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: EMC- MTP-01

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MATERIAL TRACEABILITY PROCEDURE

EMC-MTP-01

Rev. Date Comments Prepared By Approved By Reviewed By

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TABLE OF CONTENTS

S.N SUBJECT page 0 1 2

1.0 Scope

2.0 Purpose

3.0 References

4.0 Definitions

5.0 Responsibilities

6.0 Procedure
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1. SCOPE

This procedure applies to identification and traceability of material and constructed work under the
responsibility of EMC and its Subcontractors at the stages of supply, and installation.

2. PURPOSE

To ensure that:
 All installed work can be identified and traced to the applicable drawing,
inspection report, specification or other document,

 All traceability marks and certificates received are maintained

throughout the construction process,

 Contractor/Company traceability requirements are met,

3. REFERENCES

 ISO 9001:2008: Quality Systems

 : Material Control
 : Control of Non-Conforming Product

4. DEFINITIONS

Material Certificate: A certificate that provides the capability to identify the chemical analysis
and mechanical properties of materials throughout manufacturing,
construction and plant operation.
Normal Traceability: The ability to trace received permanent material to its manufacturer’s
certificate.
Total or Full Traceability: The ability to trace any installed permanent material back to its source
material and the respective material certificate.
Certification: The authoritative act of documenting compliance with requirements.
The requirements can be related to personnel, processes, products,
organizations and services
Company: SIPEM

Contractor: EMC

5. RESPONSIBILITIES
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 The Material Engineer is the overall responsible for ensuring that traceability and certification
requirements are adequately addressed and specified in the respective purchase orders for
EMC supplied permanent material.

 The Material Controller(s) is responsible for ensuring that identification and certificates are
preserved during the material receiving, storage and supply stage.

 The Construction Superintendent(s) in conjunction with the discipline QC Inspector(s) are

responsible for ensuring that identification and traceability are maintained during the
construction process.

 All project personnel involved with material/equipment acquisition, processing and installation
should be familiar and implement the requirements of this procedure.

6. PROCEDURE

6.1 EMC supplied Material Procurement

6.1.1. The Material Control Engineer in conjunction with the QC Manager shall review and
define requirements for identification, traceability and certification of material/equipment
to be procured by EMC. These requirements shall be clearly defined in the purchase
order data.

6.1.2. Where applicable, purchase order and subcontract data shall include instructions to
vendors and subcontractors to confirm material identification during production and
delivery and specifically in the case of alloy steels through Positive Material
Identification (PMI) as per applicable procedure.

6.2 Receipt and Storage of Materials

6.2.1. On receipt, materials/equipment shall be checked to ensure that appropriate

identification and material certificates are included with the consignment and this
information shall be recorded on the Material Receiving Reports.

6.2.2. For materials with full traceability or any other special requirements, or if required by the
applicable Inspection and Test Plan, QC inspectors will follow the material checks and
carry out inspection including checks of identification marks and traceability.

6.2.3. Items or bundles of items that are individually tagged and identified shall be stored in
the warehouse such as to ensure easy recognition; Material Controller(s) and
Storekeeper(s) shall ensure that identification marks and tags do not get erased or
detached.
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6.3 Issue of Permanent Materials

6.3.1 All permanent materials supplied for the project shall fulfill the
requirements specified by the contract specifications. Issue of permanent
materials and definition of EMC.s personnel involved and their activities/
interrelations .

6.3.2 The control of non conforming materials is defined in procedure.

Personnel whose activities are defined there in shall refer to paragraph
6.4 to 6.8 for certification and traceability requirements.

6.3.3 During construction/installation and until mechanical completion, all

personnel involved shall refer to paragraphs 6.4 to 6.8 for the definition of
the traceability requirements during processing materials including
installation.

6.4 Traceability of Civil Materials

6.4.1. Traceability and approval of civil materials shall be in accordance with

specifications and QC documentation.

6.4.2. Cement shall be checked as acceptable (manufacturer’s certificate) prior

to loading into the silo, only conformant cement shall be used.

6.4.3. Aggregates are received into a 'Bulk' storage area and sample tests
taken. If these are within specification they are then moved to the 'Feed'
storage or Batch Plant.

6.4.4. All water shall be tested before initial use both at source and storage
supply. Testing thereafter shall be in accordance with specifications. Mix
water shall conform to requirements in “Ready-Mixed Portland Cement
Concrete”.

6.4.5. Additives are received with a manufacturers certificate of analysis. If

stored for a period exceeding the “use by” date specified by the
manufacturer then they are tested prior to use.

6.4.6. Reinforcement (Rebar): all rebar is supplied with a manufacturer’s mill

certificate. Coated rebar is supplied with a certificate from the coating
manufacturer. Both sets of certificates shall be checked against the tags
on the bundle of bar during receiving inspection.

