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RIBO INDUSTRIES PVT LTD Section No. QCM 1.0 Rev. No 02 COVER PAGE Date 02.07.2014 Page

RIBO INDUSTRIES PVT LTD

 

Section No.

QCM 1.0

Rev. No

02

COVER PAGE

Date

02.07.2014

Page

1 of 1

QUALITY CONTROL MANUAL (QCM)

 

For construction of Power Boilers, Boiler External Piping, Pressure Vessels and their parts in accordance with ASME Code Section-I,ASME B31.1, Section – VIII Division -1 at shop and field assembly at site controlled by shop to be stamped with ASME Certification Mark with Code designator “S” or “U” as appropriate.

 

WORK SHOP ADDRESS

 

RIBO INDUSTRIES PRIVATE LIMITED SF NO 397/1, 2 & 3 LAKSHMANANPATTI VILLAGE, TIRUCHI – PUDUKOTTAI MAIN ROAD, MANDAIYUR PUDUKOTTAI DIST. TAMILNADU - 622 515, INDIA.

 
 

REGISTERED OFFICE

 

RIBO INDUSTRIES PRIVATE LIMTED

 

‘JUMAN CENTER’ PROMENADE ROAD CANTONMENT THIRUCHIRAPALLI – 620001

 

TAMILNADU

 

INDIA Phone : + 91 431 2402112 Web : www.ribo.in

 

Copy No :

Issued to :

 

Issue Date:

 

CONTROLLED COPY

UNCONTROLLED COPY

 
   
RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Table of Contents Section No. QCM 2.0 Rev.No: 02

RIBO INDUSTRIES PVT LTD

 

QUALITY CONTROL MANUAL

 

Table of Contents

 

Section No. QCM 2.0

Rev.No:02

Date :02.07.2014

 

Page 1 of 1

 
 
 

Section

   

No. of

   

No

 

Description

Rev.No

pages

Date

QCM 1.0

Cover page

02

 
  • 01 02.07.2014

QCM 2.0

Table of Contents

 

02

 
  • 01 02.07.2014

QCM 3.0

Statement of Authority

 

02

 
  • 01 02.07.2014

QCM 4.0

Glossary of Terms

 

02

 
  • 03 02.07.2014

QCM 5.0

Organization Authority and Responsibility

02

 
  • 02 02.07.2014

QCM 6.0

Control of Manual

 

02

 
  • 02 02.07.2014

QCM 7.0

Drawings, Design Calculations and Specification Control

 

02

 
  • 03 02.07.2014

QCM 8.0

Material Control

 

02

 
  • 04 02.07.2014

QCM 9.0

Examination, Inspection and Testing Program

02

 
  • 05 02.07.2014

QCM 10.0

Correction of Non Conformities

 

02

 
  • 02 02.07.2014

QCM 11.0

Welding

02

 
  • 04 02.07.2014

QCM 12.0

Non Destructive Examination

 

02

 
  • 02 02.07.2014

QCM 13.0

Heat Treatment

 

02

 
  • 02 02.07.2014

QCM 14.0

Calibration of Measurement and Test Equipment

02

 
  • 02 02.07.2014

QCM 15.0

Records Retention

 

02

 
  • 02 02.07.2014

QCM 16.0

Site Activities

 

02

 
  • 07 02.07.2014

QCM 17.0

Authorized Inspection

 

02

 
  • 02 02.07.2014

QCM 18.0

Certifications

02

 
  • 01 02.07.2014

QCM 19.0

List of Exhibits

 

02

 
  • 02 02.07.2014

     

Prepared by

Approved by

Accepted by

Engineer Quality

Head Quality

Authorized Inspector

RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Statement of Authority Section No. QCM 3.0 Rev.No: 02

RIBO INDUSTRIES PVT LTD

   

QUALITY CONTROL MANUAL

Statement of Authority

Section No. QCM 3.0

Rev.No:02

Date :02.07.2014

Page 1 of 1

RIBO INDUSTRIES PVT LTD is engaged in the Construction of Boiler and Pressure Vessels. The management of Ribo Industries Pvt Ltd is committed to manufacture Power Boiler to ASME Section- I Boiler External Piping to ASME B31.1 and Pressure Vessels to ASME Section VIII Division-1 to be applied with ASME Certification Mark and the designators “S” for Boilers and Boiler External Piping and “U” for Pressure Vessels. The company also carries out Field Assembly of Code items at controlled sites whenever called for in the contract in accordance with the relevant Code and this Quality Control Manual.

This Quality Control Manual covers the system to be implemented for the manufacture of the Code items at our shop and also for the field assembly activities carried out at sites controlled by the shop. Head Quality has full support of management and is responsible for preparation, approval, issue and revisions to this Quality Control Manual.

Head Quality has authority and organizational freedom to identify quality problems and to initiate, recommend and provide solutions.

Head Quality shall have all the authority to stop the work which does not meet the Code and this Quality Control Manual requirement. In matters of disagreements, the same can be referred to the undersigned for resolution in line with the Code requirements and this Quality Control Manual.

The Personnel referred in the various Sections of this Quality Control Manual are responsible for implementation of their respective functional duties. They can however delegate the duty, but not the responsibility to suitably qualified and competent personnel.

Date: 02.07.2014

Chief Executive Officer

RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Glossary of Terms Section No. QCM 4.0 Rev.No: 02

RIBO INDUSTRIES PVT LTD

QUALITY CONTROL MANUAL

Glossary of Terms

Section No. QCM 4.0

Rev.No:02

Date :02.07.2014

Page 1 of 3

AIA

Authorized Inspection Agency

AI

Authorized Inspector

AIS

Authorized Inspector Supervisor

ASME

The American Society of Mechanical Engineers

ASTM

American Society of Testing Materials

Code

ASME Sec.I ASME Sec. VIII Div. 1, ASME B31.1, as applicable including referenced Codes and Standards

Code items

In general, term refer ring to a Power Boiler, Pressure Vessel, and Boiler External Piping or part there off constructed in accordance with the Code.

CEO

Chief Executive Officer

COC

Certificate Of Compliance

Data Report

Manufacturer’s Data Report/Manufacturer’s Partial Data

DCR

Report Design Change Request

DCN

Design Change Note

H

Hold point

HT

Heat Treatment

IMTE

Inspection Measurement and Test Equipment

ISO

International Standards Organization

ITP

Inspection Test Plan

RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Glossary of Terms Section No. QCM 4.0 Rev.No: 02
RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Glossary of Terms Section No. QCM 4.0 Rev.No: 02

RIBO INDUSTRIES PVT LTD

QUALITY CONTROL MANUAL

Glossary of Terms

Section No. QCM 4.0

Rev.No:02

Date :02.07.2014

Page 2 of 3

MANUAL

Quality Control Manual

 

MTR

Material Test Report

MD

Managing Director

MDR

Manufacturer’s Data Report

MIV

Material issue voucher

MRS

Material Requisition Slip

MRIR

Material Receipt cum Inspection Report

MPDR

Manufacturer’s Partial Data Report

MT

Magnetic Particle Test Report

NB Stamp

National Board Stamp

National Board

National Board of Boiler and Pressure vessel Inspectors, 1055, Crupper Avenue, Columbus, OH43230-1109, U.S.A.

NCR

Non Conformity Report

 

NDE

Non Destructive Examination

OPS

Operation Process Sheet

PQR

Procedure Qualification Record

PWHT

Post Weld Heat Treatment

RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Glossary of Terms Section No. QCM 4.0 Rev.No.: 02

RIBO INDUSTRIES PVT LTD

QUALITY CONTROL MANUAL

 

Glossary of Terms

Section No. QCM 4.0

Rev.No.:02

Date :02.07.2014

Page 3 of 3

PT

Liquid Penetrant Test

 

PVT LTD

Private Limited

QCM

Quality Control Manual

QC

Quality Control

RT

Radiographic Test

R

Review point

REV NO

Revision Number

RIBO

RIBO Industries Private Limited

TC

Test Certificate which also includes MTR and COC

TDC

Technical Delivery Condition

UT

Ultrasonic Test

WPS

Welding Procedure Specification

WPQR

Welders/Welding

Operator Performance Qualification

Record

W

Witness point

 
RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Glossary of Terms Section No. QCM 4.0 Rev.No.: 02
RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Organization, Authority and Responsibility Section No. QCM 5.0 Rev.No:02

RIBO INDUSTRIES PVT LTD

 

QUALITY CONTROL MANUAL

Organization, Authority and Responsibility

Section No. QCM 5.0

Rev.No:02

Date :02.07.2014

Page

1 of

2

5.0

SCOPE

This Section describes about Ribo Industries Private Limited Organization Chart for Shop and Site activities.

5.1

RESPONSIBILITIES

  • 5.1.1 Managing Director is responsible for overall management functions.

  • 5.1.2 Chief Executive Officer responsible for overall planning and monitoring the functionary departments such as Marketing, Design, Operations, Materials and Quality.

  • 5.1.3 The responsibility and authority of the other personnel shown on the Organization Chart have been described in various Sections of this Quality Control Manual.

RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Organization, Authority and Responsibility Section No. QCM 5.0 Rev.No:02
RIBO INDUSTRIES PVT LTD

RIBO INDUSTRIES PVT LTD

RIBO INDUSTRIES PVT LTD
RIBO INDUSTRIES PVT LTD
RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Control of Manual Section No. QCM 6.0 Rev.No :02

RIBO INDUSTRIES PVT LTD

QUALITY CONTROL MANUAL

Control of Manual

 

Section No. QCM 6.0

Rev.No:02

Date : 02.07.2014

Page

1 of 2

  • 6.0 SCOPE

This Section describes the procedure for controlling Quality Control Manual and other procedures to meet the Code requirements.

  • 6.1 RESPONSIBILITY Head Quality is responsible for approval, Issue and control of this Quality Control Manual.

  • 6.2 SYSTEM

    • 6.2.1 Engineer Quality shall prepare and revise Quality Control Manual, as required, which shall be approved by the Head Quality. Head Quality shall submit the Quality Control Manual and its revisions, if any to the Authorized inspector (AI) for his review and acceptance prior to releasing the same for Code activities. He shall maintain the original copy of the Quality Control Manual. Head Quality shall issue a controlled copy of Quality Control Manual to the AI at the Shop and Field sites, as applicable. The revised Quality Control Manual shall be approved by Head Quality and accepted by Authorized Inspector.

