DOCUMENT NUMBER:
KE01-A1-000-NC-J-PR-0001-000
CONTRACT DESCRIPTION:
CONTRACT FOR THE MAIN WORKS CONSTRUCTION
AGIP KCO CONTRACT NO:
CONTRACTORS
JOB NO:
2004-0504
DOCUMENT TITLE:
HOLDS
N/A
SHEET NO.
1 OF 18
C01
Aug. 2006
S. Wingert
I. Kokkaya
C. Payne
P03
May. 2006
Preliminary Issue
S. Wingert
I. Kokkaya
C. Payne
P02
Feb. 2006
Preliminary Issue
S. Wingert
I. Kokkaya
T. Jervis
P01
Nov. 2005
Preliminary Issue
S. Wingert
I. Kokkaya
T. Jervis
REV
DATE
PREPARED
CHECKED
APPROVED
COMPANY
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
Page 2 of 18
REVISION DESCRIPTION SHEET
Rev.
Para.
Revision Description
P01
NA
P02
ALL
ALL
14
Added Attachments
P03
C01
Hold
No.
Para.
Description of Hold
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
Page 3 of 18
1.0
PURPOSE
2.0
SCOPE
3.0
REFERENCES
4.0
DEFINITIONS
5.0
ORGANIZATION
6.0
7.0
8.0
9.0
1.0 PURPOSE
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
Page 4 of 18
The purpose of this procedure is to explain North Caspian Constructors (NCC) plan for the receipt, storage and
distribution of project material needed for construction in a timely manner which meets schedule and erection
sequence. It encompasses Material Control, Purchasing, Logistics and Warehousing at Site for bulk material,
engineered equipment, shop fabrication and consumables for all engineering disciplines.
2.0 SCOPE
The scope of this procedure covers engineering, requisitioning, purchasing, warehousing and planning requirements
covering all commodity groups, for AGIP KCO supplied materials. Fluors Material Management computer program
(MatMan) will be the electronic material management system used on the project to monitor and control these
functions. Basic features of the system will manage warehousing and storage, material receiving, Overage, Shortage
& Damage recording and reconciliation, material returns, material surplus recognition & management and most
importantly, material planning. It will ensure that materials and equipment are properly received, segregated and
issued in accordance with the correct designated site area, to ensure appropriate allocation and usage.
3.0 REFERENCES
The following is a list of Project Procedures which supplement and support the Site Logistic and Material
Management Procedure.
KE01.00.000.AK.A.QP.0602.000
KE01.00.000.AK.B.PR.0601.000
KE01.00.000.AK.B.PR.0602.000
KE01.00.000.AK.B.PR.0603.000
KE01.00.000.AK.B.PR.0605.000
KE01.00.000.AK.B.PR.0606.000
KE01.00.000.AK.B.PR.0651.000
KE01.00.000.AK.B.PR.0617.000
KE01.00.000.AK.B.PR.0620.000
KE01.00.000.AK.B.PR.0621.000
KE01.00.000.AK.B.PR.0622.000
KE01.00.000.AK.B.PR.0623.000
KE01.00.000.AK.B.PR.0624.000
KE01.00.000.AK.B.PR.0637.000
KE01.00.000.AK.B.PR.0640.000
KE01.00.000.AK.B.PR.0641.000
KE01.00.000.AK.B.PR.0642.000
KE01.00.000.AK.B.PR.0643.000
KE01.00.000.AK.B.PR.0644.000
KE01.00.000.AK.B.PR.0645.000
KE01.00.000.AK.B.PR.0646.000
KE01.00.000.AK.B.PR.0647.000
KE01.00.000.AK.B.PR.0649.000
KE01.00.000.AK.B.PR.0650.000
KE01.00.000.AK.A.QP.0603.000
KE01.00.000.AK.A.QP.0660.000
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
Page 5 of 18
Information Submission
4.0 DEFINITIONS
The following are the definition of terms incorporated in this procedure.
AFC
AGIP KCO
The Company
NCC
GATE
WORK
MATERIAL
PROJECT
MATERIAL
CONSUMABLE
MATERIAL
INVENTORY
TOOLS
SPARE PARTS
QSHE
STORAGE
WAREHOUSE
LAYDOWN YARD
5.0 ORGANIZATION
The Field Material Management Department is headed by the Logistics & Material
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
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Manager, who is fully responsible for all activities related to the receipt, control and issue of all material and
equipment to North Caspian Constructors (NCC) and its Erection Contractors(s). He will be responsible for
accountability for any and all surplus materials.