6.5 Inspection, Measuring and Test Equipment Calibration

Equipment calibration traceability requirements are defined in EMC-CAL-01

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6.6 Certification and Traceability Requirements of Material

6.6.1 The following material traceability system will be used for the Project job
site. For all bulk material, certification and traceability requirements shall
be in accordance with contractual requirements.

6.7 Material requiring Normal Traceability.

Receiving inspection (Warehouse Inspection) of material

a) Upon receival of materials the Material Controller or his designee shall verify receipt of
the QC Data Book, type of Material Certificate and color code as applicable.
b) Color coding shall be along the longitudinal axis not on the circumference. Color
coding system for material is defined in the CONTRACTOR’s specification:
“Identification of Material”.
Fabrication and installation traceability of material

a) After issuing the materials to the Construction Group, the Construction Group shall be
responsible for the material control. QC Inspectors and Supervisor shall check/monitor
the Construction Group's quality control activities (incl. traceability control). Materials
shall be checked against the material isometric drawings and materials lists.
b) Color coding in accordance with the specification shall be maintained during all stages
of fabrication. When cutting material, the cut material shall be identified by color
coding.
6.8 Material requiring Full Traceability.

6.8.1 Receiving inspection (Warehouse Inspection) of material

Upon receival of material requiring full traceability, the responsible QC

Inspector shall:

 review and compile separately the material certificate as appropriate

 Register the following data (for material components) into a material certificate
/Heat No. Control Log (preferably a computerized data base) to permit tracing the
material certificate from a Heat No. originally marked on each material component
upon receipt:
 Purchase order No. (if applicable)

 Material Certificate No.

 Material identification number/grade.

 Manufacturer's name.
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 Heat number

 Size/schedule.

 File No. (QC Data Book).

Where practical, material requiring full traceability shall be stored in
geographically separated areas at the open stores yard.

6.8.2 Fabrication and installation traceability of material

a) Before requesting the issuance of material, the Material Supervisor shall check
material grade on the isometric drawing. Material issuer shall also check the material
to be issued using the information available on the “Material Request sheet”, MRS.
b) After issuing the materials to the Construction Group, the Construction
Group shall be responsible for the material control. QC Inspectors and
the responsible Material Supervisor shall check/monitor the Construction
Group's activities related to traceability control). Materials shall be
checked against the material isometric drawings and materials lists.

c) Fabrication areas for carbon steel, low temperature carbon steel, low alloy steel and
stainless steel, shall be separated to ensure that there is no mixing or misusing of
materials and welding materials.
d) During fabrication the following steps shall be followed:
 When cutting pipes, the Material Supervisor or his designee
shall ensure that the cut pipes can be identified by material
identification No. (Heat No.).

 After fit-up and before welding, the Material Supervisor or his

designee shall check the Heat No. on material components
against the marked copy of the “Material Request sheet”,
MRS.

 After checking the Heat No. the Material Supervisor or his

designee shall mark the Heat No. on the isometric drawing
and on the material identification sheet.

 The Heat No. for each block set item such as vent connection,
drain connection, pressure instrument connection, etc., shall
also be marked on the isometric drawing and on the material
identification sheet.
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 The Heat No marked on each material component shall be

recorded on each isometric drawing and on the material
identification sheet. The materials should be segregated with
every isometric drawing for its fabrication.

 Material test packs/traceability details are to be handed over to

the CONTRACTOR/COMPANY with the final hand over
documentation.
e) After pre-fabrication, and before blast/painting and/or PWHT is carried out:
The QC Inspectors shall check color code, and material identification No. (Heat No.)
on material, and on the isometric drawing.
6.9 Positive Material Identification (PMI)
6.9.1 PMI shall be carried out where required, and in accordance with client
spec.

6.10 Welding

6.10.1 Welding records including identification and traceability shall be

maintained by QC department using the welding module of the EMC
DOC. system.
6.10.2 Certification and traceability of welding consumables shall be in
accordance with client spec's
6.11 Certification and Traceability Requirements for Structural Steel

6.11.1 Receiving inspection (warehouse inspection) of structural steel:

 On the arrival of structural materials, the QC Inspector shall

check for shipping damage, quantity, size, material certificates
release notes and markings against the packing list. Material
certificate requirements shall be in accordance with contract
requirements.
 At the same time, QC Inspector shall check for the availability
of QC Data Book.
6.12 Equipment, Tagged Items, Instruments Traceability Requirements

6.12.1On the arrival of materials, the Material Controller shall check for
shipping damage, quantity, size, and marking against the packing
list.
6.12.2At the same time, the QC Inspector shall check for the availability of
QC Data Book.
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