ASME MANUAL With Exhibit 03.07

RIBO INDUSTRIES PVT LTD
Section No. QCM 1.0

Rev. No 02
COVER PAGE Date 02.07.2014
Page 1 of 1
QUALITY CONTROL MANUAL (QCM)
For construction of Power Boilers, Boiler External Piping, Pressure Vessels and their parts in accordance
with ASME Code Section-I,ASME B31.1, Section VIII Division -1 at shop and field assembly at site
controlled by shop to be stamped with ASME Certification Mark with Code designator S or U as
appropriate.
WORK SHOP ADDRESS
RIBO INDUSTRIES PRIVATE LIMITED

SF NO 397/1, 2 & 3
LAKSHMANANPATTI VILLAGE,
TIRUCHI PUDUKOTTAI MAIN ROAD,
MANDAIYUR
PUDUKOTTAI DIST.
TAMILNADU - 622 515,
INDIA.
REGISTERED OFFICE
RIBO INDUSTRIES PRIVATE LIMTED

JUMAN CENTER PROMENADE ROAD
CANTONMENT
THIRUCHIRAPALLI 620001
TAMILNADU
INDIA
Phone : + 91 431 2402112
Web : www.ribo.in
Copy No : Issued to :
Issue Date:
CONTROLLED COPY UNCONTROLLED COPY

QUALITY CONTROL MANUAL Table of Contents

Section No. QCM 2.0 Rev.No:02 Date :02.07.2014 Page 1 of 1
Section No. of
Description Rev.No Date
No pages
QCM 1.0 Cover page 02 01 02.07.2014
QCM 2.0 Table of Contents 02 01 02.07.2014
QCM 3.0 Statement of Authority 02 01 02.07.2014
QCM 4.0 Glossary of Terms 02 03 02.07.2014
QCM 5.0 Organization Authority and Responsibility 02 02 02.07.2014
QCM 6.0 Control of Manual 02 02 02.07.2014
Drawings, Design Calculations and 02 02.07.2014

QCM 7.0 03
Specification Control
QCM 8.0 Material Control 02 04 02.07.2014
Examination, Inspection and Testing 02 02.07.2014

QCM 9.0 05
Program
QCM 10.0 Correction of Non Conformities 02 02 02.07.2014
QCM 11.0 Welding 02 04 02.07.2014
QCM 12.0 Non Destructive Examination 02 02 02.07.2014
QCM 13.0 Heat Treatment 02 02 02.07.2014
Calibration of Measurement and Test 02 02.07.2014

QCM 14.0 02
Equipment
QCM 15.0 Records Retention 02 02 02.07.2014
QCM 16.0 Site Activities 02 07 02.07.2014
QCM 17.0 Authorized Inspection 02 02 02.07.2014
QCM 18.0 Certifications 02 01 02.07.2014
QCM 19.0 List of Exhibits 02 02 02.07.2014
Prepared by Approved by Accepted by

Engineer Quality Head Quality Authorized Inspector
QUALITY CONTROL MANUAL Statement of Authority

RIBO INDUSTRIES PVT LTD is engaged in the Construction of Boiler and Pressure Vessels. The
management of Ribo Industries Pvt Ltd is committed to manufacture Power Boiler to ASME Section-
I Boiler External Piping to ASME B31.1 and Pressure Vessels to ASME Section VIII Division-1 to be
applied with ASME Certification Mark and the designators S for Boilers and Boiler External Piping
and U for Pressure Vessels. The company also carries out Field Assembly of Code items at
controlled sites whenever called for in the contract in accordance with the relevant Code and this
Quality Control Manual.
This Quality Control Manual covers the system to be implemented for the manufacture of the Code
items at our shop and also for the field assembly activities carried out at sites controlled by the
shop. Head Quality has full support of management and is responsible for preparation, approval,
issue and revisions to this Quality Control Manual.
Head Quality has authority and organizational freedom to identify quality problems and to initiate,
recommend and provide solutions.
Head Quality shall have all the authority to stop the work which does not meet the Code and this
Quality Control Manual requirement. In matters of disagreements, the same can be referred to the
undersigned for resolution in line with the Code requirements and this Quality Control Manual.
The Personnel referred in the various Sections of this Quality Control Manual are responsible for
implementation of their respective functional duties. They can however delegate the duty, but not
the responsibility to suitably qualified and competent personnel.
Date: 02.07.2014 Chief Executive Officer

QUALITY CONTROL MANUAL Glossary of Terms

AIA Authorized Inspection Agency
AI Authorized Inspector
AIS Authorized Inspector Supervisor
ASME The American Society of Mechanical Engineers
ASTM American Society of Testing Materials
Code ASME Sec.I ASME Sec. VIII Div. 1, ASME B31.1, as

applicable including referenced Codes and Standards
Code items In general, term refer ring to a Power Boiler, Pressure Vessel,
and Boiler External Piping or part there off constructed in
accordance with the Code.
CEO Chief Executive Officer
COC Certificate Of Compliance
Data Report Manufacturers Data Report/Manufacturers Partial Data

Report
DCR Design Change Request
DCN Design Change Note
H Hold point
HT Heat Treatment
IMTE Inspection Measurement and Test Equipment
ISO International Standards Organization
ITP Inspection Test Plan


MANUAL Quality Control Manual
MTR Material Test Report
MD Managing Director
MDR Manufacturers Data Report
MIV Material issue voucher
MRS Material Requisition Slip
MRIR Material Receipt cum Inspection Report
MPDR Manufacturers Partial Data Report
MT Magnetic Particle Test Report
NB Stamp National Board Stamp
National Board National Board of Boiler and Pressure vessel Inspectors,
1055, Crupper Avenue, Columbus, OH43230-1109, U.S.A.
NCR Non Conformity Report
NDE Non Destructive Examination
OPS Operation Process Sheet
PQR Procedure Qualification Record
PWHT Post Weld Heat Treatment


Section No. QCM 4.0 Rev.No.:02 Date :02.07.2014 Page 3 of 3
PT Liquid Penetrant Test
PVT LTD Private Limited
QCM Quality Control Manual
QC Quality Control
RT Radiographic Test
R Review point
REV NO Revision Number
RIBO RIBO Industries Private Limited
TC Test Certificate which also includes MTR and COC
TDC Technical Delivery Condition
UT Ultrasonic Test
WPS Welding Procedure Specification
WPQR Welders/Welding Operator Performance Qualification
Record
W Witness point
QUALITY CONTROL MANUAL Organization, Authority and Responsibility
5.0 SCOPE
This Section describes about Ribo Industries Private Limited Organization Chart for Shop and Site
activities.
5.1 RESPONSIBILITIES
5.1.1 Managing Director is responsible for overall management functions.

5.1.2 Chief Executive Officer responsible for overall planning and monitoring the functionary
departments such as Marketing, Design, Operations, Materials and Quality.
5.1.3 The responsibility and authority of the other personnel shown on the Organization Chart have
been described in various Sections of this Quality Control Manual.
QUALITY CONTROL MANUAL Control of Manual

Section No. QCM 6.0 Rev.No:02 Date : 02.07.2014 Page 1 of 2
6.0 SCOPE
This Section describes the procedure for controlling Quality Control Manual and other
procedures to meet the Code requirements.
6.1 RESPONSIBILITY
Head Quality is responsible for approval, Issue and control of this Quality Control Manual.
6.2 SYSTEM
6.2.1 Engineer Quality shall prepare and revise Quality Control Manual, as required, which shall be
approved by the Head Quality. Head Quality shall submit the Quality Control Manual and its
revisions, if any to the Authorized inspector (AI) for his review and acceptance prior to releasing
the same for Code activities. He shall maintain the original copy of the Quality Control Manual.
Head Quality shall issue a controlled copy of Quality Control Manual to the AI at the Shop and
Field sites, as applicable. The revised Quality Control Manual shall be approved by Head
Quality and accepted by Authorized Inspector.
6.2.2 The approval of Quality Control Manual by the Head Quality and acceptance by the AI shall be
documented on the Table of Contents page. The old document shall be withdrawn from the
user and destroyed by Head Quality.
6.2.3 Head Quality is responsible for the controlled distribution of this QCM and its revisions, using
QCM Distribution Register (Exhibit No: 1) which includes an acknowledgement of the recipient.
The old document shall be withdrawn and distorted by Head Quality.
6.2.4 Head Quality may de-control any copy of the QCM when no longer used for Code work.
6.2.5 Head Quality may also issue uncontrolled copy as and when required to persons outside the
Organization. Uncontrolled copies shall be current at the time of issue and may not be
updated.
6.2.6 Whenever any text in one Section undergoes a revision the entire Section, the Table of
Contents and Cover Page also get revised.
6.2.7 Should there be a revision in the Exhibits; the latest affected area shall be highlighted by Cloud.
The List of Exhibits and Table of Contents and Cover Page shall be revised. The revision
indicator shall appear only on forms and formats in the QCM and not forms and formats in use.
6.2.8 The latest revision in Section text shall be highlighted in bold italic font. Previous revision
indicators, if any shall revert to normal font. Master copy of revised sections due to
change in the Quality Control Manual shall be retained by Head Quality as record of
revision till next ASME joint review.
QUALITY CONTROL MANUAL Control of Manual

