2.0ExecutiveMaterialControlPlan

1、vietnam oil and gas corporation ( petrovietnam)dung quat refinery (dqr) projectaboveground piping, painting & mechanical works2.0 executive material control plancontents1. general 2. applicable specification3. organization & duties4. pre-fabrication shop receiving material management procedures 5. m

2、aterial furnished by contractor6. material warehousing and storage7. erection material and equipment management procedures 8. return of materials to warehouse9. special tools and spare partsattachments: attachment 1: material control organization chartattachment 2: pre-fabrication material managemen

3、t flow diagramattachment 3: field erection material management flow diagramattachment 4: piping material handling / storage / preservation procedure1. general this plan covers the tccs material handling and control programme intended to be conducted at the site for subcontract works of aboveground p

4、iping, painting & mechanical works of dung quat refinery (dqr) project. this is to define the entire material control function from preparation for material receiving both at pre-fabrication shop and at site, unloading work, handling, unpacking, receiving inspection, material storage including prese

5、rvation, and material issuance, to reuse or scrap of material. 2. appliable documents contractors ps & kp documents tccs quality assurance manual and procedural documents3. organization & duties3.1 organization the field organization for the material control is shown in attachment -1 herewith.3.2 re

6、sponsibility all material controllers and warehousing keepers are on full-time assignment to site organization. their respective function and responsibility are as follow:3.2.1 material control manager(1) generalthe material control manager has the responsibility to plan and execute all functions an

7、d activities in the material control group (mcp) to lead the field work successful. material control manager will set and issue instruction to his subordinating staff, communicate with other related groups, subcontractors (if any), third party, etc., and report to the project manger.his duty also in

8、cludes activities related to materials in construction phase and certain area in engineering and procurement phase (as and when required) and to maintain close co-ordination with contractor field material control group and tcc home office to gain consistent control.(2) procedure and operation system

9、he will be involved in the coordination and implementation of the following procedures and material control system.- material control system - field material preservation procedure- field purchasing procedure(3) information on material statushe is responsible for collecting the following information

10、 related to material status to proceed with material control groups works at the site smoothly.- bill of material (b/m), its latest revisions, and field change sheets to know the finally necessary quantities of materials.- equipment list- purchase orders (p/o) - material status report (msp)- packing

11、 list provided by contractor for its supplied materials and equipment.- catalogue (equipment, tools and materials)- heavy cargos and dangerous cargoes list - storage instruction and preservation instruction from vendor.he is also responsible to maintain and arrange all material-control related docum

12、ents. essential document, such as those under-mentioned, should be systematically filed for immediate and accurate reference at all time.- cargos/material arrival notice (with packaging list)- daily receiving report- cargos/material receiving inspection report- truck from inland transportation- loca

13、l material purchase order (l-p/o)- material exception report (mer)- claim registration for marine damages and insurance if supplied by tcc- material issuance record to working crews and / or subcontractors.(4) overall planningassisted by his subordinating staff, and supported by contractors coordina

14、tor, he is responsible for setting overall plan for materials off-loading, receiving, storage and issuing.(5) mobilization plan for work forcehe is responsible for planning a work force mobilization for the materials control group which includes warehouse keeping, cargo discharging & in-site transpo

15、rtation, material transaction (receiving & issuing) etc.(6) monitoring of critical material he is responsible for monitoring material status and issuing an alarm to the field management when material shortage is expected or material delivery schedule is not consistent with fieldwork.(7) safetyhe has

16、 the full responsibility for the safety of his material control group in routine material handling activities monitoring through his material controllers.(8) securityhe will coordinate with the contractors security departments and ensure that maximum-security measures are provided to safeguard all m

17、aterials and properties under custody of the material control group. he will also monitor through his subordinate staff the proper enforcement of such system.3.2.2 material controller(1) generalthe respective material controllers are responsible for the control of all materials and equipment either

18、received from contractor or directly supplied by tcc, under each assigned category, from which they are delivered to a storage area till the issuance to working crews for fabrication or field installation.the material controller is responsible to execute receiving activities, and hand over the recei

19、ved cargoes to each category working crew in accordance with this procedure and detail procedure.(2) monitoring of shipping forecasthe shall closely monitor the arrival of each scheduled shipment as per notification of arrival from contractor, for preparation of unloading and storage plan prior to a

