10

Documentation

1 GENERAL

The final documents that are sent along with the equipment
to the client are called the manufacturer’s data report (MDR).
In order to prepare this, the manufacturer shall have a master
document pertaining to the vessel that contains all the rele-
vant details of manufacture. This is the working file of the
QAC department and shall have the following documents in
it:
1. Material test certificate for each pressure part listed
in the fabrication drawings.
2. Material identification reports by the in-house QAC
as well as appropriate third parties

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3. Stagewise inspection reports

4. Welding inspection reports
5. Nondestructive testing (NDT) reports and a sum-
mary
6. Postweld heat treatment (PWHT) reports
7. Prehydrostatic test inspection release
8. Subsequent NDT reports (if applicable)
9. Hydrostatic test report
10. Posthydrostatic test cleaning/boxing up clearance
11. Final inspection release certificate (IRC)

Apart from these, all QAC procedures, including the QAP,

welding procedure specifications (WPS), procedure qualifica-
tion records (PQRs), WQT, nondestructive testing (radio-
graphic, ultrasonic, magnetic particle, and liquid penetrant),
postweld heat treatment (PWHT), and final hydrostatic test-
ing (HT) procedures shall be compiled separately with due ap-
proval of the concerned client/third-party inspection agency.
Out of these, only the WPS needs to be incorporated in the
MDR.

2 MANUFACTURER’S DATA
REPORT DOCUMENTS

The following documents shall constitute the final MDR.

1. The facing sheet (Figure 10.1).

2. Index for the manufacturer’s data report (Figure
10.2).
3. Inspection certificate from the third-party inspec-
tion agency.
4. Certificate of manufacture or general certificate, as
applicable (Figure 10.3 or Figure 10.4).
5. ASME Forms U1, U1A, U2, U2A, U3, and U4, as
applicable.
6. Guarantee certificate (Figure 10.5).

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 Documentation 175

Figure 10.1 MDR cover sheet.

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Figure 10.2 MDR index.

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Figure 10.3 Certificate of manufacture.

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Figure 10.4 General certificate.

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 Documentation 179

Figure 10.5 Guarantee certificate.

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 180 Chapter 10

7. Material summary report with an index to materials

test certificate (MTC) (Figure 10.6).
8. Welding procedure specification summary with a
weld map (Figure 10.7).
9. Welding procedure specifications.
10. NDT summary with weld map.
11. NDT reports.
12. Pad air test reports.
13. Calibration reports of pressure gauges used for pad
air test.
14. PWHT reports and charts.
15. Calibration reports of recorders and thermocouples.
16. Hydrostatic test reports.
17. Calibration reports of pressure gauges and re-
corders.
18. Rub off of stamping on the vessel endorsed by the
third-party inspection agency (Figure 10.8).
19. Inspection release certificate (Figure 10.9).

3 MASTER DOCUMENT

When a pressure vessel is manufactured, the QAC department

shall have the following original documents for making the
MDR:

1. The original material test certificates of all pressure

parts and those attached directly to the vessel
2. Original approved QAP, ITP, WPS, PQR, WQT, NDT
procedures, PWHT procedures, HT procedures
3. All original inspection details like material identifi-
cation, fit-up, welding, etc.
4. NDT reports
5. Pad air test reports
6. PWHT reports/calibration reports
7. Hydrostatic test report/calibration reports

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Figure 10.6 Material quality report.

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Figure 10.7 Summary of welding procedure specifications.

8. Rub off
9. Inspection release certificate.

Apart from these the QAC department has many other docu-
ments which will be dealt with separately.

4 ASME CODE FORMS

For ASME U stamp vessels, it is mandatory to fill out Form

U1 or U1A, U2, U2A, U3, or U4, as specified in UG-120. These
forms shall be used to register the vessel by filing it with Na-
tional Board of Pressure Vessel Inspectors, 1055 Crupper Ave-
nue, Columbus, Ohio 43229. These formats are given in Ap-
pendix W of ASME Section VIII Div (1). The instructions for
filling out the forms are given in Table W3 and Table W3.1 of

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Figure 10.8 Details of rub off/name plate.

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Figure 10.9 Inspection release certificate.

Appendix W. A sample form U4 is shown in Appendix W Fig

W 3.1.

5 RETENTION OF RECORDS

All the originals pertaining to the above equipment shall be

maintained by the QAC department for a period of 5 years,

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and all RT films shall be kept for a period of 2 years. After this
they can be disposed of at the discretion of the manufacturer.
However, a brief summary shall be maintained in the data-
bank.

Copyright © 2002 Marcel Dekker, Inc.