Section No.

COVER PAGE
SESB QUALITY CONTROL MANUAL – EDITION 5 Revision No. 0
Date of Issue 01 – 06 - 2009
ASME SECTION VIII DIVISION 1 & DIVISION 2 Page 1 of 1

FOR

SHOP CONSTRUCTION AND FIELD ASSEMBLY

OF

PRESSURE VESSEL CONSTRUCTED

TO

ASME CODE SECTION VIII DIVISION 1

AND

ASME CODE SECTION VIII DIVISION 2

EDITION NUMBER 5
REVISION NUMBER 0
DATE OF ISSUE 01 – 06 - 2009
MANUAL CONTROL NUMBER

PLO 494, ZONE 11, JALAN KELULI 7, PASIR GUDANG INDUSTRIAL ESTATE,
81700, PASIR GUDANG, JOHOR, MALAYSIA
TEL : 6 – 07 – 2511860 FAX : 6 – 07 – 2514493
E – Mail : spheng@tm.net.my / sphtech@tm.net.my

THIS MANUAL IS THE SOLE PROPERTY OF SPHERETECH ENGINEERING SDN BHD. NO PART OR PARTS OF THIS MANUAL MAY BE
PRODUCED IN ANY FORM, WITHOUT THE PRIOR APPROVAL FROM SPHERETECH ENGINEERING SDN BHD.
 Section No. TOC
SESB QUALITY CONTROL MANUAL – EDITION 4 Revision No. 0
Date of Issue 01 – 06 - 2009
ASME SECTION VIII DIVISION 1 & DIVISION 2 Page 1 of 7
TABLE OF CONTENT
Section Content Revision No. Revision Date Page No.
Cover Page 0 1 of 1
TOC Table of Content 0 1 to 7
1.0 Statement of Policy and Authority 0 1 of 1

2.0 Quality Control Manual ( Manual ) and Manual Control 0 1 of 2

2.1 Scope 0 1 of 2
2.2 Issue and Implementation of the Manual 0 1 of 2
2.3 Responsibility for Manual’s Compliance with the Code Rules 0 1 of 2
2.4 Issue of the Quality Control Manual ( Manual ) 0 1 of 2
2.5 Assignment of Edition Number to the Manual 0 1 of 2
2.6 Review and Revision of the Quality Control Manual 0 2 of 2
2.7 Retention of the Quality Control Manual 0 2 of 2
2.8 Sample Forms

3.0 Organization, Authority and Responsibility

3.1 Organization Chart – Company’s Main Organization Chart 0 1 of 12
3.2 Authority and Responsibility 0 1 of 12
3.2.1 Quality Control Manager 0 1 of 12
3.2.2 Shop / Field Quality Control Inspector 0 3 of 12
3.2.3 Engineering Manager 0 4 of 12
3.2.4 Design Engineer 0 5 of 12
3.2.5 Manager of Project Department 0 6 of 12
3.2.6 Project Manager 0 7 of 12
3.2.7 Project Engineer 0 8 of 12
3.2.8 Fabrication Manager / Construction Manager 0 9 of 12
3.2.9 Fabrication Supervisor (Shop) / Construction
Supervisor (Field) 0 10 0f 12
3.2.10 Store Supervisor 0 11 of 12
3.2.11 Purchasing Officer 0 12 of 12

