Have you ever heard about Inward Material Inspection? This is a vital inspection process that takes place during the construction of a plant, an important inspection in the Oil and Gas industry, just like an inspection of any other piece of equipment or item that makes part of the project. It specifically serves as a quality control check to make sure that all materials designated for use in the fabrication work such as pipes, plates, flanges, and fittings, are in conformity with certain standards and regulations. It’s a necessary inspection that – alongside the rest of the material traceability process – proves the reliability of the final product.
What is Inward Material Inspection in manufacturing?
Inward material inspection is essentially the check that all the raw materials of the site store or warehouse are compliant to factory specifications. The goal is to try and check that what has been delivered conforms to the purchase orders in such terms as the quantity, the specific requirements, and the necessary accompanying documentation. That means the delivered materials are satisfactory tis Rakov and are suited to the eventual end product or processes. To that end we trim down the process to two easy steps: the material use verification documentation and the material itself.
What are the steps in Inward Material Inspection?
Material Inspection in simple terms means looking at documents related to materials and then materials. It also means accurate examination of material physically.
1. Verification of documentation
Prior to physical inspection, it is of utmost importance to ensure that relevant documents are available and correct. These documents play an important role in the conformity of such material to standards and specifications. Some of the documentations which are reviewed include the following.
Inspection Release Note (IRN): This is used to indicate the inspection of materials by the Use of approved documents.
Packing List: This contains the list of items that are shipped in the container.
Inspection and Test Reports: This includes BMT C or MTC and dimensional report.
Compliance Certificate: To certify compliance with applicable standards.
Manufacturing Record Book (MRB): This bears the manufacturing history of the material.
Installation Manual: This provides installation methods and procedures for certain equipment or components.
Not all documents are applicable to every material type, for instance: MTCs and Packing lists are often required for bulk or unitized materials, such as pipes and fittings whereas equipment’s may require MRB or installation manual.
2. Verification of materials physically
The justification for physically inspecting materials is to check on their status, their accuracy with the item in the order and that all materials are as per the order. Important areas include:
Material Quality: Rust, paint defect or other damage to the surface of the material should be checked.
Packaging: Make sure the material is packed in such a way that it cannot be damaged.
Quantity: The amount of material ordered and the amount of material supplied should tally.
Transit Damage: Check for bends, cracks or any other signs of damage caused during transportation.
In the case of alloys and stainless steels, It is customary to carry out Positive Material Identification (PMI) as a means of checking the chemical composition. The documents concerning the materials, including heat numbers and other identification markings, are crucial for ensuring traceability at this stage.
Subsequently, An Inward Material Inspection Report (IMIR) is compiled after verification of all materials and objectives with appropriate details to ensure that all materials retain their designations as applicable throughout the fabrication stage.
What is the procedure in preparing Inward Material Inspection Report (IMIR)?
IMIR is very useful to focus on each piece of an internal audit and drawing in so that, if necessary the IMIR functions exceptionally well as a cross-reference tool. Some of the important parts of the report include the following:
Report Number: When published, the report will be assigned this number, allowing accountability for the inspection report.
Purchase Order Number: Relates the inspection of materials to the order or requisition.
Inspection Date and Material Location: This information allows for time and place of the inspection to be noted.
Material Details: Descriptions of the material types, sizes, thicknesses, and relevant standards are included.
Supplier Information: This provides details as to the manufacturer or supplier.
Commodity Codes: This aids in the identification of fabricated components against the materials.
Quantity and Tags: This provides information in respect of quantity of items and number of tags attached to the assembled items.
MTC and Heat Numbers: These are used to link the materials with the respective test certificates and heat numbers.
A Unique ID: This is a unique number assigned to each of the components and is used for traceability.
Remarks: This part consists of any notes or problems noticed by the inspector during the inspection.
The IMIR not only allows us to comply with the standards, but also allows for the identification of materials during further stages of fabrication and installation.
Conclusion
Inward material inspection is an important first activity in the fabrication of piping and equipment. By performing such an inspection and cross-referencing the materials with the documentation, one can be assured that the items being used are within specification and non-defective. The preparation of an Inward Material Inspection and Report (IMIR) improves traceability issues even further, providing an effective means of tracking materials throughout their existence.
This process is essential for the prevention of loss of quality and safety of the facilities in the Oil and Gas sector. A comprehensive inward material inspection process brings risks down, enhances adherence to quality requirements, and guarantees delivery of projects.
