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8. MATERIAL CONTROL

8.1 Scope

This Section deals with system of procurement, receipt, identification, inspection

and storage of materials used in Code stamped vessels & parts.
Welding consumables shall be controlled as described in Section 10
(Welding Control) of the Manual.

8.2 Policy

All materials shall be ordered to an approved ASME specification, indicated in

the Technical Delivery Condition. (TDC)

8.3 Responsibility

Planning Engineer is responsible for creation of Material request and

indent.

Planning Manager is responsible for Authorization of Material request and

Indent.

Welding Engineer is responsible for creation of Material request and indent

for welding consumables. Also responsible for receiving inspection of
welding consumables.

QCM is responsible for authorization of Material request and indent for

welding consumable.

Supply chain Manager is responsible for Procurement of Material.

Stores Keeper is responsible for storage and maintain of PO/TDC/MTR.

8.3 Purchasing

8.3.1 Only material permitted by the Code shall be used in the construction of boilers,
pressure vessels & parts to be stamped with ASME Code symbol stamp.

8.3.2 MR other than welding consumable planning engineer is responsible for

preparation of MR as per BOM, Approved drawing and TDC
(Exhibit8.01).Planning Manager is authorizing the MR.
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The MR for other than welding consumables is prepared by the Planning

Engineer. The MR shall indicate the following information as applicable.
A) Job number.
B) Total Quantity required.

The materials are ordered by Supply Chain manager attaching the Technical
Delivery Condition (TDC) (Exhibit No. 8.01) to the Purchase Order (Exhibit No
8.03).

8.3.3 For welding consumables WE shall prepare the WTDC (Exhibit No-10.11) &
Material Request for welding consumable (Exhibit No-8.02) & QCM shall
approve.

8.3.4 TDC, WTDC & MR is forwarded to the Supply Chain Manager. The Supply
Chain Manager forwards a copy of MR along with TDC and WTDC to SK for
checking whether the material is in stock or not.

8.3.5 For the material not available in stock the Supply Chain Manager prepares
the Purchase Order (Exhibit No. 8.03) according to the MR, WTDC& TDC.

8.3.6 The Supply Chain Manager Send one set of Unpriced P.O., MR, WTDC & TDC
and all necessary attachments to SK & QCM / WE for use during receiving
inspection.

8.4 Material Receiving & Use of Stock Material

8.4.1 The SK is responsible to check the material and the delivery challan for
compliance with the MR / PO as follows but not limited to
A) Quantity and transit damage if any
B) Packaging (Defects)
C) General Condition
D) MTR/MTC Status
8.4.2 The SK prepares GIN (Goods Inward Note) on the receipt of the material
and forwards GIN (Exhibit No. 8.04) with PO /TDC/MTR for performing of
receiving Inspection to QCE /WE for Inspection clearance.

8.4.3 The QCE upon notification from SK shall verify that material is correctly
marked in accordance with the material purchase specification and
material grade as per the Code. QCE verify the markings as per the Code
requirements and shall record his observation on the IMIR (Exhibit No.
8.05). He shall also record the actual marking in the IMIR. Recertification
where necessary shall be done in accordance with Section 8.4.8.

8.4.4 For Welding consumable WE shall verify batch test certificate and clear for
further processing. Batch test may be performed where necessary in
consultation with AI.
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8.4.5 Available stock materials required to use for ASME shall be inspected by
QCE. He will review available marking to verify compliance with applicable
Code requirements. Where necessary MTR / MTC and any additional
material or inspection requirement shall be validated to ensure
conformance to the requirements of Code. If current Edition of the
Specification Call for additional tests, QCE shall raise NCR and undertake
necessary test and resolve also QCE shall certify in accordance with
Section 8.4.8.

8.4.6 Re-certifications where necessary shall be done in concurrence with the

AI. He shall also record the actual marking in the IMIR .All such accepted
stock material shall be shifted to ASME Stock yard.

8.4.7 Material produced to either US Customary or SI unit can be accepted in lieu of

each other.

8.4.8 ASME/ASTM MATERIALS AND RECERTIFICATION

Case I

Material received with ASTM materials with year of edition on MTR listed in
Mandatory Appendix II of ASME Sec II Part A/B as applicable and acceptable to
current edition.