4.0 Drawing, Design Calculation and Specification, and Specification Control 0 15-11-06 1 of 8
4.1 Scope 0 15-11-06 1 of 8
4.2 Assignment of Project Number 0 15-11-06 1 of 8
4.3 Assignment of Manufacturer’s Code Stamp Items Serial Number 0 15-11-06 1 of 8
4.4 Engineering Design Document Furnish by Spheretech
0 15-11-06 1 of 8
Engineering Sdn Bhd
4.5 Review and Approval of Engineering Design document 0 15-11-06 5 of 8
4.6 Design Appraisal and Acceptance of Engineering Design
0 15-11-06 5 of 8
Document
4.7 Engineering Design Document Furnish by Client 0 15-11-06 6 of 8
4.8 Project Specification Document / Engineering Design Document
0 15-11-06 6 of 8
Distribution and Control
4.8.1 Client’s Incoming Document Master List 0 15-11-06 6 of 8
4.8.2 Outgoing Project Document Master List 0 15-11-06 6 of 8
4.8.3 Control of Approved for Code Construction Drawing
0 15-11-06 7 of 8
( AFCC Drawing )
4.9 Additional Requirement for ASME Section VIII Division 2 0 15-11-06 7 of 8
4.9.1 Furnishing and Certification of User’s Design
0 15-11-06 7 of 8
Specifications
4.9.2 Furnishing and Certification of the Manufacturer’s
0 15-11-06 8 of 8
Design Report
4.9.3 Review and Approval of Manufacturer’s Design Report 0 15-11-06 8 of 8
4.9.4 Certification of the Manufacturer’s Design Report 0 15-11-06 8 of 8
Section No. TOC
SESB QUALITY CONTROL MANUAL – EDITION 4 Revision No. 0
Date of Issue 01 – 06 - 2009
ASME SECTION VIII DIVISION 1 & DIVISION 2 Page 2 of 7
Section Content Revision No. Revision Date Page No.
 4.9.5 Project Specification / Engineering Design Document
0 15-11-06 8 of 8
Distribution and Control
4.9.6 Control of Approved for Code Construction Drawing 0 15-11-06 8 of 8

5.0 Material Control 0 15-11-06 1 of 6

5.1 Scope 0 15-11-06 1 of 6
5.2 Intended Material for Construction 0 15-11-06 1 of 6
5.3 Raising and Approval of Material Purchasing Requisition 0 15-11-06 1 of 6
5.4 Raising and Approval of Purchasing Order 0 15-11-06 2 of 6
5.5 Additional Requirement for Materials of Construction for ASME
0 15-11-06 3 of 6
Section VIII Division 2 Code Stamp Items
5.5.1 Intended Material of Construction 0 15-11-06 3 of 6
5.5.2 Certification by Material Manufacturer 0 15-11-06 3 of 6
5.5.3 Certification of Prefabricated or Preformed Pressure
0 15-11-06 3 of 6
Parts Fabricated from Plates
5.6 Material Receiving and Storage 0 15-11-06 4 of 6
5.6.1 Receiving of Material Test Report, Certificate of
0 15-11-06 4 of 6
Compliance and Partial Data Report
5.6.2 Material Receiving and Storage 0 15-11-06 4 of 6
5.7 Material Verification Inspection and Material Verification
0 15-11-06 4 of 6
Inspection Report
5.7.1 Material Verification Inspection – Plates, Pipes, Pipe
0 15-11-06 4 of 6
Fittings, Flanges, etc.
5.7.2 Material Verification Inspection – Prefabricated or
0 15-11-06 5 of 6
Preformed Shell Section and Formed Heads
5.7.3 Additional Requirement for ASME Section VIII Division
0 15-11-06 5 of 6
2 – Material Verification Inspection
5.8 Material Issue for Fabrication / Construction – Using Material
0 15-11-06 6 of 6
Issue Note
5.9 Material Issue for Fabrication / Construction – Using Material
0 15-11-06 6 of 6
Delivery Order

