Material Acceptance - Steel Material

1. Scope
i. This Section provides a number of requirements, recommendations, and information that supplements the section 1 – General.

ii. It covers minimum requirements for inspection activities of incoming raw materials that will be fabricated, assembled and installed in accordance with “Issued for construction” drawings.

iii. This Material Acceptance describes verification method of the actual dimension, visual, and identification of incoming raw material in accordance with purchase order requirements, mill certificates and relevant codes & standards.

iv. This discussion will be purposed for new raw steel material, such as: Plates, Structural Shapes, Sheet Piling, Bar, Pipes, Flanges, Pipe Fittings, and Bolts & Nuts.

2. Reference
- Purchase Order
- Material Acceptance

3. Conflicting Requirements
In case of conflict between this discussion and specifications, the following order of precedence shall govern:
- The requirements of the purchase order
- Material Requisition Sheet
- The individual material specification
- General specification.

4. Requirements of Inspection
i. Requirements for acceptance of material shall be furnished by the material manufacturer or material supplier in complete compliance with a material specification, such as: a report of test result, manufacturing method, ordered dimension, quantity, supply condition, and heat no.

ii. When some requirements or provisions applicable to materials exceed or supplement of the material specification, the material examiner shall examine the material test reports or certificates of compliance and shall determine that it represent the material and meets requirements of the material specification.

iii. When CONTRACTOR request the presence at the inspection, prior agreement with manufacturer shall be necessary, the attendant shall exercise care not to hinder the work of manufacturer.

iv. In the case where there is any harmful defect on the surface of material, the material manufacturer shall maintain an inspection program to inspect the work to see that:
- Imperfections have been completely removed
- The limitations specified have not been exceeded
- Establish welding procedures have been followed
- Any weld deposit is acceptable as requirements of specification.

v. The inspection items and acceptance criteria shall conform to the requirements specified in relevant material specifications.

5. Supporting Documents

5.1. Purchase Order
It shall describe vendor name, consignee, shipment schedule, material specifications, shape, sizing, quantity, etc.

5.2. Packing List
It shall have detail additional information and identifications, such as: manufacturer name, heat no, materials no, weight, etc.

5.3. Mill Certificates
Material manufacturer shall furnish a certificate of inspection stating that the material has been manufactured, sampled, tested, and inspected in accordance with material specification (including year of issue), and has been found to meet the requirements.

6. Inspection
The incoming material shall be inspected by several steps depend on the material characteristics; generally evaluation will be done as follows:
i. Quantity Check
It shall refer to section 1 – General

ii. Visual Examination
a) The test method shall refer to The Visual Examination.
b) The material shall be free from defects that are detrimental to practical use, such as: scale, crack, slag, rust, moisture and grease.
c) The finish material shall be reasonably straight.
d) The actual observation of raw material shall be recorded and documented.
e) All materials to be used in constructing a pressure part/equipment shall be examined before fabrication for purpose of detecting, as far as, imperfections which would affect the safety of part/ equipment.
- Particular attention should be given to cut edges and other parts of rolled plate which would disclose the existence of serious laminations, shearing cracks, and other imperfections.
- All materials that are to be Charpy impact tested shall be inspected for surface cracks by magnetic particle testing.

iii. Dimensional Test
a) The test method shall refer to the Dimensional Test.
b) The permissible variations for dimensions shall not exceed the applicable limits in accordance with relevant material specifications.
c) One of material from each bundle or each specific material shall be taken for test specimen.
d) The inspection apparatus as below:
- Thickness meter, accuracy 0.05 mm
- Mechanical caliper, accuracy 0.05 mm
- Steel Roll Meter, accuracy 0.5 mm
e) The actual measure of raw material shall be recorded and documented.
f) Material outside the limit of size and/or thickness given of the specifications may be used if the material is in compliance with the other requirements of the specification that it no size or thickness limitation is given in the stress tables of material specification.
g) The tolerances on shape and dimension shall refer to the relevant material specifications.
h) The following information shall be included of Receiving Material Inspection record:
- Project Title, Customer Name, Contract No.
- Job No., Purchase Order No, Material Receiving Report No, Packing List No.
- Date of Inspection, Location of Inspection
- Material Specification
- Reference of dimensional and tolerances; and Visual acceptance
- Actual Identification of material
- Actual measure of dimensional and visual observation
- Test result
- Material Examiner Name, Authorize Inspector (If required), Owner (If required).

iv. Magnetic Particle Examination

It for material plates 38 mm over in nominal thicknesses that it subject to stress due to a pressure which is to be formed and welded.

v. Ultrasonic Testing
It for material plate 100 mm and over in nominal thickness.

vi. Test Report
Test reports for each heat material are required and material manufacturer or material supplier shall report the following:
a) The specification designation, including year of issue, and the grade.
b) The heat number, chemical analysis, and nominal sizes.
c) The result of tensile strength
d) The report of heat treatment (if required)
e) The result of all other tests required by the material specification, applicable supplementary requirements, and the order.

7. Evaluation
i) QA/QC engineer shall verify between the actual identifications & inspection record; and mill certificates; and relevant material specification.

ii) If all items complied, the material shall be accepted; QA/QC engineer shall publish Material Acceptance Notice and it shall be distributed to Material and Logistic Manager for inventory and Procurement Manager for information.

8. Rejection
i) Any rejection based on product analysis made in accordance with the material specification.

ii) Material that shows imperfections capable of adversely affecting subsequent to its acceptance at the fabrication or installation work.

iii) Any rejection material shall be reported to Procurement Manager for corrective action and Material and Logistic Manager to separate it.

9. Related Document
9.1. Instruction sheet of Material Receiving Report
It shall be published by Material and Logistic Department; and it shall be distributed to QA/QC Department for inspection.

9.2. Instruction sheet of Visual Examination
It shall be published by Material Examiner; and it shall be distributed to QA/QC Engineer for verification.

9.3. Instruction sheet of Dimensional test
It shall be published by Material Examiner; and it shall be distributed to QA/QC Engineer for verification

9.4. Instruction sheet of Material Acceptance Notice
It shall published by QA/QC Engineer; and it shall be distributed to Procurement Department; and Material and Logistic Department.

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