00 Za e g09609_00 Material Management

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 MATERIAL MANAGEMENT AND CONTROL

Doc. No.: 00-ZA-E-G09609 Rev. 00 Date: 19.05.2012 Page 2 of 22

AMENDMENTS AND REVISIONS Amendment and revision

Date

Page

Description

Project Director

X01

05.04.2011

All

Issued for Internal Review / Comments (first issue)

G. S

A01

11.04.2011

All

Issued for Approval

G. S

Re Issued for COMPANY Review / Approval Page 7 - Para 5.2 – Company Comment Item 3 incorporated Page 9 – Para 7.1.1 Company comment item 4 incorporated

B

05.02.2012

All

Pls also refer to COMPANY Comments Response sheet attached at the end of this document

G. S

Section 9.6, para 3, add “Drawing Marker Number should be punched” Attachment-5, Color code chart revised. Color for API-5L-Gr X65 tubulars (WHITE) included. Attachment 3: Material Request Form included Rev. 1

00

19.05.2012

All

Issued for Construction. Page 9 – para 7.1.1. step 3 revised for “MRR” & “SAIC” preparation Page 17—Attachment 1: MRR Form Rev-1 include Page 21 – Attachment 5: Revised color code chart include

G. S



INDEX AMENDMENTS AND REVISIONS........................................................................................................... 2 INDEX ....................................................................................................................................................... 3 1.

SCOPE AND PURPOSE................................................................................................................ 5

2.

PROJECT DEFINITIONS, ACRONYMS AND ABBREVIATIONS................................................ 5

3.

4.

5.

2.1

Project Definitions ......................................................................................................................5

2.2

Acronyms and Abbreviations .....................................................................................................5

REFERENCE DOCUMENTS ......................................................................................................... 6 3.1

Codes and Standards ................................................................................................................6

3.2

Company Documents ................................................................................................................6

3.3

Contractor Documents ...............................................................................................................6

RESPONSIBILITIES AND OBLIGATIONS ................................................................................... 7 4.1

Material Controller Responsability .............................................................................................7

4.2

Warehouse Supervisor / Material Coordinator:..........................................................................7

4.3

Materials Receiving Inspectors: .................................................................................................7

PROJECT MATERIALS – OVERVIEW ......................................................................................... 7 5.1

Co-ordination - SAPMT and CONTRACTOR ............................................................................7

5.2

Material Receiving Areas ...........................................................................................................7

5.3

Contractors Responsibility .........................................................................................................7

6.

EQUIPMENT AND MATERIAL RECEIPT ..................................................................................... 8

7.

GOODS INWARD QC INSPECTION............................................................................................. 8 7.1

Project Equipment and Materials ...............................................................................................8 7.1.1

8.

Receiving Material Verification.........................................................................................9

7.2

Non Conformance Reports ........................................................................................................9

7.3

Material Certificates .................................................................................................................10

7.4

Purchase Orders......................................................................................................................10

7.5

Material Status. ........................................................................................................................10

HANDLING AND STORAGE OF MATERIALS........................................................................... 11 8.1

General - All Materials .............................................................................................................11

8.2

Flanges ....................................................................................................................................11

8.3

Valves ......................................................................................................................................11

8.4

Miscellaneous Engineering Items (E.g. Stud Bolts, Nuts and Gaskets) ..................................11

8.5

Mastic (and Other General Bulk Issue Materials) ....................................................................11

8.6

Flat Plates, Pre-Formed Plates and Beams ............................................................................11

8.7

Storing and Handling of Bare Pipe for Pipelines......................................................................12

8.8

Storing and Handling of Shapes and Tubulars ........................................................................12



8.9

Electrical and Instrument Equipment .......................................................................................12

8.10 Mechanical ...............................................................................................................................12 8.11 Ancillary Equipment .................................................................................................................12 8.12 Paint and Other Toxic Material ................................................................................................12 8.13 Preservation .............................................................................................................................12 9.

10.