    • 6.2.2 The approval of Quality Control Manual by the Head Quality and acceptance by the AI shall be documented on the Table of Contents page. The old document shall be withdrawn from the user and destroyed by Head Quality.

    • 6.2.3 Head Quality is responsible for the controlled distribution of this QCM and its revisions, using QCM Distribution Register (Exhibit No: 1) which includes an acknowledgement of the recipient. The old document shall be withdrawn and distorted by Head Quality.

    • 6.2.4 Head Quality may de-control any copy of the QCM when no longer used for Code work.

    • 6.2.5 Head Quality may also issue uncontrolled copy as and when required to persons outside the Organization. Uncontrolled copies shall be current at the time of issue and may not be updated.

    • 6.2.6 Whenever any text in one Section undergoes a revision the entire Section, the Table of Contents and Cover Page also get revised.

    • 6.2.7 Should there be a revision in the Exhibits; the latest affected area shall be highlighted by Cloud. The List of Exhibits and Table of Contents and Cover Page shall be revised. The revision indicator shall appear only on forms and formats in the QCM and not forms and formats in use.

    • 6.2.8 The latest revision in Section text shall be highlighted in bold italic font. Previous revision indicators, if any shall revert to normal font. Master copy of revised sections due to change in the Quality Control Manual shall be retained by Head Quality as record of revision till next ASME joint review.

RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Control of Manual Section No. QCM 6.0 Rev.No. 02

RIBO INDUSTRIES PVT LTD

QUALITY CONTROL MANUAL

Control of Manual

 

Section No. QCM 6.0

Rev.No.02

Date : 02.07.2014

Page

2 of 2

  • 6.2.9 Quality Control Manual, Procedures and other related documents shall be reviewed within six months of issuance of new Code Edition and revised if required for compliance. Such review shall be carried out by Head Design, NDE Level III, Head Quality and Engineer Welding for their respective functions. The record of such review and recommendation shall be documented on the copies of “Summary of Changes” pages available in respective Code Sections. Head Quality shall review these records for changes noted and incorporate these by revising the Quality Control Manual, procedure etc. as required.

    • 6.2.10 The revision number on Section No. QCM 2.0, Table of Contents and Section no. QCM 1.0, Cover Page shall be revision status of the Quality Control Manual.

    • 6.2.11 The Master copy of the QCM which has the signature of approval by Head Quality and acceptance by the AI shall be marked as “Master Copy” in red in all pages and only photo copies shall be distributed as Controlled copy and Un-controlled copy.

    • 6.2.12 Head Quality shall maintain one copy of the superseded QCM for reference for a period offive years. All other superseded copies shall be destroyed.

RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Drawings, Design Calculations and Specifications Control Section No. QCM

RIBO INDUSTRIES PVT LTD

QUALITY CONTROL MANUAL

Drawings, Design Calculations and Specifications Control

Section No. QCM 7.0

Rev.No:02

Date :02.07.2014

Page

1 of 3

7.0 SCOPE

This Section describes the Procedure for preparation, verification, approval, issue, maintenance and revision of Design documents such as fabrication drawing, design calculation, Technical Delivery Condition and Material Requirement List Report for Code construction.

7.1

POLICY

7.1.1

Design activities shall be carried out to satisfy the requirements of Customer supplied data, specification and applicable Edition of the Code. Method of establishing Governing Code Editions and Cases for Code Items shall be in accordance with Appendix 43 of Section VIII Div. 1 and Appendix –VI of Section I.

7.1.2

Materials used for pressure parts shall be those permitted by Section VIII Division 1 for Pressure Vessels, Section I for Boilers and ASME B31.1 for Boiler external piping for which allowable stress values are specified in Section II part D / B31.1 as applicable.

7.1.3

Due consideration shall be given to the requirements of corrosion allowance, additional loadings, impact testing, inspection opening, Units of measurements, etc., as per the applicable Code requirements.

7.2

SYSTEM

7.2.1

On receipt of customer Purchase Order, Head Marketing shall allocate Job Order Number along with Manufacturer’s Serial Number and Purchase Order copy will be distributed to Head Design, Head Material, Head Operations, Head Quality and Engineer Welding. The acknowledgment of the same will be maintained at Marketing through Order Distribution Sheet (Exhibit No. 2). This Job Order Number shall be used as product identification and shall be indicated in all documents.

7.2.2

On receipt of the Job Order Number, customer Purchase Order and customer Technical Specification, if any, Head Design shall review customer supplied design data for adequacy of Code Compliance including PG-22 loadings for ASME Section I and UG- 22 loading for ASME Section VIII Div.1 requirements. Any clarification needs to be taken up with Customer through Head Marketing by Head Design. Engineer Design shall prepare drawings, design calculations, Material Requirement List Report (Exhibit No 3) and Technical Delivery Condition (TDC) ( Exhibit No. 4) wherever required. Head Design shall check and approve all the design documents ( Drawings, Calculations, Material Requirement List Report and TDC).Initially the drawing will be released with zero revision subsequently whenever any drawing is revised it shall be released with revision identification as 1, 2,3 etc.,

RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Drawings, Design Calculations and Specifications Control Section No. QCM
RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Drawings, Design Calculations and Specifications Control Section No. QCM

RIBO INDUSTRIES PVT LTD

QUALITY CONTROL MANUAL

Drawings, Design Calculations and Specifications Control

Section No. QCM 7.0

Rev.No:02

Date :02.07.2014

Page

2 of 3

  • 7.2.3 In case the drawings and design calculation are furnished by the purchaser, Head Design shall review them for Code compliance and adequacy for Construction and ensure that the relevant Code requirements are complied with before taking up for manufacturing. Any discrepancy shall be resolved with the customer through Head Marketing.

  • 7.2.4 Head Design shall submit design documents to the AI for his review prior to start of manufacturing activities .The review done by the AI does not relieve manufacturer of its responsibilities of ensuring accuracy in drawings and calculations and compliance with the Code, Edition and User’s Specification. Any clarification related to the design sought by the AI shall be resolved satisfactorily. Head Design shall forward approved Material Requirement List Report along with applicable TDC’S to Engineer Project for Material Indent.

    • 7.2.5 After the approval of design documents, Head Design shall issue Drawings to Head Planning with Document Transmittal (Exhibit No. 5).

    • 7.2.6 On receipt of drawings and all document, Engineer Planning shall make entry in Document Distribution(Exhibit No.6) and distribute to Head Operations, Engineer Production, Engineer Welding , Head Quality, Engineer Project and obtain acknowledgement.

    • 7.2.7 Where there is a need for changes in the drawing, including material substitutions. Head Planning will take the help of Engineer Project and shall raise Design Change Request (DCR) (Exhibit No.7) and forward the same to Head Design through Document Transmittal. Head Design shall review the proposed DCR, if acceptable, He shall prepare Design Change Note (DCN) ( Exhibit No. 8) with respect to existing and proposed and release to Head Planning. Engineer planning shall arrange to distribute the DCN to the concerned departments and mark the DCN number with date on the drawing for reference. The maximum number of DCN’s per drawing shall be limited to 5. In case of further requirement drawings will be revised and released in the next revision.

    • 7.2.8 DCN may be directly generated by Head Design, based on any change in Customer specification / design conditions. All DCNs shall be submitted to the AI for his review.

    • 7.2.9 If any of the design data/documents are revised, Head Design shall review the changes and verify whether the revisions have an effect on the design calculation, revise them as appropriate and obtain approval. All such review shall be documented. When revision in the drawing does not affect the design calculations, the design calculations shall be updated with drawing revision number by Head Design with the Note that “This revision of this drawing does not affect the design calculations”.

RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Drawings, Design Calculations and Specifications Control Section No. QCM

RIBO INDUSTRIES PVT LTD

QUALITY CONTROL MANUAL

Drawings, Design Calculations and Specifications Control

Section No. QCM 7.0

Rev.No:02

Date :02.07.2014

Page

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  • 7.2.10 The AI shall have access to all calculation, design data drawings and DCNs for his review. Revisions to the design documents shall be subjected to the same procedure and control as the original documents.

  • 7.2.11 Engineer Planning shall remove the obsolete copies promptly from the work spot and destroy them unless it is required for reference. In that case the obsolete drawings shall be marked as “Superseded”. Distribution of Design document after revision shall be the same as outlined in para 7.2.5, 7.2.6 & 7.2.7 of this Section.

  • 7.2.12 Currently computer program is not used for the design calculations. If used in future, a procedure shall be prepared by Head Design covering approval, validation and revalidation with Code Edition. All such record of validation shall be made available to the AI for review.

  • 7.2.13 If “Parts” are constructed to the drawings supplied by the Customer, Construction shall be in accordance with the applicable Code with Edition as specified by the Customer. It shall be recorded in the remarks column of the Manufacturer’s Partial Data Report that the design responsibility is out side the scope of RIBO.

RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Material Control Section No. QCM 8.0 Rev.No: 02 Date

RIBO INDUSTRIES PVT LTD

QUALITY CONTROL MANUAL

Material Control

 

Section No. QCM 8.0

Rev.No:02

Date :02.07.2014

Page

1 of 4

8.0 SCOPE

This Section deals with procurement, receipt, inspection, identification, storage, and issue of materials and components to ensure that the indented material is used for Code construction. (Except welding consumables)

8.1 POLICY

All Materials procured shall be strictly in accordance with the Code and TDC (wherever applicable) provided by Head Design.

8.2

SYSTEM

  • 8.2.1 Engineer Project shall prepare Material Indent (Exhibit No. 9) based on Material Requirement List Report and Technical Delivery Condition received from Head Design. Engineer Project forward to Material Indent along with applicable TDC to Head Material for verification of available of material in the stock.

  • 8.2.2 Stores Officer verify the stock, If material is available, he shall arrange for examination of the same by providing the Material Test Certificates and MRIR (Exhibit No:10) (Materials Receipt cum inspection Report) and material identifications to Engineer Quality, who shall verify the documents shown above along with the drawing and TDC and examine the materials. If found satisfactory, the material shall be accepted through Stock Transfer cum Inspection Report (Exhibit No: 11) prepared by Stores Officer, checked by Engineer Quality and approved by Head Quality. If the material requires upgrading to ASME requirement, Engineer Quality shall prepare NCR and process them as per Section No QCM 10.0of this Manual dealing with Correction of Non conformity.