The Warehouse Group is headed by the Warehouse Chief, who reports to the Logistics & Material Manager and is
responsible for all physical material handling during receiving, storage, issuing and maintenance of the MatMan
system. The Material Engineers report to the Warehouse Chief.
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
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Offloading of all materials and equipment when received at the jobsite warehouse/laydown facility, with the
exception of those classified as heavy lift, will be handled by NCC. This activity will take place in a receiving
quarantine area for the purpose of inspection, checking and verification. Transportation of material and equipment
from the warehouse/laydown facility to the construction areas or other storage areas will be the responsibility of
NCC, and all transfers will be fully documented for traceability in the Warehouse Module of MatMan.
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
Page 8 of 18
recommend whether to return or retain all material overages. When the material is
being provided by AGIP KCO, the overage will be retained and reflected in MatMan receiving and inventory reports.
The Field Purchasing Department will
resolve overages purchased in the field. If AGIP KCO directs a vendor to make direct shipment to the NCC
warehouse/laydown facility and there is an overage,
AGIP KOC will be notified and asked to advise disposition.
SHORTAGES
In the event there is material called for on the applicable shipping document, that can not be located at the time of
receipt, the Warehousing Group will identify the material which is short, and also, if possible, explain how the
shortage came about on the OS&D. When the shortage is a local situation that can be cleared by the field, the
receiving records may be held for a day or two while resolving the discrepancy.
This will not, however, change the responsibility of obtaining the signature of the carries agent on the shorted freight
bill at the time of delivery. When the material is
being provided or directed by AGIP KCO, they will be notified and asked to advise
recommended disposition.
DAMAGES AND DEFICIENCIES
When material is received at the warehouse/laydown facility and packages show signs of external damage, remarks
and observations will be made on the Truck Delivery Note and
claims made against the customs clearing agent and/or transporter for any damages or shortages that they may have
been responsible for. Damaged packages will be opened immediately, condition of contents checked and notification
given to prevent further loss or damage. If the damage is not apparent upon delivery and concealed damage is
discovered during unpacking and checking, notations will be made on the packing list, given full description and
extent of the damage. Whenever possible, photographs of the damage will be taken in order to support possible claim
action against the responsible party. In any case, an OS&D will be issued and recorded in the Overage, Shortage
and Damaged Log with a sequential number. Accurate records will be kept recording all backchargable expenses
incurred in correction of the damage and become a part of the OS&D.
Copies of OS&D reports and all other backup paperwork to support a claim will be forwarded to AGIP KCO,
except for those on Field Purchase Orders, for resolution
and action by the responsible Procurement Department. Repairs to damages will not be performed prior to written
approval, unless jobsite requirements necessitate this,
and in this case written approval must be given by the Field Construction Manager
or his designee. When this course of action is taken, AGIP KCO will be advised immediately and accurate records
kept recording all backchargable expenses incurred in connection with the repair. These records will be filled with the
OS&D and retained for claim processing.
Where the deficiency concerns the provision of material documentation or certifications such as MTR or PMI
reports, the materials will be quarantined to prevent inadvertent use. The use of a Deficiency Report may be delayed
for a maximum of five working days. During this period, the Logistics & Material Manager or his designee, will
expedite receipt of the documentation from the appropriate supplier. If, at the end of this period, the documentation
has not been received, a formal Deficiency Report will be completed and circulated for action.
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
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minimize weather protection.
-Switchgear, Panels and other sensitive Electrical and Instrumentation items will always
be stored under covered storage. Climate environmentally controlled storage conditions
for delicate items shall be maintained as required and included in warehouse design.
-Inside storage facilities will be provided with ventilation, sufficient shelving, fire
protection and adequate lighting. A security program will be established to keep all
unauthorized personnel out of warehouse facilities.
-Materials will be segregated by account numbers.
-Materials stored on shelves will be grouped by type and size.
-Tagged items will be grouped by type.
-Storage shelves will be marked with row, shelf and bin numbers.
-Where there is insufficient space on a shelf, the balance of the material will be placed in
bulk storage.
-The Warehouse Chief will perform continuous inspection to ensure that good
housekeeping practices are being maintained.
LAYDOWN AREAS
-Material laydown areas will be grated, well drained, fenced and lighted for security. Only
authorized personnel will be allowed inside these areas.
-Material stored outside will be stored off the ground by using sleepers, dunnage, concrete
slabs or rail road ties.
-Materials will be segregated by account number within preplanned storage bays and will
be grouped by type and size.