6.0 Examination and Inspection Program 0 15-11-06 1 of 17

6.1 Scope 0 15-11-06 1 of 17
6.2 Free Access For Inspector 0 15-11-06 1 of 17
6.3 Responsibility for the Fabrication of Code Stamp Items 0 15-11-06 1 of 17
6.4 Document Furnished to Fabrication Manager For Use During
0 15-11-06 2 of 17
Fabrication of the Code Stamp Items
1. AFCC / AFC Drawing 0 15-11-06 2 of 17
2. Inspection and Test Plan 0 15-11-06 2 of 17
3. Welding Procedure Specification and Welder List 0 15-11-06 3of 17
4. Material Cutting Plan 0 15-11-06 3 of 17
5. As – Built Control Report 0 15-11-06 3 of 17
6. Repad Air Test Procedure 0 15-11-06 4 of 17
7. Hydrostatic Test Procedure 0 15-11-06 4 of 17
6.5 Identification and Traceability of Code Stamp Items Component
0 15-11-06 5 of 17
Material
6.6 Fabrication, and Examination and Inspection During Fabrication 0 15-11-06 6 of 17
6.6.1 Material Marking, Cutting and Forming by Rolling 0 15-11-06 6 of 17
6.6.2 Fit – Up of Code Stamp Component into A Completed
0 15-11-06 7 of 17
Code Stamp Items
6.6.3 Tack Weld and Production Welding Perform on Code
0 15-11-06 8 of 17
Stamp Items Component
6.7 Repair of Weld Defect 0 15-11-06 9 of 17
6.8 Inspection and Examination of Welding 0 15-11-06 9 of 17
6.8.1 Visual Inspection 0 15-11-06 9 of 17
6.8.2 NDE Examination 0 15-11-06 10 of 17

Section No. TOC

SESB QUALITY CONTROL MANUAL – EDITION 4 Revision No. 0
Date of Issue 01 – 06 - 2009
ASME SECTION VIII DIVISION 1 & DIVISION 2 Page 3 of 7
Section Content Revision No. Revision Date Page No.
 6.9 Final Inspection of Fabricated Code Stamp Items 0 15-11-06 10 of 17
6.10 Hydrostatic Test and Issuance of Hydrostatic Test Certificate 0 15-11-06 10 of 17
6.11 Pneumatic Test and Issuance of Pneumatic Test Certificate 0 15-11-06 12 of 17
6.12 Code Stamp Items Marking, Code Symbol Stamp and Data
0 15-11-06 13 of 17
Report
6.12.1 Code Stamp Items Marking – Name Plate 0 15-11-06 13 of 17
6.12.2 Manufacturing Inspection Book - MIB 0 15-11-06 13 of 17
6.12.3 Code Symbol Stamp 0 15-11-06 14 of 17
6.13 National Board of Boiler and Code Stamp Items Inspector –
0 15-11-06 14 of 17
National Board
6.14 Distribution and Control of MDR and DATA REPORT 0 15-11-06 15 of 17
6.15 Additional Requirement for ASME Section VIII Division 2 Code
0 15-11-06 15 of 17
Stamp Items

7.0 Welding

7.1 Scope 0 15-11-06 1 of 8

7.2 Welding Procedure Specification - WPS 0 15-11-06 2 of 8
7.3 Procedure Qualification records - PQR 0 15-11-06 3 of 8
7.4 Control of WPS and PQR 0 15-11-06 4 of 8
7.5 Welder / Welding Operator Performance Qualification - WPQ 0 15-11-06 5 of 8
7.6 Control of Welder and Welding Operator 0 15-11-06 6 of 8
7.7 Welder Qualification Continuity Log 0 15-11-06 6 of 8
7.8 Production Welding and Identification & Traceability of
0 15-11-06 6 of 8
Production Welding
7.9 Welding Consumables 0 15-11-06 6 of 8
7.9.1 Purchasing, Storage and issue of Welding
0 15-11-06 6 of 8
Consumables
7.9.2 Storage and Issue of Welding Consumables 0 15-11-06 6 of 8
7.9.3 Welding Flux 0 15-11-06 7 of 8
7.9.4 Submerged Arc Welding Wire 0 15-11-06 8 of 8
7.10 Control of Subcontractor’s Welders 0 15-11-06 8 of 8
7.11 Additional Requirements for ASME Section VIII Division 2 0 15-11-06 8 of 8