  • 8.2.3 If materials are not available in stock, Stores Officer shall forward the Material Indents along with applicable TDC to Head Material for procurement.

  • 8.2.4 Head Material shall raise Supply Purchase Order (Exhibit No.12) for procurement of the material. The Supply Purchase Order and TDC (wherever applicable) shall be distributed to Engineer Project and Stores Officer for the purpose of verification at the receiving Inspection stage.

  • 8.2.5 If the indented material is not available in the market, a proposal for alternate material shall be submitted to Head Design through Engineer Project for his approval through DCR as per paragraph 7.2.7 and 7.2.8. of Section No QCM 7.0 of this Manual dealing with Drawings, Design calculations and Specification control.

RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Material Control Section No. QCM 8.0 Rev.No: 02 Date

RIBO INDUSTRIES PVT LTD

QUALITY CONTROL MANUAL

Material Control

 

Section No. QCM 8.0

Rev.No:02

Date :02.07.2014

Page

2 of 4

  • 8.2.6 On receipt of the materials, Stores Officer shall offer the material to Engineer Quality for Inward Inspection clearance along with MRIR, Material Test Certificate, Supply Purchase Order and TDC. (wherever applicable)

  • 8.2.7 Engineer Quality shall carryout examination of the material/parts with respect to Supply Purchase Order and TDC (wherever applicable). The above examination of material/parts shall include as a minimum the following.

  • 8.2.8 Attributes of the material to be checked by the Engineer Quality includes but not limited to:

    • a) Review of Material Test Report (for conformity with Code and TDC requirements).

    • b) Verification of Original Markings on material and

part.

.

  • c) Visual and dimensional inspection including thickness measurement wherever applicable.

  • d) Physical distortion / damage to item or packing.

  • e) Contents of Manufacturer’s Partial Data Reports for “parts” supplied by ASME accredited manufacturers.

  • f) Record of measuring instruments used during dimensional measurement on the MRIR

  • 8.2.9 If the material /items meet the requirements, the Engineer Quality shall sign the MRIR.

    • 8.2.10 If the Material/parts are not acceptable, the same shall be reported on Non conformity Report(NCR) (Exhibit No.13) and shall be dealt as per Section No. QCM 10.0 of this Manual dealing with Correction of Non conformities. NCR number shall be indicated on the MRIR.

    • 8.2.11 If ASTM material is received, with Edition different from the latest adopted Edition , EngineerQualityshall verify the same against Table II – 200 – 1 of ASME Section II for other acceptable Edition as permitted and certify with evidence acceptable to the AI. If the material is not acceptable, and for other non-ASTM material Engineer Quality shall raise a Non-Conformity Report and resolve as described in QCM 10.0 of this Quality Control Manual dealing with Correction of Non conformities. ASTM / Non ASTM materials if used shall be re-certified to required Edition of ASME Specification and corresponding material shall be marked with ASME specification in the presence of Engineer Quality.

    • 8.2.12 If ASME materials certified to Year of Edition that are different than the required Edition as per drawing, Engineer Quality shall review the Material Test Report to the required Edition of the Material Specification , If acceptable same shall be certified on the Material Test Certificates.

    • 8.2.13 Any additional material testing to be conducted for acceptance /upgrading the material, the same shall be witnessed by Head Quality and certified by him and test report attached to the MRIR.

RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Material Control Section No. QCM 8.0 Rev.No: 02 Date

RIBO INDUSTRIES PVT LTD

QUALITY CONTROL MANUAL

Material Control

 

Section No. QCM 8.0

Rev.No:02

Date :02.07.2014

Page

3 of 4

  • 8.2.14 MRIR shall be offered to the AI for his review and acceptance. Fabricated parts when received with Manufactures Partial Data Report shall be examined by the Head Quality for compliance with the Code and Addenda Requirements. Fabricated parts with Manufacture’s Partial Data Report shall be offered to the AI for his verification prior to further processing.

  • 8.2.15 Stores Officer shall store the material with proper identification in the designated areas in a suitable manner to prevent from deterioration. Non conforming materials shall be identified and segregated in accordance with Section No. QCM 10.0 of this Quality Control Manual dealing with Correction of Non conformities.

  • 8.2.16 Based on Material Requisition Slip (Exhibit No.15) prepared by Engineer Production and approved by Head Operations along with cutting plan prepared by Engineer Planning and approved by Head Planning, Stores Officer shall prepare Materials Issue Voucher (MIV) (Exhibit No. 14) and issue the material after Inspection by Engineer Quality and obtain signature of Engineer Production.

  • 8.2.17 After receipt of materials from Stores Officer, Engineer Production shall offer the material to Engineer Quality for examination. Engineer Quality shall inspect the correctness of materials for Code compliance with respect to the Job order Number, drawing and record the identification details in Material Identification Report (Exhibit No.16).

  • 8.2.18 Engineer Quality shall ensure that one completed set of original identification markings as required by the material specification are available on all material used for pressure parts. If these markings are likely to be removed due to some operation like cutting and machining, the completed set of marking as required by specification shall be transferred along with drawing number and part number in the presence of Engineer Quality prior to such cutting or machining operation. After ensuring accurate transfer of markings, Engineer Quality shall apply his RIBO QC Stamp near the transferred markings. If the transfer of total marking is not practicable on small parts, the coded marking traceable to original identification may be applied in a manner acceptable to the AI as described in procedure.

  • 8.2.19 Material identity shall be maintained throughout by hard stamping/ engraving. Hard stamping shall not be applied when service conditions prohibits or when thickness of ferrous materials less than 6mm and non ferrous materials less than 13mm thickness. In this case marking shall be done by etching, engraving or paint marking.

RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Material Control Section No. QCM 8.0 Rev.No: 02 Date

RIBO INDUSTRIES PVT LTD

QUALITY CONTROL MANUAL

Material Control

 

Section No. QCM 8.0

Rev.No:02

Date :02.07.2014

Page

4 of 4

  • 8.2.20 Material supplied by Customer for Code construction shall be examined in the manner described above for Compliance. Any discrepancy shall be resolved with Customer with in the Code requirements.

  • 8.2.21 Activities such as rolling, forming, heat treatment testing etc. where sub-contracted, a Work Order(Exhibit No.35) with required specification shall be issued by Head Planning .

  • 8.2.22 Material delivered to subcontractor for rolling and forming shall be identified by stamping with Job Order Number and marking as per material specification to permit traceability to Material Test Report in the presence of Engineer Quality. This shall be identified in the Work Order to the subcontractor.

  • 8.2.23 When the boiler or pressure vessel heads and other pressure boundary parts are cold formed by others, the required certification for the part shall indicate whether or not the part has been heat treated.

RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Examination, Inspection and Testing Program Section No. QCM 9.0

RIBO INDUSTRIES PVT LTD

QUALITY CONTROL MANUAL

Examination, Inspection and Testing Program

Section No. QCM 9.0

Rev. No:02

Date :02.07.2014

Page

1 of 5

  • 9.0 SCOPE

This Section deals with examination, Inspection and Testing Program requirements during construction of Code item.

  • 9.1 POLICY

All examination inspection and testing during construction of Code item shall be in accordance with Code and this Manual.

  • 9.2 SYSTEM

    • 9.2.1 All pressure vessels, boilers and their parts shall be fabricated in accordance with requirements of the applicable ASME Code and this Quality Control Manual.

    • 9.2.2 Head Quality is responsible for preparation and approval of the Inspection and Test Plan (ITP)( Exhibit No:17) based on the drawing, customers specification and Code requirement indicating the Examination / Inspection Stages, Characteristic to be checked, Reference Standard, Acceptance criteria, Format of record and Provision for Identifying the AI Inspection Hold/Witness/Review Points. Head Quality shall submit the Inspection and Test Plan to the AI for indicating his Hold/Witness and Review points.

    • 9.2.3 For vessels where access opening is not provided due to size constraints, internal inspection by the AI shall be arranged before setting up of final closing of the vessel, an inspection stage shall be identified as a Hold point suitably in the Inspection and Test Plan.

    • 9.2.4 Head Quality shall forward the copy of Inspection and Test Plan to Head Planning through Document Transmittal.

    • 9.2.5 Using drawing and ITP, Engineer Welding shall prepare and approve Applicable WPS List

(ExhibitNo.18) indicating Joint No and WPS Number. Engineer Welding shall submit the Applicable WPS List to the AI for his review. After review by the AI, Engineer Welding shall forward copy of Applicable WPS List to Head Planning through Document Transmittal.

  • 9.2.6 Based on the Inspection and Test Plan, Drawing and Applicable WPS List, Engineer Planning shall prepare Operation Process Sheet ( Exhibit No:19) listing the all the stages of operation during fabrication and transferring the AI Hold, Witness, Review Points. Operation Process Sheet shall indicate the relevant manufacturing procedures, WPS Number, provision for welder Identification Number, Record reference of examination / Inspection stages for Engineer Quality and the AI as per the Inspection and Test Plan.

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  • 9.2.8 Head Planning shall issue Operation Process Sheet to Engineer Production through Document Distribution.

  • 9.2.9 For execution of the job, Engineer Production shall maintain the Operation Process Sheet and obtain the clearance from the Engineer Quality during various stages as indicated in the Operation Process Sheet.

    • 9.2.10 Engineer Quality is responsible for offering required inspection stages to the AI with adequate advance notice. The AI shall signify his acceptance by signing on the Operation Process Sheet.

    • 9.2.11 Whenever the drawings are revised, Inspection and Test Plan, Applicable WPS List and Operation Process Sheet shall be reviewed for any changes and the same shall be revised accordingly. If there is no change, the same shall be documented on the respective document by Head Quality, Engineer Welding and Head Planning respectively.

    • 9.2.12 Revision to the Inspection Test Plan, Applicable WPS List , Operation Process Sheet require the same procedure and review and acceptance as for the first issue.

    • 9.2.13 The Performance of Inspections shall be documented with Signatures with date on the Operation Process Sheet by Engineer Quality and the AI.

    • 9.2.14 All the records of the inspection and Stage Inspection Reports (Exhibit no.38) as referenced in the Operation Process Sheet shall be prepared progressively by Engineer Quality and made available to the AI for review.

9.3 Inspection Points

  • 9.3.1 Hold Points are designated by “H” on the Inspection and Test Plan and Operation Process Sheet. These are Operations that shall not be by passed and require advance notification by the Head Quality for the AI’s Inspection and acceptance before proceeding further.

