograph accompanying with the other identification required by Code and client’s specification (if any).
6.7
Tack Welds
6.7.1
Tacks weld whether left in place or completely removed, are made by qualified welders using a qualified WPS.
6.7.2
If left in place, the ends of each tack weld are ground to ensure complete fusion into the final weld and the welder's symbol is marked on the Code item and recorded on the weld map accordingly.
6.7.3
After preparation, each tack weld is visually examined by the QC Inspector, and if found defective it shall be removed completely.
6.8 ，，，， 6.8.1
Welding Material
6.8.2
Welding material is stocked in a dry storage space and issued to welders by Warehouse Keeper.
6.8.3
It is advisable that Low Hydrogen coated electrodes be received in hermetically sealed containers. When container cover is opened or broken, the electrodes are to be placed in a holding oven maintained at the temperature recommended by the electrode manufacturer, before issue to welders.
6.8.4
Welding materials shall be stocked at dry storage space (humidity controlled) and identified by its specified AWS specification and classification. The storekeeper will provide “Daily Welding Consumable Report” (Exhibit 6-3) to record the issuance and returning control of welding material.
6.8.5
Low Hydrogen covered electrodes should be issued only in a quantity sufficient to complete the weld or for a period not to exceed four (4) hours.
6.8.6
Unconsumed Low Hydrogen covered coated electrodes returned to storage are examined for condition, cleanliness and identification before return to a segregated storage for reconditions purposes. Damaged, unidentified or wet electrodes are to be scrapped/discarded immediately with the concurrence of store keeper.
6.9
Production Test Plates
All welding material is purchased and received as described in Section 3 of this Manual.
Section 6 page 3 of 4
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Where production test plates are required by Code it shall be prepared in accordance with a procedure prepared by the Design Engineer and Welding Engineer and listed on the Fabrication Sequence Sheet and ITP, which shall includes: - Number, identification, specification and grade, attached location and dimensions of required coupon ; - Preheat temperature and PWHT requirements; - Acceptance criteria of tension bend and impact tests and other test and examination as required ; - Retest requirements ;
6.9.2
The Welding Supervisor supervises the welding of test coupons, which are prepared and tested by a qualified testing house whose test report is reviewed by the Welding Engineer. The Al shall be notified in advance prior to the test who may witness the test if he desires to do so.
6.9.3
Test results are to be submitted for review by the AI.
6.10
Welding Records ，，， All fabrication/production weld records mentioned in this section are to be made available for review by the Al prior to be retained in the QC Engineer and Fabrication Engineer job file.
Section 6 page 4 of 4
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SECTION 7 7
NON-DESTRUCTIVE EXAMINATION
7.0
General
7.0.1
All NDE required by the Code is specified on ITP and drawing, and is performed by a qualified and certified NDE in-house/ subcontractor personnel. Written Practice for NDE personnel and specified NDE procedures shall be reviewed by QC Manager for Code compliance and approved by the NDE Level III.
7.0.2
All NDE method specified on ITP, drawing/weld map shall be performed by NDE Personnel who are qualification and certification in accordance with Company’s Written Practice prepared in accordance with SNT-TC-1A Current Code accepted Edition & Addenda.
7.1
NDE Level III and Written Practice Company used services of out side individual as NDE level III who is appointed by Director by issuing Letter of Appointment.
7.1.1
The appointment of company level III base on the following: 7.1.1.1 Qualification and certification in accordance with Company’s written practice. 7.1.1.2 Valid endorsement on his ASNT Level III certificate for RT, UT, MT, PT method. 7.1.1.3 Experience in providing level III services to others Manufacture. 7.1.1.4 Experience in developing NDE procedure & monitoring NDE activities including evaluation of result to ASME Code requirement.
7.1.2
The Level III shall be responsible for : 7.1.2.1 Establishing, maintaining and approving company’s written practice for training, qualification and certification of NDE personnel based on SNT-TC-1A, accepted by Code Edition and Addenda. 7.1.2.2 Training, examination, qualification and periodic technical evaluation of company NDE personnel. 7.1.2.3 Approving company NDE procedure for RT, UT, MT, PT. 7.1.2.4 Demonstration, qualification and certification of NDE procedures. 7.1.2.5 Monitoring and control of NDE sub-contractor. Section 7 page 1 of 3
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7.2
NDE Personnel
7.2.1
The QC Manager, shall review and approve all subcontractor NDE personnel used on Code NDE have the training, experience, qualifications and are certified for the methods as described in the SNT-TC-1A and applicable ASME Edition and Addenda requirements, in accordance with their Company's Written Practice and the applicable Code Sections.