Section No. QCM 6.0 Rev.No.02 Date : 02.07.2014 Page 2 of 2
6.2.9 Quality Control Manual, Procedures and other related documents shall be reviewed within six
months of issuance of new Code Edition and revised if required for compliance. Such review
shall be carried out by Head Design, NDE Level III, Head Quality and Engineer Welding for
their respective functions. The record of such review and recommendation shall be
documented on the copies of Summary of Changes pages available in respective Code
Sections. Head Quality shall review these records for changes noted and incorporate these by
revising the Quality Control Manual, procedure etc. as required.
6.2.10 The revision number on Section No. QCM 2.0, Table of Contents and Section no. QCM 1.0,
Cover Page shall be revision status of the Quality Control Manual.
6.2.11 The Master copy of the QCM which has the signature of approval by Head Quality and
acceptance by the AI shall be marked as Master Copy in red in all pages and only
photo copies shall be distributed as Controlled copy and Un-controlled copy.
6.2.12 Head Quality shall maintain one copy of the superseded QCM for reference for a period
offive years. All other superseded copies shall be destroyed.
Drawings, Design Calculations and

QUALITY CONTROL MANUAL
Specifications Control
7.0 SCOPE
This Section describes the Procedure for preparation, verification, approval, issue, maintenance
and revision of Design documents such as fabrication drawing, design calculation, Technical
Delivery Condition and Material Requirement List Report for Code construction.
7.1 POLICY
7.1.1 Design activities shall be carried out to satisfy the requirements of Customer supplied data,
specification and applicable Edition of the Code. Method of establishing Governing Code
Editions and Cases for Code Items shall be in accordance with Appendix 43 of Section VIII Div. 1
and Appendix VI of Section I.
7.1.2 Materials used for pressure parts shall be those permitted by Section VIII Division 1 for Pressure
Vessels, Section I for Boilers and ASME B31.1 for Boiler external piping for which allowable stress
values are specified in Section II part D / B31.1 as applicable.
7.1.3 Due consideration shall be given to the requirements of corrosion allowance, additional loadings,
impact testing, inspection opening, Units of measurements, etc., as per the applicable Code
requirements.
7.2 SYSTEM
7.2.1 On receipt of customer Purchase Order, Head Marketing shall allocate Job Order Number along
with Manufacturers Serial Number and Purchase Order copy will be distributed to Head Design,
Head Material, Head Operations, Head Quality and Engineer Welding. The acknowledgment
of the same will be maintained at Marketing through Order Distribution Sheet (Exhibit No. 2). This
Job Order Number shall be used as product identification and shall be indicated in all documents.
7.2.2 On receipt of the Job Order Number, customer Purchase Order and customer Technical
Specification, if any, Head Design shall review customer supplied design data for adequacy of
Code Compliance including PG-22 loadings for ASME Section I and UG- 22 loading for ASME
Section VIII Div.1 requirements. Any clarification needs to be taken up with Customer through
Head Marketing by Head Design. Engineer Design shall prepare drawings, design calculations,
Material Requirement List Report (Exhibit No 3) and Technical Delivery Condition (TDC) ( Exhibit
No. 4) wherever required. Head Design shall check and approve all the design documents (
Drawings, Calculations, Material Requirement List Report and TDC).Initially the drawing will be
released with zero revision subsequently whenever any drawing is revised it shall be released with
revision identification as 1, 2,3 etc.,

7.2.3 In case the drawings and design calculation are furnished by the purchaser, Head Design shall
review them for Code compliance and adequacy for Construction and ensure that the relevant
Code requirements are complied with before taking up for manufacturing. Any discrepancy shall be
resolved with the customer through Head Marketing.
7.2.4 Head Design shall submit design documents to the AI for his review prior to start of manufacturing
activities .The review done by the AI does not relieve manufacturer of its responsibilities of
ensuring accuracy in drawings and calculations and compliance with the Code, Edition and Users
Specification. Any clarification related to the design sought by the AI shall be resolved
satisfactorily.
Head Design shall forward approved Material Requirement List Report along with applicable
TDCS to Engineer Project for Material Indent.
7.2.5 After the approval of design documents, Head Design shall issue Drawings to Head Planning with
Document Transmittal (Exhibit No. 5).
7.2.6 On receipt of drawings and all document, Engineer Planning shall make entry in Document
Distribution(Exhibit No.6) and distribute to Head Operations, Engineer Production, Engineer
Welding , Head Quality, Engineer Project and obtain acknowledgement.
7.2.7 Where there is a need for changes in the drawing, including material substitutions. Head Planning
will take the help of Engineer Project and shall raise Design Change Request (DCR) (Exhibit
No.7) and forward the same to Head Design through Document Transmittal. Head Design shall
review the proposed DCR, if acceptable, He shall prepare Design Change Note (DCN) ( Exhibit
No. 8) with respect to existing and proposed and release to Head Planning. Engineer planning
shall arrange to distribute the DCN to the concerned departments and mark the DCN number with
date on the drawing for reference. The maximum number of DCNs per drawing shall be limited
to 5. In case of further requirement drawings will be revised and released in the next revision.
7.2.8 DCN may be directly generated by Head Design, based on any change in Customer specification
/ design conditions. All DCNs shall be submitted to the AI for his review.
7.2.9 If any of the design data/documents are revised, Head Design shall review the changes and verify
whether the revisions have an effect on the design calculation, revise them as appropriate and
obtain approval. All such review shall be documented. When revision in the drawing does not
affect the design calculations, the design calculations shall be updated with drawing revision
number by Head Design with the Note that This revision of this drawing does not affect the
design calculations.

7.2.10 The AI shall have access to all calculation, design data drawings and DCNs for his review.
Revisions to the design documents shall be subjected to the same procedure and control as the
original documents.
7.2.11 Engineer Planning shall remove the obsolete copies promptly from the work spot and destroy
them unless it is required for reference. In that case the obsolete drawings shall be marked as
Superseded. Distribution of Design document after revision shall be the same as outlined in
para 7.2.5, 7.2.6 & 7.2.7 of this Section.
7.2.12 Currently computer program is not used for the design calculations. If used in future, a procedure
shall be prepared by Head Design covering approval, validation and revalidation with Code
Edition. All such record of validation shall be made available to the AI for review.
7.2.13 If Parts are constructed to the drawings supplied by the Customer, Construction shall be in
accordance with the applicable Code with Edition as specified by the Customer. It shall be
recorded in the remarks column of the Manufacturers Partial Data Report that the design
responsibility is out side the scope of RIBO.
QUALITY CONTROL MANUAL Material Control

8.0 SCOPE
This Section deals with procurement, receipt, inspection, identification, storage, and issue of
materials and components to ensure that the indented material is used for Code construction.
(Except welding consumables)
8.1 POLICY
All Materials procured shall be strictly in accordance with the Code and TDC (wherever
applicable) provided by Head Design.
8.2 SYSTEM
8.2.1 Engineer Project shall prepare Material Indent (Exhibit No. 9) based on Material Requirement
List Report and Technical Delivery Condition received from Head Design. Engineer Project
forward to Material Indent along with applicable TDC to Head Material for verification of
available of material in the stock.
8.2.2 Stores Officer verify the stock, If material is available, he shall arrange for examination of the
same by providing the Material Test Certificates and MRIR (Exhibit No:10) (Materials Receipt
cum inspection Report) and material identifications to Engineer Quality, who shall verify the
documents shown above along with the drawing and TDC and examine the materials. If
found satisfactory, the material shall be accepted through Stock Transfer cum Inspection
Report (Exhibit No: 11) prepared by Stores Officer, checked by Engineer Quality and
approved by Head Quality. If the material requires upgrading to ASME requirement, Engineer
Quality shall prepare NCR and process them as per Section No QCM 10.0of this Manual
dealing with Correction of Non conformity.
8.2.3 If materials are not available in stock, Stores Officer shall forward the Material Indents along
with applicable TDC to Head Material for procurement.
8.2.4 Head Material shall raise Supply Purchase Order (Exhibit No.12) for procurement of the
material. The Supply Purchase Order and TDC (wherever applicable) shall be distributed to
Engineer Project and Stores Officer for the purpose of verification at the receiving Inspection
stage.
8.2.5 If the indented material is not available in the market, a proposal for alternate material shall
be submitted to Head Design through Engineer Project for his approval through DCR as per
paragraph 7.2.7 and 7.2.8. of Section No QCM 7.0 of this Manual dealing with Drawings,
Design calculations and Specification control.

8.2.6 On receipt of the materials, Stores Officer shall offer the material to Engineer Quality for Inward
Inspection clearance along with MRIR, Material Test Certificate, Supply Purchase Order and
TDC. (wherever applicable)
8.2.7 Engineer Quality shall carryout examination of the material/parts with respect to Supply Purchase
Order and TDC (wherever applicable). The above examination of material/parts shall include as a
minimum the following.
8.2.8 Attributes of the material to be checked by the Engineer Quality includes but not limited to:
a) Review of Material Test Report (for conformity with Code and TDC requirements).
b) Verification of Original Markings on material and part. .
c) Visual and dimensional inspection including thickness measurement wherever applicable.
d) Physical distortion / damage to item or packing.
e) Contents of Manufacturers Partial Data Reports for parts supplied by ASME accredited
manufacturers.
f) Record of measuring instruments used during dimensional measurement on the
MRIR
8.2.9 If the material /items meet the requirements, the Engineer Quality shall sign the MRIR.
8.2.10 If the Material/parts are not acceptable, the same shall be reported on Non conformity
Report(NCR) (Exhibit No.13) and shall be dealt as per Section No. QCM 10.0 of this Manual
dealing with Correction of Non conformities. NCR number shall be indicated on the MRIR.
8.2.11 If ASTM material is received, with Edition different from the latest adopted Edition ,
EngineerQualityshall verify the same against Table II 200 1 of ASME Section II for other
acceptable Edition as permitted and certify with evidence acceptable to the AI. If the
material is not acceptable, and for other non-ASTM material Engineer Quality shall raise a
Non-Conformity Report and resolve as described in QCM 10.0 of this Quality Control
Manual dealing with Correction of Non conformities. ASTM / Non ASTM materials if used
shall be re-certified to required Edition of ASME Specification and corresponding material
shall be marked with ASME specification in the presence of Engineer Quality.
8.2.12 If ASME materials certified to Year of Edition that are different than the required Edition as per
drawing, Engineer Quality shall review the Material Test Report to the required Edition of the
Material Specification , If acceptable same shall be certified on the Material Test Certificates.
8.2.13 Any additional material testing to be conducted for acceptance /upgrading the material, the same
shall be witnessed by Head Quality and certified by him and test report attached to the MRIR.