8.0 Correction to Non – Conformities

8.1 Scope 0 15-11-06 1 of 3
8.2 Definition of Non – Conformity 0 15-11-06 1 of 3
8.3 Responsibility to Report Non – Conformity Conditions 0 15-11-06 1 of 3
8.4 Correction of Non – Conformities 0 15-11-06 2 of 3
8.4.1 Use – AS IS 0 15-11-06 2 of 3
8.4.2 Repair / Re – Work 0 15-11-06 2 of 3
8.4.3 Repair to Base Metal by Welding 0 15-11-06 2 of 3
8.4.4 Scrap / Return to Vender 0 15-11-06 2 of 3
8.5 Verification of Correction to NCR 0 15-11-06 3 of 3
8.6 Quality Control Action Memo for Non – Pressure Parts 0 15-11-06 3 of 3
8.7 Closing of Issued NCR 0 15-11-06 3 of 3
8.8 Retention of Issued NCR 0 15-11-06 3 of 3
8.9 Additional Requirement for ASME Section VIII Division 2 0 15-11-06 3 of 3

9.0 Non – Destruction Examination – NDE

9.1 Scope 0 15-11-06 1 of 4
9.2 Requirement for NDT Examination 0 15-11-06 1 of 4
9.3 NDE Examination Procedures 0 15-11-06 1 of 4
9.4 NDE Examination Personnel / Technician Qualification and
0 15-11-06 2 of 4
Certification
9.5 NDE Examination Records and Reports 0 15-11-06 3 of 4
9.6 Additional NDE Examination Requirement for ASME Section VIII
0 15-11-06 3 of 4
Division 1 and Division 2
9.8 Year of Acceptable Edition of Referenced Standard Acceptable
0 15-11-06 4 of 4
to the current Code Rules
Section No. TOC
SESB QUALITY CONTROL MANUAL – EDITION 4 Revision No. 0
Date of Issue 01 – 06 - 2009
ASME SECTION VIII DIVISION 1 & DIVISION 2 Page 4 of 7
Section Content Revision No. Revision Date Page No.
 9.7 Certification of NDE Procedures, NDE Practices, NDE Records
0 15-11-06 4 of 4
and NDE Reports
9.8 Year of Acceptable Edition of Referenced Standard Acceptable
0 15-11-06 4 of 4
to the current Code Rules

10.0 Heat Treatment – HT

10.1 Scope 0 15-11-06 1 of 2
10.2 General 0 15-11-06 1 of 2
10.3 Written PWHT Procedure 0 15-11-06 1 of 2
10.4 PWHT Operation 0 15-11-06 2 of 2
10.5 PWHT Records 0 15-11-06 2 of 2
10.6 Pre – Heating of Base Metal During Welding 0 15-11-06 2 of 2

11.0 Calibration of Measurement and Testing Equipment

11.1 Scope 0 15-11-06 1 of 2
11.2 Calibration Procedure 0 15-11-06 1 of 2
11.3 Calibration Records 0 15-11-06 2 of 2
11.4 Discrepant Equipment 0 15-11-06 2 of 2
11.5 Thickness and Temperature Measuring Equipment 0 15-11-06 2 of 2
11.6 Welding Rectifier and SAW Welding Machine 0 15-11-06 2 of 2

12.0 Record Retention

12.1 Scope 0 15-11-06 1 of 3
12.2 Compilation of Manufacturing Inspection Book 0 15-11-06 1 of 3
12.3 Review and Approval of the Manufacturing Inspection Book 0 15-11-06 2 of 3
12.4 Furnishing of DATA REPORT and Signing of the DATA REPORT
0 15-11-06 2 of 3
by the Authorized Inspector
12.5 Code Symbol Stamp and the Application 0 15-11-06 2 of 3
12.6 National Board of Boiler and Code Stamp Items Inspector –
0 15-11-06 2 of 3
National Board
12.7 Distribution and Control of Manufacturing Inspection Book and
0 15-11-06 3 of 3
DATA REPORT
12.8 Additional Requirement for ASME Section VIII Division 2 Code
0 15-11-06 3 of 3
Stamp Items
12.9 Retention of MDR and DATA REPORT 0 15-11-06 3 of 3

