Doc. No.

ASY-ASME-1

Alexandria Shipyard Company Edition 1

Rev. 0

QUALITY CONTROL MANUAL Section 7

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EXAMINATION AND INSPECTION PROGRAM Date 02-09-2020

7.0 EXAMINATION AND INSPECTION PROGRAM

7.1 Prior to start of fabrication/assembly, the QC Inspector/Field QA/QC

Inspector prepares the "Inspection and Test Plan" (Exhibit 7.01) for all Shop/
Fieldwork. The Inspection and Test Plan lists the fabrication, examination,
and inspection operations and contains spaces for the QC Inspectors/Field
QA/QC Inspector, Authorized Inspector and Client Inspector as required to
sign off operations they approve/accept.

7.2 The QSD shall review and approve the Inspection and Test Plan and offer to
the Authorized Inspector for his designation of inspection points prior to the
start of work. The AI signs the ITP for acceptance. Revision to the ITP
requires the same procedure of review and acceptance as for the First Issue.
The ITP shall be reviewed for any changes due to drawing revisions. If no
change is required, the review shall be documented in the remarks column of
the ITP.

7.3 The CSD is responsible for work performed on all Code items and is
responsible for conformance with the Shop drawings.

7.4 The TGM releases the job by forwarding the drawings and the ITP to the
concerned Workshop Manager. They are responsible to offer for examination
and Inspection at identified examination/inspection Hold/Witness points.

7.5 The QSD is responsible for keeping the Authorized Inspector informed of
fabrication progress. QSD shall give advance information to the Authorized
Inspector to attend witness and Hold inspection points.

7.6 Stage wise inspection (Visual, Thickness and Dimension Inspection) shall be
carried out by QC Inspector/QC Engineer.

7.7 Final visual & dimensional checks shall be carried out after completing all
NDE requirements as recorded in "Final Inspection Report" (Exhibit QC 6)
shall be prepared by the QC Inspector.

7.8 When entry inside the vessel is restricted due to size or any other reasons, an
inspection stage shall be identified as Hold to enable the AI to perform his
visual inspection of internal surface prior to setting up of closing weld seam.
All areas of NDE are selected by the QSD to Construction Code requirements.
Location of Spot RT is selected by the AI. QSD and AI may designate
additional examination/Inspection. When AI has been notified in advance and
cannot be present or otherwise make the selection, QSD may exercise his own
judgement in selecting the spots.
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7.9 Pressure tests shall be conducted by the Workshop Manager in accordance

with a written procedure reference document no ( ) approved by the QSD
and accepted by the Authorized Inspector. Pressure tests shall be
documented on the "Hydrostatic Test Report" (Exhibit 7.06).

7.10 Nonconforming work or material shall be identified by a “Deviation Card” tag

(Exhibit QC 21) and a Non-conformance Report shall be raised. NCR is
handled as described in Section 8.0 "Correction of Non-Conformities".

7.11 Upon completion of a Code item and receiving advice from QSD, the Quality
Assurance GM shall prepare the Manufacturer’s Data Report from the final
records and QSD shall review for correctness and completeness and shall
certify by signing for ‘ASY. The completed MDR, together with the drawings,
design documents and QC records are then presented to the Authorized
Inspector for review and his signature.

7.12 The QSD has custody and control of the ASME Certification Mark Stamps and
The National Board “NB” and “R” Stamps.

7.13 The QSD shall be responsible to collect all required records and reports and
verify that all stages in the ITP has been completed and signed off
satisfactorily by the designees. The QSD shall issue the ASME certification
Mark Stamp for use only when all fabrication, field assembly, examinations,
tests, and inspections are completed and the AI has authorized application of
Certification Mark Stamping. ASME Certification Mark Stamp shall be applied
in presence of the AI.

7.14 The QSD shall be responsible for correctness of the nameplate/stamping data

a) The Design Engineer shall specify the marking requirements on the

drawings. This information shall also include type of Certification
Designator to be included in the marking. The Certification Designator
depends upon construction Code and can be punched, engraved or
embossed on the name plate.
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b) For Section VIII, Division 1 vessels/Parts, the ASME Certification Mark

Stamp is applied on a name plate (Exhibit 5.04)/ (Exhibit 5.05) which
is permanently attached to the item or applied directly on the item.
Removable Parts of a vessel shall be identified with manufacturer’s
serial number and ASY for traceability.

c) If Stamping of the ASME Certification Mark on the Name plate, after it

is attached to vessel, is not practical, it shall be applied to the
nameplate before it is attached to the vessel. The QSD shall ensure
that correct nameplate is attached to the correct item. Any
nonconformity which cannot be corrected shall require removal of the
name plate and certification mark.

7.15 Certification Mark Stamping and Certification for Field Activities

The custody of ASME Certification Mark Stamp and NB stamp shall be

transferred to Field QA/QC Inspector for use at Field Site and shall be
immediately returned back to QSD after use. All field/site records are sent to
the QSD in the shop for retention as described in Section 12(Record
Retention).

7.16 National Board

a) If required by customer or if the final location is U.S.A. or Canada the

MDR shall be registered with the National Board of Boiler and Pressure
Vessel Inspectors.

b) The National Board serial numbers shall be controlled and issued by

the QSD.

c) The National Board serial numbers shall start with 1 without prefixes
or suffixes and shall be a whole number in numerical order without
skips or gaps of unused numbers or duplication of numbers. The NB
numbers are assigned on completion of pressure test or when the
pressure test is not carried out at the shop the NB numbers are
assigned at the time of certification of data reports.
d) The QSD shall maintain a NB Register Log Book (Exhibit-7.08) of
National Board serial numbers issued, showing National Board serial
number, description of the item stamped, customer and location, date
MDR certified and the date of dispatch of MDR to the National Board
for registration.

7.17 Distribution of Manufacturer’s Data Reports (MDR)

For pressure vessels (U Designator) a copy of the MDR shall be furnished to:
a) Client/Owner/User or their designated Agent
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b) Upon request to the AI

c) Jurisdictional Authorities at the place of installation when required by
law.
d) Keep a copy of the MDR on file in a safe custody for at least 5 years.

For parts, Manufacturer’s Partial Data Reports shall be furnished in duplicate

to the manufacturer of the complete vessel and Boiler.

e) When items are required to be registered with the National Board, the
QSD shall send the original MDR with applicable attachments to the
National Board within 30 days of signature by the AI. The data reports
shall be sent to:

National Board of Boilers & Pressure Vessel Inspectors

1055, Cruppers Avenue
Columbus, Ohio 43229, U.S.A.

7.18 As-Built Drawing

If required by the purchaser an “As built”-drawing of the dimensions of the

finished pressure vessel shall be prepared by the Design Engineer and
reviewed and approved by the DGM and shall be submitted to the AI for
review. This “As built”-drawing is filed by the QSD in the Job file and any
other file as required.