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MANUFACTURING PROCEDURE SPECIFICATION

MPS : 001/FS/MPS/EXC/IV/2018
Revision :0

MANUFACTURING PROCEDURE SPECIFICATION ( MPS )


INSPECTION AND TEST PLAN ( ITP )

Customer : PT. WIJAYA KARYA


Project : -
Specification : Steel Pipe Pile, ASTM A 252 Grade 2
Spiral Welded Type

Pipe Size : Ø 914.4mm x 14mm x 50m


: Ø 711.2mm x 11.9mm x 50m
: Ø 610mm x 12.7mm x 50m
: Ø 610mm x 12.7mm x 24m
COIL VISUAL
HOT ROLL COIL UNCOILING
INSPECTION

INSIDE SKELP END INSIDE &


FORMING
WELDING OUTSIDE WELDING

VISUAL & DIMENSIONAL


GAS CUTTING TO IDENTIFICATION OF
INSPECTION
(PIPE & WELD SEAM) LENGTH PIPE
NOT
GOOD REJECT
SAMPLING FOR MECHANICAL WELDING REPAIR
AND CHEMICAL ANALYSIS TEST

NDT INSPECTION, VISUAL GOOD


& DIMENSIONAL ENDFACING
INSPECTION

MARKING FINAL INSPECTION

PAINTING - COATING REPAIR


STEEL MAKING, HOT ROLL COIL
STEEL MAKING
Process of steel produce and slab is at PT. GUNUNG RAJA PAKSI / PT.KRAKATAU STEEL electric arc
furnace. Slab which be rolled in the HMS is produced in Slab Steel Plant (SSP).
HOT ROLL COIL
Chemical Composition Refer to Mill Certificate

JIS G3101 SS400


ELEMENT
OR EQUIVALENT
Carbon -
Silicon -
Manganese -
Phosphorus Max. 0.05
Sulphur Max. 0.05
Mechanical Properties ( Refer to Mill Certificate)

TENSILE STRENGTH YIELD STRENGTH ELONGATION


GRADE
Psi N/mm² Psi N/mm² (%)

JIS G3101 58015 - 79771 400 - 550 29733 - 35534 205 – 245 25 - 30
SS400

• ASTM A 252 Grade 2 For thickness 7,9 mm or more.


• ASTM A 252 Grade 2 Tensile Strenght = 415 N/mm² (60.000 psi)
• ASTM A 252 Grade 2 Yield Strenght = 240 N/mm² (35.000 psi ) and Elongation min 25
VISUAL INSPECTION OF COIL ( HRC )
Visual and Dimensional Inspector will check the coil, before the coil is brought into uncoiler
(machine) as follows :
1. Check label and verified with the Mill Test Certificate.
2. Check and measure for coil width, thickness and weight.
3. Record
• Heat Number
• Coil Number
• Specification
• Width
• Wall Thickness
• Weight

UNCOILING
1. After the coil is inspected, the coil is put into the uncoiler
2. Unwind the coil, the edge of the skelp should run in the grooves of the strip guide rolls all the way to the
pivot line.
3. Drive the strip Straightener Rolls and Leveling the strip.
SKELP ENDS WELDING ( BUTT JOINT )

Procedure :
1. The out going coil is beveled with Gas Flame Cutting
2. The incoming coil after being flattened, it then cut and beveled with oxy – acctylene cutter
3. Line up the edges on these coils
4. Set the Gap between the coil
5. Tack weld a tab plate on both side of the Strip
6. Set current, voltage and speed
7. Start submerged are welding along the joint ( flux and wire is the same as for the spiral pipe )
8. Run another pass if it is required
9. Take off the tabs and make a good finishing by grinding
Sketch : AWS D1.1
GROOVE
( B-L1a-S)

DESCRIPTION INSIDE WELDING AWS Class


Wire (WELDTEX) or Eqv AWS A5.17 or Eqv. EM 12K
Wire dia. (mm) 3.2 or 4.0
Flux (WELDTEX) or Eqv F7A4 or Eqv. F7A4
Current (Ampere) 500 – 900
Voltage (Volt) 30 – 37
Welding Speed (m/minutes) 0,6 – 1,1
FORMING AND INSIDE AND OUTSIDE WELDING
FORMING
1. Before the coil comes into the forming rollers its edged are milled beveled by two Milling Machine.
• Weld joint preparation drawing

cx
Sketch :

Note :
R = 0 to 1 mm
β = 20˚ to 60˚

2. Driving the Strip by Main Drive to the Forming Roll to formed pipe by bending it through three sets of
forming rollers at certain Helix Angle.
3. After forming the pipe, check the outside diameter.
INSIDE & OUTSIDE WELDING
1. After the has been formed, the pipe will be welded from inside and followed by the outside
Submerged Are Welding.
2. Set current, voltage, nozzle angle, wire position, flux feeding and welding speed to achieve a good
quality welding (See Table 2).
Table
Inside & Outside Welding Parameter