8.2.14 MRIR shall be offered to the AI for his review and acceptance. Fabricated parts when received
with Manufactures Partial Data Report shall be examined by the Head Quality for compliance
with the Code and Addenda Requirements. Fabricated parts with Manufactures Partial Data
Report shall be offered to the AI for his verification prior to further processing.
8.2.15 Stores Officer shall store the material with proper identification in the designated areas in a
suitable manner to prevent from deterioration. Non conforming materials shall be identified and
segregated in accordance with Section No. QCM 10.0 of this Quality Control Manual dealing with
Correction of Non conformities.
8.2.16 Based on Material Requisition Slip (Exhibit No.15) prepared by Engineer Production and
approved by Head Operations along with cutting plan prepared by Engineer Planning and
approved by Head Planning, Stores Officer shall prepare Materials Issue Voucher (MIV)
(Exhibit No. 14) and issue the material after Inspection by Engineer Quality and obtain
signature of Engineer Production.
8.2.17 After receipt of materials from Stores Officer, Engineer Production shall offer the material to
Engineer Quality for examination. Engineer Quality shall inspect the correctness of materials for
Code compliance with respect to the Job order Number, drawing and record the identification
details in Material Identification Report (Exhibit No.16).
8.2.18 Engineer Quality shall ensure that one completed set of original identification markings as
required by the material specification are available on all material used for pressure parts. If
these markings are likely to be removed due to some operation like cutting and machining, the
completed set of marking as required by specification shall be transferred along with drawing
number and part number in the presence of Engineer Quality prior to such cutting or machining
operation. After ensuring accurate transfer of markings, Engineer Quality shall apply his RIBO
QC Stamp near the transferred markings. If the transfer of total marking is not practicable on
small parts, the coded marking traceable to original identification may be applied in a manner
acceptable to the AI as described in procedure.
8.2.19 Material identity shall be maintained throughout by hard stamping/ engraving. Hard stamping
shall not be applied when service conditions prohibits or when thickness of ferrous materials less
than 6mm and non ferrous materials less than 13mm thickness. In this case marking shall be
done by etching, engraving or paint marking.
8.2.20 Material supplied by Customer for Code construction shall be examined in the manner described
above for Compliance. Any discrepancy shall be resolved with Customer with in the Code
requirements.
8.2.21 Activities such as rolling, forming, heat treatment testing etc. where sub-contracted, a Work
Order(Exhibit No.35) with required specification shall be issued by Head Planning .
8.2.22 Material delivered to subcontractor for rolling and forming shall be identified by stamping with Job
Order Number and marking as per material specification to permit traceability to Material Test
Report in the presence of Engineer Quality. This shall be identified in the Work Order to the
subcontractor.
8.2.23 When the boiler or pressure vessel heads and other pressure boundary parts are cold formed by
others, the required certification for the part shall indicate whether or not the part has been heat
treated.
Examination, Inspection and Testing

Program
Section No. QCM 9.0 Rev. No:02 Date :02.07.2014 Page 1 of 5
9.0 SCOPE
This Section deals with examination, Inspection and Testing Program requirements during
construction of Code item.
9.1 POLICY
All examination inspection and testing during construction of Code item shall be in accordance
with Code and this Manual.
9.2 SYSTEM
9.2.1 All pressure vessels, boilers and their parts shall be fabricated in accordance with requirements
of the applicable ASME Code and this Quality Control Manual.
9.2.2 Head Quality is responsible for preparation and approval of the Inspection and Test Plan (ITP)(
Exhibit No:17) based on the drawing, customers specification and Code requirement indicating
the Examination / Inspection Stages, Characteristic to be checked, Reference Standard,
Acceptance criteria, Format of record and Provision for Identifying the AI Inspection
Hold/Witness/Review Points. Head Quality shall submit the Inspection and Test Plan to the AI
for indicating his Hold/Witness and Review points.
9.2.3 For vessels where access opening is not provided due to size constraints, internal inspection by
the AI shall be arranged before setting up of final closing of the vessel, an inspection stage shall
be identified as a Hold point suitably in the Inspection and Test Plan.
9.2.4 Head Quality shall forward the copy of Inspection and Test Plan to Head Planning through
Document Transmittal.
9.2.5 Using drawing and ITP, Engineer Welding shall prepare and approve Applicable WPS List
(ExhibitNo.18) indicating Joint No and WPS Number. Engineer Welding shall submit the
Applicable WPS List to the AI for his review. After review by the AI, Engineer Welding shall
forward copy of Applicable WPS List to Head Planning through Document Transmittal.
9.2.6 Based on the Inspection and Test Plan, Drawing and Applicable WPS List, Engineer Planning
shall prepare Operation Process Sheet ( Exhibit No:19) listing the all the stages of operation
during fabrication and transferring the AI Hold, Witness, Review Points. Operation Process Sheet
shall indicate the relevant manufacturing procedures, WPS Number, provision for welder
Identification Number, Record reference of examination / Inspection stages for Engineer Quality
and the AI as per the Inspection and Test Plan.
9.2.7 Operation Process Sheet shall be reviewed by Head Quality for accurate transfer the AI Stages
and approved by Head Planning. Head Quality shall offer Operation Process Sheet to the AI
for his review with respect to correct transfer of his Hold, Witness and Review Points prior
to commencement of manufacturing.

Program
9.2.8 Head Planning shall issue Operation Process Sheet to Engineer Production through
Document Distribution.
9.2.9 For execution of the job, Engineer Production shall maintain the Operation Process Sheet
and obtain the clearance from the Engineer Quality during various stages as indicated in the
Operation Process Sheet.
9.2.10 Engineer Quality is responsible for offering required inspection stages to the AI with
adequate advance notice. The AI shall signify his acceptance by signing on the Operation
Process Sheet.
9.2.11 Whenever the drawings are revised, Inspection and Test Plan, Applicable WPS List and
Operation Process Sheet shall be reviewed for any changes and the same shall be revised
accordingly. If there is no change, the same shall be documented on the respective
document by Head Quality, Engineer Welding and Head Planning respectively.
9.2.12 Revision to the Inspection Test Plan, Applicable WPS List , Operation Process Sheet require
the same procedure and review and acceptance as for the first issue.
9.2.13 The Performance of Inspections shall be documented with Signatures with date on the
Operation Process Sheet by Engineer Quality and the AI.
9.2.14 All the records of the inspection and Stage Inspection Reports (Exhibit no.38) as
referenced in the Operation Process Sheet shall be prepared progressively by
Engineer Quality and made available to the AI for review.
9.3 Inspection Points
9.3.1 Hold Points are designated by H on the Inspection and Test Plan and Operation Process
Sheet. These are Operations that shall not be by passed and require advance notification by
the Head Quality for the AIs Inspection and acceptance before proceeding further.
9.3.2 Witness Points are designated by W on the Inspection and Test Plan and Operation
Process Sheet shall be offered to the AI with adequate notification giving the opportunity to
witness and verify on activity. If the AI is unable to witness the Inspection activities, the
fabrication operation can be proceed with prior permission from the AI. The waived witness
points shall be documented on the Operation Process Sheet and records shall be available
for the AIs review on his next visit.
9.3.3 Review Points designated by R on the Inspection and Test Plan and Operation Process
Sheet and are referring to review of documents.

Program
9.4Examination and Inspection during fabrication
9.4.1 Engineer Production shall sign of the Operation Process Sheet on completion of the
individual stages and offer to Engineer Quality for examination at the designated stages.
Engineer Quality shall carryout examination of the designate stage if satisfactory, he shall
sign of the Operation Process Sheet with date, if there is stage Non Destructive Examination,
Engineer Production shall send a Non Destructive Examination Requisition Slip through
Engineer Quality for carrying out NDE as per the Drawing and Operation Process Sheet
requirements.
9.4.2 Engineer Quality shall also record reference of the Inspection Report / NDE Report/ Test
Reports in the Operation Process Sheet.
9.4.3 Head Quality shall inform the AI with sufficient notice to enable him to carry out his inspection
at the identified stages and sign off in the Operation Process Sheet to record his acceptance.
9.4.4 All Welding shall be carried out in accordance with the approved welding procedure
specification by qualified welders as per Section No. QCM 10.0 dealing with Welding.
9.5PRESSURE TEST
9.5.1 Prior to the pressure test, Head Quality shall ensure all examinations and inspections, NDE,
Heat treatment if required shall have been performed and Non Conformities if any shall have
been closed out and shall be referenced in the Operation Process Sheet.
9.5.2 Engineer Production shall carryout the pressure test as per procedure acceptable to the AI.
Head Quality shall inform the AI in advance for witnessing the pressure test.
9.5.3 Any Non Conformities observed during fabrication, examination, Inspection and Testing shall
be handled as per Section No. QCM10.0 dealing with Correction of Non Conformities.
9.5.4 Based on final dimensional reports given by Engineer Quality through Engineer Project As-
Built drawings for the finished Code item shall be prepared by Engineer Design and
reviewed and approved by Head Design before application of ASME Certification mark.
Copies of these drawings shall be filed in Manufacture Data Dossier.

