SECTION : 14

QUALITY CONTROL MANUAL Page : 1 of 4

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EDITION NO.1
Date : 17/09/2023
FIELD ASSEMBLY

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1.1. SCOPE:

This Section describes the system for assuring that all requirements of Code and
customer’s specifications are met with respect to site work required in connection
with the construction of Code item. Site work will only consist of assembly of
power boilers, fabrication and assembly of power piping and/or completion of
pressure vessels which because of size or convenience cannot be completed at
the shop. Repairs and Alterations may also be carried out at site.

The Site Manager is responsible for the overall activities at field site.

1.2. PREPARATION OF DRAWINGS, DESIGN CALCULATIONS AND

SPECIFICATIONS:

1.2.1. The preparation, approval and review of these documents shall be

handled in accordance with Section 3 (DRAWINGS, DESIGN
CALCULATION & SPECIFICATIONS) of this Quality Control Manual.
All documents for Code Site work shall be marked with the “SITE WORK”
Stamp.

1.2.2. All revisions to these documents shall be handled in the same manner as
the originals.

1.3. DISTRIBUTION AND REVISION OF SITE ASSEMBLY DATA:

The distribution of site assembly data as well as the distribution of revisions to site
assembly data shall be handled in accordance with Section 3 (DRAWINGS,
DESIGN CALCULATION & SPECIFICATIONS) of this Quality Control Manual.

1.4. MATERIAL CONTROL:

1.4.1. ORDERING OF CODE MATERIAL:

All materials to be used for site work shall be ordered in accordance with
Section 4 (MATERIAL CONTROL) of this Quality Control Manual.
Purchasing of material at field sites is not permitted.

1.4.2. MATERIAL RECEIVING INSPECTION:

 All materials are subject to receiving inspection in accordance with
Section 4 (MATERIAL CONTROL) of this Quality Control Manual.
This shall be performed by the Quality Control Site Inspector and
documented on the Material Receiving Report.
 When a stamped parts by others received at the field site it shall be
dealt with as per sec.4 Para 4.4 of this manual except that the AI will
be the same AI of the field site.
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1.4.3. CONTROL OF CODE MATERIAL:

Only material procured, inspected and released at WA workshop shall be
used for Code site work, and the general procedure shall be in
accordance with Section 4 (MATERIAL CONTROL) of this Quality
Control Manual, except that the Quality Control Site Inspector assumes
the duties of the Quality Control Manager.

1.4.4. ORDERING OF WELDING MATERIAL:

Welding material shall be ordered in accordance with Section 4
(MATERIAL CONTROL) of this Quality Control Manual.

1.4.5. RECEIVING INSPECTION OF WELDING MATERIAL:

All incoming welding material shall be subject to receiving inspection in
accordance with Section 4 (MATERIAL CONTROL) of this Quality Control
Manual. This shall be performed by the Quality Control Site Inspector.

1.4.6. STORAGE OF WELDING MATERIAL:

Welding material shall be stored in accordance with Section 7 (WELDING
CONTROL) of this Quality Control Manual. The Site Store Keeper
(Electrodes) shall be responsible for the correct storage.
1.4.7. Part fabricated items at shop can be sent to the field site along with ITP
duly signed by QC Manager and AI at shop for the stages completed at
shop.
On receipt at site, QC site inspector shall carry out receipt examination
for identification and damage if any before further assembly at site and
offer the items to AI at site for inspection.

1.5. EXAMINATION AND INSPECTION PROGRAM:

All site work shall be controlled through the use of the field Inspection and Test
Plan (ITP) in accordance with Section 5 (EXAMINATION AND INSPECTION
PROGRAM) of this Quality Control Manual, except that the Authorized Inspector
at field site and the Quality Control Site Inspector shall designate their own
inspection points on the Field Inspection and Test Plan (ITP)It is the responsibility
of the Quality Control Site Inspector to review the Field Inspection and Test Plan
(ITP) with the Authorized Inspector prior to commencement of site assembly work.
Examination along with test reports shall be made available to QC manager for
his certification of Data report.