13.0 Authorized Inspector

13.1 Scope 0 15-11-06 1 of 3
13.2 General Requirement 0 15-11-06 1 of 3
13.3 Service and Inspection Contract 0 15-11-06 1 of 3
13.3.1 Service Contract for ASME Review 0 15-11-06 1 of 3
13.3.2 Service Contract for Inspection of Code Stamp Items 0 15-11-06 1 of 3
13.4 Review and Acceptance Engineering Design Document and
0 15-11-06 2 of 3
Quality Control Document
13.5 Inspection of Code Stamp Items 0 15-11-06 2 of 3
13.6 Non – Conformance Report 0 15-11-06 2 of 3
13.7 Manufacturing Inspection Book and DATA REPORT 0 15-11-06 3 of 3
13.8 Application of Code Symbol Stamp 0 15-11-06 3 of 3
13.9 Review and Acceptance to New Edition, Revisions of the Quality
0 15-11-06 3 of 3
Control Manual

Section No. TOC

SESB QUALITY CONTROL MANUAL – EDITION 4 Revision No. 0
Date of Issue 01 – 06 - 2009
ASME SECTION VIII DIVISION 1 & DIVISION 2 Page 5 of 7
 Section Content Revision No. Revision Date Page No.

14.0 Field Assembly

14.1 Scope 0 15-11-06 1 of 7
14.2 General Requirement 0 15-11-06 1 of 7
14.3 Quality System Implemented at Field Site 0 15-11-06 1 of 7
14.3.1 Section 1.0 Statement of Quality Policy and
0 15-11-06 1 of 7
Authority
14.3.2 Section 2.0 Organization, Authority and
0 15-11-06 1 of 7
Responsibility
14.3.3 Section 3.0 Manual Control 0 15-11-06 2 of 7
14.3.4 Section 4.0 Engineering Drawing, Design
0 15-11-06 2 of 7
Calculation and Specification
14.3.5 Section 5.0 Material Control 0 15-11-06 2 of 7
14.3.6 Section 6.0 Examination and Inspection
0 15-11-06 3 of 7
Program
14.3.7 Section 7.0 Welding 0 15-11-06 5 of 7
14.3.8 Section 8.0 Correction to Non – Conformities 0 15-11-06 5 of 7
14.3.9 Section 9.0 Non – Destructive Examination –
0 15-11-06 5 of 7
NDE
14.3.10 Section 10.0 Heat Treatment 0 15-11-06 6 of 7
14.3.11 Section 11.0 Calibration of Measuring and Test
0 15-11-06 6 of 7
Equipment
14.3.12 Section 12.0 Record Retention 0 15-11-06 6 of 7
14.3.13 Section 13.0 Authorized Inspector 0 15-11-06 7 of 7
14.3.14 Field Assembly Not Performed By Spheretech
0 15-11-06 7 of 7
Engineering Sdn Bhd.

Certification and Acceptance of Edition / Revisions of the Quality Control Manual

SESB General Manager SESB Quality Control Manager Authorized Inspector
Review and Approval of Revision Review and Certification of Revision Review and Acceptance of Revision
Revision Number Revision Number Revision Number
Date of Issue Date of Issue Date of Issue

Signature Signature Signature

Date Date Date
Review and Approval of Revision Review and Certification of Revision Review and Acceptance of Revision
Revision Number Revision Number Revision Number
Date of Issue Date of Issue Date of Issue

Signature Signature Signature

Date Date Date
Review and Approval of This Edition Review and Certification of Revision Review and Acceptance of This Edition

