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BLOW OUT STATION
PHOSPHORIC ACID WASH & HIGH BLASTED SURFACE PRESSURE WATER RINSE INSPECTION
EPOXY APPLICATION BOOTH ADHESIVE & POLYETHYLENE / POLYPROPYLENE APPLICATION BOOTH
WELSPUN GUJARAT STAHL ROHREN LTD
QUENCHING ZONE THICKNESS, VISUAL CHECK AND TEST STATION
STENCILLING AND READY FOR DESPATCH
HOLIDAY, REAPIR & FINAL INSPECTION
PURPOSE: The purpose of this procedure is to provide instructions for carrying out and monitoring the three-layer polyethylene coating process on bare pipe surface. GLOSSARY:
SEQUENCE OF OPERATIONS FOR 3LPE COATING BARE PIPE RECEIVING Bare pipes shall be received from client either by purchase order or as a free issue material. The rack is installed with a slope to ensure pipes natural movement towards the blast-cleaning conveyor and is equipped with kick out device./ job No/ diameter/ wall thickness.NOT TO BE COATED R. Pipe shall be unloaded by vacuum crane/ MOBILE / EOT WITH rubber padded hooks. All the required tests are performed on these pipes before regular production. 3LPE --. Pipe shall be stored in the yard in stacks physically separated by order No. diameter and other relevant marking details shall be checked and matched with the received packing list from the pipe manufacturer. --. BARE PIPE INSPECTION AT INLET Pipes are unloaded by EOT crane of 15-ton capacity with rubber-padded hooks on to the rack.QUALITY CONTROL AND TEST PLAN NTC --. Job No. COATING SYSTEM REQUIREMENTS: PROCEDURE QUALIFICATION TEST As mentioned in the QTP or randomly five pipes are selected for PQT.RELATIVE HUMIDITY REFRENCES: DIN 30670 SSPC SP-10 SIS 055900 CAN/CSA/Z 245. 2 .H.20-02 ASTM D-1238 RESPONSIBILITY: The Production Manager or his authorized person is responsible for carrying out the coating process. / order No. Wall thickness.THREE LAYER POLYETHYLENE QTP --.
Each pipe shall be identified by its mill No. SSPC SP-10 standard and roughness between 50-70µm. Relative Humidity dew point shall be measured by suitable instruments and by suitable means. such as bevel damage.Bare pipe shall be visually checked for steel defects. After inspection of bare pipe coupling shall be attached on one end of pipe for smooth coating. Flatness. The coupling will be slightly heated to makeup for the heat loss at the time of induction heating due to additional thickness of the coupling. lamination etc and for any kind of contamination. Pipes received at blasting inspection rack are checked for below mentioned parameters as per approved QTP • Cleanliness • Dustiness • Roughness • Salt level • Visible steel defects • Magnetic Intensity All the measuring instruments are calibrated as per approved QTP. grit sieving & spent particle removal. Each machine is capable to clean up to SA 2½. Each machine consists of four turbines with 75-kw/100 hp motors. Any pipe not complying the QTP requirement will be marked as “NTC” by and sent for rectification. scratch. QC inspector at inlet station shall make sure that all data of pipes found is in order. Preheating of pipe is to be done. 3 . if the pipe surface temperature is less than 3°C above dew point or if relative humidity is more than 90% or as per customer requirement. Before starting the cleaning operation. Each machine is equipped with dust vacuum suction and grit reclaim system. ABRASIVE BLASTING Two shot blasting machines are placed one after another. PREHEATING Heating system is equipped with 6 gas fired oven of 430000 kcal / hr each. It can heat up to 306 ton steel per hour and up to 100°c. dent. After blasting pipes are moved to blowout station where all dusts. Pipe Temp. shots & grits are blown out from inside pipe surface.