MATERIAL REQUEST AND ISSUE............................................................................................ 13 9.1

Material Request......................................................................................................................13

9.2

Material Issue...........................................................................................................................13

9.3

Stock Control Records .............................................................................................................13

9.4

Control of Material at Sub-Contractors ....................................................................................13

9.5

Control of Material at Barge .....................................................................................................14

9.6

Traceability...............................................................................................................................14

9.7

Color Coding ............................................................................................................................14

9.8

Identification .............................................................................................................................15

9.9

System, Components and Installation Materials......................................................................15

TRACEABILITY ........................................................................................................................... 15 10.1 Traceability during the Assembly .............................................................................................15 10.2 Traceability of the Secondary Structures.................................................................................15 10.3 Traceability during Installation .................................................................................................15 10.3.1

Material Return.............................................................................................................15

10.3.2

Material Substitution.....................................................................................................16

11.

Records ....................................................................................................................................... 16

12.

ATTACHMENTS .......................................................................................................................... 16



1. SCOPE AND PURPOSE This procedure shall be implemented for Material Management and Control of all project material relevant to the execution of ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES Project. The scope of this procedure is to define the system for controlling receiving, storing and distribution of all project materials. This procedure is based on the requirements of ISO 9001:2008 that defines the control mechanism for: Material receiving inspection Material Handling, storage and transportation The purpose of this procedure is to provide a project material controlling system. Subcontractors utilized within Contractor’s Project framework, shall carry out their activities in accordance with the contents of this procedure as well. This procedure doesn’t include fabrication consumable materials like welding rods, welding wires, flux etc. to which the procedure Control, Storage and Distribution of Welding Consumable, (Doc. # 00-ZA-E-G09661) apply. 2. 2.1

PROJECT DEFINITIONS, ACRONYMS AND ABBREVIATIONS Project Definitions

COMPANY

Saudi Arabian Oil Company (IK) / Aramco Overseas Company B.V. (OOK)

CONTRACTOR

Snamprogetti Saudi Arabia Ltd (IK) and Saipem S.p.A. (OOK)

VENDOR

All Subcontractors and Suppliers

MAIN CONTRACT

Contract awarded to CONTRACTOR

SUBCONTRACT

Contract signed by SUBCONTRACTOR and CONTRACTOR for the performance of the portion of the WORK within the Project

PROJECT

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES

DOCUMENTS

All incoming and outgoing correspondence (letters and faxes), and technical documents

2.2

Acronyms and Abbreviations

PD

Project Director

PQM

Project Quality Manager

QCM

Quality Control Manager

STAR

Saipem Taqa Al Rushaid Fabrication Company

QA

Quality Assurance

QC

Quality Control

CIM

Company Issued Materials

G.I.

General instruction



M.I.

Manual Instruction

O.I.

Operating Instruction

NCR

Non-Conformance Record

MRF

Material Request Form

MRR

Material Receiving Report

RMV

Return Material Voucher

MTC

Material Test Certificate

PO

Purchase Order

SAPMT

Saudi Aramco Project Management Team

SAPID

Saudi Aramco Project Inspection Department

3.

REFERENCE DOCUMENTS

3.1

Codes and Standards

ISO 9001:2008

Quality Management System – Requirements

ISO 9000:2005

Quality Management System – Fundamentals and Vocabulary

3.2

Company Documents

DE-119885

Procedure for QA/QC

DE-119892

Material Procurement, Receiving, Handling and Storage

Schedule “B” of Contract

Job Specification

Schedule “G” of Contract

Material, Tools and Equipment

Schedule “Q” of Contract

Quality Assurance and Control, Inspection and Testing

SAEP-361

Storage. Handling and Installation of Weight Coated Pipes

PE GTH325/PE GTH326

Scope of Work

SAIC /SATIP

Aramco check list / ITPs

3.3

Contractor Documents

00-ZA-E-G09600

Project Quality Plan

00-ZA-E-G09601

Procurement Quality Plan

00-ZA-E-G09604

Non Conformance Management Procedure



4.

RESPONSIBILITIES AND OBLIGATIONS

4.1

Material Controller Responsability Dedicated Material controllers in the Fabrication Yards and Construction Premises are responsible for Materials management and control of all Project materials, from uplift and delivery of materials and/or equipment to receipt and control at the nominated Fabrication Yard and Barge.

4.2 -

4.3 -

5. 5.1

Warehouse Supervisor / Material Coordinator: Responsible for timely goods receipt checking (discrepancy in shortage, visible damage and documentation correctness), proper storage of all materials and equipment in the designated Areas, including open storage, climatic control rooms and segregated areas for hazardous materials and gases. Responsible for maintaining a record for the periodic inspections of equipment in accordance with manufacturer’s storage and preservation procedures. Responsible for the issuance of all materials and equipment to the construction Areas. Materials Receiving Inspectors: Responsible for goods inward inspection of all materials and equipment received at the site for visible damage, discrepancy, defect, and certification.