7.2.2
NDE Personnel Register (Exhibit 7-1) are available for review by the AI, who may request requalification if he has specific reason to question the NDE personnel’s ability to perform the NDE examination.
7.2.3
Copies of the following NDE personnel qualification records for all NDE Personnel performing Code NDE are kept on file by the QC Manager, and made available for review by the AI and by the NDE Level III upon request: a) b) c) d)
Name of certified individual Level of certification and NDE method. Educational background and experience of certified individuals. Statement indicating satisfactory completion of training in accordance with Employer’s Written Practice. e) Result of the vision examination f) Current examination copy (ies) or evidence of successful completion of examinations. g) Other suitable evidence of satisfactory qualifications, when such qualifications are used in lieu of the specific examination. h) Composite grade(s) or suitable evidence of grades. i) Signature of Level III that verified qualifications of candidate for certification j) Dates of Certification and/or re-certification in each method qualified and the dates of assignments to NDE. k) Certification expiration date. l) Signature of Company's QC Manager.
7.3
Sub- Contractor of NDE Sub contractor shall provide following documents for review and verification:
7.3.1
Their written practice meeting with SNT-TC-1A requirement.
7.3.2
Personnel & certificate records.
7.3.3
Calibration record of NDE instruments. All above document shall be verified by company or Level III. Copies of this document shall be kept for record & review by Authorized Inspector. QC Manager shall be responsible to verify that all sub-con NDE personnel qualified and certified in accordance with their employer written practice. Sub contractor can use either company NDE procedure or alternatively their own procedure provided the same are approved by company NDE Level III. Evaluation of test result shall be carried out by sub-contractor or company certified and qualified NDE Level II. NDE Reports
7.4
Section 7 page 2 of 3
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7.4.1
All reports of NDE, including RT film, are reviewed and accepted by the NDE Level II before submittal to the AI for his review. For Code NDE performed at a field site, the QC Inspector may perform the review.
7.4.2
NDE reports, including RT film for full and partial Code RT, are filed by the QC Manager for retention as described in Section 10 of this Manual.
7.5
Additional NDE Requirement Before completion of pneumatic tests permitted by ASME Code Section VIII Division 1, the full length of the following welds are examined by MT or PT, whichever is applicable, for the purpose of detecting possible cracks.
7.5.1
All welds around openings
7.5.2
All attachment welds, including welds attaching non-pressure parts to pressure parts, having a throat thickness greater than ¼" or 6 mm.
7.6
Requirement for Section VIII Div.2 All Type 1 joint shall be 100% Radio graphed. Permitted types of welds and required examination shall be in accordance with table 7.2 of ASME Section VIII Division 2.
7.6.1.
Offset (Joggle) Joint Welds are prohibited
7.6.2.
Unless specifically exempted, all welds shall be NDE examined as required as per table 7.2.
7.6.3.
For examination of Chromium Alloy cladding or lining shall refer to 7.4.8.1 and 7.4.8.2.
7.6.4.
In accordance with table 7.2 after final edge preparation, cut edges shall be examined in accordance with section V article 7 for MT or article 6 for PT
Section 7 page 3 of 3
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8
HEAT TREATMENT
8.1
Heat Treatment (HT) shall be conducted at the shop and field site by the subcontractor, Heat Treatment (HT) Procedures shall be prepared by the Design Engineer to meet the requirements of the applicable Code. The QC Manager shall review the Heat Treatment Instruction and sign and date them to indicate his approval. The Al concurrence is to be sought.
8.2
The Fabrication Engineer is responsible for heat treatment and to indicate on the Heat Treatment Furnace Chart the following information:
，，，，
a) The vessels and parts to be heat treated by job number, drawing number and component identification mark. b) The number of the Heat Treatment Procedure with revision status and date， c) The date of heat treatment (commencing and ending date and time) d) The sketch of placement location of all calibrated thermocouples and Chart speed. e) Chart shall be signed and dated by the QC Engineer prior commencing and at the completion of heat treatment. f) PWHT Procedure number used for heat treatment.
