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4.0. The system described in this section assures that the material received is properly
identified and has documentation including material test reports to satisfy the code
requirements. The system through receiving inspection, storage, issue and
identification assures that only intended material is used.

1.1. MATERIAL REQUISITION :

1.1.1. All Material Requisitions (Exhibit No.04-01) for Code material are prepared
by the Design Engineer, except for welding material is prepared by the
Welding Engineer and controlled in accordance with Para 4.6 below.
1.1.2. The Material Requisition includes the material specification, type, class or
grade selected from those permitted by the appropriate stress tables of the
applicable construction Code.
1.1.3. Technical Delivery conditions (Exhibit No 04-02) shall be prepared by the
Design Engineer and reviewed and approved by the Engineering Manager
and shall include all technical information and ordering information as per the
material specification of ASME Code Section II Part A and/or B as applicable
such as the size, Supply Condition, Heat Treatment, Markings, material test
report,…. , in addition to the requirements of the Construction Code Section
such as that of UG-79, UCS-79, special testing, Charpy impact test at MDMT
and grain size and the requirement of Sec.1 whenever applicable and the
supplementary requirements of the design if any, and any other instructions
to the supplier.
1.1.4. Completed Material Requisitions are signed, dated and approved by the
Engineering Manager, then forwarded to the Material Control Engineer to
verify the material available on stock to establish the quantity required to be
purchased. Copy is forwarded to Q.C. Inspector for use in examination of
received as well as stock material.

1.2. PURCHCASE ORDER:

1.2.1. The Material Control Engineer using the approved Material Requisition
prepares the Purchase Order (Exhibit No. 04-03) and attaches the Technical
Delivery Conditions to it, which is forwarded to the QC Manager for review
and then to Engineering Manager for approval and then sent to the selected
vendor.
1.2.2. Copy of the Purchase order along with Technical Delivery Conditions is sent
to the Q.C. Inspector for use during receiving examination.
1.2.3. For material to be sent to a field site, the Engineering Manager forwards
copy of the Purchase order to the Q.C. Site Inspector.
1.2.4. Changes to Purchase Order shall be prepared, reviewed and approved from
revised Material Requisitions in the same manner as the originals.
1.2.5. Substitution of material is not permitted without prior approval of the
Engineering Manager. In such case, revised drawings, calculations, Material
Requisition shall be prepared as necessary and approved same manner as
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originals. Acceptance of AI and customer (when required by contract) is

obtained for any substitution of material.

1.3. RECEIVING EXAMINATION AND INSPECTION:

1.3.1. The warehouse keeper shall check the coming material at the shop for
quantity and visible damage against the Purchase Order and when accepted
to him, it shall be placed in a hold area identified with a signboard “Hold
ASME Material”.
1.3.2. The Warehouse Keeper shall make entry in his store register and inform the
QC inspector to perform the examination.
1.3.3. The Q.C. Inspector, using his copy of the Purchase Order (or Material
Requisition for stock material), examines all Code material (except welding
material which is received as described in paragraph 4.6 below) for
dimensions including formed and shell radii using correct templates, for
marking, condition and quantity.
1.3.4. All material marking and dimensions are recorded on the Material Receiving
Report (Exhibit No. 04-04).
1.3.5. For all plate material and for other products for which the material
specification, purchase order or Code Section requires markings traceability,
the Q.C. Inspector reviews the material test report, chemical analysis,
mechanical properties and other test results against those listed in the
applicable material specification. The material marking are recorded on the
Material Receiving Report.
1.3.6. For materials formed by others, if the original material markings are
transferred by others, it shall either be the full markings or coded markings
as described in Para 4.5 below.
1.3.7. When acceptable, the Q.C. Inspector signs and dates the Material Test
Report and the Material Receiving Report and are then forwarded to the
Quality Control Manager for approval by signature and date. The material
shall be moved to the “Accepted ASME Material” after acceptance of the Q.C
Inspector.
1.3.8. Material which does not meet Purchase Order and Technical Delivery
Conditions requirements, the Q.C. Inspector marks the material with a red
color spot and segregated in reject area. For small items the container shall
be marked with red color. Such material are considered nonconforming and
controlled as described in (CORRECTION OF NONCONFORMITIES)
Section 6 of this Manual.

