QUALITY CONTROL

MANUAL

Edition 0 Section 5 Page 1 of 3 Rev. 0 Date 25-07-2009

5. EXAMINATION AND INSPECTION PROGRAM

5.1. FABRICATION : 5.1.1. Fabrication of Code items is controlled using ITP Exhibit No. ES-WP-28-F-01 prepared

by the Quality Control Engineer from shop drawings, and lists the sequence of fabrication, examination and inspection operations for each item in the spaces provided.

5.1.2. The completed ITP will be reviewed and approved by the QA/QC Manager. When completed, he reviews the ITP and shop drawings with the Authorized Inspector for his designation of inspection points prior to commencement of fabrication.

5.1.3. The QA/QC Manager and the Authorized Inspector sign and date the ITP in the space provided to document their review and to release the ITP to start Code fabrication.

5.1.4. The ITP 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. 5.2. INSPECTION POINTS : 5.2.1. HOLD POINT: A Hold point is an inspection point beyond which fabrication shall NOT proceed until signed off satisfactory by the designees. 5.2.2. 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. 5.2.3. REVIEW POINT: It is a document review process ,beyond which the fabrication may proceed : provided no Certification shall be granted to the Code Item till it has been accepted by the Party (ies )concerned 5.2.4. MONITOR POINT: an inspection point which is being carried out by the designee during performance of a fabrication activity.

5.3. FINAL INSPECTION : 5.3.1. When fabrication of a Code item is completed, the QC Engineer performs his inspection, if found in compliance with Code as well as contractual requirements, he will document such by singing the ITP in the relevant column. 5.3.2. QA/QC Manger will notify with sufficient time the A.I. to perform his designated inspection points in particular the final inspection following by hydrostatic test required by the Code. If parts not tested until field assembly is completed, such will be reported in the relevant Manufacturer Data Reports. 5.3.3. When a pressure vessel is not provided with an opening or other means of access to inspect the internal surface, a Hold point will be shown on the ITP, for the Quality Control

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QUALITY CONTROL

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Edition 0 Section 5 Page 2 of 3 Rev. 0 Date 25-07-2009

Engineer. That Matter will be discussed with the A.I. who has the right to assign a hold point to inspect the vessel internally prior the closure of which.

5.4. HYDROSTATIC TEST: 5.4.1. Code required hydrostatic tests are witnessed by the Quality Control Engineer 5.4.2. The QA/QC 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. 5.4.3. The pressure test shall be carried out in accordance with the applicable written procedure which covers the applicable Code requirements. 5.4.4. When the test meets Code requirements and is accepted by the Quality Control Engineer he will initial and date the ITP in the space provided and sign, the hydrostatic test report Exhibit No. ES-WP-49-F-01 5.4.5. Upon completion of test and final inspection, the ITP is returned to the QA/QC Manager for review and filing as described in Section 12 of this Manual.

5.5. TEST GAUGES : 5.5.1. One directly connected calibrated indicating test gauge mounted on the utmost point of the vessel, 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 1 nor more than 4 times that pressure in case of vessels manufactured to section VIII Div. 1. For boiler manufactured to Section I the range of the test gauge shall not be less than 1 the test pressure. 5.5.2. 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. 5.6. CODE STAMPING AND DATA REPORTS :

5.6.1. The QA/QC Manager has custody and control of the Code Symbol Stamps. He will issue the required stamp for use at the shop or field site when fabrication or field assembly is completed. Satisfactorily 5.6.2. The Code stamping is applied directly on the Code item, for section VIII Division 1, stamping could be applied on metallic nameplate as in sec 15. The Nameplate shall be permanently attached to the vessel. It is verified as correct by the Quality Control Engineer before he initials the ITP 5.6.3 The Code stamping shall be applied on the name plate as in sec 15. 5.6.4. Quality Control Engineer shall ensure that the name plate with correct marking has been applied to the proper vessel. 5.6.5. Upon completion of fabrication of a Code item, the Quality Control Engineer at shop or field site prepares the Manufacturers Data Report from the inspection final records and submits it to the QA/QC Manager for review and certification.

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QUALITY CONTROL

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5.6.6 The completed Manufacturers Data Report, together with the relevant supporting

records shall be submitted to the A.I. for review. All Manufacturers Data Report should be signature by A.I.

5.6.7. All records are returned to the QA/QC Manager for retention as described in section 12 of this Manual.

5.7. NONCONFORMITIES:

All nonconformities found during fabrication are controlled and corrected as described in Section 6 of this Manual.

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5.6. CODE STAMPING AND DATA REPORTS :

5.6.1.The QA/QC Manager has custody and control of the Code symbol stamps. He will issue the required stamp for use at the shop or field site when fabrication or field assembly is complete.

5.6.2.The Code stamping is applied directly on the Code item, or on a Nameplate, when permitted by the construction Code. Marking is as indicated in Section 15 of this QC Manual. The nameplate shall be permanently attached to the vessel. The marking, on the Code item or on Nameplate, is verified as correct by the QC Engineer before he initials the ITP.

5.6.3.When stamping the Code symbol on the nameplate after attachment to the item is not possible, the Code symbol stamp may be applied to the nameplate before it is affixed to the Code item. The QC Engineer is responsible for ensuring that the nameplate information is correct and it is applied to the correct Code item. The AI shall be notified for his verification.

5.6.4.Upon completion of fabrication of a Code item, the QC Engineer at shop or field site prepares the Manufacturers Data Report from the inspection final records and submits it to the QA/QC Manager for review and certification.

5.6.5The completed Manufacturers 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 Code symbol stamp and countersign the Manufacturers Data Report.

5.6.6.All records are returned to the QA/QC Manager for retention as described in section 12 of this Manual.