  • 9.3.2 Witness Points are designated by “W” on the Inspection and Test Plan and Operation Process Sheet shall be offered to the AI with adequate notification giving the opportunity to witness and verify on activity. If the AI is unable to witness the Inspection activities, the fabrication operation can be proceed with prior permission from the AI. The waived witness points shall be documented on the Operation Process Sheet and records shall be available for the AI’s review on his next visit.

  • 9.3.3 Review Points designated by “R” on the Inspection and Test Plan and Operation Process Sheet and are referring to review of documents.

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9.4Examination and Inspection during fabrication

  • 9.4.1 Engineer Production shall sign of the Operation Process Sheet on completion of the individual stages and offer to Engineer Quality for examination at the designated stages. Engineer Quality shall carryout examination of the designate stage if satisfactory, he shall sign of the Operation Process Sheet with date, if there is stage Non Destructive Examination, Engineer Production shall send a Non Destructive Examination Requisition Slip through Engineer Quality for carrying out NDE as per the Drawing and Operation Process Sheet requirements.

  • 9.4.2 Engineer Quality shall also record reference of the Inspection Report / NDE Report/ Test Reports in the Operation Process Sheet.

  • 9.4.3 Head Quality shall inform the AI with sufficient notice to enable him to carry out his inspection at the identified stages and sign off in the Operation Process Sheet to record his acceptance.

  • 9.4.4 All Welding shall be carried out in accordance with the approved welding procedure specification by qualified welders as per Section No. QCM 10.0 dealing with Welding.

9.5PRESSURE TEST

  • 9.5.1 Prior to the pressure test, Head Quality shall ensure all examinations and inspections, NDE, Heat treatment if required shall have been performed and Non Conformities if any shall have been closed out and shall be referenced in the Operation Process Sheet.

  • 9.5.2 Engineer Production shall carryout the pressure test as per procedure acceptable to the AI. Head Quality shall inform the AI in advance for witnessing the pressure test.

  • 9.5.3 Any Non Conformities observed during fabrication, examination, Inspection and Testing shall be handled as per Section No. QCM10.0 dealing with Correction of Non Conformities.

  • 9.5.4 Based on final dimensional reports given by Engineer Quality through Engineer Project “As- Built” drawings for the finished Code item shall be prepared by Engineer Design and reviewed and approved by Head Design before application of ASME Certification mark. Copies of these drawings shall be filed in Manufacture Data Dossier.

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  • 9.5.5 Head Quality shall keep the ASME Certification Mark and National Board Mark under his custody. He shall verify the satisfactory completion of all stipulated examination, inspection and testing of the Code item before the application of Certification Mark on the Name plate/Direct stamping, as applicable. He shall verify the correctness of the Nameplate/ Direct stamping (Exhibit Nos.20,22,22A to 26) before the application of the ASME Certification Mark which shall be arranged in the presence of the AI.

  • 9.5.6 Engineer Quality shall prepare the Manufactures Data Report (MDR) / Manufactures Partial Data Report (MPDR)based on “As Built” Drawings, Inspection Records. Head Quality shall certify the MDR/MPDR and submit to the AI for his signature.

  • 9.5.7 Copies of completed MDR along with applicable MPDR attached, if any, shall be distributed by Head Quality to the purchaser, the Authorized Inspector, appropriate enforcement authority (if so required) in the jurisdiction in which vessel is to be installed and retaining a copy for record in line with Section No. QCM 15.0 of this Manual dealing with Records Retention.

  • 9.5.8 After completion the MPDR will be distributed for the Code parts in duplicate to the Manufacturer of the completed power boiler or pressure vessel.

    • 9.6 NATIONAL BOARD REGISTRATION

      • 9.6.1 Code items which require registration with the National Board of Boiler and Pressure Vessels Inspectors (National Board) shall be assigned with the National Board number by Head Quality shall maintain a National Board Number Log Register (Exhibit No. 27) of registered Code items which shall contain

        • a) Entry Serial No,

        • b) Manufacturer’s Serial number

        • c) National Board Number

        • d) Date of allotment of NB number,

        • e) Description of the item,

        • f) Installation location (If known)

        • g) Signature date on MDR/MPDR by the AI

        • h) Date of posting MDR/MPDR to NB for Registration

        • i) Head Quality signature

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  • 9.6.2 The National Board number shall be assigned starting with 1 with out skips or gaps of unused numbers or duplication of numbers. No prefixes or suffixes, either alphabetical or numerical shall be used with NB number.

  • 9.6.3 National Board numbers shall be issued after the completion of the Pressure Test. In the event of an item not being pressure tested in the shop; the National Board Number shall be issued at the time of certification of MDR/MPDR.

  • 9.6.4 Head Quality is responsible for the control and issuance of National Board numbers. He shall keep the National Board Mark under his custody. National Board Mark shall be applied with the National Board Number for items requiring National Board registration.

  • 9.6.5 Head Quality shall forward original MDR and MPDR with in 30 days of certification by the AI to “National Board of Boiler and Pressure vessel Inspectors, 1055, Crupper Avenue, Columbus, OH43230-1109, and U.S.A.

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RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Correction of Non Conformity Section No. QCM 10.0 Rev.No:

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QUALITY CONTROL MANUAL

 

Correction of Non Conformity

   

Section No. QCM 10.0

Rev.No:02

 

Date :02.07.2014

   

Page

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  • 10.0 SCOPE

 
 

This

Section

describes

the

identification,

segregation,

correction

and

disposition

of

Non

Conformities.

 
  • 10.1 POLICY

 
  • 10.1.1 A Non Conformity is any condition which does not comply with the applicable rules of the Code, Quality Control Manual, Procedures or other specified requirements.

10.1.2. Non Conformities must be corrected before the completed Code items can be considered to comply with the Code.

  • 10.1.3 Head Quality is responsible for final disposition of the Non conformities.

  • 10.1.4 Repair of defects in welded joint detected by Non Destructive Examination/Visual Examination need not be reported through Non Conformance Report (NCR)(Exhibit No.13), but shall be recorded on NDE reports/Inspection reports. The repairs shall be carried out using qualified procedures & personnel after acceptance by the AI and documented in the respective OPS/inspection Report/NDE report.

  • 10.1.5 In case of repairs in materials/ Code items, prior concurrence of the AI shall be obtained for the proposed method and extent of repair.

10.2

SYSTEM

  • 10.2.1 Non conformance when noticed shall be handled as per procedure given below

  • 10.2.2 Engineer Quality shall raise NCR.

  • 10.2.3 Engineer Quality shall identify the Non Conforming materials / Code items by affixing “HOLD ”tag and marking in red ink and segregate them (wherever possible). He shall also ensure that no further processing is done until the NCR is finally dispositioned.

  • 10.2.4 Based on the nature of the Non conformity, Head Quality may give the acceptance on proposed correction or If the proposed action involves design justification or substitution of material, he shall forward the same to Head Design for his review and corrective action.

  • 10.2.5 Head Design shall provide the comments on proposed corrective action and when this proposed corrective action Code justification, he shall prepare necessary documents and present for the AI’s review.

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  • 10.2.6 When resolution of Non-Conformity has bearing on the Code requirement, the same shall be submitted to the Authorized Inspector for his review by Head Quality prior to taking corrective action.

  • 10.2.7 Based on the comment, the AI acceptance, corrective action shall be carried out by Engineer Production Head Material or the concerned personnel and the corrective action shall be recorded on NCR by Engineer Quality.

  • 10.2.8 If rework /repair is recommended, a supplementary Inspection and Test Plan/Operation Process Sheet shall be prepared, if required, to specify additional examination/inspection stages in the same manner as per Section No QCM 9.0 of this Manual dealing with Examination, Inspection and Testing Program.

  • 10.2.9 After the rework/repair, the item shall be examined by Engineer Quality and inspection by the AI in accordance with the revised Inspection and Test Plan. After satisfactory corrective action of Non Conformity the item shall be released for further processing by Head Quality.

10.2.10 When Material/Code item is rejected, the same shall be identified by painting as “Rejected” or affixing “Rejected” tag (Exhibit No. 28)

10.2.11HeadQuality shall submit all NCRs to the AI and obtain the AI’s signature for his review.

10.2.12Verification of corrective action, disposition shall be filed by Head Quality or his designee in the job file.

10.2.13Head Quality shall maintain List of NCR for each Job Order Number wise in Non Conformity Log Register (Exhibit No. 29)

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RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Welding Section No. QCM 11.0 Rev.No: 02 Date :

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QUALITY CONTROL MANUAL

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Section No. QCM 11.0

Rev.No: 02

Date :02.07.2014

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11.0SCOPE

This Section describes the welding quality control for items to meet the Code requirements.

11.1 POLICY

  • 11.1.1 All welding carried out on Code construction shall conform to the requirements of ASME Section IXand relevant Code of construction.

  • 11.1.2 Welders, welding operators and all welding procedure specification shall be qualified as per ASME Section IX and applicable Code Section.

  • 11.1.3 All welding consumables shall meet ASME Section – II Part-C or as otherwise permitted by the applicable Code Section.

11.2

SYSTEM

11.2.1 WELDING PROCEDURES

  • 11.2.1.1 Engineer Welding shall prepare a welding procedure specification and arrange to carry out procedure qualification as and when required. Welding Engineer shall monitor and record the actual welding variable used during procedure qualification test. He is also responsible for witnessing of relevant testing as required by ASME Section IX and Code. based on satisfactory test result, Engineer Welding shall certify PQR.

  • 11.2.1.2 Welding Procedure Specification (WPS) shall be approved by Engineer Welding to ensure all essential, non essential and supplementary essential variables are addressed as per ASME Section IX, if there are any changes in essential and supplementary essential variable the procedure to be re-qualified. If there are any changes in the non-essential variables the WPS shall be revised or new WPS may be issued.

  • 11.2.1.3 Engineer Welding shall prepare Applicable WPS List ((Exhibit No.18).for each Job Order Number based on applicable drawing, Inspection and Test Plan and Customer specifications, if any. The Applicable WPS List is reviewed / approve by the Engineer Welding and same shall be presented to the AI for review.

The copies of The Applicable WPS List shall be issued through Head Planning to the following

  • 1. Head Quality

  • 2. Engineer Production

  • 11.2.1.4 Engineer Welding shall be responsible for making the WPS available to the Welders/Welding Operators in the work area.

