035-PROCEDURE FOR MATERIAL TRACEABILITY AND MARKING.pdf

Pearl GTL Project

LINDE ENGINEERING

Shell Project No: HP-3000-QAT Contractor Project No: 5887

Project Document Number: T- 4.250.928 Project Rev.: C Page 2 of 12

Purchase Order Number:

2MH127

Tag/Item Number(s): N/A

Unit(s): ASU

PCWBS: Z

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

G C 17.01.09 Issued for Review (This procedure supersedes and

cancels T.4.251.033) SK EO AG IFR

F B 11.12.08 As per Site Condition , Issued for Review SK EO AG IFR

E B 02.12.08 As per Site Condition , Issued for Review SK EO AG IFR

D A 24.04.08 Ready For Construction BR UA ZG RFC

C O 05.12.07 Issued for Company comments BR AU/MC ZG ICC

B 23.11.07 Issued for Review BR AU/MC ZG IFR

A 20.11.07 Issued for Internal Review BR AU/MC ZG IIR

GAMA Rev.

Project Rev

Date Description Prepared

By Checked

By

Approved By

Status

No. No. ORIGINATOR

LINDE ENGINEERING AG

Document Title:

PROCEDURE FOR MATERIAL TRACEABILITY AND MARKING

Contractor

Gama Qatar Co. W. L. L.

Document No. LOC470

GAM PRO QAC GTL 035 G

Org.

Code

Doc.

Type

Disc. Code

Geogr. Area

Seq.

No

Rev. No

Vendor Code

Project Document Number: T- 4.250.928

Rev No:C

Doc. Title : PROCEDURE FOR MATERIAL TRACEABILITY AND MARKING

Doc No: : GAM-PRO-QAC-GTL-035 Rev. G Date 17.01.2009

T-4.250.928 REV-C

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1. SCOPE ____________________________________________________________________________ 5

2. PURPOSE _________________________________________________________________________ 5

3. HSSE _____________________________________________________________________________ 5

4. REFERENCE ______________________________________________________________________ 5

5. DEFINITIONS _____________________________________________________________________ 6

6. RESPONSIBILITY __________________________________________________________________ 7

6.1. Execution of the Procedure _______________________________________________________________ 7

6.2. Users of the Procedure __________________________________________________________________ 7

6.3. spool preparation team __________________________________________________________________ 7

6.4. qa/qc manager _________________________________________________________________________ 7

6.5. Site Supervisors ________________________________________________________________________ 8

6.6. QC Inspectors _________________________________________________________________________ 8

7. IMPLEMENTATION ________________________________________________________________ 8

8. IDENTIFICATION & TRACEABILITY OF PRODUCTS AND MATERIALS __________________ 9

8.1. Identification of bulk material ____________________________________________________________ 9

8.2. Identification of cut pieces _______________________________________________________________ 9

8.3. Identification of items forming the part of spools _____________________________________________ 9

8.4. Identification of finished spools __________________________________________________________ 10

8.5. Field material traceability _______________________________________________________________ 10

9. MARKING OF MATERIALS _________________________________________________________ 11

9.1. General ______________________________________________________________________________ 11

9.2. Content of Marking ____________________________________________________________________ 11

9.3. Methods of Marking ___________________________________________________________________ 11

9.4. Size of Marking _______________________________________________________________________ 11

9.5. Highlighting of Marking ________________________________________________________________ 12

10. IDENTIFICATION AND TRACEABILITY OF WELDED JOINTS _______________________ 12

11. QUALITY ASSURANCE __________________________________________________________ 12



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1. SCOPE

This procedure applies to the materials (including raw materials, sub products and products presented to the customer) and welds traceability & Marking of shop and field fabrication of piping and welding to be performed at C2 ASU PEARL GTL PROJECT by Gama Qatar

2. PURPOSE

The main purpose of this procedure is to outline the requirements for generating and maintaining records to assure that LINDE identification and heat numbers of all stainless steel, carbon steel materials are traceable to the certified test reports. Moreover, the identification and traceability of welded joints are also described in this procedure.

3. HSSE

All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL and/or its PMC requirements and instructions. In addition all employees and GAMA subcontractor employees on site will have through LINDE ENGINEERING AG Site Safety Induction and GAMA Qatar Safety induction for site safety, health, environmental and security prior to work activities. Other training courses will be attended as required by LINDE ENGINEERING AG or QSGTL and/or its PMC as required.