5 M3/Hr. surplus powder suction & recycling plant. 510KW extruder vacuum granule suction with hopper “Y” shaped feeding neck of capacity 1600Kg/Hr. capacity.PHOSPHORIC ACID TREATMENT APPLICATION (if required) If the incoming pipe is tested positive for salt contamination. The temperature shall lie between 180 .240 °C or as per epoxy manufacturer recommendation. It is provided with vacuum feeding unit of capacity 400Kg/Hr. then phosphoric acid treatment is done and thereafter rinsed with high pressure demineralized water. CHROMATE TREATMENT APPLICATION (if required) To enhance the bond strength between the substrate and fusion bonded epoxy layer chromate layer is applied using rubber wiper. and a hopper neck with heating control unit POLYETHYLENE PPLICATION The system is provided with 150mm diameter. Pipe surface temp is recorded using temperature gauge with roller type probe. The acid application cabinet is equipped with 4 nozzles of 1. COOLING ZONE In the cooling zone coated pipe shall be subsequently quenched & cooled in water for a period which shall sufficiently lower the temp of pipe coating to permit handling & inspection 4 . APPLICATION STATION FUSION BONDED EPOXY APPLICATION Pipes are heated by 2 consecutive induction coils of 300 Hz capacity. with temperature control system PE and Adhesive film temperature is measured using digital infrared thermometer. The system is also equipped with fluidized bed with venture pumps. ADHESIVE APPLICATION The system is 222 mm diameter equipped with lifting platform. Application of epoxy primer is carried out using 20 electrostatic guns of capacity 1000kg/hr for 1500 µm thickness.
full circle electronic detector with audible & precise voltage control If any damage observed it is marked manually by chalk and repaired as per approved repair procedure. Accepted pipes are assigned with unique TPI no after final inspection. Chiller capacity 18 m3/hr. END CLEANING Brushing machines equipped with 2 electric motors of capacity 45 hp.C. bond strength of coating is measured using suitable apparatus. If any defect appears on coating such as coating damage due to peel test the pipe is then sent to the repair bed. glossy and free from any irregularities. After holiday colour codification is given as per approved QTP FINAL INSPECTION Coated Pipes Are Visually Checked. with adjustable brush to create bevel to PE. hydraulic power units & motors. Cutback length shall be as per customer requirement in approved QTP. 125 tr Cooling water circulation rate 400m3/hr ON LINE INSPECTION STATION Here the thickness of the applied coating is measured by means of magnetic thickness gauge. 5 . Brushes to remove coating up to steel and form taper end.This zone is 38 M Long. The holiday detector shall be low pulse D. Coating film shall be uniform in thickness. HOLIDAY TEST AT 25 KV Each pipe is passed through the holiday ring to check for any discontinuity in coating. Apply white wash (emulsion paint) on 3 LPE coated pipes to protect UV attack if required by the customer.. Bevel ends shall be free of coating material Repair should be done as per approved repair procedure. Stencil marking at the end of external surface of the coated pipes is carried out using spray gun. provided with water distribution system.
YARD HANDLING AND STORAGE After final Inspection.Have knowledge of Pressure vessels (vessels.Prepare data sheets and should be able to prepare various reports. . 6 . . if reqd. SAW(SAWL. Compressors.Maintain master copy of all discipline deliverables.Be familiar with the preparation of specifications. .To be familiar with various statutory requirements. TEMA. .SAWH): Spiral Welded SSAW: Spiral Submerged-arc Welded LSAW (Longitudinal Submerge-arc Welded) UO(UOE)、RB(RBE)、JCO(JCOE) DSAW (Double Submerged arc welded) ERW (Electric Resistance Welded) HFI (High Frequency Induction) EFW(ELECTRIC FUSION WELDED TUBE) HFW(High-Frequency Welding) . Scrubber. . ASME Sect. NACE).To be familiar with the testing and inspection requirements.To participate in various reviews. . coated pipes are fitted with bevel protectors and lifted from final skid by EOT/cranes padded with rubber hooks and loaded on trailers for transportation to stockyard. .Have knowledge of Rotating (Pumps. .To check various vendor design calculations/ vendor drawing & documents. WRC 107/297.To guide drafting team. PV Elite. II & VIII.Prepare Material Handling study report. . . Packaged equipments). Material Handling.
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