8.3
The QC Inspector shall sign and date the Heat Treatment furnace chart when he is satisfied that the heat treatment has been carried out in accordance with the applicable procedure and the Code.
8.4
All PWHT records are to be submitted to the Al for his review and are retained in the QC Engineer job file.
8.5
QC Inspector shall monitor all heat treatment operation whether done in house or at subcontractor’s facilities and shall inspect the heat treated items for identification and damage.
8.6
QC Inspector shall verify that all heat treatment is performed using calibrated equipment.
Section 8 page 1 of 1
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9
CALIBRATION OF MESUREMENT AND TEST EQUIPMENT
9.1
General
9. 1.1
All measurement, examination and test equipment used in fulfillment of relevant Code requirements shall be calibrated in accordance with this section and written specified calibration procedures approved by the QC Manager or by the NDE Level III,
9.2
Calibration Procedure
9.2.1
The QC Manager is responsible for identifying all measurement, examination and test equipment or it’s container with a equipment serial number and shop ID number.
9.2.2
The QC Manager is responsible for maintaining equipment in calibration, unless out of service and clearly marked “NOT CALIBRATED- DO NOT USE”.
9.2.3
Calibration may be performed by the qualified in-house personnel in the shop or testing house/laboratory which provides certified records of calibration and has suitable standards whose accuracy is traceable to the National Standards.
9.2.4
The frequency of calibration is as determined from the manufacturer’s recommendations or from company experience with the instrument accuracy，
9.2.5
Pressure gauges used for hydrostatic, pneumatic or proof testing are calibrated against a deadweight tester or calibrated master/standard gauge at least once in every 6 months period.
9.2.6
Dead-weight tester or master/standard gauges are re-calibrated at a frequency of three years or as per recommendation of the gauges manufacturer, whichever is the lesser.
9.3
Calibration Records :
9.3.1
Each calibrated instrument is listed in Measuring Equipment List (Exhibit 9-1) maintained by the QC Engineer in the calibration file.
9.3.2
All equipment is identified with a calibration sticker which records the item serial number or shop identification mark, date of last calibration, initials of a person who performed the calibration and due date for the next calibration.
9.3.3
The QC Engineer makes calibration records, including those of subcontractors who perform NDE, Heat Treatment and mechanical testing machine, available for review.
9.4
Discrepant Equipment
9.4.1
When instruments are found out of calibration or damaged, the QC Engineer tags the item with “ REJECTED“ and “NOT TO BE USED” stickers and subsequently removes it from the work area and arranges for calibration or replacement.
9.4.2
All Code items checked with such discrepant instruments are nonconforming until the QC Engineer has verified that they meet all Code requirements, or they are re-tested with accurate instruments/standard gauges.
9.4.3
Traceability is provided from “Tool Room” issue records or by recorded serial numbers of Section 9 page 1 of 2
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instruments used in examination and test. 9.4.4
After removal of a calibrated instrument or pressure temperature gauges from a shop or field site it shall be immediately calibrated so as to verify that the gauges was in calibration status when last used at the shop or field site.
Section 9 page 2 of 2
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10
RECORD RETENTION
10.1
The QC Engineer collects all records described in this Manual at the completion of the job and reviews them for completeness, correctness and Code compliance before prepare the Manufacturer’s Data Report. The Manufacturer’s Data Book completed shall be send to the QC Section Manager for review and approval.
10.2
Manufacturer's Data Reports, after certification in ink by the QC Section Manager and signed by the AI, are filed with the costumer or his designated Agent, purchaser, pressure vessel manufacturer, jurisdiction and AI as required by the Code.
10.3
Partial Data Report shall be issued in duplicate to the customer and a copy to AI on request.