1.6. CORRECTION OF NONCONFORMITIES:

All Nonconformities found during site work shall be handled in accordance with
Section 6 (CORRECTION OF NONCONFORMITIES) of this Quality Control
Manual, except that the Quality Control Site Inspector shall be holding the Quality
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FIELD ASSEMBLY

control manager responsibility and the authorize inspector will be the AI at field
site.

1.7. WELDING CONTROL:

The preparation and qualification of Welding Procedure Specifications, Welder

performance Qualification and Welding Control shall be handled in accordance
with Section 7 (WELDING CONTROL) of this Quality Control Manual.
Welding Procedures shall be qualified at the shop, and welders may be qualified
either in the shop or at field site. The Quality Control Site Inspector shall be
responsible for the certification of welder performance qualification records at field
site.
In case of using individual welders at field site refer to Para 7.11 of this Manual
except that the responsibility lies on the site QC manger.

1.8. HEAT TREATMENT:

When it is necessary to perform heat treatment at field site, it will be performed by

a qualified subcontractor in accordance with WA procedures, using calibrated
equipment.
The heat treatment procedures shall be prepared and approved in accordance
with Section 9 (HEAT TREATMENT) of this Quality Control Manual.
The Quality Control Site Inspector shall be responsible for verifying calibration of
subcontractor’s equipment. Copies of heat treatment time/temperature charts and
any other records shall be reviewed by the Quality Control Site Inspector and will
be made available to the Authorized Inspector at site for review

1.9. NONDESTRUCTIVE EXAMINATION:

The control and implementation of NDE procedures at site shall be handled in

accordance with Section 8 (NONDESTRUCTIVE EXAMINATION) of this Quality
Control Manual.

1.10. 14.10. CONTROL OF MEASURING AND TEST EQUIPMENT:

Calibration of measuring instruments to be used at site shall be handled in

accordance with Section 10 (CALIBRATION OF MEASUREMENT AND TEST
EQUIPMENT) of this Quality Control Manual. Measuring and test equipment of
subcontractors shall be calibrated with their procedures which shall be reviewed
by the Quality Control Manager. It is the responsibility of the Site Manager to
ensure that only calibrated and identified equipment is used for site work.
Instruments retuned from site shall be calibrated for validation of measurements
made at site.

1.11. RECORDS RETENTION:

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Quality Control documents shall be prepared and retained in accordance with

Section 12 (RECORDS RETENTION) of this Quality Control Manual. All field site
records are maintained at the shop location by the QC manger.

1.12. AUTHORIZED INSPECTOR:

The contractual relationship with the Authorized Inspection Agency, access for the
Authorized Inspector at field site and coordination with the Authorized Inspector
shall be handled in accordance with Section 11 (AURTHORIZED INSPECTOR) of
this Quality Control Manual, except that the contact person with the Authorized
Inspector will be the Quality Control Site Inspector.

1.13. MDR AND CODE STAMPING AT SITE:

14.13.1. On completion of field assembly, QC inspector shall verify and Quality

control manager shall certify the MDR.
14.13.2. Custody and control of Code and NB stamps shall be transferred to QC
site inspector for use at field site and returned immediately after use to
QC Manager.
14.13.3. NB Number for field completed items is allocated by QC Manager.
14.13.4. Completed MDR together with QC records shall be presented to AI at
site for his review. When satisfied that all Code requirements have been
met AI at site shall authorize and witness application of Code /NB
stamp and sign the field assembly portion of MDR
14.13.5. Field assembly of vessels constructed to Section VIII Div.1, WA shall
follow all the requirements as per U-2(h). In all alternatives, the party
completing and signing the Form U-1 or U-1A Manufacturer’s Data
Report assumes full Code responsibility for the vessel.
14.13.6. Field assembly of boilers constructed to Section I, WA shall follow all
the requirements as per PG-107 including responsibility of certification.