The QCE shall verify the material against all the requirements of the required
year/addenda of material specification. After satisfactory verification,
QCE shall re-certify the material on the MTR.

The re-certified material shall be stamped as respective ASME material.

No NCR shall be raised for this case.

Case II

ASTM materials produced to newer or older Editions than those listed in

Mandatory Appendix II of Section II Part A/B as applicable.

The QC Engineer shall raise NCR and verify the material against all the
requirements of the required year/addenda of material specification. After
satisfactory verification, he shall re-certify the material on the MTR and submitted
to the AI for his acceptance. He shall prepare a Material Comparison List (Sample
Form- Exhibit 8.09) and attach along with material records as an evidence of
satisfactory verification.

The re-certified material shall be stamped as respective ASME material.

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CASE III

ASME materials produced and certified to earlier editions of the ASME

material specifications.

1. ASME materials produced and certified to earlier editions of the ASME

material specifications .Such material shall be verified as per Section II
Part-A/B that have been identified by subtitle as identical or similar to an
ASTM or non-ASTM material specification edition and they encompassed
by the range of year-dates of both received and acceptable editions
(Table-II-200-1 & 2) of Appendix II in Section II Part-A/B, are also
acceptable for use in construction to the required Edition.
No NCR shall be raised and no Material Comparison List shall be prepared
for this case.

2. If ASME materials as specified above does not fall in encompassed range of

year-dates of other acceptable editions (Table-II-200-1 & 2) of Appendix II in
Section II Part-A/B, QCE shall raise NCR and verify the material against all the
requirements of the required year/addenda of material specification using
Material Comparision List. After satisfactory verification, he shall re-certify the
material on the MTR and submitted to the AI for his acceptance. QCE shall
accept the materials, document the acceptance on the GRN and IMIR. The
accepted material shall be taken in to Job stock.

8.4.9 The SK is responsible for proper handling, marking and storage of the material
in the ASME stock yard until release. Also SK to take necessary validation for
compliance.
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8.4.10 All accepted material shall be Hard punched the LTEW metal stamp by
QCE. While hard stamping the accepted material necessary care to be
taken as per clause 8.5.Such cases code marking shall be applied in
accordance with Clause 8.7.4.
The loose parts like pipe fittings etc., are attached with a material status
sticker as “ACCEPTED” (Exhibit No. 8.08) and shall be kept in stores.

8.4.11 If the material does not confirm to the requirements of the ASME Code,
specification & PO. QCE will put the remarks on the IMIR & it shall be considered
as Non Conformities and to be handled as per Chapter 14 of the Manual.

8.4.12 All materials which are not conforming to the requirement shall be attached
with a tag/sticker “HOLD“(Exhibit No. 8.08) sticker until NCR is resolved.

8.4.13 Rejected material shall be attached with a tag/sticker “REJECTED”

(Exhibit No. 8.08) and shall not be allowed to be kept in the ASME Stock yard
and stores and the same stored at a separate identified location.

8.5 Stamping

Hard stamping shall not be applied to ferrous material less than ¼” (6 mm) and
non ferrous material less than ½” (12 mm) thickness or where the service
conditions prohibit die-stamping for material identification, and so specified by
the user. In this case marking shall be done preferably by etching or engraving or
by permanent paint marker. For ASME Sec VIII Div 2 items, hard stamping shall
be done by commercially available low stress die stamps as per para 3.2.7.2 of
part-3 of ASME Section VIII-Div-2.

8.6 Material issue for Fabrication

8.6.1 Stores keeper shall issue the accepted material for production, against Indent
(Exhibit No 8.07) requested by Planning Engineer.

8.6.2 After receipt of accepted material Production Engineer shall ensure the
correctness of the material being issued and mark the required further markings
and offer the same to QCE.

8.6.3 QC Engineer shall verify identification of individual components & prepare

Material Heat Chart (Exhibit No 8.06) and offer for the AI’s review along with the
MTR for plates and pressure parts.