PROJECT MATERIALS – OVERVIEW Co-ordination - SAPMT and CONTRACTOR

Contractor Materials Manager will liaise and coordinate with the Saudi Aramco Materials Specialist to ensure a smooth and auditable transfer of all Company supplied materials are transferred from the Company designated materials yard to the Contractors fabrication yard or barge (for relevant pipeline activities) The Contractor’s Materials Inspector shall check the physical status of the materials and equipment prior to loading onto trucks or barge.

5.2

Material Receiving Areas

The materials receiving areas will be: Saipem Dhahran Base located in Al Khobar & near to the Port of Dammam for all sea-freighted materials and equipments relevant to the Fabrication activities, after their acceptance, the materials and equipments will be then shipped to STAR fabrication yard in Dammam, approximately 400 kilometers north east of Riyadh, Saudi Arabia and CONTRACTOR Dammam Base located 40 kilometers far from the STAR yard according to the Project Execution Plan. The materials and equipments relevant to the TPs decks Fabrication, will be shipped directly from the manufacturer to P.T. Saipem Indonesia yard located in Karimun island. All the bare pipes relevant to the Pipelines installation will be load-in from the arrival Seaport of Dammam located approximately 100 kilometers north east from Dammam and transported directly to the IK coating plant(s); after coating the pipes will be load-out from the Port of Al Jubail, upon obtaining permission by Company, to the Saipem lay barges. At times there may be work subcontracted to other Yards or third party fabrication contractors. This Material Management & Control Procedure will apply to all work sites. 5.3

Contractors Responsibility

Contractor will be responsible for the inward receipt, material control, storage and eventual load-out of the materials. All materials will be controlled using an auditable material control procedure.



All Material Receiving Reports will be issued according the Material Request and Issue Procedure within 7 days of arrival at the materials store and signed by an approved Contractor’s representative. All Material Receiving Reports, when finalized, will be countersigned by SAPID. 6.

EQUIPMENT AND MATERIAL RECEIPT

The Contractor’s material Controllers shall ensure the correct and safe off loading of all equipment and materials on receipt at the storage areas or Fabrication Yards, the bare pipes relevant to the Pipelines installation will inspected by Contractor Third Party at the manufacturer premises, then upon their arrival to Coating Subcontractor yard will be re-checked for major damages, cleanliness and the correctness of the traceability by pipe tallies. The materials will be checked for quantity and transport damage immediately after offloading against the packing list or delivery note and the relevant purchase order. Provision shall be made at each location where materials are used, for delivery into a defined "receiving area", this area shall be used to check, test or inspect materials prior to storage or issue for use. Where practicable similar materials supplied from different sources should be stored separately from each other. Material shall be handled in a manner which maintains its quality and condition. Materials coordinator will confirm P.O. number, Aramco stock code, material grade and size shall be marked with waterproof marker, on the received items. Where it is not possible to inspect at the point of receipt; i.e. where no appropriately qualified personnel are available, or that packaging has to remain intact to protect and preserve condition during storage and shipment or time factors preclude on-receipt inspection, then inspection shall be carried out at final destination. The Material control Staff will then prepare the Material Receiving Report, (Form -AH- 0023 Attachment 1) attaching the supporting delivery note. The original copy of the MRR is passed to the contractor’s inward inspection QA team along with the delivery note. 7.

GOODS INWARD QC INSPECTION

7.1

Project Equipment and Materials

All project equipment and materials (CIM & Contractor supplied) will be inspected by the materials receiving QC Inspector. The material will be inspected based on applicable Company requirements (relevant SATIPs), delivery / release notes, drawings, Contractor PO, (aligning to relevant SATIP - Company’s or Contractor’s where Company’s does not exist) leaded by relevant SATIP and, upon filling up relevant SAICs, QC Inspector will complete the MRR with the designated heat number, MTC Number and final status of material. Conformance to the order requirements will be verified on inspection including checking all certification and Material Safety Data Sheets where necessary and qty as per the delivery note. Any material received without all the required material / test certification or other specified documentation will be segregated and quarantined "ON HOLD" pending receipt of the missing documentation. The missing documentation shall be submitted within 3 days otherwise an NCR is to be raised. Materials urgently required for production use prior to completion of all necessary checks, tests and inspections may only be issued for use / further operations provided, the following three criteria can all be satisfied:a) b) c)