DESCRIPTION INSIDE WELDING OUTSIDE WELDING AWS Class


Wire WELDTEX or Eqv. WELDTEX or Eqv. EM 12K
Wire Dia. (mm) 3.2 – 4.0 3.2 – 4.0
Flux WELDTEX or Eqv. WELDTEX or Eqv. F7A4
Current (Amper) DC 700 - 900 Amper DC 700 – 900 Amper
Voltage (Volt) 30 – 37 Volt 30 – 37 Volt
Speed (m/min) 0,6 – 1,1 0,6 – 1,1
Wire Angle (deg) 10” – 15” 10” – 15”
Type Ideal Arc Ideal Arc
Capacity DC 1500 A DC 1500 A
VISUAL & DIMENSIONAL INSPECTION, GAS FLAME CUTTING TO LENGTH,
IDENTIFICATION OF PIPE & NDT INSPECTION

VISUAL AND DIMENSIONAL INSPECTION ( See ITP Table 10.1 )

Visual inspector should inspect circumference, weld seam and pipe body visual while pipe is rotating.
Visual and Dimensional Inspection is conducted to detect following :
1. Visual : Surface detect in weld & pipe body
2. Dimensional :
a. Diameter pipe inspection is conducted by measuring pipe diameter
b. Circumference on both end pipe
c. Length

GAS FLAME CUTTING TO LENGTH

1. Gas Flame Cutting to Length


2. The pipes are cut to the required length
3. Procedure :
a. Hold thigh the measuring tape along the pipe surface between ends.
b. One end, the tape reads 0 (zero) and the other reads the length of the pipe
IDENTIFICATION OF PIPE

1. Every pipe that coming out of machine from particular coil is given identification individually by paint
mark on the outside as follows :
2. Inside :
a. Work Order Number
b. Pipe Number
c. Length of Pipe
d. Heat Number/ Coil Number
e. Status of Inspection : OK = ACC
Rep = Repair
Reject = Reject

3. These marking are born through all processed and reports until the final inspection is done. One the final
inspection, the pipe will be identified by the said unique pipe number and heat number
SAMPLING FOR MECHANICAL TEST & CHEMICAL ANALYSIS
1. Samples for mechanical test & chemical analysis are taken by the Cutting Operator and identified with
the Work Order Number, Heat Number, Coil Number / Pipe Number.
2. The Laboratory Technician shall prepare the test coupons and also prepare Tensile Test Report and
Chemical Analysis Report.
3. Test are as follow according to ASTM A 252 Grade 2 :

KIND OF TEST FREQUENCY ACCEPTANCE LIMIT AND TESTING METHOD


TS Elongation
YS
Tensile Test 1/50 Pipe (12 ( N/mm²), In 2 inch ( % )
( N/mm²), min
M) min min
Longitudinal Pipe or fraction
Axis / Transverse there of each 415 240 25
Pipe Axis size
Transverse Welding 415
Chemical Analysis 1/50 Pipe (12
Phosphorus max 0.05%
Product Analysis M)
4. Retest
If the result of the mechanical test & product analysis of any lot do no conform to the requirement, retest
shall be made on additional length of druble the original number from the same lot, each of which shall
conform to the requirement specified.

WELDING REPAIR
1. Welding Repair
2. Repair welding process shall be performed in accordance with Welding Procedure Specification (WPS),
carried out by specifically qualified welding personnel and by the use of qualified welding equipment.
3. Welding Method : Shielded Metal Arc Welding ( SMAW – Manual )
4. Outline of the repair welding procedure :
a. The effective part of the weld shall be clearly pointed out on the pipe so that the defect can be
easily localized and repaired.
b. Grinding to remove the defect or grooved by arc – air gouging
c. Welding condition :
i. Diameter electrode : 3.2 mm / 4.0 mm
ii. Current : 90 – 140 A / 130 – 190 A
iii. Classification : AWS A.5.1 E 7018 (70 xx)
d. Position : Flat position
ENDFACING
Both ends of the pipe are straight and straight.
FINAL INSPECTION AND MARKING
FINAL INSPECTION ( ITP )
Final Inspector will inspect each pipe, as follows :
TABLE
FINAL INSPECTION
Item of Method of Own
Acceptance Limit FS Contractor Ref.
Inspection Inspection er
Surface Surface defect in Max depth 25% of the nominal ASTM
Defect weld and Pipe Body WT shall be permitted. (may be A.252
are Inspected while explored by grinding or milling) Para 14.2
rotating pipe under Depth exceed 25% WT shall be & 14.3
adequate repaired Repair by welding shall
illumination be permitted when the depth of
defect does not exceed 33 ½%
WT

NDT Manual Ultrasonic AWS D1.1


Item of Method of Own
Acceptance Limit FS Contractor Ref.
Inspection Inspection er
DIMENSIONAL :
Outside Tape measurement ± 1% from the diameter specified ASTM
Diameter A.252
Para 12.2
Wall Micrometer or The minimum WT at any point ASTM
Thickness thickness gage shall not be more than 5% under A.252
the nominal wall thickness Para 12.3
specified
Length Tape measurement ± 1 inch ASTM
A.252
Para 13.1
Weight Using calculation - 5% ASTM
+ 15% A.252
Para 12.1
Straightness Taut string is held along the pipe surface, measure the ASTM
max deviation with steel ruler A.252
Reasonably Straight or 0.1% of length Para 14.1
Testing 1/50 Pipe (12 M) ASTM
Product A.252
Para 9.1 &
9.2
MARKING
Every pipe is marked individually as follows :
All pipes shall be marked as follows :
OD_______mm x WT_______mm x L_______M
ASTM A.252 Grade 2
Pipe No.__________
Heat No.__________