1.3.9. Issue of material:

Production Engineer shall make a request for a material using Material
Request / Release Note (Exhibit No. 04-05) this request will be signed by
Production Manager and the issuance by warehouse keeper after signature
of the QC Inspector.
Only QC Inspector accepted material shall be issued for fabrication.
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1.4. RECEIVING EXAMINATION AND INSPECTION OF CODE STAMPED PARTS:

"Orders for fabricated parts shall only be placed on suppliers having required ASME
certificate of authorization".
1.4.1. Code stamped Parts are unloaded in the hold area, and examined by the
Q.C. Inspector for damage, Code stamping and identification marking to
provide traceability to the Manufacturer’s Partial Data Report and drawing.
1.4.2. Manufacturer’s Serial Number and National Board Serial Number (if
registered) for each item received is recorded by the Q.C. Inspector on the
Material Receiving Report, who shall enter the date of receipt of all
Manufacturer’s Partial Data Reports certifying these parts.
1.4.3. The applicable partial Data Report shall be reviewed and verified, before it
can be released by the Q.C. Inspector for installation or further fabrication.
1.4.4. The Authorized Inspector shall be afforded the right to inspect and verify all
parts against the applicable Manufacturer’s Partial Data Report prior to
further use.
1.4.5. Parts and material that do not meet all Code requirements are considered
nonconforming and are controlled as described in (CORRECTION OF
NONCONFORMITIES) Section 6 of this Manual.
1.4.6. When WA is the manufacturer of the completed vessel or Certification Mark–
stamped Part , The QC Manager shall ensure that parts furnished under the
provisions of UG -11 (b), (c), (d) and (e) for pressure vessels. And for boilers
the provisions of PG-11 (b), (c), (d) and (e) and meet all the applicable Code
requirements.

1.5. IDENTIFICATION AND TRACEABILITY

1.5.1. Material identification of all pressure parts and non-pressure parts attached
to pressure parts shall be maintained through the process of manufacture,
either full markings (original or transferred) or coded markings as per Para
4.5.4 below.
The code marking system shall be accepted by the AI.
1.5.2. Record of original marking is maintained on the Material Receiving Report.
1.5.3. If the material is to be cut, the original identification markings shall be
transferred to all parts before cutting. QC Inspector shall witness transfer of
markings.
1.5.4. The markings shall be transferred as follows:
 For Shell Plates – Material specification, grade, type, heat no & plate
no.
 For Heads- Material Specification, grade, type or class, heat no., plate
no. and Head identification no.
 For Pipes - Material specification type, grade and heat no.
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 For Permanent attachment to pressure parts – Material specification &

Heat no.
 Special markings on plates (for example MT, LTV etc.) shall also be
transferred.
 Temporary attachments shall be identified by Material specification or
by P number markings.
 For standard flanges and fittings, the original markings are retained. In
case such markings are required to be removed for fabrication purpose,
the rub-off or transcript of original marking shall be kept in inspection
records.
1.5.5. Transfer of markings shall be done by stampings or by using permanent
marker. However for very small parts, where stamping or marking is not
possible, records shall be kept on Material Receiving Report (Exhibit No. 04-
04) and Material Traceability Report (Exhibit No. 04-06)
1.5.6. When service conditions prohibit hard stamping, other methods such as
stenciling or painting may be used to transfer the marking
1.5.7. When material is formed into shapes by anyone other than WA and the
original markings as required by the applicable material specification are
unavoidably cut out, or the material is divided into two or more parts, the
manufacturer of the shape shall either:
(1) Transfer the original identification markings to another location on the
shape; or
(2) Provide for identification by the use of a coded marking traceable to the
original required marking, using a marking method agreed upon and
described in the quality control system of WA of the completed pressure
vessel.
(3) When the vessel shell section, heads, or other pressure boundary parts
are cold formed by others, the required certification for the part shall
indicate whether or not the part has been heat‐treated

1.6. WELDING MATERIAL

4.6.1 All welding consumables shall meet the requirement of ASME SEC II Part C
or as otherwise permitted by the Code
4.6.2 Standard welding consumables shall be purchased in accordance with
Welding Consumables Requisition (Exhibit No. 04-07) prepared by the
Welding Engineer for welding materials used in production and approved by
Q.C Manager.
4.6.3 Based on new projects requirements the Welding Engineer prepares the
Welding Consumables Purchase Order (Exhibit No. 04-08) and attaches a
copy of the Welding Consumables Requisition (Exhibit No. 04-07) and TDC
for Filler Wires (Exhibit No. 04-09) and then sends to Welding Manager for
review and Purchasing Manger to send to the appropriate vendor.
4.6.4 Copies are then used for receiving examination.
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4.6.5 Welding consumables are subject to receiving examination by the Welding