Program
9.5.5 Head Quality shall keep the ASME Certification Mark and National Board Mark under his
custody. He shall verify the satisfactory completion of all stipulated examination, inspection
and testing of the Code item before the application of Certification Mark on the Name
plate/Direct stamping, as applicable. He shall verify the correctness of the Nameplate/ Direct
stamping (Exhibit Nos.20,22,22A to 26) before the application of the ASME Certification Mark
which shall be arranged in the presence of the AI.
9.5.6 Engineer Quality shall prepare the Manufactures Data Report (MDR) / Manufactures Partial
Data Report (MPDR)based on As Built Drawings, Inspection Records. Head Quality
shall certify the MDR/MPDR and submit to the AI for his signature.
9.5.7 Copies of completed MDR along with applicable MPDR attached, if any, shall be distributed
by Head Quality to the purchaser, the Authorized Inspector, appropriate enforcement
authority (if so required) in the jurisdiction in which vessel is to be installed and retaining a
copy for record in line with Section No. QCM 15.0 of this Manual dealing with Records
Retention.
9.5.8 After completion the MPDR will be distributed for the Code parts in duplicate to the
Manufacturer of the completed power boiler or pressure vessel.
9.6 NATIONAL BOARD REGISTRATION
9.6.1 Code items which require registration with the National Board of Boiler and Pressure Vessels
Inspectors (National Board) shall be assigned with the National Board number by Head
Quality shall maintain a National Board Number Log Register (Exhibit No. 27) of registered
Code items which shall contain
a) Entry Serial No,
b) Manufacturers Serial number
c) National Board Number
d) Date of allotment of NB number,
e) Description of the item,
f) Installation location (If known)
g) Signature date on MDR/MPDR by the AI
h) Date of posting MDR/MPDR to NB for Registration
i) Head Quality signature


Program
Section No. QCM 9.0 Rev. No: 02 Date :02.07.2014 Page 5 of 5
9.6.2 The National Board number shall be assigned starting with 1 with out skips or gaps of
unused numbers or duplication of numbers. No prefixes or suffixes, either alphabetical or
numerical shall be used with NB number.
9.6.3 National Board numbers shall be issued after the completion of the Pressure Test. In the
event of an item not being pressure tested in the shop; the National Board Number shall be
issued at the time of certification of MDR/MPDR.
9.6.4 Head Quality is responsible for the control and issuance of National Board numbers. He
shall keep the National Board Mark under his custody. National Board Mark shall be applied
with the National Board Number for items requiring National Board registration.
9.6.5 Head Quality shall forward original MDR and MPDR with in 30 days of certification by the
AI to National Board of Boiler and Pressure vessel Inspectors, 1055, Crupper Avenue,
Columbus, OH43230-1109, and U.S.A.
QUALITY CONTROL MANUAL Correction of Non Conformity

10.0 SCOPE
This Section describes the identification, segregation, correction and disposition of Non
Conformities.
10.1 POLICY
10.1.1 A Non Conformity is any condition which does not comply with the applicable rules of the Code,
Quality Control Manual, Procedures or other specified requirements.
10.1.2. Non Conformities must be corrected before the completed Code items can be considered to
comply with the Code.
10.1.3 Head Quality is responsible for final disposition of the Non conformities.
10.1.4 Repair of defects in welded joint detected by Non Destructive Examination/Visual Examination
need not be reported through Non Conformance Report (NCR)(Exhibit No.13), but shall be
recorded on NDE reports/Inspection reports. The repairs shall be carried out using qualified
procedures & personnel after acceptance by the AI and documented in the respective
OPS/inspection Report/NDE report.
10.1.5 In case of repairs in materials/ Code items, prior concurrence of the AI shall be obtained for the
proposed method and extent of repair.
10.2 SYSTEM
10.2.1 Non conformance when noticed shall be handled as per procedure given below
10.2.2 Engineer Quality shall raise NCR.
10.2.3 Engineer Quality shall identify the Non Conforming materials / Code items by affixing HOLD tag
and marking in red ink and segregate them (wherever possible). He shall also ensure that no
further processing is done until the NCR is finally dispositioned.
10.2.4 Based on the nature of the Non conformity, Head Quality may give the acceptance on proposed
correction or If the proposed action involves design justification or substitution of material, he shall
forward the same to Head Design for his review and corrective action.
10.2.5 Head Design shall provide the comments on proposed corrective action and when this proposed
corrective action Code justification, he shall prepare necessary documents and present for the
AIs review.
QUALITY CONTROL MANUAL Correction of Non Conformity

10.2.6 When resolution of Non-Conformity has bearing on the Code requirement, the same shall be
submitted to the Authorized Inspector for his review by Head Quality prior to taking corrective
action.
10.2.7 Based on the comment, the AI acceptance, corrective action shall be carried out by Engineer
Production Head Material or the concerned personnel and the corrective action shall be
recorded on NCR by Engineer Quality.
10.2.8 If rework /repair is recommended, a supplementary Inspection and Test Plan/Operation Process
Sheet shall be prepared, if required, to specify additional examination/inspection stages in the
same manner as per Section No QCM 9.0 of this Manual dealing with Examination, Inspection
and Testing Program.
10.2.9 After the rework/repair, the item shall be examined by Engineer Quality and inspection by the AI
in accordance with the revised Inspection and Test Plan. After satisfactory corrective action of
Non Conformity the item shall be released for further processing by Head Quality.
10.2.10 When Material/Code item is rejected, the same shall be identified by painting as Rejected or
affixing Rejected tag (Exhibit No. 28)
10.2.11HeadQuality shall submit all NCRs to the AI and obtain the AIs signature for his review.
10.2.12Verification of corrective action, disposition shall be filed by Head Quality or his designee in the
job file.
10.2.13Head Quality shall maintain List of NCR for each Job Order Number wise in Non Conformity Log
Register (Exhibit No. 29)
QUALITY CONTROL MANUAL Welding

Section No. QCM 11.0 Rev.No: 02 Date :02.07.2014 Page 1 of 4
11.0SCOPE
This Section describes the welding quality control for items to meet the Code requirements.
11.1 POLICY
11.1.1 All welding carried out on Code construction shall conform to the requirements of ASME Section
IXand relevant Code of construction.
11.1.2 Welders, welding operators and all welding procedure specification shall be qualified as per
ASME Section IX and applicable Code Section.
11.1.3 All welding consumables shall meet ASME Section II Part-C or as otherwise permitted by the
applicable Code Section.
11.2 SYSTEM
11.2.1 WELDING PROCEDURES
11.2.1.1 Engineer Welding shall prepare a welding procedure specification and arrange to carry out
procedure qualification as and when required. Welding Engineer shall monitor and record the
actual welding variable used during procedure qualification test. He is also responsible for
witnessing of relevant testing as required by ASME Section IX and Code. based on satisfactory
test result, Engineer Welding shall certify PQR.
11.2.1.2 Welding Procedure Specification (WPS) shall be approved by Engineer Welding to ensure all
essential, non essential and supplementary essential variables are addressed as per ASME
Section IX, if there are any changes in essential and supplementary essential variable the
procedure to be re-qualified. If there are any changes in the non-essential variables the WPS
shall be revised or new WPS may be issued.
11.2.1.3 Engineer Welding shall prepare Applicable WPS List ((Exhibit No.18).for each Job Order
Number based on applicable drawing, Inspection and Test Plan and Customer specifications, if
any. The Applicable WPS List is reviewed / approve by the Engineer Welding and same shall
be presented to the AI for review.
The copies of The Applicable WPS List shall be issued through Head Planning to the following
1. Head Quality
2. Engineer Production
11.2.1.4 Engineer Welding shall be responsible for making the WPS available to the Welders/Welding
Operators in the work area.