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11.3.1 WELDERS/WELDING OPERATORS PERFORMANCE QUALIFICATION

  • 11.3.1.1 Engineer Welding shall identify welder/welding operators to the qualified for Code welding as per approved WPS. Engineer Welding shall supervise welders/welding operator qualification welding and produce a record of actual variables used as per ASME Sec IX and applicable Code Section. Engineer Welding shall witness the welders /welding operator qualification and testing based on the satisfactory test results, Engineer Welding shall certify welders/welding operators Performance Qualification(WPQR). Each welder/welding operator shall be allocated a unique identification number after qualification. Engineer Welding shall maintain a List of ASME Qualified Welders (Exhibit No.30), which includes the Qualification range and validity. The List of ASME Qualified Welders are reviewed and approved by Engineer Welding. A copy of the list shall be distributed to:

    • 1. Head Quality

    • 2. Engineer Production

  • 11.3.1.2 Engineer Welding shall maintain a Welder/Welding Operator Continuity Record (Exhibit No.31) for all the welders//welding operators for Code construction. Engineer Welding shall examine this engagement log every 3 months for the purpose of extending the validity of welder’s qualification in the List of ASME Qualified Welders.

  • When Welder has not welded with a process during a period of 6 months or more his qualification for that process shall expire unless within the six months period prior to his expiration of qualification

    • a) A welder has welded with the process using manual or semi-automatic welding under the supervision and control of Engineer Production.

    • b) A welding operator has welded with the process using machine or automatic welding under the supervision and control of Engineer Production.

    • 11.3.1.3 When there is specific reason to question welders ability to deposit sound weld such welders or welding operators shall be re-qualified for welding

    • 11.3.1.4 The AI may seek requalification of welder/welding operator or procedure at any time or witness tests of the welding procedures, welders/welding operators qualification.

    • 11.3.1.5 Individual may be engaged for their service as welders/welding operators by RIBO on contract or agreement with following conditions

      • a) All Code construction shall be the responsibility of RIBO including ASME Certification Marking.

      • b) All welding shall be performed in accordance with RIBO’s Welding Procedure Specification which have been qualified by the Engineer Welding in accordance with the requirements of Section IX

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    • c) All welders shall be qualified by Engineer Welding in accordance with the Section IX. Each welder shall be given an unique identification number after qualification.

    • d) Engineer Welding is responsible for complete and exclusive administrative technical supervision of welders / welding operators.

    • e) Engineer Welding shall have the authority to assign / remove welders / welding operators at his discretion without the involvement of any other party.

    • f) Head Quality shall obtain the AIA acceptance for the above mentioned programme.

    • g) RIBO shall be responsible for Code compliance of the vessel or part including ASME certification marking providing data report forms properly executed and certified by Head Quality and the AI.

    11.4.1 WELDING CONSUMABLES

    • 11.4.1.1 Engineer Welding shall prepare the Material Indent for welding consumables based on estimated requirements and forward to Head Material. Welding consumables shall be procured strictly in accordance with the approved List of welding consumables meeting the Code requirement / TDC condition, if applicable.

    • 11.4.1.2 Head Material shall arrange to procure the required welding consumables from approved vendors.

    • 11.4.1.3 Engineer Welding with the help of Stores Officer shall receive all the welding consumables and shall carryout examination as described in Section No QCM 8.0 of this Manual dealing with Material Control.

    • 11.4.1.4 Engineer Welding shall carry out examination of the consumables and release the same, if acceptable. He shall also verify the required markings and the conditions of packing. If not acceptable NCR will be raised by Engineer Welding for proposing suitable action as per Section No QCM No.10.0 of this Manual dealing with Correction of Non Conformities

    • 11.4.1.5 All accepted consumables shall be stored in a room sufficiently dry and weather proof in their designated locations.

    • 11.4.1.6 Stores Officer shall re-dry all covered electrodes and fluxes as per the guidelines issued by Engineer Welding which is based on manufacturer’s recommendation and keep them in holding ovens until they are issued to the Welders/Welding Operators.

    • 11.4.1.7 Welders/welding operators shall draw the consumables from the Stores using a Welding Consumables Requisition Cum Issue Slip (Exhibit No: 32) duly authorized by Engineer Production. A maximum of 15 covered electrodes may be issued to welder at a time. The low hydrogen electrodes shall be stored in a portable oven by welders. All unused electrodes shall be returned to the Stores Officer by the Welders. These returned electrodes if not damaged shall be stored separately by Stores Officer and shall not be used for Code items.

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    11.4.1.8 Engineer Production shall prepare welding – work Instructions Sheet (Exhibit No: 33)for each welder based on the WPS mentioned on the Applicable WPS List.

    • 11.5.1 PRODUCTION WELDING

    11.5.1.1 Production welding during construction shall be supervised by Engineer Production, he is responsible for engagement of qualified welders and control of production welding on Code item. During construction he shall record and maintain the actual identity of welder used during the tack welding / production welding on the OPS. Additionally welder may apply his stamp adjacent to weld and at intervals of not more than 1 meter along the welds.

    11.5.1.2 Tack welds used to secure alignment shall either be removed completely when they have served their purpose or their starting and stopping ends shall be properly prepared by grinding or other suitable means so that they may be satisfactory incorporated into the final weld.

    11.5.1.3Tack welds whether removed or left in place shall be made using welding procedure qualified in accordance with ASME Section IX and the applicable Code Sections.

    11.5.1.4Tack welds shall be made by welders/welding operators qualified in accordance with ASME Section IX and the applicable Code sections. Tack welds shall be examination visually for defects if found to be defective, shall be removed.

    11.5.1.5Temporary attachments to pressure parts shall be welded using qualified WPS and qualified welders. After removal of such attachments, the area shall be examined for any defects.

    • 11.6 REPAIRS TO MATERIALS / CODE ITEMS Method and extent of repair by welding to materials/Code items shall have prior acceptance of the AI.

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    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Non Destructive Examination Section No. QCM 12.0 Rev.No: 02

    RIBO INDUSTRIES PVT LTD

       

    QUALITY CONTROL MANUAL

    Non Destructive Examination

     

    Section No. QCM 12.0

    Rev.No:02

    Date :02.07.2014

    Page 1 of 2

    12.0

    SCOPE

    This Section describes the preparation and approval of NDE procedures and qualification of personal, identification of type and extent of NDE and reporting.

    12.1

    POLICY

    • 12.1.1 All Non Destructive Examination except PT,MT may be subcontracted to outside agency. Qualification and certification of NDE personnel engaged in methods Radiographic Testing (RT), Ultrasonic Testing (UT), Liquid Penetrant Testing (PT) , Magnetic particle Testing (MT) shall be carried out in accordance with their employer’s Written Practice approved by the RIBO NDE LEVEL-III in line with SNT-TC-1A current Code accepted Edition. VT personal shall be Qualified in line with B 31.1 Code requirements by Head Quality .

    • 12.1.2 Chief Executive Officer shall appoint a qualified NDE Level–III examiner through an appointment letter based on the individual’s qualification, experience and examination for the respective techniques in accordance with RIBO’s NDE Written Practice which has been reviewed and accepted by the Head Quality. All NDE Level II Personnel shall be certified by Head Quality.

    • 12.1.3 The NDE Level III shall be responsible for approval of Written Practice and NDE Procedures, calibration of NDE equipment and qualification of NDE personnel for production shop and site.

      • 12.1 NDE PROCEDURES

        • 12.2.1 All NDE procedures such as PT, MT, UT, RT, shall be prepared in line with ASME Sec-V and applicable Code Sections. These procedures shall be reviewed and approved by RIBONDE Level III and certified by Head Quality. PT, MT and UT procedures shall be qualified by demonstration to the satisfaction of the AI before under taking Code Construction as per Article-1, Para-T 150 of ASME Section –V and so certified by NDE Level – III in accordance with the approved procedures. Whenever there is change inessential variables, procedure shall be re qualified by demonstration to the satisfaction of the AI. Whenever there is change in non-essential variables , procedures shall be revised and demonstration not required.

    12.2.2Copies of applicable NDE Procedures shall be readily available to the NDE Level II / Level I and also at sites for reference and use as identified in the Inspection and Test Plan/ Operation Process Sheet

    12.2.3All NDE shall be carried out in accordance with the requirement of drawing, Inspection and Test

    Plan and Customer’s

    specification if any, using approved procedures.

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    • 12.3 QUALIFICATION OF PERSONNEL

      • 12.3.1 All NDE Level I, Level II and Level III personnel shall be qualified and certified as per RIBO NDE Written Practice.

      • 12.3.2 NDE certified Level I, Level II and Level III shall have a vision examination for their vision acuity and ability to distinguish and differentiate colors and / or shades of gray used in method at initial certification and annually thereafter.

      • 12.3.3 The NDE Level-III is responsible for training, qualifying and examination of all NDE Personnel and to maintain the records for production shop. Head Quality is responsible for certification of NDE personnel who are qualified and certified in accordance with RIBO NDE Written Practice approved by NDE Level –III and accepted by the Head Quality.

    12.4SYSTEM

    • 12.4.1 At the designated stage in the Operation Process Sheet , Engineer Production shall offer the Code item for NDE to Head Quality by raising Non Destructive Examination Requisition Slip(Exhibit No.33A)

    • 12.4.2 Engineer Quality shall verify the Code item with respect to completeness and readiness and offer the same to NDE Level II.

    • 12.4.3 NDE shall be carried out by certified personnel as per the approved procedures and the results shall be evaluated by RIBO NDE Level-II or NDE Level-III.

    • 12.4.4 Head Quality shall offer the NDE report for the AI’s review. Engineer Quality shall clear the stage by signing off the Operation Process Sheet based on the satisfactory NDE report. He shall mention the NDE report number in the Operation Process Sheet.

    • 12.4.5 When Non Destruction Examination is subcontracted to an outside agency, the RIBO Level III shall verify that the agency NDE Written Practice is in line with Code accepted Edition of SNT- TC-1A and NDE personnel are qualified and certified accordingly by their employer, which meets RIBO requirement. The NDE shall be carried out as per approved RIBO procedure and demonstrated to the satisfaction of the AI.

    • 12.4.6 All NDE procedures and record of NDE personnel shall be made available by the RIBONDE Level III to the AI.

    • 12.4.7 The Authorized Inspector may call for requalification of any procedures/personnel at any time.