4. REFERENCE

ASME B 31.3 Process Piping ASME Section II Part A Ferrous Material Specification

Part B Nonferrous Material Specification Part C Specification for Welding Rods, Electrodes And Filler Metals

ASME Sec. V Non-destructive Examination ASME Sec. IX Welding and Brazing Qualification

DEP 31.38.01.11 Piping general requirements DEP 31.38.01.31 Shop & Field Fabrication of Steel Piping



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DEP 30.48.00.31 Painting & Coating for New Construction Projects

T-13.376.799 Amendment to DEP 30.48.00.31

-Technical Specification for Painting T-4.234.542 Project Quality Plan T-4.250.927 Material Handling and Storage T-4.250.932 Equipment Preservation T-4.250.913 Post Weld Heat Treatment Procedure T-4.251.032 Project Quality Procedure for Material Receiving

Inspection T-4.250.935 Procedure for Piping Fabrication A/G and U/G T-13.377.437E Certification and Marking of Materials

5. DEFINITIONS

Company : QSGTL/or its PMC

Contractor : LINDE ENGINEERING AG Sub Contractor : GAMA QATAR Contract : QSGTL Pearl Plant - C2 ASU Project ITP : Inspection and Test Plan QCR : Quality Control Record QCP : Quality Control Procedure QCE : Quality Control Engineer QCI : Quality Control Inspector QA/QC : Quality Assurance / Quality Control TPI : Third Party Inspection MTR : Material Traceability Record.



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Product Identification: The identification such as code, colour or party number used to distinguish a product or production party from its pair or other products.

Traceability: The ability to reach the previous information by identifying the product and the materials constituting the product.

Label: The information or the codes put/pasted or directly written on the product for its identification.

QSHE: Quality, Environmental Protection, Occupational Health and Safety Management System

6. RESPONSIBILITY

6.1. EXECUTION OF THE PROCEDURE

Purchasing Manager, Project Manager, Factory Manager, Site Manager, Group Chiefs, Quality Assurance and Quality Control Units shall be responsible for the execution of this procedure.

6.2. USERS OF THE PROCEDURE

Site field engineers, Quality Control Units, Warehouse Chief, and Purchasing Unit shall be the users of this procedure.

The users of this procedure should read and evaluate this procedure together with the Project Management and Execution Procedure (Document No: T-4.251.46) in order to fully understand what is expected from him/her. They are expected to try their best to make the project management easier.

6.3. SPOOL PREPARATION TEAM

The Team is responsible for

Define the spooling of each isometric, to be made in such a manner to minimize the

field welding, taking in account the transport needs. Produce the cutting diagrams, in such a manner to optimize the use of material; Delivering the spooled isometric to Contractor.

6.4. QA/QC MANAGER

QA/QC manager is responsible for the implementation of this procedure including the administration of non-conformance management in close co-operation with various related departments.



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6.5. SITE SUPERVISORS

The Supervisors are responsible for maintaining the identification of products and weld joints during prefabrication and erection stages. They are also responsible for transferring the marking of materials for all stainless steel, carbon steel materials.

6.6. QC INSPECTORS

QC Inspector is responsible to verify that products are properly identified according to this procedure. He is also responsible for co-ordinating with Contractors Inspectors and preparation of quality records.

7. IMPLEMENTATION

GAMA shall maintain the full traceability of the material identity number, heat/lot number from the receipt of material at the job site, during the storage, fabrication, erection and testing stages till the turnover of the documentation to the Contractor.

All materials shall be received and inspected in accordance with GAMA material handling procedure T-4.250.927

All received materials shall be handled, stored and preserved in accordance with GAMA procedure T-4.250.927 & T-4.250.932

Stainless steel Material shall be stored separately in storage yard from Carbon Steel materials. Moreover separate fabrication bay, completely isolated from each other shall be maintained for Carbon Steel and Stainless Steel spool fabrication.

The following records and data by drawing number shall be maintained for all piping system:

Welding procedure; Welder identification; Non-destructive examinations; Weld joint numbers; Reinforcing pad air test Post Weld Heat Treatment charts; Weld repair details Hardness tests Heat No



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8. IDENTIFICATION & TRACEABILITY OF PRODUCTS AND MATERIALS

8.1. IDENTIFICATION OF BULK MATERIAL

The identification of bulk material during storage is assured by identification stamped on the materials by Supplier If the identification appears damaged or undefined, a non-conformance reports in accordance with T-4.251.035, non-conformances reporting procedure shall be prepared and material shall be disposed according to the resolution.

8.2. IDENTIFICATION OF CUT PIECES

Identity and heat numbers of the original pipe shall be transferred before cutting, on each end of the cut pieces, to be used in prefabrication, in order to maintain full traceability to the relevant certificate. The heat number shall be hard stamped 50 mm to 75 mm from each end of the cut piece; Contractor Inspector shall witness this transfer of heat number to pipe off-cuts. Identification number and heat number shall be transferred by authorized Gama personnel

On ferrous materials with a thickness under 5 mm, (austenitic stainless steels under 10 mm) and on all non-ferrous materials by engraving.

On ferrous materials with a thickness of 5 mm and over, (austenitic stainless steels 10mm and over), marking shall be applied by low-stress hard die-stamping on painted background. Low-stress die-stamps shall be round-nosed with a radius of 0.25 mm minimum.

In case if it is not feasible to apply the required markings, such as small size, it is acceptable to apply the markings on a durable, securely affixed metal tag provided that the codes used are traceable to the relevant certificates.