10.4
Records shall be maintained as specified below. For ASME Section VIII Div.1 items and parts 1) 2) 3)
Radiographs films: Until Data Report signed by the Authorized Inspector. Data reports: Five years or retained by the National Board if registered. The following record shall be maintained for a period of at least 3 years : • Manufacturer’s partial Data Report • Manufacturing drawings • Design calculations • Material Test and report and/or material certifications • Welding Procedure Specification and Procedure Qualification Record • Welder Qualification Records • RT and UT reports • Inspection and Test Plan • Heat Treatment record and test results • Post weld heat treatment records • Nonconformance’s and dispositions • Hydrostatic test record
For ASME Section VIII Division 2, The Manufacturer shall maintain a file for three (3) years after stamping of the vessel and furnish to the user and, upon request, to the inspector the reports and records shown below. a. b. c. d. e. f. g. h. i. j. k. l.
User’s Design Specification Manufacturer’s Design Report Manufacturer’s Data Report Manufacturer’s Construction Record and Partial Data Reports Tabulated list of all material used for fabrication with Material Certification and Material Test Reports and a record of any repairs along with the repair procedures. Fabrication information including all heat treatment requirements, forming and rolling procedure when prepared, an inspection and test plan identifying all inspection points required by the user and signed inspection report. List of any subcontracted services or parts, if applicable. WPS, PQR, weld map and welder or welding operator qualification test results. Record of all heat treatments including post weld heat treatment. Results of production test plate, if applicable. NDE Procedures, records of procedure qualification and records of personnel demonstration. All reports stating the results of inspection, nondestructive examination and testing Section 10 page 1 of 2
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including radiographic examination, ultrasonic examination, magnetic particle examination, liquid dye penetrant examination, and hardness test. m. All non-conformance reports including resolution and a detailed description of any repairs including repair procedures, a sketch, photo or drawing indicating the location and size of the repaired area. n. Charts or other records of required hydrostatic, pneumatic, or other test. Test logs shall include the test date, testing fluid, duration of the test, temperature of the test fluid, and test pressure. o. Dimensional drawings of the as-built condition.
Section 10 page 2 of 2
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11
FIELD ASSEMBLY
11.1
Scope
11.1.1
This section describes the procedure used to ensure the proper field assembling of Code item in accordance with the applicable sections of this Manual and the referenced applicable sections of ASME Section VIII Division 1 & 2.
11.2
Responsibility:
1 1.2.1 The Fabrication Engineer shall retain the responsibility as describes in section 1 of this Manual. 11.3
Drawings, Design Calculations and Specifications:
11.3.1
The Engineering Manager shall be responsible to submit the Drawing to the Quality Control Manager for review as per section 2.
11.3.2
All “RELEASED FOR ASME CODE CONSTRUCTION” documents are transmitted，，，，，，，，to Fabrication Engineer as per Section 2. Documents distributions at site is controlled by Distribution Sheet (Exhibit 2-1).
11.3.3
The revised Drawings and Material List distributed to the Quality Control Manager and Fabrication Manager following their review are made and approved by the Engineering Manager and shall be reissued to the Fabrication Engineer.
11.3.4
The QC Manager is responsible to provide the Authorized Inspector with all Drawings, Design Calculations “Owner/User Design Specification”, Manufacturer's Design Report”, Material List through QC Inspector for his review. The Authorized Inspector shall include his inspection points, initial and date the ITP (Exhibit 4-IA) prior to the start of the field assembly.
11.3.5
Any question raise by the Al in conjunction with the Drawings or Design Calculations shall be resolved prior to the start of field assembly.
11.4
Material Control
11.4.1 ， All requisition for the materials including welding consumable shall be prepared as per section 3.1.1, 3.1.2, 3.1.3, 3.1.4 and 3.2. 11.4.2
Purchasing of pressure retaining material shall be performed from the shop only.
11.4.3
All free issued material shall be received and inspected by the Quality Control Inspector for Code Compliance. The Quality Control Inspector shall ensure that any sub assembly part supplied to the field by subcontracted certificate holder shops shall be provided with Partial Data Report and shall be attached to the final Manufacturer's Data Report.
11.4.4 ， All shop material required for field work shall be field receipt inspected, for shipment damage and loss of traceability marking by the field QC inspector with the help of the Store Keeper.