11.3.1 WELDERS/WELDING OPERATORS PERFORMANCE QUALIFICATION
11.3.1.1 Engineer Welding shall identify welder/welding operators to the qualified for Code welding as
per approved WPS. Engineer Welding shall supervise welders/welding operator qualification
welding and produce a record of actual variables used as per ASME Sec IX and applicable
Code Section. Engineer Welding shall witness the welders /welding operator qualification and
testing based on the satisfactory test results, Engineer Welding shall certify welders/welding
operators Performance Qualification(WPQR). Each welder/welding operator shall be allocated
a unique identification number after qualification. Engineer Welding shall maintain a List of
ASME Qualified Welders (Exhibit No.30), which includes the Qualification range and validity.
The List of ASME Qualified Welders are reviewed and approved by Engineer Welding. A copy
of the list shall be distributed to:
1. Head Quality
2. Engineer Production
11.3.1.2 Engineer Welding shall maintain a Welder/Welding Operator Continuity Record (Exhibit No.31)
for all the welders//welding operators for Code construction. Engineer Welding shall examine
this engagement log every 3 months for the purpose of extending the validity of welders
qualification in the List of ASME Qualified Welders.
When Welder has not welded with a process during a period of 6 months or more his qualification for that
process shall expire unless within the six months period prior to his expiration of qualification
a) A welder has welded with the process using manual or semi-automatic welding under the
supervision and control of Engineer Production.
b) A welding operator has welded with the process using machine or automatic welding under
the supervision and control of Engineer Production.
11.3.1.3 When there is specific reason to question welders ability to deposit sound weld such welders or
welding operators shall be re-qualified for welding
11.3.1.4 The AI may seek requalification of welder/welding operator or procedure at any time or witness
tests of the welding procedures, welders/welding operators qualification.
11.3.1.5 Individual may be engaged for their service as welders/welding operators by RIBO on contract
or agreement with following conditions
a) All Code construction shall be the responsibility of RIBO including ASME Certification
Marking.
b) All welding shall be performed in accordance with RIBOs Welding Procedure Specification
which have been qualified by the Engineer Welding in accordance with the requirements of
Section IX

c) All welders shall be qualified by Engineer Welding in accordance with the Section IX. Each
welder shall be given an unique identification number after qualification.
d) Engineer Welding is responsible for complete and exclusive administrative technical

supervision of welders / welding operators.
e) Engineer Welding shall have the authority to assign / remove welders / welding operators at
his discretion without the involvement of any other party.
f) Head Quality shall obtain the AIA acceptance for the above mentioned programme.
g) RIBO shall be responsible for Code compliance of the vessel or part including ASME
certification marking providing data report forms properly executed and certified by Head
Quality and the AI.
11.4.1 WELDING CONSUMABLES
11.4.1.1 Engineer Welding shall prepare the Material Indent for welding consumables based on
estimated requirements and forward to Head Material. Welding consumables shall be procured
strictly in accordance with the approved List of welding consumables meeting the Code
requirement / TDC condition, if applicable.
11.4.1.2 Head Material shall arrange to procure the required welding consumables from approved
vendors.
11.4.1.3 Engineer Welding with the help of Stores Officer shall receive all the welding consumables and
shall carryout examination as described in Section No QCM 8.0 of this Manual dealing with
Material Control.
11.4.1.4 Engineer Welding shall carry out examination of the consumables and release the same, if
acceptable. He shall also verify the required markings and the conditions of packing. If not
acceptable NCR will be raised by Engineer Welding for proposing suitable action as per Section
No QCM No.10.0 of this Manual dealing with Correction of Non Conformities
11.4.1.5 All accepted consumables shall be stored in a room sufficiently dry and weather proof in their
designated locations.
11.4.1.6 Stores Officer shall re-dry all covered electrodes and fluxes as per the guidelines issued by
Engineer Welding which is based on manufacturers recommendation and keep them in holding
ovens until they are issued to the Welders/Welding Operators.
11.4.1.7 Welders/welding operators shall draw the consumables from the Stores using a Welding
Consumables Requisition Cum Issue Slip (Exhibit No: 32) duly authorized by Engineer
Production. A maximum of 15 covered electrodes may be issued to welder at a time. The low
hydrogen electrodes shall be stored in a portable oven by welders. All unused electrodes shall
be returned to the Stores Officer by the Welders. These returned electrodes if not damaged
shall be stored separately by Stores Officer and shall not be used for Code items.

11.4.1.8 Engineer Production shall prepare welding work Instructions Sheet (Exhibit No: 33)for each
welder based on the WPS mentioned on the Applicable WPS List.
11.5.1 PRODUCTION WELDING
11.5.1.1 Production welding during construction shall be supervised by Engineer Production, he is

responsible for engagement of qualified welders and control of production welding on Code
item. During construction he shall record and maintain the actual identity of welder used during
the tack welding / production welding on the OPS. Additionally welder may apply his stamp
adjacent to weld and at intervals of not more than 1 meter along the welds.
11.5.1.2 Tack welds used to secure alignment shall either be removed completely when they have served
their purpose or their starting and stopping ends shall be properly prepared by grinding or other
suitable means so that they may be satisfactory incorporated into the final weld.
11.5.1.3Tack welds whether removed or left in place shall be made using welding procedure qualified in
accordance with ASME Section IX and the applicable Code Sections.
11.5.1.4Tack welds shall be made by welders/welding operators qualified in accordance with ASME
Section IX and the applicable Code sections. Tack welds shall be examination visually for
defects if found to be defective, shall be removed.
11.5.1.5Temporary attachments to pressure parts shall be welded using qualified WPS and qualified
welders. After removal of such attachments, the area shall be examined for any defects.
11.6 REPAIRS TO MATERIALS / CODE ITEMS
Method and extent of repair by welding to materials/Code items shall have prior acceptance of
the AI.
QUALITY CONTROL MANUAL Non Destructive Examination

12.0 SCOPE
This Section describes the preparation and approval of NDE procedures and qualification of
personal, identification of type and extent of NDE and reporting.
12.1 POLICY
12.1.1 All Non Destructive Examination except PT,MT may be subcontracted to outside agency.
Qualification and certification of NDE personnel engaged in methods Radiographic Testing (RT),
Ultrasonic Testing (UT), Liquid Penetrant Testing (PT) , Magnetic particle Testing (MT) shall be
carried out in accordance with their employers Written Practice approved by the RIBO NDE
LEVEL-III in line with SNT-TC-1A current Code accepted Edition. VT personal shall be Qualified in
line with B 31.1 Code requirements by Head Quality .
12.1.2 Chief Executive Officer shall appoint a qualified NDE LevelIII examiner through an appointment
letter based on the individuals qualification, experience and examination for the respective
techniques in accordance with RIBOs NDE Written Practice which has been reviewed and
accepted by the Head Quality. All NDE Level II Personnel shall be certified by Head Quality.
12.1.3 The NDE Level III shall be responsible for approval of Written Practice and NDE Procedures,
calibration of NDE equipment and qualification of NDE personnel for production shop and site.
12.1 NDE PROCEDURES
12.2.1 All NDE procedures such as PT, MT, UT, RT, shall be prepared in line with ASME Sec-V and
applicable Code Sections. These procedures shall be reviewed and approved by RIBONDE Level
III and certified by Head Quality. PT, MT and UT procedures shall be qualified by demonstration to
the satisfaction of the AI before under taking Code Construction as per Article-1, Para-T 150 of
ASME Section V and so certified by NDE Level III in accordance with the approved
procedures. Whenever there is change inessential variables, procedure shall be re qualified by
demonstration to the satisfaction of the AI. Whenever there is change in non-essential variables ,
procedures shall be revised and demonstration not required.
12.2.2Copies of applicable NDE Procedures shall be readily available to the NDE Level II / Level I and
also at sites for reference and use as identified in the Inspection and Test Plan/ Operation
Process Sheet
12.2.3All NDE shall be carried out in accordance with the requirement of drawing, Inspection and Test
Plan and Customers specification if any, using approved procedures.
QUALITY CONTROL MANUAL Non Destructive Examination

12.3 QUALIFICATION OF PERSONNEL
12.3.1 All NDE Level I, Level II and Level III personnel shall be qualified and certified as per RIBO NDE
Written Practice.
12.3.2 NDE certified Level I, Level II and Level III shall have a vision examination for their vision acuity
and ability to distinguish and differentiate colors and / or shades of gray used in method at initial
certification and annually thereafter.
12.3.3 The NDE Level-III is responsible for training, qualifying and examination of all NDE Personnel
and to maintain the records for production shop. Head Quality is responsible for certification of
NDE personnel who are qualified and certified in accordance with RIBO NDE Written Practice
approved by NDE Level III and accepted by the Head Quality.
12.4SYSTEM
12.4.1 At the designated stage in the Operation Process Sheet , Engineer Production shall offer the
Code item for NDE to Head Quality by raising Non Destructive Examination Requisition
Slip(Exhibit No.33A)
12.4.2 Engineer Quality shall verify the Code item with respect to completeness and readiness and
offer the same to NDE Level II.
12.4.3 NDE shall be carried out by certified personnel as per the approved procedures and the results
shall be evaluated by RIBO NDE Level-II or NDE Level-III.
12.4.4 Head Quality shall offer the NDE report for the AIs review. Engineer Quality shall clear the
stage by signing off the Operation Process Sheet based on the satisfactory NDE report. He
shall mention the NDE report number in the Operation Process Sheet.
12.4.5 When Non Destruction Examination is subcontracted to an outside agency, the RIBO Level III
shall verify that the agency NDE Written Practice is in line with Code accepted Edition of SNT-
TC-1A and NDE personnel are qualified and certified accordingly by their employer, which
meets RIBO requirement. The NDE shall be carried out as per approved RIBO procedure and
demonstrated to the satisfaction of the AI.
12.4.6 All NDE procedures and record of NDE personnel shall be made available by the RIBONDE
Level III to the AI.
12.4.7 The Authorized Inspector may call for requalification of any procedures/personnel at any time.
12.4.8 All NDE reports and radiographs shall be retained as specified in Section No QCM: 15.0of this
Manual dealing with Records Retention.
QUALITY CONTROL MANUAL Heat Treatment

