SECTION : 05

QUALITY CONTROL MANUAL Page : 1 of 3

Rev. : 0
EDITION NO.1
Date : 17/09/2023
EXAMINATION AND INSPECTION PROGRAM

1.1. FABRICATION :

1.1.1. Fabrication of Code items are controlled using Inspection & Test Plan
(Exhibit No. 05-01) prepared by the Quality Control Inspector from shop
drawings, and lists the sequence of fabrication, examination and inspection
operations for each item in the spaces provided.
1.1.2. Completed Inspection & Test Plan shall be submitted to the Quality Control
Manager, for review and approval. When completed, he submits ITP and
shop drawings to the Authorized Inspector for his review and designation of
inspection points.
1.1.3. The Quality Control Manager and the Authorized Inspector sign and date
Inspection and Test Plan in the space provided to document their review and
to release the Inspection and Test Plan prior start Code fabrication.
1.1.4. The Inspection & Test Plan contains columns for the initials and date of the
Quality Control Inspector on the applicable line for those operations he
accepts, and for the Authorized Inspector to initial and date in the column
provided for him to signify the operations he accepts.
1.1.5. When fabrication drawing is revised, the ITP shall be reviewed by the QC
Inspector for any changes and if no change is required, then he shall
document the same on the cover sheet of the ITP.

1.2. EXAMINATION AND INSPECTION POINT :

1.2.1. “H” HOLD POINT: A Hold point is an inspection point beyond which
fabrication shall NOT proceed until signed off satisfactory by the designees.
All stages of examination, testing, fabrication shall be considering hold point
for the QC Inspector.
1.2.2. “W” WITNESS POINT: A Witness point is an inspection point beyond which
fabrication may proceed provided the designee has been notified in time, and
when he is unable to attend has waived the inspection or is able to witness at
a later date. The notification to AI shall be documented on ITP.
1.2.3. “R” REVIEW POINT: A Review point is an inspection point beyond which
fabrication may proceed and inspection, NDE or any quality records are
required to be reviewed by the Authorized Inspector, such as Material Test
Reports, radiographs, PWHT charts, etc.

1.3. STAGE EXAMINATION AND INSPECTION:

5.3.1 During the work progress the Q.C inspector shall make his examination as
per the ITP.
5.3.2 When the results are accepted to him he shall sign on the ITP and prepare
the request for Non-destructive examination or heat treatment as required by
the ITP.
5.3.3 If the inspection point is hold or witness for the AI, the Q.C inspector shall
contact the AI and arrange for his inspection.
 SECTION : 05
QUALITY CONTROL MANUAL Page : 2 of 3
Rev. : 0
EDITION NO.1
Date : 17/09/2023
EXAMINATION AND INSPECTION PROGRAM

1.4. FINAL EXAMINATION AND INSPECTION:

1.1.1. When fabrication of a Code item is completed, the Quality Control Inspector
performs his final inspection, and initials the Inspection and Test Plan when
the item meets all Code and dimensional requirements.
1.1.2. The Authorized Inspector makes his final inspection following the hydrostatic
test required by the Code. For parts not tested until field assembly is
completed, he makes his inspection after fabrication of the part is completed.
1.1.3. When a Code item is not provided with an opening or other means of access
to inspect the internal surface, a Hold point will be shown on the Inspection
Test Plan, for the Quality Control Inspector and the Authorized Inspector, to
permit internal inspection before setting up of the final closure of the Code
item.

1.5. PRESSURE TEST :

1.5.1. Code required Pressure tests are witnessed by the Quality Control Inspector
and the Authorized Inspector.
1.5.2. The Quality Control Manager will verify that the Authorized Inspector has
been notified sufficiently in advance of each test to enable him to witness the
test and complete his inspection.
1.5.3. The pressure test shall be carried out in accordance with the applicable
written procedure which covers the applicable Code requirements and the
results shall be recorded in the Hydrostatic Test Record (Exhibit No.05-02)
1.5.4. When the test meets Code requirements and is accepted by the Quality
Control Inspector and the Authorized Inspector, they shall initial and date the
Inspection & Test Plan in the space provided.
1.5.5. Upon completion of test and final inspection, the Inspection and Test Plan is
returned to the Quality Control Manager for review and filing as described in
(RECORDS RETENTION) Section 12 of this Manual.
1.5.6. When conditions make hydro-test impracticable, Pneumatic test shall be
performed in accordance with UW-50 and UG-100 for pressure vessels only
if agreed by A.I.