-When required, materials will be covered by tarpaulins to protect against weathering.
-Routine preservation and maintenance programs will be established for stored materials
and will be performed by the Warehouse Chief under the supervision of the Field
Logistics & Material Manager/Quality Control Group.
-Special areas will be established and designated for storing flammable and hazardous
material in accordance with manufacturers requirements.
Attachment 1 is the Material Storage Table which provides a breakdown of planned storage
Locations between warehouses and laydown yards for all commodity groups.
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
Page 10 of 18
be removed by unauthorized personnel.
FIELD MATERIAL RECEIVING REPORTS
-Upon completion of the physical receipt of materials, the receiving documents will be
forwarded to the Warehouse Group for processing, MatMan data entry and filing.
-Material Receiving Reports (MRR) numbers will be assigned by MatMan to each
individual shipment received and all pertinent receiving and OS&D information will be
entered into the MatMan computer.
-MatMan generated MRRs, after being reviewed and approved, will be filed with
supporting documentation in the warehouse files.
-All MRRs and associated OS&Ds will be forwarded daily to AGIP KCO and
responsible Purchasing Departments, when applicable, for notification of material receipt
and resolution of OS&Ds as necessary.
-MatMan generated Daily and Weekly Receiving Reports will be distributed to involved
parties for notification of material received and available for issue.
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
Page 11 of 18
Material Engineers, who will collect, bag and issue the material.
-Upon completion of material issue, the Picking Ticket or Consolidated Picking
Ticket is signed by Construction Management confirming receipt.
-The signed Picking Ticket or Consolidated Picking Ticket will be returned to the
Warehouse Group for filing in the warehouse files.
-The FMR will be used when requesting material not shown on BM/FMRs, such
as incorrect material take off (MTO), material required for temporary facilities,
lost or damaged in the field, etc. When the additional material is due to MTO
shortages, field revisions to isometrics or change orders, the FMR must be
approved by the Field Engineering Department so that drawing revisions can be
generated, if required. The FMR will then be processed in the same manner as
a BM/FMR and the material will be issued to the requesting party.
ISSUE OF ELECTRICAL AND INSTRUMENTATION CABLE
-The Warehouse Group will log all cable receipts into two cable books, one for the
Electrical account and one for the Instrumentation account.
-FMRs will only be used for requisitioning cable from the warehouse/laydown
facility. Cable requirements specified on the FMR will be from the cable schedule
and include the list of the drawings involved.
-FMRs for cable must be approved by the Field Electrical or Instrumentation
Department Lead Engineer prior to being submitted to the Logistics & Material
Manager or his designee.
-The FMR will be checked to ensure that the cable has been received and not
issued. MatMan will assign a sequential Electrical or Instrumentation account
number to the FMR and issue a Picking Ticket which will automatically update
the warehouse stock. This information will also be entered into the appropriate
reel data report log book.
-Upon completion of cable issue the Picking Ticket is signed by Construction
Management to confirm material receipt.
-The signed Picking Ticket will be returned to the Warehouse Group for filing
in the warehouse files by account number.
-Empty cable reels with deposits will be returned to the supplier expeditiously.
BACK ORDERED MATERIAL
-In the event that a certain requested item on a BM/FMR or FMR is not available
for issue, it will be tracked by MatMan as an issued shortage.
-MatMan will track these short issues and upon receipt a Picking Ticket will be
processed and the back ordered material items will be issued to the requisitioner.
RETURN OF MATERIAL TO THE WAREHOUSE
-All material returned to the warehouse for storage by NCC will be accomplished
using the FMR form.
-The material items and completed FMR will be given to the Logistics & Material
Manager or his designee.
-The Warehouse Group will acknowledge receipt and after checking the material
will forward the FMR for MatMan input, updating the warehouse stock.
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
Page 12 of 18
When the Logistics & Material Manager and/or Material System Manager establishes that a certain commodity of
material is surplus to the project requirements after review of the final material take off (AFC MTO), this
information will be recorded on a Surplus Material Inventory (SMI) report in draft format and forwarded to the
Field Engineering Department and Field Construction Manager. Their review will verify if there is, or is not, any
further foreseeable project requirement for these commodities and return the draft, with their comments to the
Logistics & Material Manager and/or Material System Manager. Material identified as no longer required on the
draft are now recorded on an official SMI, sequentially numbered by MatMan by account number, and issued to
AGIP KCO for comment. AGIP KCO will advise the Logistics & Material Manager as to the disposition of the
surplus material. They may instruct NCC to return the surplus to their control for reallocation to other AGIP KCO
work or restocking arrangements with the original supplier, or simply to take no action and leave the surplus under
the control of NCC.