Pipes and cut pieces which are not utilized shall be stocked in a proper area at Contractor disposal. Stock area of unused pipe cut pieces shall be separately designated for Carbon Steel, Stainless Steel and materials.

8.3. IDENTIFICATION OF ITEMS FORMING THE PART OF SPOOLS

GAMA shall mark up an isometric drawing by assigning a mark number to identify each item of piping material used (pipe, fitting, flange, etc.) The piece marks shall be



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sequential and shall be "Mk-" followed by the numbers (-1, -2, -3, etc) for each separate item on each spool on the isometric drawing. Each cut pieces shall be properly identified with the following information: Isometric No. Spool number (1, 2, etc.) Position of the piece in the spool (Letters “Mk” followed by progressive

number –1, -2 etc as specified in the spooled isometric drawing). Identification of material heat number Linde ID number

8.4. IDENTIFICATION OF FINISHED SPOOLS

When all spools are fabricated as per the spooled isometric, Pipe spools shall not be released from the shop until the piping spool inspection report (GAM-QCR-QAC-GTL-098) (T-4.318.599) has been signed by both parties.

Each spool shall be identified with the following information: Area No. Isometric No Spool number Heat No Linde ID no All marking shall be done in accordance with the project specifications. All pipe spools shall be marked with the isometric/spool number in one location on the pipe. Small diameter items may be tagged with a stainless steel wire attaching the tag. The straps/bands and tags shall be stamped with the Area/Isometric/linde ID no/Heat no/Spool numbers. All traceability records/logs, isometric supplementary shall be complete before spools are released for painting. If identification of spool is missing or it appears damaged or undefined, the spool shall be segregated and stored in separate area and will be utilized only when other methods (i.e. drawing of spooling) can establish its identification without any doubt.

8.5. FIELD MATERIAL TRACEABILITY

Prior to the Piping erection activities GAMA QC inspector shall verify and confirm that linde ID number, heat number/codes or identification number of field installed materials such as: valves, supports, lugs, cleats, reinforcing Pad etc. are legible and easily recognizable.

The linde ID no/heat numbers on the field-installed items shall be recorded against the pre-assigned mark number on the WSD data base sheet



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On completion of field installation work, GAMA and Contractor shall verify the accuracy of the information of the field components before signing the spooled isometric and isometric supplement sheet, Pipe spool inspection report(GAM-QCR-QAC-GTL-086) (T.4.318.599). This shall be done at every stage of prefabrication to installation of the spools.

GAMA shall verify that all isometrics in a test pack are complete and have been signed by the Contractor.

9. MARKING OF MATERIALS

9.1. GENERAL

All required markings shall be clearly visible at completion of manufacture i.e., after painting or coating Any material or component found to be untraceable, because it does not bear legible marking showing the information required, shall be rejected.

9.2. CONTENT OF MARKING

All materials and components / items, regardless of their application, shall be marked in accordance with the material standard to which they have been manufactured. All pressure-containing parts of piping systems, pressure vessels and other equipment shall also be marked in accordance project specificationT.13.377.437E and WSP 1501

Commodity codes and/or TAG numbers shall be clearly marked on all valves and special pipe items.

9.3. METHODS OF MARKING

Where it is impractical to apply all of the required marking because of the size of the component, the marking shall be applied to a durable stainless steel tag securely attached to the component.

Marking on all non-ferrous materials, austenitic stainless steels below 10 mm and in steels (up to 9% Ni) below 12 mm shall be applied by engraving.

On thicker materials of these types, and on non-impact-tested ferrous materials of any thickness, the marking shall be applied by low-stress hard-die stamping. The low-stress stamps shall be round-nosed with a minimum radius of 0.25 mm. On castings, heat number / charge number shall be cast into the material.

9.4. SIZE OF MARKING

Individual characters in the marking shall not be less than 6 mm high.



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9.5. HIGHLIGHTING OF MARKING

To ensure that engraved or die stamped markings are readily found on components, after engraving / die stamping the area shall be given a protective lacquer coat, the completed marking shall be ringed around with white paint.

10. IDENTIFICATION AND TRACEABILITY OF WELDED JOINTS

Each weld on the isometrics will be pre-numbered during spooling drawing preparation in accordance with sequence of weld numbering system specified in the GAMA procedure T-4.250.935. As the spools are being fabricated drawing and other welding details will be recorded in the daily welding report and the same will be submitted to Contractor senior Welding Inspector not later than the following working day. The joint number and welder number shall be marked nearby each weld after the welding is completed.

During pre-fabrication all weld and NDE details will be recorded in daily welding Report as well as WSD system. The GAMA and LINDE welding inspector shall compare and approve the details recorded on the weld and NDE summary report with the visible marking on the spools, NDE reports, PWHT and other pertinent information before signing the shop release.

11. QUALITY ASSURANCE

A Quality Assurance System shall be operated conforming to related standards. Controls and checks shall be established and documented.

Documents

035-PROCEDURE FOR MATERIAL TRACEABILITY AND MARKING.pdf