It will still be possible to perform the requisite checks, tests and inspections satisfactorily after the material has been issued to production / further operations. Full traceability can be ensured. Total recall of such material can be guaranteed should this subsequently prove necessary.



d) 7.1.1

Approved from Company. Receiving Material Verification

Receipt inspection of items will include checking (as a minimum) the following for compliance with specified requirements (Company / PO Requirements), and any other contractual requirement COMPANY might ask for:      

Material description Material condition (If visible) Material identity/markings (Stock Number) Packaging (Any lost or displaced protection i.e. wrapping, protective packaging, etc. Special handling requirements Accompanying documentation

The inspection status of all materials must be positively identifiable at all stages, including receipt, by means of tagging, PO marking, physical location or other suitable means. Material identity markings must be maintained through all stages from initial receipt through to use for production or eventual return / disposal at project completion and on all cut off materials. MRR should be prepared by Warehouse Clerk with the following  Material Supplier  Material Description  P.O. / Stock Number  Quantity  Heat Number Material QC Inspector shall prepare the applicable SAIC to verify the material quality at site against the MRR along with MTC and will record the Accept / Reject Status in MRR. SAIC will not generated for the non structural bulk materials (Ex: Bolt, nut, washers) and tertiary items. MRR will be used to record the inspection result. The whole process of QC inward inspection needs to be completed within 21 days. 7.2

Non Conformance Reports

The Materials QA Inspector will raise a Non Conformance Report (As specified in procedure “Non-Conformity Management” 00-ZA-E-G09604 for any materials not conforming to the purchased specification. The NCR will clearly state the violations with remedial action where necessary and cross referenced to the applicable MRR. NCR can be issued at any stage of production if the material found non compliance with the requirement of standard and Specification. For all material NCR’s, it is the responsibility of the Contractor's Materials Supervisor in conjunction with the Procurement Department to finalize and close out each NCR in an expeditious manner. The NCR will be submitted to the Company’s Project QA Supervisor for final approval. The Contractor's QA Supervisor will maintain and update a status report of all NCR’s. The outstanding NCR status will be issued by Contractor as an attachment to their weekly progress report. All materials are subjected to the following checks and reports. This does not apply to materials directly procured by sub-contractors as part of their sub-contracts. Preserved materials shall in no case be depreserved for receiving inspection purpose.



In case of conflict between this procedure and some other document, it shall be resolved by using the following order of precedence: 1. 2. 3. 4. 5.

Contract Company-furnished construction drawings Scope of Work Construction Procedures Company Standards and COMPANY Standard Drawings (SAEP, SAES, SAMSS, Approved Coating Products List, G.I., M.I, O.I. 6. Industry Codes and Standards referenced therein In addition to all above QC Material Inspector shall ensure that the following conditions are satisfactory to avoid the material non conformance:

a) Quantitative check: -To check on arrival at the storage area the quantities received against quantities shown on the packing list and ascertain delivery status of the Purchase order. b) Quality check: -This check comprises of a visual inspection for damage including an inspection of the conformity of the identification marking of the material certificates and the purchase order. c) Delivery note: - Satisfactory checking of the quantities, the delivery note should be signed by an authorized person. d) Join Inspection with SAPMT/SAPID for the Equipments like Skid, Valves Size above 12” etc with satisfactory results. All signed originals of MRR will be retained and sequentially filed by the Material QC Inspector or his delegate at site. Any material / equipment not clearing inspection will be held in a quarantined area under the responsibility of the Site Material Controller and returned to the vendor after detailed investigation and findings if required. 7.3

Material Certificates

All copies of material and test certificates will be suitably identified with the respective purchase order number and shall be retained by the Material Receiving Inspector. 7.4

Purchase Orders

All copies of delivery notes will be suitably identified with the respective purchase order number and shall be retained by the Material Controller. Originals shall be kept by account department. 7.5

Material Status.