8.7 Marking Transfer

8.7.1 Before material is cut into two or more pieces, or the original marking is cut out,
the following details shall be marked / stamped on materials for proper
Traceability of materials on each piece and Balance Material.
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Plates: Job No, Part No, MSN, Material Specification and Grade/Type/class
and additional Marking such as MTLTV, UT, Heat No & Plate No.

Pipes: Job No, Part No, MSN, Material Specification and Grade, Heat No/Lot no,
Size and Schedule no.

For standard parts such as Flange, Coupling etc., In addition to Manufacturer’s

marking, Job No,MSN and part No shall be marked.

The QCE shall confirm the proper transfer of marking as per above and record
including IMIR in the Material Heat Chart (Exhibit No 8.06).

8.7.2 If hard stamping of the material is not permitted, the marking shall be done by
engraving or other suitable methods.

8.7.3 For small parts (on which full transfer of identification is not feasible), shall be
Identified with the relevant Part No. and Material grade, other details of such
Material i.e. Heat No, Plate No etc. shall be documented on Material Heat Chart
(Exhibit No. 08.06).

8.7.4 Code marking if used QCM shall establish a procedure and accepted by AI.

8.8 Substitution of Material

8.8.1 Substitution of Material is authorized by the Design Engineer & approved by DEM
shall be subject to the acceptance of the QCM. All material Substitutions require
AI’s acceptance

8.8.2 The Design Engineer shall document material substitution in the design
calculations, if applicable, and shall record the material substitution on the
drawings and TDC which shall be revised as described in this QC Manual
Section 7.9

8.9 Nonconforming material

Nonconforming material shall be handled as described in Chapter 14.

8.10 Material Testing

When supplementary material testing is required (e.g. impact testing) the QCM
shall be responsible for subcontracting to laboratory complying with the Code
requirements for calibration and certification.

8.11 Incoming Material Inspection Report (IMIR)

All IMIR mentioned in this chapter are made available by the QCM with all
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Accepted test results for review to the AI and are filed in the job file.

8.12 Receiving Inspection of Code Stamped Parts

8.12.1 Any item received with a Partial Data Report shall be inspected by the QCE for
possible damage and identification with the Partial Data Report.

8.12.2 The QCM shall review the Partial Data Report for completeness and then submit
it to the AI prior to it being used in fabrication.

8.13 Customer Supplied Material

8.13.1 All Code material supplied by the customer or his designee is received and
inspected as described in section 8.2, 8.3, 8.4 & 8.5.

8.13.2 Non Conforming material is handled as described in Chapter 14.

8.14 Repairs to Material :

Repairs to materials may be permitted provided that acceptance by the AI is

obtained prior to repair for the method and extend of repair. The client’s
concurrence shall be obtained wherever required as per projects specifications.

8.15 Rejection of Materials :

8.15.1 Materials which do not confirm to Code requirements shall be rejected by QCE in
concurrence with the QCM with the appropriate comments on the corresponding
NCR.

8.15.2 Rejected materials shall be identified with “REJECTED” (Exhibit No. 8.08) tag
and will be stored at separate identified location.

8.16 Additional requirements for equipment to be stamped with U2 designator in

accordance with ASME Sec VIII Div-2.

Ordering of Material

In addition to the DIV-1, PO/TDC of DIV.2 material shall include all the supplemental
requirements of the part 3 including but not limited to the following:

a) Certification of the material as per Para 3.2.6 of part-3 of Section VIII-Div-2.

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b) Specific location and no.of test specimen

c) Simulation, HT and Test Coupons.
d) Additional NDE Requirements

e) Impact and other supplementary requirements. Test temperature and acceptable

test value shall be specified.
f) No weld repair is permitted without prior approval of LTEW.

8.16.1 Certification requirements

Requirements for the material manufacturer to certify that all requirements including
special requirements if any of the material specified have been complied with.

Material received and not satisfy the TDC and PO requirement. The missed
requirement shall be tested by LTEW and it complies the material shall be
certified by LTEW QCE.

The Material test reports shall be made available to AI for his review.

8.16.2 Material Substitution

Handled as section 7.9 any material substitution by LTEW shall be subjected to

approval of the user/user’s PE as per Para 2.3.2.2 of Part-2 of ASME Section VIII Div-2.