11.5
Field Examination and inspection Program Section 11 page 1 of 3
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
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11.5.1
Erection or assembling of site fabricated items shall be controlled by the FSS and ITP. The Fabrication Sequence Sheet shall be prepared by the Fabrication Engineer whilst the ITP prepared by the QC Engineer. Both FSS and ITP along with approved drawings to be forwarded to the field Fabrication Engineer and QC Inspector. The field site Fabrication Engineer and QC Inspector initial and date their acceptance on the lTP. The QC Inspector shall forward the AFC drawing, FSS, ITP and other required document to the AI for his review to allow him to designate his inspection points prior o commence with the field site assembly.
11.5.2
Field test and examination of pressure retaining part shall be performed as per Section 4.3 (Examination and Inspection Program). The Quality Control Inspector shall inspect at the various inspection stages as determined. The Authorized Inspector shall make his required inspection points as indicated on the ITP.
11.6
Control and Correction of Nonconformities
11.6.1
All Nonconformities shall be handled as per section 5.
11.6.2
The Quality Control inspector shall be responsible for maintaining any Nonconformance Report (Exhibit 5-1) and informing the Quality Control Engineer and Manager of any nonconformities for disposition and resolution purposes purpose. The AI concurrence shall be sought.
11.7
Welding Control
11.7.1
Welder not in the employee of the company may be used to construct Code item in accordance with the applicable code section, provided all of the following conditions are met. a) b)
AII Code construction shall be the responsibility of the company. An welding shall be performed in accordance with the ’Welding Procedure Specification ， which have been qualified by the company in accordance with the requirements of Section Ix and the related construction code section. c) An welders shall be qualified by the company in accordance with the requirements ， ， of Section IX. d) The Welding Engineer has the complete and excusive administrative and technical supervision of all Welders and Welding Operators and has the authorization to assign/remove Welders and Welding Operator at his discretion without involvement of any organization. e)，The Welding Engineer shall have evidence that this program has been accepted by the field A.I.A. which provides the inspection services. f) The originals of the Welder Qualification Test Record are maintained by the Welding Engineer who shall provide the Authorized Inspector copies of WPS, PQR, Welder Qualification Record of welders or welding operator prior to assigning on Code construction. g) The Quality Control Inspector shall be responsible for verifying that all the fitters and welders on field site are qualified and conversant with the displayed WPS. h) The welding engineer has the authority to assign welder identification symbol on each qualified welder
11.8
Non Destructive Examination (NDE)
11.8.1
All field NDE shall be performed in accordance with section 7. Section 11 page 2 of 3
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
Edition. : Revision No. : Section :
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1 1.8.2 A11 report of NDE shall be reviewed and accepted by the Quality Control Inspector ，，，，before submitting to the Authorized Inspector for his review for Code compliance. 11.9
Hydrostatic Testing
11.9.1
Hydrostatic Testing and any additional NDE shall be in accordance with Section 4 and 7 respectively.
11.10
Heat Treatment
11.10.1 Approved Heat Treatment procedures shall be issued by the Welding Engineer and forward to the field Site QC Inspector and it shall be performed in accordance with Section 8 of this manual. The field site heat treatment unless otherwise mentioned should be conducted by using electric resistance element for localized heat treatment by a subcontractor PWHT firm. The subcontractor heat treatment procedures, facilities, equipment shall be reviewed and accepted by the QC Manager. 1.11
Calibration of Measurement and Test Equipment
11.11.1 Calibration of Measurement and Test Equipment shall be performed in accordance，，，，，，，with Section 9. The Quality Control Inspector shall be responsible for ensuring that all equipment are calibrated and range is suitable for the intended operation. 11.12
Code Stamping and Data Reports
11.12.1 Upon Completion of the construction of Code item, the Quality Control Manager shall certify the Manufacturer's Data Report prior to submit to the field Authorized Inspector for his review, signature and date. The Authorized Inspector shall witness the application of the Code Stamp directly to a Code item or to the nameplate attached to the item. 11.1.2
The Quality Control Engineer shall have total control and custody of the Code Symbol Stamp to the Quality Control Inspector, who shall have custody and total control at，，，，neld site and shall return it to the Quality Control Engineer immediately upon completion of the field site work.
11.11.3 All records shall be controlled by the Quality control Inspector and returned to the ，，，，Quality Control Department for retention as per section 10.
Section 11 page 3 of 3
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
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12
AUTHORIZED INSPECTOR
12.1
The Al is Inspector required by the Code, employed by an ASME Accredited Authorized Inspection Agency (AIA of record ) with whom the Company has a contract to perform the inspection services required by the Code.