All accepted material will be identified by means of a post with the notice “Material Accepted with Facility identification” if stored in open storage area. The Material inside of the warehouse will be identified using their MRR posted near to the material. Rejected material will be quarantine and identified with the NCR # and marked “HOLD” in dedicated area with facility identification. Return material will be stored in dedicated area with the facility identification and by mentioning the RMV (Form AH 0024 attachment 4) on the material. Material with out any identification stated above are considered as” Under Receiving Inspection”



8. 8.1

HANDLING AND STORAGE OF MATERIALS General - All Materials

All project allocated material will be stored in appropriate areas clearly designated and identified. Materials will be stored such that different types and grades are readily identifiable and retrievable. The Site Material Coordinator shall ensure that materials and /or equipment received shall be protected from pilferage, damage or adverse climatic conditions when placed in storage. Warehouse / Yard personnel shall be responsible for monitoring the condition of materials in storage during the course of their normal duties, reporting any anomalies to the Materials Coordinator. The QC Supervisor / Material QC Inspector shall during routine surveillance verify that the condition of stored project materials is maintained. Methods adopted for the handling and storage of all materials at all stages from receipt through to installation (including when in transit and during storage prior to use) must be such as to prevent damage, deterioration or loss. Lifting activities shall comply with the requirements of the Lifting Operations procedure. Ref: Attachment 2: Preservation Inspection Report (FORM- AH- 0026) 8.2

Flanges

Flanges will only be removed from protective packing for checking and inspection, after which they will be replaced until required. Flange faces shall be greased and protected from damage by plywood or similar material when not bolted to mating flanges. Flanges will be stored face down on pallets prior to use. 8.3

Valves

Protective packing will not be removed from valves except for visual inspection, after which it will be replaced until the valves are required for incorporation into tee assemblies. Valves should generally be soft seated and supplied in the open position. They should remain in this position and should not be moved until required for use. Valves must not be “stroked” during the receiving inspection. The valves 3 inch and smaller shall be stored indoor. The valves over 3 inch maybe stored in outdoor sheltered areas providing suitable vapor barriers and necessary to be protected from corrosion and deterioration 8.4

Miscellaneous Engineering Items (E.g. Stud Bolts, Nuts and Gaskets)

Will be lifted and handled by methods appropriate to their packaging and stored in accordance with suppliers’ instructions. 8.5

Mastic (and Other General Bulk Issue Materials)

Shall be transported in bags within half height containers. 8.6

Flat Plates, Pre-Formed Plates and Beams

All plates will be stored in a horizontal attitude, on firm ground and kept above any standing water. Supports will be provided to minimize distortion or water accumulation. They will be stored away from areas where they are not liable to contamination from grease, oil, paint or other harmful substances. Measures will be put in place to prevent damage when handling plates that have been primed or galvanized. Precautions shall be enforced to minimize distortion during handling. Off cuts will be marked for traceability with relevant Heat / Cast numbers and stored adjacent to new stocks.



8.7

Storing and Handling of Bare Pipe for Pipelines

Pipe will be handled with precautions segregated and stored such that different sizes, readily identifiable and retrievable. Special care will be required for the Inconel cladded bare pipe that even if are the same grade and size of the Megline 12” need to be stored separately. Pipe shall be adequately protected and timber bearers shall be provided both in transportation and during storage. 8.8

Storing and Handling of Shapes and Tubulars

Raw steel materials such as shapes and tubulars will be handled and stored with precautions similar to that enforced on plate material. Pipe will be segregated and stored such that different sizes, types, grades etc, (e.g. carbon steel and stainless steel pipes will be stored in different locations) are readily identifiable and retrievable. Pipe shall be adequately protected and timber bearers shall be provided both in transportation and during storage. Pipe fittings 6” diameter and below shall be stored in containers or under cover. Pipe fittings 8” diameter and above shall be stored outside on pallets or timbers, with flange faces protected with water repellent. Non ferrous metals will be stored separately from ferrous metals. All pipe fitting and flanges stored outdoor shall be protected by weather proof covering and adequately secured to prevent the covering from being removed during storage. 8.9