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    Section No. QCM 13.0

    Rev.No:02

    Date :02.07.2014

    Page 1 of 2

    • 13.0 HEAT TREATMENT :

    13.1

    SCOPE Heat Treatment, if required by the Code or by the customer, is performed by a approved subcontractor in accordance with the RIBO approved procedure and drawing,

    The Head Quality shall verify and approve subcontractor’s heat treatment equipment and calibration records before issuance of Work Order for PWHT. The Work Order shall assure free access for RIBO representative and the AI.

    • 13.2 POLICY

    All PWHT or HT shall be performed to the requirement of applicable Code , this Manual.

    13.3PWHT Procedure

    • 13.3.1 All PWHT /HT is performed as specified in drawing, Heat Treatment procedure and Heat Treatment Requisition Slip (Exhibit No. 34)prepared by the Engineer Production and reviewed and approved by Head Quality which describes as a minimum.

      • 1. Description of item.

      • 2. Type of heat treatment and loading sketch.

      • 3. Rate of Heating.

      • 4. Soaking time and temperature.

      • 5. Rate of cooling.

      • 6. Number, location, method of attachment of thermocouples.

      • 7. In case of localized heat treatment, the heating bandwidth and the insulation requirements.

  • 13.3.2 On receipt of approved Heat Treatment Requisition Slip, Head Planning shall release the Work Order (Exhibit no. 35) along with the Heat Treatment Requisition Slip and approved procedure. The loading diagram received from subcontractor shall be reviewed and approved by Head Quality prior to heat treatment.

  • 13.3.3 Component to be sent for heat treatment to the sub-contractor shall be properly identified and marked by heat resistant paint or hard stamp with Job order Number/ part number and this identification shall be verified by Engineer Quality prior to shipment.

  • 13.3.4 Engineer Quality shall verify the calibration records of thermocouple and the recorders used for heat treatment for their accuracy and periodicity.

  • 13.3.5 If production weld test coupon plate are stipulated in the drawing, they may be heat treated by simulating the prescribed heat treatment prior to product heat treatment. Alternatively the test coupon may be heat treated with the Code items.

  • RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Heat Treatment Section No. QCM 13.0 Rev.No: 02 Date
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    • 13.3.6 In case of combined loading, Head Quality in consultation with the Engineer Welding shall indicate the appropriate heat treatment cycle on the Heat Treatment Requisition Slip taking into consideration welding qualifications and simulated heat treatment of materials.

    • 13.4 PWHT/ HT Records

      • 13.4.1 All PWHT /HT shall be recorded on automated chart which indicate the temperature, time. The time-temperature chart shall be signed by the furnace operator with date at the start and end of the heat treatment. The Heat Treatment chart shall also contain the identification of thermocouple and recorders. Heat Treatment chart shall be reviewed by Engineer Quality after completion of Heat Treatment.

      • 13.4.2 PWHT/HT records shall reference the procedure used and shall be reviewed and approved by the Head Quality to document compliance with the Code, drawing and procedure requirement.

      • 13.4.3 PWHT/HT records are submitted to the AI for his review and retained as per Section No.15.0 of this Manual dealing with Records Retention.

  • 13.5 Receiving Inspection

    • 13.5.1 Each Code Item returning after PWHT from the subcontractor’s facility shall be visually examined by the Engineer Quality, for identification markings, physical damage due to transit and flame impingement if any Engineer Quality shall also review the records of Heat treatment for compliance to the Code / procedure.

    • 13.5.2 Any Non Conformities noticed shall handled as Correction of Non Conformities.

  • per

    Section No

    QCM 10.0 dealing

    with

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Heat Treatment Section No. QCM 13.0 Rev.No: 02 Date
    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Calibration of Measurement and Test Equipment Section No. QCM

    RIBO INDUSTRIES PVT LTD

       

    QUALITY CONTROL MANUAL

    Calibration of Measurement and Test Equipment

    Section No. QCM 14.0

    Rev.No:02

    Date :02.07.2014

    Page 1 of 2

    14.1

    SCOPE

    This Section describes the control for Calibration and Re-Calibration of Inspection, Measurement and test equipment Used for the acceptance of material and Code item.

    14.2POLICY

    • 14.2.1 Inspection, measurement and test equipment (IMTE) used for acceptance of Code activity affecting quality shall be in valid state of calibration with traceability to National/International standard/Manufacture’s Standard. calibration shall be carried out either In-house or external agency.

    • 14.2.2 Impact testing of materials & Welds if required by the Code shall be carried out on a charpy impact testing machine Calibrated annually in accordance with ASTM-E23 or ISO 148(parts 1,2&3). Temperature measuring devices shall have been calibrated within six months of their use. Head Quality shall verify the record and ensure the calibration of the above.

    • 14.2.3 Responsibility of calibration of various inspection measurement and test equipment are as follows.

      • 1. Pressure gauges, Linear and other measuring instruments by Engineer Quality.

      • 2. All electrical equipment such as volt meter, ammeter, thermocouples, Temperature recorder and welding machines by Engineer Maintenance

      • 3. NDE equipment by NDE level-II or NDE Level III

    14.3

    SYSTEM

    • 14.3.1 Inspection, measurement and test equipment shall be procured either with calibration certificate or shall be calibrated prior to their use.

    • 14.3.2 Each Inspection, measurement and test equipment shall be allocated and marked permentally with an unique serial number and entered in the Master List of Measurement and Test Equipment (Exhibit No. 36 )

    • 14.3.3 Personnel responsible for calibration shall arrange for re-calibration of the IMTE before their expiry. Calibration of the IMTE shall be carried out by using sub-contracting agency. Pressure gauges calibrated with a dead weight tester or verified with a master gauge shall be used for hydro test.

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Calibration of Measurement and Test Equipment Section No. QCM
    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Calibration of Measurement and Test Equipment Section No. QCM

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    QUALITY CONTROL MANUAL

    Calibration of Measurement and Test Equipment

    Section No. QCM 14.0

    Rev.No:02

    Date : 02.07.2014

    Page 2 of 2

    • 14.3.4 Personnel responsible for calibration shall review the calibration report to determine the acceptance of such equipment and shall maintain the relevant records.

    • 14.3.5 Each accepted equipment shall be affixed with Calibration sticker (Exhibit No.37) showing the Reference No/equipment No, Calibration date and Calibration due date. Alternatively, Calibration Sticker may be affixed on the box with traceability duly engraved on the equipment.

    • 14.3.6 If IMTE is found out of calibration, or damaged the same shall be immediately segregated to avoid usage. This shall be reported an NCR for taking necessary action. Head Quality shall validate test results of those Material/Code items which were examined earlier using such faulty equipment. For measuring IMTE traceability, identification number shall be specified on the inspection reports.

    • 14.3.7 Records related to calibration of verification.

    equipment shall be made available to the AI for his

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Calibration of Measurement and Test Equipment Section No. QCM
    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Records Retention Section No. QCM 15.0 Rev.No: 02 Date

    RIBO INDUSTRIES PVT LTD

       

    QUALITY CONTROL MANUAL

    Records Retention

    Section No. QCM 15.0

    Rev.No:02

    Date :02.07.2014

    Page 1 of 2

    15.1

    SCOPE

    This Section describes the controls required for maintenance and retention of records as required by Code.

    15.2

    SYSTEM

    15.2.1 The following table indicates the records description, retention period, Personnel responsible to submit document to Head Quality, and retention responsibility for the various records maintained.

         

    Retention Period

    Responsibility of

    Retention

    responsibility

    Sl.No

    Record Description

     

    ASME

    ASME Sec.

    Providing the

    Sec.I&B31.1

    VIII Div.1

    document

    01

    Manufactures Partial Data

         

    Head

    Report

    5

    Years

    Head Quality

    Quality shall

    02

    Manufacturing Drawings

     

    --

    Head Design

    compile the

     

    Quality

     

    including As Built drawings Design calculations including

       

    Dossier with

    03

    any applicable proof test

     

    --

    Head Design

    the help of

     

    Engineer

    04

    reports Material Test

     

    --

    Engineer Quality

    Quality.

     

    Reports/Certifications Pressure part documentation and Certifications

     

    Engineer Quality

    Head Quality

    05

    (MRIR/Material Identification

    shall retain

    Report)

    one

    06

    WPS and PQR

     

    --

     

    complete set

     

    Welder Qualifications for each

     

    Engineer Welding

    of Quality

    07

    welder who welded on the Code Item

     

    --

    3

    Years

    Dossier

    08

    NDE Personal Qualification record

     

    --

     

    NDE Level II

    09

    RT report and UT report

     

    --

    NDE Level II

    10

       

    --

    Head Quality

     

    Repair procedure and records Inspection and Test

       

    11

    Plan/Operation Process Sheet,

     

    --

    12

    Applicable WPS List Heat treatment records and test results

     

    --

    13

    PWHT records

     

    --

    Head Quality

    14

    Non Conformances and dispositions (NCR)

     

    --

    15

    Hydrostatic Test Reports Pneumatic Test Report

     

    --

    16

    RT films

    5

    Years

    Till MDR is signed by AI

    NDE Level II

    17

    Manufacture’s Data report

    5

    Years

    3

    Years

    Head Quality

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Records Retention Section No. QCM 15.0 Rev.No: 02 Date

    RIBO INDUSTRIES PVT LTD

    QUALITY CONTROL MANUAL

    Records Retention

    Section No. QCM 15.0

    Rev.No:02

    Date :02.07.2014

    Page 2 of 2

    Note:

    Originals of WPS, PQR, Welder/Welding operator Performance Qualification and NDE operator qualification records shall be maintained permanently.

    All records shall be made available to the AI and AIS for his review and ASME Team Leader when requested.

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Site Activities Section No. QCM 16.0 Rev.No: 02 Date

    RIBO INDUSTRIES PVT LTD

    QUALITY CONTROL MANUAL

    Site Activities

    Section No. QCM 16.0

    Rev.No:02

    Date :02.07.2014

    Page 1 of 7

    • 16.0 SCOPE

    This Section describes how RIBO shall control operations for Code Items when final assembly is conducted at field sites controlled from the shop.

    • 16.1 Field Site Organisation For each field site, a Site Manager shall be designated by Head Operations. His responsibility shall cover all activities of the Head Operations in this QCM and arranging for fabrication as per Code/drawings and administrative control of site activities. All other activities and responsibilities described in this QCM shall be handled in the same manner as in the shop and as shown on the Organization chart in Section No. QCM 5.0 dealing with Organization.