20、ctual arrival at site.(3) arrangement of unloading areahe shall decide whether the arriving cargo is to be unloaded at on-site warehouse, off-site storage area (piping fabrication shop) or directly to the construction site under coordination with contractors material controller. if some materials wh

21、ose storage area is not same are arrived in the same box or same truck, unloading work shall be done at one storage area temporarily. thereafter he shall immediately transfer the material to correct storage area under coordination with contractors material controllers.(4) daily receiving report and

22、os&d reporthe shall prepare and distribute daily receiving report every day for all the cargo receiving on the day and os&d report after receiving visual inspection achieved.(5) work force mobilization planhe shall set the schedule for mobilization of labors, construction equipment, tools, gears and

23、 other necessities for material handling activities, and submit to the material control manager for approval.(6) material handling operationhe is responsible to supervise all warehouse activities, which is material receiving, storage including preservation, and issuing. he shall cautiously pay close

24、 attention to the handling of dangerous items required proper protection from high/low temperature, vibration, moisture, dust, various form of corrosion, as well as materials subject to traceability he shall prepare daily materials control report for submission to material control manager. any damag

25、ed materials received after visual checks shall be quarantined and reporting to material control manager and contractor material controller.(7) periodic inventory check / inventory status reporthe shall physically conduct periodic stocktaking on all categories of material held at warehouses/yards an

26、d update their inventory records accordingly. the inventory status reports shall be prepared and submitted to contractor periodically.“random spot-check” on selective material quantity can be done daily, but inventory auditing shall be at least on a quarterly basis. each category may be on rotation

27、manner (for example, check all elbows on the first day, all reducers on the 2nd day, and so on) during the quarterly auditing.(8) safetyhe is responsible to keep all equipment utilized in the material control group in good condition. he also shall monitor on the safety of the material control group

28、and report to the material control manager accordingly. he shall take immediate action to warn those concerned persons whenever he encounters a dangerous act; monitor it continuously until corrective action is completely taken and the situation returns back to normal.(9) securityhe shall coordinate

29、with contractors security department and ensure that all security measures are fully enforced. he shall also forward his recommendation to the material control manager if additional steps are to be taken to improve the security system. the material control manager will liaise with the hse manager or

30、 contractor hse manager as required. the detailed security plan shall refer to the bid form15 subcontractor health, safety and environment plan.3.2.3 warehouse keeperthe warehouse keeper is responsible for all material receiving, storage and issuing activities in the respective warehouse of assignme

31、nt under cooperation with and instruction by his material controller.his function basically includes the following:- inspect and maintain warehousing equipment and tools.- supervise his labors and patrol storage areas- regularly and properly arrange materials in the storage area and the warehouse so

32、 as to facilitate receiving of new materials and issuing.- regularly check the quantities and quality of materials when receiving and issuing them, tracing the material utilization for inventory records.- carry out material identification and assist qc inspector and material controller in alloy veri

33、fication test for piping material.- prepare daily incoming materials register, and other necessary reports on material shortages or damages and if any found, he shall report to his respective material controller.- conduct appropriate housekeeping in warehouses and surrounding storage yards to mainta

34、in safe working environment for all staff.- ensure there is no dangerous act or safety negligence at places of work and all safety rules and regulations are absolutely complied.- keep close watch and supervise the routine performances of labor force in the material control group.- inspect material h

35、andling equipment, such as wire-slings, belts, hooks, shackles, and etc. to ensure its serviceable condition poses no danger to users and materials.- ensure all security measures in his area of responsibility are full enforced. he shall forward recommendation to his material controller if any improv

36、ement to the security system is necessary.3.2.4 logistic coordinatorthe logistic coordinator is to maintain close coordination with related disciplines in the smooth execution of customs clearance (if imported from overseas), discharging of cargoes from carriers, inland transportation and final off-

37、loading at storage yards.his function basically includes the following:- co-ordination with local customs and port authorities regarding matter in importation of construction materials (also exportation of materials, such as items to be repaired or modified at vendors factory, etc., whenever require

38、d)- co-ordination with contractor appointed agent for customs clearance procedures and inland transportation of cargoes- daily reporting of arrival shipping and shipping arrival schedule to material control manager.- ensure each truck/air-way-bill is correctly issued by transportation agent and all

39、shipped cargoes are totally delivered and received by the material control group.- co-ordination with equipment erection group and warehouse keeper for heavy equipment conveying process.- apply site safety regulations to all working crews / subcontractors and direct hired labor in their work at the