13.0 HEAT TREATMENT :
13.1 SCOPE
Heat Treatment, if required by the Code or by the customer, is performed by a approved
subcontractor in accordance with the RIBO approved procedure and drawing,
The Head Quality shall verify and approve subcontractors heat treatment equipment and
calibration records before issuance of Work Order for PWHT. The Work Order shall assure free
access for RIBO representative and the AI.
13.2 POLICY
All PWHT or HT shall be performed to the requirement of applicable Code , this Manual.
13.3PWHT Procedure
13.3.1 All PWHT /HT is performed as specified in drawing, Heat Treatment procedure and Heat
Treatment Requisition Slip (Exhibit No. 34)prepared by the Engineer Production and reviewed
and approved by Head Quality which describes as a minimum.
1. Description of item.
2. Type of heat treatment and loading sketch.
3. Rate of Heating.
4. Soaking time and temperature.
5. Rate of cooling.
6. Number, location, method of attachment of thermocouples.
7. In case of localized heat treatment, the heating bandwidth and the insulation requirements.
13.3.2 On receipt of approved Heat Treatment Requisition Slip, Head Planning shall release the Work
Order (Exhibit no. 35) along with the Heat Treatment Requisition Slip and approved procedure.
The loading diagram received from subcontractor shall be reviewed and approved by Head
Quality prior to heat treatment.
13.3.3 Component to be sent for heat treatment to the sub-contractor shall be properly identified and
marked by heat resistant paint or hard stamp with Job order Number/ part number and this
identification shall be verified by Engineer Quality prior to shipment.
13.3.4 Engineer Quality shall verify the calibration records of thermocouple and the recorders used for
heat treatment for their accuracy and periodicity.
13.3.5 If production weld test coupon plate are stipulated in the drawing, they may be heat treated by
simulating the prescribed heat treatment prior to product heat treatment. Alternatively the test
coupon may be heat treated with the Code items.
QUALITY CONTROL MANUAL Heat Treatment

13.3.6 In case of combined loading, Head Quality in consultation with the Engineer Welding shall
indicate the appropriate heat treatment cycle on the Heat Treatment Requisition Slip taking into
consideration welding qualifications and simulated heat treatment of materials.
13.4 PWHT/ HT Records
13.4.1 All PWHT /HT shall be recorded on automated chart which indicate the temperature, time. The
time-temperature chart shall be signed by the furnace operator with date at the start and
end of the heat treatment. The Heat Treatment chart shall also contain the identification of
thermocouple and recorders. Heat Treatment chart shall be reviewed by Engineer Quality after
completion of Heat Treatment.
13.4.2 PWHT/HT records shall reference the procedure used and shall be reviewed and approved by
the Head Quality to document compliance with the Code, drawing and procedure requirement.
13.4.3 PWHT/HT records are submitted to the AI for his review and retained as per Section No.15.0 of
this Manual dealing with Records Retention.
13.5 Receiving Inspection
13.5.1 Each Code Item returning after PWHT from the subcontractors facility shall be visually
examined by the Engineer Quality, for identification markings, physical damage due to transit
and flame impingement if any Engineer Quality shall also review the records of Heat treatment
for compliance to the Code / procedure.
13.5.2 Any Non Conformities noticed shall handled as per Section No QCM 10.0 dealing with
Correction of Non Conformities.
Calibration of Measurement and Test

Equipment
14.1 SCOPE
This Section describes the control for Calibration and Re-Calibration of Inspection,
Measurement and test equipment Used for the acceptance of material and Code item.
14.2POLICY
14.2.1 Inspection, measurement and test equipment (IMTE) used for acceptance of Code activity
affecting quality shall be in valid state of calibration with traceability to National/International
standard/Manufactures Standard. calibration shall be carried out either In-house or external
agency.
14.2.2 Impact testing of materials & Welds if required by the Code shall be carried out on a charpy
impact testing machine Calibrated annually in accordance with ASTM-E23 or ISO 148(parts
1,2&3). Temperature measuring devices shall have been calibrated within six months of their
use. Head Quality shall verify the record and ensure the calibration of the above.
14.2.3 Responsibility of calibration of various inspection measurement and test equipment are as
follows.
1. Pressure gauges, Linear and other measuring instruments by Engineer Quality.

2. All electrical equipment such as volt meter, ammeter, thermocouples, Temperature
recorder and welding machines by Engineer Maintenance
3. NDE equipment by NDE level-II or NDE Level III
14.3 SYSTEM
14.3.1 Inspection, measurement and test equipment shall be procured either with calibration
certificate or shall be calibrated prior to their use.
14.3.2 Each Inspection, measurement and test equipment shall be allocated and marked permentally
with an unique serial number and entered in the Master List of Measurement and Test
Equipment (Exhibit No. 36 )
14.3.3 Personnel responsible for calibration shall arrange for re-calibration of the IMTE before their
expiry. Calibration of the IMTE shall be carried out by using sub-contracting agency. Pressure
gauges calibrated with a dead weight tester or verified with a master gauge shall be used for
hydro test.
Calibration of Measurement and Test

Equipment
Section No. QCM 14.0 Rev.No:02 Date : 02.07.2014 Page 2 of 2
14.3.4 Personnel responsible for calibration shall review the calibration report to determine the
acceptance of such equipment and shall maintain the relevant records.
14.3.5 Each accepted equipment shall be affixed with Calibration sticker (Exhibit No.37)
showing the Reference No/equipment No, Calibration date and Calibration due date.
Alternatively, Calibration Sticker may be affixed on the box with traceability duly engraved on
the equipment.
14.3.6 If IMTE is found out of calibration, or damaged the same shall be immediately segregated to
avoid usage. This shall be reported an NCR for taking necessary action. Head Quality shall
validate test results of those Material/Code items which were examined earlier using such
faulty equipment. For measuring IMTE traceability, identification number shall be specified on
the inspection reports.
14.3.7 Records related to calibration of equipment shall be made available to the AI for his
verification.
QUALITY CONTROL MANUAL Records Retention

15.1 SCOPE
This Section describes the controls required for maintenance and retention of records as
required by Code.
15.2 SYSTEM
15.2.1 The following table indicates the records description, retention period, Personnel responsible to
submit document to Head Quality, and retention responsibility for the various records
maintained.
Retention Period Responsibility of

Retention
Sl.No Record Description ASME ASME Sec. Providing the
responsibility
Sec.I&B31.1 VIII Div.1 document
01 Manufactures Partial Data Head
5 Years Head Quality
Report Quality shall
02 Manufacturing Drawings -- Head Design compile the
including As Built drawings Quality
Design calculations including Dossier with
03 any applicable proof test -- Head Design the help of
reports Engineer
Material Test Quality.
04 -- Engineer Quality
Reports/Certifications
Pressure part documentation
and Certifications Engineer Quality Head Quality
05 shall retain
(MRIR/Material Identification
Report) one
06 WPS and PQR -- complete set
Welder Qualifications for each of Quality
Engineer Welding Dossier
07 welder who welded on the --
Code Item 3 Years
08 NDE Personal Qualification -- NDE Level II

record
09 RT report and UT report -- NDE Level II
10 Repair procedure and records -- Head Quality
Inspection and Test
11 Plan/Operation Process Sheet, --
Applicable WPS List
Heat treatment records and
12 --
test results
13 PWHT records -- Head Quality
14 Non Conformances and
--
dispositions (NCR)
15 Hydrostatic Test Reports
Pneumatic Test Report --
Till MDR is NDE Level II

16 RT films 5 Years
signed by AI
17 Manufactures Data report 5 Years 3 Years Head Quality
QUALITY CONTROL MANUAL Records Retention

Note:
Originals of WPS, PQR, Welder/Welding operator Performance Qualification and NDE operator
qualification records shall be maintained permanently.
All records shall be made available to the AI and AIS for his review and ASME Team Leader when
requested.
QUALITY CONTROL MANUAL Site Activities

16.0 SCOPE
This Section describes how RIBO shall control operations for Code Items when final assembly is
conducted at field sites controlled from the shop.
16.1 Field Site Organisation
For each field site, a Site Manager shall be designated by Head Operations. His responsibility
shall cover all activities of the Head Operations in this QCM and arranging for fabrication as per
Code/drawings and administrative control of site activities.
All other activities and responsibilities described in this QCM shall be handled in the same
manner as in the shop and as shown on the Organization chart in Section No. QCM 5.0 dealing
with Organization.
16.2 Responsibility
16.2.1 Head Operations shall be responsible for designation of Site Manager for controlling the field
site activities in accordance with this Section. Before the start of field assembly, the Head
Quality shall audit the site to ensure adequate facility and infrastructure for meeting the Quality
Control Manual.
16.2.2 Engineer Quality Site directly reports to Site Manager with functional responsibility to Head
Quality. Engineer Quality Site shall be responsible for the performance of all field site
examinations as required by the Code and this Quality Control Manual.
16.2.3 Responsibilities and authorities of personnel at shop shall be same as per other Sections of this
QCM as supplemented by this Section.
16.2.4 Responsibilities and authorities of personnel at field site similarly designated with site shall be
same as per other Sections of this Quality Control Manual as supplemented by this Section.
16.2.5 Controlled copy of this Quality Control Manual shall be issued by Head Quality to Site Manager,
Engineer Quality Site and the AI at site.
16.2.6 Field assembly of Code items may be performed as follows,
a) RIBO completes the Code item in the field site and completes the field assembly portion of
the MDR.
RIBO may receive parts of Code item from other manufacturer holding valid Certificate of
Authorization along with MPDR and RIBO makes the final assembly, welding, required
NDE, Final Pressure Test and completes the MDR and apply Certification mark with
appropriate Code designator on the finished Code Item