1.6. TEST GAUGES :

1.6.1. One directly connected calibrated indicating test gauge, visible to the
operator controlling the pressure, and having a dial graduated over a range
of about double the intended maximum test pressure but not less than 1½
nor more than 4 times that pressure for Sec. VIII, div. 1 items, double the test
pressure and not less than 1½ the test pressure for Sec. I items, shall be
used for all types of test.
1.6.2. An additional indicating gauge may be necessary to allow the pressure to be
visible to the operator at all times during the test, and to prevent excessive
pressure being applied.
 SECTION : 05
QUALITY CONTROL MANUAL Page : 3 of 3
Rev. : 0
EDITION NO.1
Date : 17/09/2023
EXAMINATION AND INSPECTION PROGRAM

1.7. APPLICATION OF CERTIFICATION MARK AND CERTIFICATION OF DATA

REPORT :

1.7.1. The Quality Control Manager has custody and control of the ASME
certification mark. He shall issue the required ASME certification mark for use
at the shop or field site when fabrication or field assembly is complete.
1.7.2. The ASME certification mark is applied directly on the Code item, or on a
Nameplate, when permitted by the construction Code, Marking/Name Plate
for ‘S’ certification mark, Marking/Name Plate for ‘U’ certification mark and
‘PP’ certification mark (Exhibits Nos. 05-03, 05-04) upon authorization from
AI and in his presence. The nameplate shall be permanently attached to the
vessel. The marking, on the Code item or on Nameplate, is verified as correct
by the Quality Control Inspector before he initials the Inspection & Test Plan.
1.7.3. For pressure vessels and parts the certification mark shall be applied after
the hydro test or pneumatic test. For Parts, the certification mark may be
applied before the hydro test.
1.7.4. The nameplate may be marked before it is affixed to the vessel, in which
case HICC shall ensure that the nameplate with the correct marking has
been applied to the proper vessel, and the Inspector shall satisfy himself that
this has been done.
1.7.5. For boilers; HICC shall stamp each boiler, superheater, waterwall, or
economizer constructed with Section I in the presence of the AI after the
hydrostatic test marking and for power piping shall be as per (Exhibit.05-03)
1.7.6. Upon completion of fabrication of a Code item, the Quality Control Inspector
at shop or field site prepares the Manufacturer’s Data Report/ MPDR from
the inspection final records and submits it to the Quality Control Manager for
review and certification.
1.7.7. The completed Manufacturer’s Data Report, together with the final records
are then presented to the Authorized Inspector for his review and
acceptance. When he has satisfied himself that all Code requirements have
been met, he will authorize the application of the ASME certification mark
and countersign the Manufacturer’s Data Report /MPDR along with his
National Board commission No.
1.7.8. All records are returned to the Quality Control Manager for retention as
described in (RECORDS RETENTION) section 12 of this Manual.

1.8. NONCONFORMITIES:
All nonconformities found during fabrication are controlled and corrected as
described in (CORRECTION OF NONCONFORMITIES) Section 6 of this Manual.
All nonconformities shall be resolved and closed prior to certification of MDR/ PDR.

1.9. Related Exhibits

1. Inspection & Test Plan (Exhibit No. 05-01)
2. Hydrostatic Test Record (Exhibit No.05-02)
3. Marking/Name Plate for ‘S’ certification mark (Exhibits Nos. 05-03)
4. Marking/Name Plate for ‘U’ certification mark (Exhibits Nos. 05-04)
5. Marking/Name Plate for ‘PP’ certification mark (Exhibits Nos. 05-05)