suly Customer complaot analysis and corrective ation . ate: 26102020 11.11.2020 Department Producon/ Qe Cstomer Zam PE/A Nim Seuten PEA 2033578 Sa noticaon: 10213007205/30211007709 Summary > We received complaint of crack between web and flange from Zamil PEB in the supplied PEA | 200-355iR under ON 7680032063 and 7080032063, Heat no -1200070, Supplied aty: 60 MT. >> Similar complaint is received from A Nimr inthe supplied IPEA 200-3551R under DN 7080029655, ‘and 7080023656, Heat no~ 1200070. Supplied aty: 50 MT ‘Aion > Visited Zamil PEB yard en 8th Nov to verify the complaint. Customer informed that they are {getting crack in some bars during fabrication, Minor crack found in two bars of raw material Observati > Depression ine mark's visible in all ars andit is suspected that this may be the reason of crack between lange and wed in some bars during fabrication. Depression between web and ange (aw material) Crack between web and flange {fabrication} > Cracks not visible in raw material except 1-2 bar ight crack in total lot) however depression ‘mark is presenti all bars. During fabrication or after sand blasting these light cracks are visible In random locations in nany bars. After grinding up-to Imm these cracks ae disappearing but ‘ot completely removed. ‘ans/FoRw/oos/mev 2>> Material wos rolled in 19” Feb 2020 and was supplied on 26% April 2020, Crack was not observed ‘during ling however @C Inspection sheet mention roughness at top web, 25 MT ofthis heat 11200070 in 1PEA 200-3551R was hold due to out of straightness and re-straightening was done for ‘this quantity, OMT was supplied to Zam PEB and SO MT was Supplied to Al Ninw. |. Chemical composition Chemical composition of supplied heats are OK. No abnormality is observed, 2, Section and Grade : ‘This section has web thekness of only 4.5 mm and ductility i es in GrS0 compare to 2751R, soit there i stress concentration near radus, there is possibility of small racks during straightening 3: Casting parameters Casting parameters were checked with Sulb Bahrain and got confirmation that there was no abnormality during castag ofthese heats rolled for IPEA200. 4, Rolling parameters > There is possibility that some bars got racked during straightening or re-staightening. These liaht cracks were not detected during alin and appeared during fabrieation when beams are subjected to deiling and cutting and sand blasting at customer yar, > Defect appears tobe originating from improper roll radius in toprol Itcan be seen from photograph that toprol root radius isnot formed propery and resulting in depression mark throughout. This may bed to improper roll uring or excessive localized roughness in top roll and subsequent deprestion mark during straightening During restraightening some bars got cracked du to stress concentration du to improper transition root rads Improper ras wa ‘as/FoR¥/o08/ReV 2“epresson line along with improper radius Corrective actions 41, Root radius willbe increased from 8 mm to 10 mm and will be checked If depression ine isnot appearing. nthe prevcus DIN standard root radius was defined in standard but latest EN standard gives flexibly of selecting root radius to manufacturer. 2, Template for checking rol radius is avallable for finishing tands only. If there is any issue of. radius, t wall not get corected by fishing stands. Template shall be prepared for checking radius for every stand sarting from roughing upto finishing. 3. Rollradius checking tobe included in the oll shop machining checklist, Previousiy ony roll ameter value was encoded in the form. Currently radius should form as per program loaded in. ‘CNC machine andi is ereced through template fr finishing rolls only. Now t will be checked {or ll ols and recorded in checklist as well, Form RS-F-00 is revised as Rev 2 a = ‘aMs/FOR¥/005/REV 2“GC inspectors were checking root radius during section star up only, Now onwards root radius checking to be done aftr secton/cassette change as wells every 25MT along with checking of ‘web and flange dimensions value shall be recorded in QC inspection frm. QC inspection form has been revised t include this data lathe checlst. alo al ER eee Siar et | t oh 5. Straightener machine Upgrade: Existing straightener machine is 20 years old and has only roll position feedback. Ope‘ators ae contraling only horizontal and vertical positions to correct ‘camber/sweep values, There ino repeatablity of straightener st values, Straightener machine ‘hall be replaced with edvanced cantrol and Feedback system so that excessive loads can be limited and controled ial disposition 1. Zam PEB informed that this materials going for use in ARAMCO project and they can-not take the risk with this material, There Is possbilty to take 41 MT back for resinspection and check if ivis possible to convert it to PEAR 200 as less eritical commercial application. already fabricated 19M vllbe scrapped. 2. It is dificult to take back material from Dubai Al Nimr (SOMT), hence sales can settle It commercially with customer. Target Date: Dec 2020 Signature : Review Audit Date Signature = Prepared by: oted By ‘Approved by: a Zubsie Ahmad Samson Samuel ‘Ahmad Al Ghamdl Dy Manager (QA/0C) Production Suptdt. Gwess, ‘aMs/FoR¥/oos/neV 2