Electrical and Instrument Equipment

Electrical and Instrument equipment will be stored in specific areas in accordance with manufacturer’s instructions and approved preservation procedures. Electrical and Instrument cables will be stored in a High Security area. Issue of cables will be on as needed basis in accordance with the cable drum schedule issued by Engineering. When a length of cable is cut off a reel the cable end will be kept dry and resealed as soon as possible and the remaining quantity recorded on the database. 8.10 Mechanical In general, major mechanical equipment will be stored in Moderate Security areas and in accordance with manufacturer’s instructions and approved maintenance and preservation procedures. Vessels etc. will be stored in designated outdoor areas with suitable whether water proof covers. In case of piping for mechanical equipment that cannot remain installed on the equipment during handling or transportation shall be packed in wooden boxes or crates and stored in indoor areas. 8.11 Ancillary Equipment All ancillary equipment, accessories and shipped loose materials will be stored separately from the main item and will be marked with a brief description, tag number and purchase order number and item number. 8.12 Paint and Other Toxic Material Hazardous items are stored separate from all other materials. Safety activities will be in accordance with HSC safety plan. The storage requirement shall be as per Paint manufacturer recommendation and Project specification DE-119892. 8.13 Preservation To be developed in accordance with each manufacturer requirements.



Material preservation forms will be attached to this procedure when the required information is received from the manufacturers. 9. 9.1

MATERIAL REQUEST AND ISSUE Material Request

Request for materials will be sent to the Material Controller in the appropriate Materials Request Form (FORM-AH-0025 Attachment 3) by the user in order to obtain (all or part) of the items required for works and shall contain the required minimum information such as:     

The construction drawing(s). The item(s) in the drawing(s). The type of materials and the necessary quantities. The grade of material as detailed on the drawing. The line (or area) concerned.

For issue of steel plate, tubular or sections, the material identification will be requested as per the applicable nesting drawing. 9.2

Material Issue

Stores personnel will check that material requests bear the necessary information required and the authorized signatures. Materials will be issued to site against a Material Request Form (MRF) which will contain the following details.     9.3

The construction drawing. The item(s) issued in the drawing. Description of item(s) and quantities issued. On issue of items the stock card assigned against each item will be updated and entered. Stock Control Records

This record is computerized and shall continuously be updated on database by the Material Control personnel as a record of reference. Site Material Controller will make periodic stock-checks of selected materials for reconciliation purposes of any remaining unused stocks. CONTRACTOR Material Controller with the assistance of store personnel will carry out regular stock checks. Material Controller shall take all necessary measures to ensure that records are updated. Where a discrepancy is found the following actions shall result: a) b) c) d) e) f)

Re-check physical stock Re-check all recorded transactions Enter discrepancy as surplus or deficiency and reason Advise Procurement Manager of discrepancy Enter relevant remarks on Stock Verification Report Adjust stock control records

Checked stock control records shall be entered with stock check details and ensured by Site Material Controller. 9.4

Control of Material at Sub-Contractors

The sub-contractors material control Personnel report hierarchically to the sub-contractors Manager and functionally to the CONTRACTOR Material Controller. They shall use and comply with this Material Control Procedure issued by the CONTRACTOR and they shall in no case use their own procedures.

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 Doc. No.: 00-ZA-E-G09609 Rev. 00 Date: 19.05.2012

MATERIAL MANAGEMENT AND CONTROL

Page 14 of 22

9.5

Control of Material at Barge

The Material Management at Barge will be managed as per the PTS Procedure (00-ZA-E-G09622). Issue of Material to Fabrication. The nominated receiving personnel will sign for any material issued to fabrication from the stockyard/warehouse facilities. 9.6

Traceability

When required the full Traceability shall be maintained throughout the life of the material. The Site Material Controller /QC Inspector / Store Keeper will be responsible to maintain the database to which provides the identification and traceability of material and provide identification for materials to correlate with the relevant documents / certificates. P.O. Number and Item number to be verified. All project material including cut off shall be traceable and color coded. Process piping / pipeline shall be given color code different from structural tubulars and same to be done for structural plates and tank / vessels (Attachment 5: Material Color Code) MRF number shall be marked by Paint marker on CAT A, B, C members for the details of traceability like mark number, Heat No, plate No and Mill certificate. Drawing Mark number should be punched Production Supervisors are responsible for the material identification and transfer subsequent to construction and during fabrication / erection activities. It is a function of Quality Control Department to ensure traceability markings and proper identification marks are carried out. The Quality Control Inspector shall ensure that all sections cut from a piece are marked in a manner that assures permanent cross-reference with the source identification and color coding. 9.7

Color Coding

Color coding on raw material shall be as stated below (refer Attachment 5 Material color code), regardless of its size. Materials like flat bars, round bar, angle bar, anodes and any galvanic or painted items are excluded from this requirement. If there is no proper access to color code while the material is stacked, color coding to be done once the material on the top is removed. Equivalent material will be identified by same color of its original.