Description
(1) Piping Materials
a) Steel and stainless
b)
Small
tube
for
instrumentation
c) Vinyl pipe, hose, etc.
d) Fittings
e) Flanges
f) Manually operated valves
g) Automatic valves
h) Valves (non-ferrous)
Storage Location
Open Storage
Warehouse
X*
Separated by size,
X
X*
X*
X*
X
X
X
X
X
X
j) Gaskets
k) Spring hangers
l) Hangers
m) Steam traps
n) Steel plate, strip steel
o) Copper plate, wire
p) Welding rods
(2)Electric & Instrument
a) Cable on drum
b) Electric wire
c) Lighting fixtures
d) Distribution
control
panels,
e) Transformer
f) Motors
g) Insulators
h) Meters
i) Instruments
j) Materials for electrical and
instrumentation work
(3) Rotation Equipment
(4) Static Equipment
a) Vessels, Drums, Heat
Exchangers, Stacks, etc.
b)
Small
items
and
accessories
(5) Oils and Gases
a) Gasoline, thinner
X
X
Remarks
X*
On Racks
Vinyl pipe on Racks.* Over
4"
* Larger than 8"
* Larger than 8"
Washers bagged,
bolts & nuts binned
loosely Separated by
type and size
* Less than the weight of
1X kg
X
X
X
X
X
X
X
X
X
X
X
X*
X*
* Indoor service
* Up to 5 HP
X
X
X
X
X*
* Or Direct Delivery
Materials
X
of
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
Page 13 of 18
14.0 ATTACHMENTS
MATERIAL STORAGE LOCATION TABLE
Description
Storage Location
Open
Storage
b) Paint, oil
c) Gases
d) Chemicals
(6) Catalyst and Packing
a) Catalyst
b) Packing Materials
(7)
Equipment
Containing
Radioactive Material
(8)
Insulation
and
Fireproof Materials
a) Heat insulating materials
b) Fireproofing materials
(9) Precious Metals
(10) Spare Parts
(11) Special Tools
Warehouse
Remarks
Stored
separately
warehouse
Stored separately out
sunlight
Stored
separately
warehouse
X*
X*
* If requested by
Vendor's manual
X
X
X
X
X
in
of
in
Stored in a separate
fenced storage area
X
X
X*
X*
X
X
X
* After unpacking
* Powder type materials
Special Secure Store Stored
separately to all
other Materials. Area
clearly marked "Spare Parts /
Equipment No."
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
Page 14 of 18
MRF FORMAT
REQUEST NR:
DISCIPLINE:
CONTRACTOR: NCC
DATE:
DRAWING NR
ITEM NR
QTY
REQ.
QTY
ISS.
TAG NR
PO NR / MMT NR
DESCRIPTION
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
Page 15 of 18
Materials issued for a given ISO/DWG must only be used for that ISO/DWG
NOTE:
DATE:
________________________
( EP CONSTRUCTION COORDINATOR)
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
Page 16 of 18
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
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K.M.W.
Kashagan Main
Construction Works Project
MRR No:
Page : of
MRF No:
Requisition No :
Coli
(Package,bundle) No
Date of arrival at
site
Place
storage(GATE)
of
OPENNING STAGE
The above mentioned coli was opened under the supervision of NCC/GATE and AGIP on :
. / / 200..
Description of contents :
Damage
of parts :
No O
Yes O
00
CONFIRMATION
The Company
Name
Surname
Date
Signature
GATE QA/QC
and
OS&D REPORT
AGIP
KE01-A1-000-NC-J-PR-0001-000
Rev. C01 August 2006
Page 18 of 18
CLIENT
LOCATION
: AGIP
KAZAKHSTAN
ATYRAU
KARABATAN
PROJECT : KMW
Date of Unloading:
Report Date :
Arrival Date:
No.
Material Code
Report No. :
Material
Description
Quantity
Unit
Package No.
Received
Overage
Shortage
Damaged
NOTE:
PREPARED BY
CONTROLLED BY
..............................
SIGNATURE
NAME & SURNAME
TITLE
DATE
GATE (QA/QC)
NCC
SIGNATURE
NAME & SURNAME:
TARGUTAY
TITLE : Material Lead
DATE :
APPROVED BY
Omer
OWNER (AGIP)
SIGNATURE
SIGNATURE
TITLE
TITLE
DATE
DATE