12.2，，For those contracts which require the use of different AIA other than the AIA of record is a special requirement, their services for Code inspection may be provided only after signing a separate contract for such work with the second AIA. 12.3
The QC Manager arranges for the Al and AIS to have free access to the shop and field sites include the sub-contractor work/shop whenever Code work is being executed and to such parts of all plants that are concerned with the construction and supply of materials for the Code item, when those above inspectors request to do so.
12.4
lf requested by the AI, his inspection points shall be inserted on the ITP for those operations he may wish to witness or inspect before the work proceeds.
12,5
The QC Manager at the shop, or the QC Inspector at the field site, arc the Company representative in assisting the AI.
12.6 ， ， The Al shall be provided with access to all drawings, calculations, specifications, procedures. Fabrication Sequence Sheets, repair written proposals, test and examination results, inspection records and any other documents required as to allow him to perform his duties as appropriate, 12.7
All Nonconformance Reports for Code non-conformities and propose disposition and /or resolution are to be submitted to the AI or his review and acceptance.
12.8
The QC Manager or QC Inspector will notify the Al sufficiently in advance of all tests and examinations so that he could present himself to witness the test.
12.9
The final records, together with the completed ASME Manufacturer's Data Report ，，，，signed by the QC Manager or Design Engineer, are submitted to the Al for his authorization to apply the Code Symbol stamp and sign the MDR.
12.10
A current copy of the QC Manual shall be made available for use by the Al at the shop as well as at the field site.
12.11
The Al will review and accept an changes to the QC Manual which affect the Code requirements, before they are issued to Manual Holders.
12.12
The QC Manager will assist the AI Supervisor during his required audits, and the AI whilst monitoring the QC system.
Section 12 page 1 of 1
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL 13
Edition. : Revision No. : Section :
2 1 13
LISTING OF EXHIBITS Exhibit
Title of Form
Page No.
0-1
QC Manual Distribution List
3
1
January 24, 2008
0-2
Log of Revision
4
1
January 24, 2008
0-3
Document Transmittal Advise
5
1
January 24, 2008
0-4
Code Review Record
6
1
January 24, 2008
2-1
Distribution Sheet
7
1
January 24, 2008
2-2
Construction Program
8
1
January 24, 2008
3-1
Material Requisition List
9
1
January 24, 2008
3-2
Purchase Requisition
10
1
January 24, 2008
3-3
Purchase Order Batam
11
1
January 24, 2008
3-4
Material/Receiving Report
12
1
January 24, 2008
3-5
reject/Hold/Accepted Tag
13
1
January 24, 2008
3-6
Material Identification and Traceability Record
14
1
January 24, 2008
3-7
Material Request Card
15
1
January 24, 2008
3-8
Material Return Slip
16
1
January 24, 2008
3-9
Material Inventory List
17
1
January 24, 2008
3-10
Cutting Plan
18
1
January 24, 2008
3-11
Material Control sheet
19
1
January 24, 2008
4-1(A)
Inspection and Test Plan
20
1
January 24, 2008
4-1(B)
Fabrication Sequence Sheet
21
1
January 24, 2008
4-2
Name Plate/Stamping Information
22
1
January 24, 2008
5-1
Nonconformance Report
23
1
January 24, 2008
5-2
Nonconformance Register
24
1
January 24, 2008
Exhibit
Title of Form
Page Section 13 page 1 of 30
Revision No.
Revision
Date
Date
P.T. TOYO KANETSU INDONESIA BATAM FABRICATION PLANT QUALITY CONTROL MANUAL
Edition. : Revision No. : Section : No.
2 1 13
No.
6-1
Approved Welder/Welding Operator Register
25
1
January 24, 2008
6-2
Monthly record Welder Log and Qualification
26
1
January 24, 2008
6-3
Daily Welding Consumable Report
27
1
January 24, 2008
7-1
NDE Examiner register
28
1
January 24, 2008
9-1
Measuring Equipment List
29
1
January 24, 2008
10-1
National Board Log
30
1
January 24, 2008
Approved by : QC Manager
Date : January 24, 2008
Accepted by : Authorized Inspector
Date : January 24, 2008
Section 13 page 2 of 30