    • 16.2 Responsibility

      • 16.2.1 Head Operations shall be responsible for designation of Site Manager for controlling the field site activities in accordance with this Section. Before the start of field assembly, the Head Quality shall audit the site to ensure adequate facility and infrastructure for meeting the Quality Control Manual.

      • 16.2.2 Engineer Quality Site directly reports to Site Manager with functional responsibility to Head Quality. Engineer Quality Site shall be responsible for the performance of all field site examinations as required by the Code and this Quality Control Manual.

      • 16.2.3 Responsibilities and authorities of personnel at shop shall be same as per other Sections of this QCM as supplemented by this Section.

      • 16.2.4 Responsibilities and authorities of personnel at field site similarly designated with “site” shall be same as per other Sections of this Quality Control Manual as supplemented by this Section.

      • 16.2.5 Controlled copy of this Quality Control Manual shall be issued by Head Quality to Site Manager, Engineer Quality Site and the AI at site.

      • 16.2.6 Field assembly of Code items may be performed as follows, a) RIBO completes the Code item in the field site and completes the field assembly portion of the MDR.

    RIBO may receive parts of Code item from other manufacturer holding valid Certificate of Authorization along with MPDR and RIBO makes the final assembly, welding, required NDE, Final Pressure Test and completes the MDR and apply Certification mark with appropriate Code designator on the finished Code Item

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Site Activities Section No. QCM 16.0 Rev.No: 02 Date

    RIBO INDUSTRIES PVT LTD

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    Site Activities

    Section No. QCM 16.0

    Rev.No:02

    Date :02.07.2014

    Page 2 of 7

    b)

    The field portion of the work is completed by other manufacturer holding valid Certificate of Authorization shall submit MPDR for the field work (including data on the pressure test if perform by him) to RIBO. RIBO shall apply the ASME Certification Mark with appropriate Code Designator on the finished Code Item in the presence of the AI at site and complete the MDR. In all three cases RIBO assumes full Code responsibility for the items.

    • 16.3 Drawings, Design Calculations and Specifications

      • 16.3.1 The necessary drawings and specifications are prepared, reviewed and approved as per Section No QCM 7.0 dealing with Drawings, Design Calculations and Specification Control.

      • 16.3.2 Engineer Quality Site is responsible for providing the Authorized Inspector at sight with all approved drawings and necessary documents for review at site.

        • 16.4 Material Control Receiving Examination

          • 16.4.1 Receiving examination of material item which are received at site shall be in accordance with Section NoQCM8.0 dealing with Material Control.

          • 16.4.2 For Code items, which involve activities both in shop and site, Head Quality shall prepare a single Inspection and Test Plan that reflects both the activities at shop and field site.

          • 16.4.3 The shop activities shall be offered to the AI at shop for inspection. Upon his satisfaction the OPS shall be signed off up to completed stage at shop. The item(s) will be dispatched along with original OPS, Applicable WPS List, Inspection and Test Plan and other relevant documents such as MTR, Material Identification Report, welding records (as applicable) etc. to site.

    • 16.4.4 All the items/ materials shipped to site shall be clearly marked with:

      • a) Job Order Number

      • b) Part Number

      • c) Section Number/Sub Assembly Number if applicable.

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Site Activities Section No. QCM 16.0 Rev.No: 02 Date
    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Site Activities Section No. QCM 16.0 Rev.No: 02 Date

    RIBO INDUSTRIES PVT LTD

       

    QUALITY CONTROL MANUAL

    Site Activities

    Section No. QCM 16.0

    Rev.No:02

    Date :02.07.2014

    Page 3 of 7

    • 16.4.5 Upon receipt of these items at site, Engineer Quality Site shall verify the extent of completed work and any damage during transit to site. When satisfied he offers those items to the AI at field site for inspection before proceeding with any work at site.

    • 16.4.6 Upon completion of above activities, Engineer Production Site shall record details of each item in respect of quantity , supporting document and test report, inspection acceptance etc in a bound register.

    • 16.4.7 For all Code material received directly at the field site the assigned Engineer Production Site is responsible for verifying the quantities and receiving documents.

    • 16.4.8 Head Material sends a copy of Supply Purchase Order along with TDC to Engineer Production Site for use in receiving examination as mentioned below.

    • 16.4.9 All Code material, items or Code parts are unloaded in the assigned lay-down area, and examined by the Engineer Quality Site for:

      • a) Physical damage, which may have occurred during transport.

      • b) Proper tagging and identification of each item, which provides traceability to assembly drawings

      • c) Review of Chemical and physical properties (Material Test Report).

      • d) In case of items supplied with Manufacturers Partial Data Reports the stamping shall be verified against the Data Report.

      • e) The required material marking.

    • 16.4.10 Site Store Keeper is responsible for storage of accepted materials and shall be released for fabrication when requested by Engineer Production Site using Material Issue Voucher.

    • 16.4.11 Engineer Production Site shall send all the information to the Head Material at shop i.e. the status of the material (Examination status) along with the copy of MRIR for records.

    • 16.4.12 All welding consumables requested by the Site Manager shall be ordered as described in Section No.QCM11.0 dealing with Welding.

    • 16.4.13 Items shall be released for fabrication at field sites after the Field site AI’s acceptance. This activity shall be endorsed by the Field site AI in OPS.

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Site Activities Section No. QCM 16.0 Rev.No: 02 Date

    RIBO INDUSTRIES PVT LTD

       

    QUALITY CONTROL MANUAL

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    Section No. QCM 16.0

    Rev.No:02

    Date :02.07.2014

    Page 4 of 7

    • 16.4.14 Accepted welding consumables shall be shipped to the field site with a copy of MRIR and reference on the container along with CoC.

    • 16.4.15 Accepted welding consumables shall be stored by Site Store Keeper in a locked storage area in their original package in accordance with the Manufacturer’s recommendations.

    • 16.4.16 Parts, items and material that do not meet all requirements are considered non-conforming and the Engineer Quality Site shall prepare a Non Conformity Report in accordance with Section No. QCM 10.0 dealing with Correction of Non Conformities and as per 16.6 of this Section.

      • 16.5 Field Examination and Inspection Program

        • 16.5.1 The field assembly of Code items is controlled by assembly drawings, Inspection and Test Plan, Applicable WPS List and OPS which is prepared and reviewed as per Section No QCM 9.0 dealing with Examination, Inspection and Testing Program.

        • 16.5.2 The approved Inspection and Test Plan, Applicable WPS List and Operation Process Sheet are sent to the Engineer Quality Site by the Head Quality.

        • 16.5.3 Prior to start of fabrication, all the prepared and approved documents such as ITP and Applicable WPS List shall be submitted by Engineer Quality Site to the AI at field site for review and selection of his inspection Hold, Witness and Review points.

        • 16.5.4 Engineer Quality Site shall transfer the Hold, Witness and Review points of the AI field Site on the OPS.

    Prior

    • 16.5.5 to

    the

    pressure

    test,

    Engineer

    Quality

    Site

    shall

    ensure

    all

    examinations and

    inspections,

    NDE,

    Heat

    treatment

    if

    required

    shall

    have

    been

    performed

    and

    Non

    Conformities if any shall have been closed out and shall be referenced in the Operation Process Sheet.

    • 16.5.6 Code required pressure tests shall be carried out as specified by the procedure &ITP, and under the supervision of the Engineer Quality Site Authorized Inspector.

    and always in the presence of the Site

    • 16.5.7 Upon completion of the field assembly of a Code item, the Engineer Quality Site shall verify and certify the field assembly portion of MDR and obtain the ASME Certification Mark and NB Mark if applicable from Head Quality. Engineer Quality Site shall keep the Certification Mark and NB Mark if applicable in his safe custody.

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Site Activities Section No. QCM 16.0 Rev.No: 02 Date

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    Section No. QCM 16.0

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    • 16.5.8 The completed MDR, together with the final records is then presented to the field Authorized Inspector for review. When satisfied that all Code requirements have been met, the field Authorized Inspector shall authorize and verify the application of ASME Certification Mark and NB Mark if applicable to the Nameplate or on item as applicable and sign the Data Report.

    • 16.5.9 All records shall be returned to the Head Quality at the shop for retention as described in Section No QCM 15.0 dealing with Records Retention.

      • 16.5.10 ASME Certification Mark and NB Mark shall be returned to Head Quality after completion of the Stamping.

      • 16.5.11 Distribution of MDR/MPDR, registration with National Board if required shall be in accordance with Section No. QCM 9.0 dealing with Examination, Inspection and Testing Program by Head Quality.

        • 16.6 Correction of Non-conformities

          • 16.6.1 Nonconformities found during field assembly are recorded on the OPS next to the operation where they occurred and are controlled as described in Section No. QCM10.0 dealing with Correction of Non-Conformities.

          • 16.6.2 However for nonconformities where the disposition is “Reject”, the Engineer Quality Site is authorized to make such dispositions.

          • 16.6.3 All Non Conformity Reports shall be transmitted by fax or by Email for obtaining the written disposition from the Head Quality with exception as described above in Section 16.6.2 prior to taking any action.

          • 16.6.4 Engineer Quality Site shall inform the Site Manager of all dispositions and all corrective action to be taken.

          • 16.6.5 All Non Conformance Report shall be sent to Head Quality for retention as described in Section No. QCM 15.0 dealing with Records Retention.

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Site Activities Section No. QCM 16.0 Rev.No: 02 Date

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    • 16.7 Welding Control

      • 16.7.1 All welding shall be done in accordance with SectionNoQCM11.0 dealing with Welding and in addition the Site Manager, together with the Engineer Quality Site shall establish the action necessary to protect the welding activities from adverse weather conditions such as wind, rain, temperature and humidity.

      • 16.7.2 All reviewed/approved WPS’s and supporting PQR’s provided to the Site Manager by the Engineer Quality Site, shall then be distributed to the Engineer Production Site. WPSs shall be made available to the welder for their use. All WPSs and PQRs shall be made available to the field Authorized Inspector at the field site for review.

      • 16.7.3 Welders shall be qualified as described in Section No QCM11.0 dealing with Welding. Qualified welders from RIBO shop shall be sent to the field sites or RIBO may employ individual welders by contract as described in Section No. QCM 11.0 dealing with Welding.