Signature Signature Signature

Official Stamp General Manager Official Stamp QC Manager Official Stamp Authorized
Inspector
Date : Date : Date :

Section No. TOC

SESB QUALITY CONTROL MANUAL – EDITION 4 Revision No. 0
Date of Issue 01 – 06 - 2009
ASME SECTION VIII DIVISION 1 & DIVISION 2 Page 6 of 7
SAMPLE FORMS Use with this Manual
Sample Form
Rev. No. Description of SAMPLE FORM Section
Exhibit No.
Exhibit 1 0 Controlled Quality Control Manual Distribution Record Section 3.0
Exhibit 2 0 Quality Control Manual Tranmittal Section 3.0
Exhibit 3 0 Client’s Incoming Project Document Master List Section 4.0
Exhibit 4 0 Outgoing Project Document Master List Section 4.0
Exhibit 5 0 Drawing/Document Transmittal Section 4.0
Exhibit 6 0 Purchase Requisition Section 5.0
Exhibit 7 0 Purchase Order Section 5.0
Exhibit 8 0 Material Purchasing Specification Section 5.0
Exhibit 9 0 Material Verification Inspection Stickers Section 5.0
Exhibit 10 0 Material Receiving / Inspection Report Section 5.0
Exhibit 11 0 Store Issue Note Section 5.0
Exhibit 12 0 Inspection and Test Plan Section 6.0
Exhibit 13 0 Final Dimensional Report Section 6.0
Exhibit 14 0 Code Name Plates For U Section 6.0
Exhibit 15 0 Code Name Plates For U2 Section 6.0
Exhibit 16 0 Welder’s Performance Qualification Continuity Log Sheet Section 7.0
Exhibit 17 0 Non – Conformance Report Section 8.0

The Forms and Procedures used in the Quality Control System, as mentioned above for the relevant Sections of
this Quality Control Manual are available for Review and Acceptance by the Authorized Inspector ( For Code Stamp
Items ), Third Party Inspector, Client’s QA / QC Manager, Inspector from DOSH.

Certification of Review of QC Manual for Code Rules’ Compliance

This is to Certify that I have review the Quality Control Manual and All the Other Supporting Specifications,
Procedures and Practices for Code Rule’s Compliance.

Code Rule Edition 2004 Addenda NA

Certification of the Review By Approval of Certification

Quality Control Manager General Manager

Signature and Date Signature and Date
This is to Certify that I have review the Quality Control Manual and All the Other Supporting Specifications,
Procedures and Practices for Code Rule’s Compliance.

Code Rule Edition 2004 Addenda 2005

Certification of the Review By Approval of Certification

Quality Control Manager General Manager

Signature and Date Signature and Date

Section No. TOC

SESB QUALITY CONTROL MANUAL – EDITION 4 Revision No. 0
Date of Issue 01 – 06 - 2009
ASME SECTION VIII DIVISION 1 & DIVISION 2 Page 7 of 7

Certification of Review of QC Manual for Code Rules’ Compliance

This is to Certify that I have review the Quality Control Manual and All the Other Supporting Specifications,
Procedures and Practices for Code Rule’s Compliance.

Code Rule Edition 2007 Addenda NA

Certification of the Review By Approval of Certification

Quality Control Manager General Manager

Signature and Date Signature and Date

Review of QC Manual for Code Rules’ Compliance - Notes

This is to Certify that I have review the Quality Control Manual and All the Other Supporting Specifications,
Procedures and Practices for Code Rule’s Compliance.

Code Rule Edition 2007 Addenda 2008

Certification of the Review By Approval of Certification

Quality Control Manager General Manager

Signature and Date Signature and Date

This is to Certify that I have review the Quality Control Manual and All the Other Supporting Specifications,
Procedures and Practices for Code Rule’s Compliance.

Code Rule Edition 2007 Addenda 2009

Certification of the Review By Approval of Certification

Quality Control Manager General Manager

Signature and Date Signature and Date