40、various warehousing/loading/offloading locations.4. pre-fabrication shop receiving material management procedueresreceiving, handling, storing and issuing of all items of equipment and materials received from contractor shall be controlled based on following procedures:attachment 2: “pre-fabrication

41、 material management flow diagram” is shown hereafter.4.1 receiving of cargoesone week prior to the material delivery, contractor will issue the material delivery notification together with po to tcc fabrication shop material controller, by such, tcc shop warehousing charger man shall make preparati

42、ons necessary for receiving cargoes. such preparations shall be carried out for each shipment, based on p.o.(1) monitoring of shipping forecastmaterial controller shall closely monitor the arrival of each scheduled shipment as per p.o, for preparation of unloading and storage plan prior to actual ar

43、rival at site. and also he shall distribute the material delivery notification to group concerned attached with p.o prior to the actual arrival of material.(2) unloading and material receiving report (mrr)the on-shore procurement of piping materials will be directly delivered to tccs pre-fabrication

44、 shop warehouse. the material controller will be responsible for unloading from the transporting vehicles, he shall certify and sign-off each receipt once satisfactorily clearly without any damage and/or shortage, and shall fill and submit the mrr to contractor material controller.in case some mater

45、ials whose storage area is not same are arrived in the same box or same truck, unloading work shall be done at one storage area temporally. thereafter the material shall be immediately transferred to correct storage area under coordination between contractor material controller and tccs material con

46、trollers.4.2 unpacking, visual inspection and os&d reports(1) unpacking upon the material received, with attendance of contractors material controller, the warehouse keeper shall arrange to unpack all arrived cargoes cautiously with additional care to those fragile or sensitive items per vendors ins

47、truction or advice from concerned category engineer. the unpacking will be done against the po and packing lists.(2) visual inspection immediately after unpacking, the visual inspection will be carried out by warehouse keeper, who shall check the po and packing list on the numbers, specifications, a

48、nd appearance. priority shall be given to those packages sustained shipping damages in appearance. tccs material controller shall immediately report to contractors material controller on the receipt of any damages / shortage or suspected damage / shortage for dispositions. this would ensure early di

49、scovery of concealed damages, and assist contractor to proceed claiming for marine insurance within effective term.(3) overage, shortage and damaged cargo and reports material controller shall confirm that actual landed quantity and condition of each package in accordance with p.o and shipment packi

50、ng list or other relevant shipping document.if there is any overage, damaged or short-landed cargo encountered, report shall be immediately made to the contractor material controller for the cargoes supplied by contractor.4.3 material utilization traceability controlin general, the pmi shall follow

51、with the project specification issued by contractor in the bidding stage.(1) purpose of identificationto avoid the misuse of the materials to achieve the traceability of the products to its original status.(2) contents of identification specifications and types of materials. sources of materials. th

52、e installation locations of the final materials of special natures.(3) code of identificationthe identifications established for the materials shall be applied to each piece or lot.the identifications shall be made by labeling, tagging, or paint marking, etc., meanwhile, the relevant records shall b

53、e made and maintained, the records cover the receiving, warehousing, custody, quality certificates, or other technical documents.(4) transferring of the identificationswhile the identified equipment, instrument and materials are handed to the field erection and installation, the certificates, test r

54、eports, etc. and markings shall be transferred to field construction supervisor, and the transferring records shall be established properly.(5) the identifications of inspection and examination statusduring the whole period of the construction, the spools and materials required to be inspected or ex

55、amined on its delivery to site shall be identified with the status of the inspection or examinations, in order to avoid the misuse of the materials without inspection or examination, or the off-spec products.the identification of the inspection or examination are classified as: the acceptable materi

56、als after the inspection or examination, the unacceptable materials after the inspection or examination, the holding materials after the inspection or examination, the materials without inspection or examination. (6) traceability traceability of materials will be kept in documentation such as vendor

57、s inspection, it is ensured that identification markings are in order, if any identification marking is lost, a new marking will be applied referring to the documents keeping the traceability of the material, and verified by material controller.traceability of special materials and components will be maintained by identification marking, location of materials, and the relevant documentation through fabrication up to final inspection at the site. 4.4 material quarantine inventory after visual inspection, and os&d checks, the materials with defects, damaged, or of off-s