b) The field portion of the work is completed by other manufacturer holding valid Certificate of
Authorization shall submit MPDR for the field work (including data on the pressure test if perform
by him) to RIBO. RIBO shall apply the ASME Certification Mark with appropriate Code Designator
on the finished Code Item in the presence of the AI at site and complete the MDR. In all three
cases RIBO assumes full Code responsibility for the items.
16.3 Drawings, Design Calculations and Specifications
16.3.1 The necessary drawings and specifications are prepared, reviewed and approved as per
Section No QCM 7.0 dealing with Drawings, Design Calculations and Specification Control.
16.3.2 Engineer Quality Site is responsible for providing the Authorized Inspector at sight with all
approved drawings and necessary documents for review at site.
16.4 Material Control
Receiving Examination
16.4.1 Receiving examination of material item which are received at site shall be in accordance with
Section NoQCM8.0 dealing with Material Control.
16.4.2 For Code items, which involve activities both in shop and site, Head Quality shall prepare a
single Inspection and Test Plan that reflects both the activities at shop and field site.
16.4.3 The shop activities shall be offered to the AI at shop for inspection. Upon his satisfaction the
OPS shall be signed off up to completed stage at shop. The item(s) will be dispatched along
with original OPS, Applicable WPS List, Inspection and Test Plan and other relevant
documents such as MTR, Material Identification Report, welding records (as applicable) etc.
to site.
16.4.4 All the items/ materials shipped to site shall be clearly marked with:
a) Job Order Number
b) Part Number
c) Section Number/Sub Assembly Number if applicable.


16.4.5 Upon receipt of these items at site, Engineer Quality Site shall verify the extent of completed
work and any damage during transit to site. When satisfied he offers those items to the AI at
field site for inspection before proceeding with any work at site.
16.4.6 Upon completion of above activities, Engineer Production Site shall record details of each
item in respect of quantity , supporting document and test report, inspection
acceptance etc in a bound register.
16.4.7 For all Code material received directly at the field site the assigned Engineer Production Site is
responsible for verifying the quantities and receiving documents.
16.4.8 Head Material sends a copy of Supply Purchase Order along with TDC to Engineer
Production Site for use in receiving examination as mentioned below.
16.4.9 All Code material, items or Code parts are unloaded in the assigned lay-down area, and
examined by the Engineer Quality Site for:
a) Physical damage, which may have occurred during transport.
b) Proper tagging and identification of each item, which provides traceability to assembly
drawings
c) Review of Chemical and physical properties (Material Test Report).
d) In case of items supplied with Manufacturers Partial Data Reports the stamping shall be
verified against the Data Report.
e) The required material marking.
16.4.10 Site Store Keeper is responsible for storage of accepted materials and shall be released for
fabrication when requested by Engineer Production Site using Material Issue Voucher.
16.4.11 Engineer Production Site shall send all the information to the Head Material at shop i.e. the
status of the material (Examination status) along with the copy of MRIR for records.
16.4.12 All welding consumables requested by the Site Manager shall be ordered as described in
Section No.QCM11.0 dealing with Welding.
16.4.13 Items shall be released for fabrication at field sites after the Field site AIs acceptance. This
activity shall be endorsed by the Field site AI in OPS.

16.4.14 Accepted welding consumables shall be shipped to the field site with a copy of MRIR and
reference on the container along with CoC.
16.4.15 Accepted welding consumables shall be stored by Site Store Keeper in a locked storage area
in their original package in accordance with the Manufacturers recommendations.
16.4.16 Parts, items and material that do not meet all requirements are considered non-conforming
and the Engineer Quality Site shall prepare a Non Conformity Report in accordance with
Section No. QCM 10.0 dealing with Correction of Non Conformities and as per 16.6 of this
Section.
16.5 Field Examination and Inspection Program
16.5.1 The field assembly of Code items is controlled by assembly drawings, Inspection and Test
Plan, Applicable WPS List and OPS which is prepared and reviewed as per Section No QCM
9.0 dealing with Examination, Inspection and Testing Program.
16.5.2 The approved Inspection and Test Plan, Applicable WPS List and Operation Process Sheet
are sent to the Engineer Quality Site by the Head Quality.
16.5.3 Prior to start of fabrication, all the prepared and approved documents such as ITP and
Applicable WPS List shall be submitted by Engineer Quality Site to the AI at field site for
review and selection of his inspection Hold, Witness and Review points.
16.5.4 Engineer Quality Site shall transfer the Hold, Witness and Review points of the AI field Site
on the OPS.
16.5.5 Prior to the pressure test, Engineer Quality Site shall ensure all examinations and
inspections, NDE, Heat treatment if required shall have been performed and Non
Conformities if any shall have been closed out and shall be referenced in the Operation
Process Sheet.
16.5.6 Code required pressure tests shall be carried out as specified by the procedure &ITP, and
under the supervision of the Engineer Quality Site and always in the presence of the Site
Authorized Inspector.
16.5.7 Upon completion of the field assembly of a Code item, the Engineer Quality Site shall verify
and certify the field assembly portion of MDR and obtain the ASME Certification Mark and NB
Mark if applicable from Head Quality. Engineer Quality Site shall keep the Certification Mark
and NB Mark if applicable in his safe custody.

16.5.8 The completed MDR, together with the final records is then presented to the field Authorized
Inspector for review. When satisfied that all Code requirements have been met, the field
Authorized Inspector shall authorize and verify the application of ASME Certification Mark
and NB Mark if applicable to the Nameplate or on item as applicable and sign the Data
Report.
16.5.9 All records shall be returned to the Head Quality at the shop for retention as described in
Section No QCM 15.0 dealing with Records Retention.
16.5.10 ASME Certification Mark and NB Mark shall be returned to Head Quality after completion of
the Stamping.
16.5.11 Distribution of MDR/MPDR, registration with National Board if required shall be in accordance
with Section No. QCM 9.0 dealing with Examination, Inspection and Testing Program by
Head Quality.
16.6 Correction of Non-conformities
16.6.1 Nonconformities found during field assembly are recorded on the OPS next to the operation
where they occurred and are controlled as described in Section No. QCM10.0 dealing with
Correction of Non-Conformities.
16.6.2 However for nonconformities where the disposition is Reject, the Engineer Quality Site is
authorized to make such dispositions.
16.6.3 All Non Conformity Reports shall be transmitted by fax or by Email for obtaining the written
disposition from the Head Quality with exception as described above in Section 16.6.2 prior
to taking any action.
16.6.4 Engineer Quality Site shall inform the Site Manager of all dispositions and all corrective action
to be taken.
16.6.5 All Non Conformance Report shall be sent to Head Quality for retention as described in
Section No. QCM 15.0 dealing with Records Retention.

16.7 Welding Control
16.7.1 All welding shall be done in accordance with SectionNoQCM11.0 dealing with Welding and
in addition the Site Manager, together with the Engineer Quality Site shall establish the
action necessary to protect the welding activities from adverse weather conditions such as
wind, rain, temperature and humidity.
16.7.2 All reviewed/approved WPSs and supporting PQRs provided to the Site Manager by the
Engineer Quality Site, shall then be distributed to the Engineer Production Site. WPSs shall
be made available to the welder for their use. All WPSs and PQRs shall be made available
to the field Authorized Inspector at the field site for review.
16.7.3 Welders shall be qualified as described in Section No QCM11.0 dealing with Welding.
Qualified welders from RIBO shop shall be sent to the field sites or RIBO may employ
individual welders by contract as described in Section No. QCM 11.0 dealing with Welding.
16.7.4 The List of Qualified Welders shall be prepared by Engineer Welding Site for site qualified
welders and forwarded to Engineer Welding. Engineer Welding shall be responsible for
allocating unique welder identification number and issue of List of ASME Qualified
Welders and used for site work.
16.7.5 The Engineer Production Site and Site Store Keeper are responsible for the issuance of
welding consumables in accordance with Section No QCM 11.0 dealing with Welding. The
Engineer Welding is responsible for transmitting the manufacturers recommendations for
handling and storage of the welding consumables to the field location.
16.8 Non-destructive Examination
16.8.1 All NDE shall be carried out in accordance with Section No. QCM 12.0 dealing with Non
Destructive Examination. Records of all NDE personnel shall be maintained by the Engineer
Quality Site and be made available to the field Authorized Inspector.
16.8.2 All radiographs and test reports shall be made available to the field Authorized Inspector for
review. After completion of the Data Report and certification by Engineer Quality site
and the field AI, all radiographs and test reports shall be forwarded to the Head Quality.