      • 16.7.4 The List of Qualified Welders shall be prepared by Engineer Welding Site for site qualified welders and forwarded to Engineer Welding. Engineer Welding shall be responsible for allocating unique welder identification number and issue of List of ASME Qualified Welders and used for site work.

      • 16.7.5 The Engineer Production Site and Site Store Keeper are responsible for the issuance of welding consumables in accordance with Section No QCM 11.0 dealing with Welding. The Engineer Welding is responsible for transmitting the manufacturer’s recommendations for handling and storage of the welding consumables to the field location.

    • 16.8 Non-destructive Examination

      • 16.8.1 All NDE shall be carried out in accordance with Section No. QCM 12.0 dealing with Non Destructive Examination. Records of all NDE personnel shall be maintained by the Engineer Quality Site and be made available to the field Authorized Inspector.

      • 16.8.2 All radiographs and test reports shall be made available to the field Authorized Inspector for review. After completion of the Data Report and certification by Engineer Quality site and the field AI, all radiographs and test reports shall be forwarded to the Head Quality.

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Site Activities Section No. QCM 16.0 Rev.No: 02 Date
    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Site Activities Section No. QCM 16.0 Rev.No: 02 Date

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    Section No. QCM 16.0

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    Page 7 of 7

    • 16.9 Heat Treatment

      • 16.9.1 Post weld Heat Treatment, when required shall be carried out in accordance with SectionNoQCM13.0 dealing with Heat Treatment.

      • 16.9.2 After completion of the Data Report and certification by Engineer Quality site and the field AI,, the time/temperature charts shall be forwarded to the Head Quality for retention.

        • 16.10 Calibration of Measuring and Test Equipment All required measuring and test equipment to be used for acceptance shall be calibrated directly prior to shipment to the field site and shall be marked as described in Section No: QCM 14.0 dealing with Calibration of Measurement and Test Equipment.

        • 16.11 Authorized Inspector

          • 16.11.1 Engineer Quality Site shall be responsible for the coordination with the field Authorized Inspector at the field location.

          • 16.11.2 A controlled hard copy of this QCM shall be available for use by the field Authorized Inspector at the field location

          • 16.11.3 Engineer Quality Site is responsible for safe custody of AI bound dairy.

    Engineer Quality

    Site shall return AI bound dairy to Head Quality as soon as the work at the field site is complete.

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Authorized Inspection Section No. QCM 17.0 Rev.No: 02 Date

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    QUALITY CONTROL MANUAL

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    Section No. QCM 17.0

    Rev.No:02

    Date :02.07.2014

    Page 1 of 2

    • 17.1 SCOPE

    This Section describes about the coordination with the Authorized Inspection Agency, Authorized Inspector, and Authorized Inspector Supervisor during Code activities and the maintenance of the Quality Control System.

    • 17.2 POLICY

      • 17.2.1 Written agreement shall be made with an Authorized Inspection Agency for providing authorized Inspection service as required by the Code, i.e. LR Insurance Inc.is identified as AIA of record for providing the services of Code activities.

      • 17.2.2 The AI and AIS shall have free access at all time to all place including material manufacture’s or supplier’s where manufacturing or field assembly work is being carried out on Code items.

      • 17.2.3 The AI shall be provided with facilities to perform required duties including quality control system monitoring by the AI and audit of AI’s activities by an AIS. Head Quality shall submit the Inspection and Test Plan, Applicable WPS List , Operation Process Sheet and Head Design shall submit the design calculations and drawings prior to start of fabrication to the AI for his review. The AI shall indicate his Hold, Witness and Record review points in Inspection and Test Plan.

      • 17.2.4 Head Quality is responsible for safe keeping of the AI’s bound diary.

      • 17.2.5 Head Quality shall give the AI reasonable advance notice when vessels or parts will be ready for required tests or internal inspection of the vessel before final closure of the vessel.

      • 17.2.6 Head Quality shall provide opportunity to Radiography.

    the

    AI

    to

    select spot location

    in case

    of

    spot

    • 17.2.7 In case of a situation where the purchaser request another AIA to perform inspection at the shop or field site on its projects or Code jobs, the request shall be in writing, and same shall be made available to AIA of record before taking up the job.

    • 17.2.8 If LR Insurance Inc. cannot provide coverage for inspection at specific field site, necessitating the use of another AIA, shall also be documented suitably.

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    Section No. QCM 17.0

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    Page 2 of 2

    • 17.2.9 In case of S.No 17.2.7 & 17.2.8 the following shall be ensured

    1)

    Al AIA’s performing inspection shall follow the system laid down in the Quality Control Manual accepted by the AIA of record.

    2) All AIA’s performing inspection shall have a contract or agreement for the specific Code work.

    3) The AIA of record, LR Insurance Inc. shall review and accept all changes to the Quality Control Manual.

    4) Each AI shall be provided with a controlled copy of the Quality Control Manual.

    • 17.3.0 SYSTEM

    • 17.3.1 An Authorized Inspector is an employee of an ASME accredited Authorized Inspection Agency, in accordance with the latest edition of ASME QAI-1, and who is qualified by written examination under the rules of any state of the United States or provinces of Canada which has adopted the Code. The AI shall have a valid National Board Commission card with “A” endorsement.

    • 17.3.2 Head Quality shall liaise with the AI/AIS during Code activities and QC system monitoring visits.

    • 17.3.3 AI prior concurrence shall be obtained for carrying out any repair of material/component and welds for the proposed method and extent repair.

    • 17.3.4 One copy of the certified Manufacturer’s Data Report/Manufacture’s Partial Data Report shall be provided to the AI.

    • 17.3.5 The AI shall include his National Board Commission number with endorsements when signing the Data Reports.

    • 17.3.6 Whenever the agreement with AIA is cancelled or changed to another AIA, RIBO shall notify the same to ASME.

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL Certifications Date : 02.07.2014 Section No. QCM 18.0 Rev.No

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    Section No. QCM 18.0

    Rev.No: 02

    Page 1 of 1

    18.1

    SCOPE

    This Section describes the procedure for certifications, authorizations and approvals of documents and reports during various stages of constructions

    18.2

    POLICY

    At Present only written signatures are used for certifications, authorizations and approvals.

    Whenever in future other methods are employed for indicating certifications, authorizations and approvals, a procedure shall be established by Head Quality and outlined in this section to describe the required control and safeguard to ensure the integrity of the certifications and approval process. This procedure shall be offered to the AI for his review and acceptance before implementation.

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL List of Exhibits Section No. QCM 19.0 Rev.No :

    RIBO INDUSTRIES PVT LTD

     

    QUALITY CONTROL MANUAL

    List of Exhibits

       

    Section No. QCM 19.0

    Rev.No: 02

    Date :02.07.2014

     

    Page 1 of 2

     
     

    Exhibit No

     

    Description

    Rev.No

    Date

     

    1

    QCM Distribution Register

     

    00

    14.04.2014

     

    2

    Order Distribution Sheet

     

    00

    14.04.2014

     

    3

    Material Requirement list Report

     

    00

    14.04.2014

     

    4

    Technical Delivery Condition (TDC)

     

    00

    14.04.2014

     

    5

    Document Transmittal

     

    00

    14.04.2014

     

    6

    Document Distribution

     

    00

    14.04.2014

     

    7

    Design Change Request

     

    00

    14.04.2014

     

    8

    Design Change Note (DCN)

     

    00

    14.04.2014

     

    9

    Material Indent

    00

    14.04.2014

     

    10

    Materials Receipt cum Inspection Report

     

    00

    14.04.2014

     

    11

    Stock Transfer cum Inspection Report

     

    00

    14.04.2014

     

    12

    Supply Purchase Order

     

    00

    14.04.2014

     

    13

    Non – Conformity Report

     

    00

    14.04.2014

     

    14

    Materials Issue Voucher

     

    01

    02.07.2014

     

    15

    Material Requisition Slip

     

    00

    14.04.2014

     

    16

    Material Identification Report

     

    00

    14.04.2014

     

    17

    Inspection and Test Plan

     

    00

    14.04.2014

     

    18

    Applicable WPS List

     

    00

    14.04.2014

     

    19

    Operation Process Sheet

     

    00

    14.04.2014

     

    20

    Nameplate Details For ASME Section VIII DIV 1 Vessel

     

    01

    02.07.2014

     

    21

    Direct stamping Details For ASME Section VIII Div 1Vessel

     

    01

    02.07.2014

     

    22

    Nameplate Detail for ASME Section VIII Div 1Vessel Part

     

    01

    02.07.2014

     

    22A

    Direct stamping Detail for ASME Section VIII Div 1Vessel Part

     

    01

    02.07.2014

     

    23

    Direct stamping Details for ASME Section I Boiler

     

    01

    02.07.2014

     

    24

    Direct stamping Detail for ASME Section I Part

     

    01

    02.07.2014

     

    25

    Nameplate Details for ASME Section I Boiler

     

    01

    02.07.2014

    RIBO INDUSTRIES PVT LTD QUALITY CONTROL MANUAL List of Exhibits Section No. QCM 19.0 Rev.No: 02

    RIBO INDUSTRIES PVT LTD

    QUALITY CONTROL MANUAL

    List of Exhibits

     

    Section No. QCM 19.0

    Rev.No:02

    Date :02.07.2014

    Page 2 of 2

     

    Exhibit No

     

    Description

    Rev.No

    Date

    26

    Nameplate Detail for ASME Section I Part

     

    01

    02.07.2014

    27

    National Board Number Log Register

     

    01

    24.06.2014

    28

    Rejected

     

    00

    14.04.2014

    29

    Non Conformity Log Register

       

    00

    14.04.2014

    30

    List of ASME Qualified Welders

       

    01

    24.06.2014

    31

    Welder / welding operator Continuity Record

     

    01

    24.06.2014

    32

    Welding Consumables Requisition cum issue Slip

     

    00

    14.04.2014

    33

    Welding- Work Instructions Sheet

       

    01

    24.06.2014

    33A

    Non-Destructive Examination Requisition Slip

     

    00

    14.04.2014

    34

    Heat Treatment Requisition Slip

       

    00

    14.04.2014

    35

    Work Order

     

    01

    02.07.2014

    36

    Master list Measurement and Test Equipment

     

    00

    14.04.2014

    37

    Calibration Sticker

       

    00

    14.04.2014

    38

    Stage Inspection report

       

    00

    02.07.2014

    RIBO INDUSTRIES PVT LTD

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