Pipe

Plate



9.8

Identification

Identification and recording of cut structural steel (plates, shapes, tubulars and pipes) shall be carried out so that any particular item of steel can be identifiable by reference to drawings and material records. 9.9

System, Components and Installation Materials

System, equipment, component or parts shall be traceable to manufacturer’s serial number. Manufacturer’s serial number shall be provided on the items by name plates, metal tag and engraving. An inventory shall be prepared for such materials and shall be identified by their serial number. The Material controller shall maintain this information. The inventory system tracks items received from the vendor by associating to the purchase order numbering system serial number and placement location. The Material Controller applies serialization tags, on items maintaining individual traceability and documents it, as required by contract.

10.

TRACEABILITY

10.1 Traceability during the Assembly The Materials shall be traceable to the heat numbers, cast numbers or lot numbers stenciled on each piece. And the following details shall be by paint marked for production traceability:  

MRF numbers Drawing Number

Material Test Certificate shall be the reference documents for the traceability of these materials. For batch traceable materials, the numbers shall be identified on at least one piece or through tags tied on to the lot. For batch traceable materials (Nipples, Stud Bolts, Nuts, Gratings, Cable Gland Etc), individual pieces going into the construction shall not be separately identified. Materials requiring full traceability shall be individually identified by their Heat / cast / lot number / Tag No and they shall be individually traceable to their reference documents. 10.2 Traceability of the Secondary Structures. The material traceability for the ladders, stairs and handrails, E & I supports, piping supports will be considered as bulk items based on the MRR and MRF. The material traceability and materials summary will not be applicable for these items and Contractor will release the items after completion of fabrication with internal release note by QC. Materials Traceability is required only for items directly welded on pressure containing piping and pipe line spools. 10.3 Traceability during Installation During installation, the foreman and the QC inspector shall check identification of the components by drawing number, part number or serial number, prior to installation. In case any Items are found without traceability, Contractor shall issue NCR. 10.3.1 Material Return



Any surplus material shall be returned to the stock yard / warehouse with the (Attachment 4: Material Return Form –AH-0024) duly signed by the Discipline Responsible or his delegate via the Site Materials Controller. The Material Return Form shall contain the following details: a) Description of item and identification marks (Heat No, Part No etc) b) Quantity received, Quantity used and Quantity returned. c) Reason for return if any. Upon return of any surplus material, the stock-card for the item will be updated immediately and the current stock level entered into the materials database. 10.3.2 Material Substitution No material will be substituted or modified without prior written approval from CONTRACTOR Engineering Manager or where applicable the Client. 11.

Records

All personnel referred to in this procedure are responsible for systematic compilation of the records relating to their work activities and for progressively forwarding such records to the project QC Supervisor for incorporation into the As-built dossier. The results of all checks, tests, measurements and inspections must be recorded legibly, completely accurately using appropriate record / report forms. All test and inspection record / report forms must be signed and dated by the persons who performed the checks / inspections. All tests and inspections must be performed only by competent qualified personnel and in accordance with defined (documented) procedures using calibrated equipment. Personnel responsible for performing final inspection / testing must include a check to verify that the results of all previously required test / inspections as detailed in applicable QC plans/procedures / specifications have been adequately documented to permit verification that:    

All required test / inspections have in fact been performed The results were in all cases satisfactory The actual results have been recorded All test / inspection records are complete, dated, and signed by appropriate personnel

Any deficiencies detected above will necessitate quarantining the items in question "ON HOLD" pending investigating and resolution of the deficiencies identified.

12.

ATTACHMENTS

Attachment 1:

Material Receiving Report (FORM-AH-0023)

Attachment 2:

Preservation Inspection Report (FORM-AH-0026)

Attachment 3:

Material Request Form (FORM-AH-0025)

Attachment 4:

Material Returned Voucher (FORM-AH-0024)

Attachment 5:

Material Color Code

Attachment 6:

Material Inspection flow chart.



Attachment 1:

Material Receiving Report (FORM-AH-0023)



Attachment 2:

Material Preservation Inspection Report (FORM-AH-0026)



Attachment 3: Material Request Form (FORM-AH-0025)



Attachment 4: Material Returned Voucher (FORM-AH-0024)



Attachment 5: Material Color Code



Attachment 6: Material Inspection Flow chart.

00 Za e g09609_00 Material Management

Recommend Documents