16.9 Heat Treatment
16.9.1 Post weld Heat Treatment, when required shall be carried out in accordance with
SectionNoQCM13.0 dealing with Heat Treatment.
16.9.2 After completion of the Data Report and certification by Engineer Quality site and the
field AI,, the time/temperature charts shall be forwarded to the Head Quality for retention.
16.10 Calibration of Measuring and Test Equipment
All required measuring and test equipment to be used for acceptance shall be calibrated
directly prior to shipment to the field site and shall be marked as described in Section No:
QCM 14.0 dealing with Calibration of Measurement and Test Equipment.
16.11 Authorized Inspector
16.11.1 Engineer Quality Site shall be responsible for the coordination with the field Authorized
Inspector at the field location.
16.11.2 A controlled hard copy of this QCM shall be available for use by the field Authorized
Inspector at the field location
16.11.3 Engineer Quality Site is responsible for safe custody of AI bound dairy. Engineer Quality
Site shall return AI bound dairy to Head Quality as soon as the work at the field site is
complete.
QUALITY CONTROL MANUAL Authorized Inspection

17.1 SCOPE
This Section describes about the coordination with the Authorized Inspection Agency,
Authorized Inspector, and Authorized Inspector Supervisor during Code activities and the
maintenance of the Quality Control System.
17.2 POLICY
17.2.1 Written agreement shall be made with an Authorized Inspection Agency for providing
authorized Inspection service as required by the Code, i.e. LR Insurance Inc.is identified as
AIA of record for providing the services of Code activities.
17.2.2 The AI and AIS shall have free access at all time to all place including material manufactures
or suppliers where manufacturing or field assembly work is being carried out on Code items.
17.2.3 The AI shall be provided with facilities to perform required duties including quality control
system monitoring by the AI and audit of AIs activities by an AIS.
Head Quality shall submit the Inspection and Test Plan, Applicable WPS List , Operation
Process Sheet and Head Design shall submit the design calculations and drawings prior to
start of fabrication to the AI for his review. The AI shall indicate his Hold, Witness and Record
review points in Inspection and Test Plan.
17.2.4 Head Quality is responsible for safe keeping of the AIs bound diary.
17.2.5 Head Quality shall give the AI reasonable advance notice when vessels or parts will be ready
for required tests or internal inspection of the vessel before final closure of the vessel.
17.2.6 Head Quality shall provide opportunity to the AI to select spot location in case of spot
Radiography.
17.2.7 In case of a situation where the purchaser request another AIA to perform inspection at the
shop or field site on its projects or Code jobs, the request shall be in writing, and same shall
be made available to AIA of record before taking up the job.
17.2.8 If LR Insurance Inc. cannot provide coverage for inspection at specific field site, necessitating
the use of another AIA, shall also be documented suitably.
QUALITY CONTROL MANUAL Authorized Inspection

17.2.9 In case of S.No 17.2.7 & 17.2.8 the following shall be ensured
1) Al AIAs performing inspection shall follow the system laid down in the Quality Control
Manual accepted by the AIA of record.
2) All AIAs performing inspection shall have a contract or agreement for the specific Code
work.
3) The AIA of record, LR Insurance Inc. shall review and accept all changes to the Quality
Control Manual.
4) Each AI shall be provided with a controlled copy of the Quality Control Manual.
17.3.0 SYSTEM
17.3.1 An Authorized Inspector is an employee of an ASME accredited Authorized Inspection

Agency, in accordance with the latest edition of ASME QAI-1, and who is qualified by
written examination under the rules of any state of the United States or provinces of
Canada which has adopted the Code. The AI shall have a valid National Board Commission
card with A endorsement.
17.3.2 Head Quality shall liaise with the AI/AIS during Code activities and QC system monitoring
visits.
17.3.3 AI prior concurrence shall be obtained for carrying out any repair of material/component and
welds for the proposed method and extent repair.
17.3.4 One copy of the certified Manufacturers Data Report/Manufactures Partial Data Report shall
be provided to the AI.
17.3.5 The AI shall include his National Board Commission number with endorsements when signing
the Data Reports.
17.3.6 Whenever the agreement with AIA is cancelled or changed to another AIA, RIBO shall notify
the same to ASME.
QUALITY CONTROL MANUAL Certifications

18.1 SCOPE
This Section describes the procedure for certifications, authorizations and approvals of
documents and reports during various stages of constructions
18.2 POLICY
At Present only written signatures are used for certifications, authorizations and approvals.
Whenever in future other methods are employed for indicating certifications, authorizations and
approvals, a procedure shall be established by Head Quality and outlined in this section
to describe the required control and safeguard to ensure the integrity of the
certifications and approval process. This procedure shall be offered to the AI for his
review and acceptance before implementation.
QUALITY CONTROL MANUAL List of Exhibits

Exhibit No Description Rev.No Date

1 QCM Distribution Register 00 14.04.2014
2 Order Distribution Sheet 00 14.04.2014
3 Material Requirement list Report 00 14.04.2014
4 Technical Delivery Condition (TDC) 00 14.04.2014
5 Document Transmittal 00 14.04.2014
6 Document Distribution 00 14.04.2014
7 Design Change Request 00 14.04.2014
8 Design Change Note (DCN) 00 14.04.2014
9 Material Indent 00 14.04.2014
10 Materials Receipt cum Inspection Report 00 14.04.2014
11 Stock Transfer cum Inspection Report 00 14.04.2014
12 Supply Purchase Order 00 14.04.2014
13 Non Conformity Report 00 14.04.2014
14 Materials Issue Voucher 01 02.07.2014
15 Material Requisition Slip 00 14.04.2014
16 Material Identification Report 00 14.04.2014
17 Inspection and Test Plan 00 14.04.2014
18 Applicable WPS List 00 14.04.2014
19 Operation Process Sheet 00 14.04.2014
20 Nameplate Details For ASME Section VIII DIV 1 Vessel 01 02.07.2014
21 Direct stamping Details For ASME Section VIII Div 1Vessel 01 02.07.2014
22 Nameplate Detail for ASME Section VIII Div 1Vessel Part 01 02.07.2014
Direct stamping Detail for ASME Section VIII Div 1Vessel
22A 01 02.07.2014
Part
23 Direct stamping Details for ASME Section I Boiler 01 02.07.2014
24 Direct stamping Detail for ASME Section I Part 01 02.07.2014
25 Nameplate Details for ASME Section I Boiler 01 02.07.2014
QUALITY CONTROL MANUAL List of Exhibits

Exhibit No Description Rev.No Date

26 Nameplate Detail for ASME Section I Part 01 02.07.2014
27 National Board Number Log Register 01 24.06.2014
28 Rejected 00 14.04.2014
29 Non Conformity Log Register 00 14.04.2014
30 List of ASME Qualified Welders 01 24.06.2014
31 Welder / welding operator Continuity Record 01 24.06.2014
32 Welding Consumables Requisition cum issue Slip 00 14.04.2014
33 Welding- Work Instructions Sheet 01 24.06.2014
33A Non-Destructive Examination Requisition Slip 00 14.04.2014
34 Heat Treatment Requisition Slip 00 14.04.2014
35 Work Order 01 02.07.2014
36 Master list Measurement and Test Equipment 00 14.04.2014
37 Calibration Sticker 00 14.04.2014
38 Stage Inspection report 00 02.07.2014

ASME MANUAL With Exhibit 03.07

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RIBO INDUSTRIES PVT LTD

Section No. QCM 1.0

QUALITY CONTROL MANUAL (QCM)

WORK SHOP ADDRESS

RIBO INDUSTRIES PRIVATE LIMITED

RIBO INDUSTRIES PRIVATE LIMTED

CONTROLLED COPY UNCONTROLLED COPY

QUALITY CONTROL MANUAL Table of Contents

QCM 2.0 Table of Contents 02 01 02.07.2014

QCM 3.0 Statement of Authority 02 01 02.07.2014

QCM 4.0 Glossary of Terms 02 03 02.07.2014

QCM 5.0 Organization Authority and Responsibility 02 02 02.07.2014

QCM 6.0 Control of Manual 02 02 02.07.2014

Drawings, Design Calculations and 02 02.07.2014

Examination, Inspection and Testing 02 02.07.2014

QCM 11.0 Welding 02 04 02.07.2014

QCM 12.0 Non Destructive Examination 02 02 02.07.2014

QCM 13.0 Heat Treatment 02 02 02.07.2014

Calibration of Measurement and Test 02 02.07.2014

QCM 16.0 Site Activities 02 07 02.07.2014

QCM 17.0 Authorized Inspection 02 02 02.07.2014

QCM 18.0 Certifications 02 01 02.07.2014

QCM 19.0 List of Exhibits 02 02 02.07.2014

Prepared by Approved by Accepted by

QUALITY CONTROL MANUAL Statement of Authority

Date: 02.07.2014 Chief Executive Officer

QUALITY CONTROL MANUAL Glossary of Terms

AIA Authorized Inspection Agency

AIS Authorized Inspector Supervisor

ASME The American Society of Mechanical Engineers

ASTM American Society of Testing Materials

Code ASME Sec.I ASME Sec. VIII Div. 1, ASME B31.1, as

CEO Chief Executive Officer

COC Certificate Of Compliance

Data Report Manufacturers Data Report/Manufacturers Partial Data

DCR Design Change Request

DCN Design Change Note

IMTE Inspection Measurement and Test Equipment

ISO International Standards Organization

ITP Inspection Test Plan

QUALITY CONTROL MANUAL Glossary of Terms

MANUAL Quality Control Manual

MTR Material Test Report

MDR Manufacturers Data Report

MIV Material issue voucher

MRS Material Requisition Slip

MRIR Material Receipt cum Inspection Report

MPDR Manufacturers Partial Data Report

MT Magnetic Particle Test Report

NB Stamp National Board Stamp

National Board National Board of Boiler and Pressure vessel Inspectors,

1055, Crupper Avenue, Columbus, OH43230-1109, U.S.A.

NCR Non Conformity Report

NDE Non Destructive Examination

OPS Operation Process Sheet

PQR Procedure Qualification Record

PWHT Post Weld Heat Treatment

QUALITY CONTROL MANUAL Glossary of Terms

PT Liquid Penetrant Test

PVT LTD Private Limited

QCM Quality Control Manual

REV NO Revision Number

RIBO RIBO Industries Private Limited

TC Test Certificate which also includes MTR and COC