Engineer as follows and recorded on Welding Consumable Receiving
Inspection Record (Exhibit No. 04-10):
1.1.1.1. Verify the marking on the consumables identification label against
the Welding Material Requisition. For coated electrodes, one
package is opened to verify electrode markings. Low hydrogen
coated electrodes, shall be baked by placing in the baking oven in
accordance with procedure of handling of welding material.
1.1.1.2. Accepted welding consumables are then stored in the welding
material storeroom

1.7. CUSTOMER SUPPLIED MATERIAL:

All Code material supplied by the customer or his designee is received and
examined by the QC Inspector as described in 4.3. above, using a copy of the
Customer’s Material Requisition or Purchase Order. Alternatively the Company’s
Material Requisition approved as described in 4.1. above shall be used to verify
compliance with Code and customer requirements. Customer’s Purchase Order or
Material Requisition shall be reviewed for Code compliance and approved by the
Quality Control Manager.

1.8. STOCK MATERIAL:

The QC Inspector verifies that stock material purchased to an earlier Edition of

material specification meets all the requirements of the Code Edition for the new
contract. The QC Inspector verifies compliance of the material test report against
the applicable material specification and performs an inspection on the material
using his copy of Material Requisition.
A new material Receiving Inspection Report shall be issued for the accepted stock
material.

1.9. ASTM / ASME MATERIALS

4.9.1 ASME Material specifications with applicable Edition are specified on

Material Requisition for materials. Acceptable ASTM specification for
material with year/date is listed in Appendix II of ASME Code Sec. II Parts A
& B.
4.9.2 If the material is received with ASTM specification only and year/date is
acceptable to appendix II part A of Sec. II, then the material test reports are
verified by QC Inspector against applicable ASME material specification and
if found acceptable, the MTR is endorsed, and material stamped as verified
against ASME Sec. II Part A/B with applicable Edition.
4.9.3 If the material is received as certified to ASME material specification with
year/date older than the one specified on Material Requisition, material is
verified by QC Inspector against the requirements of adopted ASTM
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year/date and if found acceptable, MTR is enclosed as Verified against

ASME Sec. II Part A/B with applicable Edition. Refer guidelines in Appendix
II of section II.
4.9.4 If the material is received with ASTM/ASME specification with year/date
either newer or older than the one specified in appendix II part A of Sec. II,
the material shall be verified by QC Inspector against all the requirements of
applicable material specification and re-certified with objective evidence of
verification acceptable to AI. Recertification records shall be maintained and
MTR shall be endorsed by QC Inspector as Verified against appendix II part
A of Sec. II and Recertified and material stamped, for compliance with
permitted specification.

1.10. FURTHER MATERIAL TESTING:

Further material testing, if required, the Quality Control Inspector shall identify the
number, size, location and orientation of the test pieces required. The test shall be
performed by a qualified testing laboratory which provides testing reports and shall
be accepted by the Quality Control Manager by signature and date. The test reports
shall be made available to the Authorized Inspector for his review and shall be
marked by as required by the permitted specification.

1.11. MATERIAL RECORDS:

All records including Material Test reports referenced in this Section are made
available for review by the Authorized Inspector and are filed in the job file
maintained by the Quality Control Manager.

1.12. Related Exhibits

1. Material Requisitions (Exhibit No. 04-01)
2. Technical Delivery conditions (Exhibit No. 04-02)
3. Purchase Order (Exhibit No. 04-03)
4. Material Receiving Report (Exhibit No. 04-04)
5. Material Request / Release Note (Exhibit No. 04-05)
6. Material Traceability Report (Exhibit No. 04-06)
7. Welding Consumables Requisition (Exhibit No. 04-07)
8. Welding Consumables Purchase Order (Exhibit No. 04-08)
9. TDC for Filler Wires (Exhibit No. 04-09)
10. Welding Consumable Receiving Inspection Record (Exhibit No. 04-10)