QUALITY SYSTEM PROCEDURE Doc. No.

: SPFPL-WI-01
Rev No. : 00
WORK INSTRUCTIONS Date : 01.01.2013
Page : 1 of 5

BW FORMING

SCOPE: This work instruction is related to forming operation of BW Forming

of Pipe Fittings like Elbow , Tee, Reducer, Cap etc.,

1. Set the Die in to the Hydraulic Press along with Punch properly arranged.

2. Heat the Pipe to form, according to the requirement in the furnace.

3. After the Temperature of the Pipe reached to the required level, place the
pipe in to the die by proper handling method and press in to the die with
punch to the full die level.

4. Remove the punch formed fitting from the die and check for dimensions
as per the required standard.

5. If the dimensions are as per standard, then continue the same to the
balance quantity.

6. If dimension is not meeting the required repeat the above process till it
gets the correct dimension.

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 QUALITY SYSTEM PROCEDURE Doc. No. : SPFPL-WI-01
Rev No. : 00
WORK INSTRUCTIONS Date : 01.01.2013
Page : 2 of 5

SW & FLANGE FORGING

SCOPE: This work instruction is related to forming operation of SW Forging of

Pipe Fittings like Elbow , Tee, Reducer, Cap , Flanges etc.,

1. Set the Die in to the Forging Press along with Punch properly arranged.

2. Heat the Bar to form, according to the requirement in the furnace.

3. After the Temperature of the Bar reached to the required level, place the
Bar in to the die by proper handling method and forge it in to the die with
punch to the full die level.

4. Remove extra burs which are formed during forging by use of cutting
press to get raw forging.

5. Check the forging for dimensions as per the required standard.

6. If the dimensions are as per standard, then continue the same to the
balance quantity.

7. If dimension is not meeting the required repeat the above process till it
gets the correct dimension.

PREPARED BY REVIEWED BY APPROVED BY

 QUALITY SYSTEM PROCEDURE Doc. No. : SPFPL-WI-01
Rev No. : 00
WORK INSTRUCTIONS Date : 01.01.2013
Page : 3 of 5

MACHINING

SCOPE: This work instruction is related to Machining operation of BW & SW

Pipe Fittings like Elbow , Tee, Reducer, Cap , & Flanges etc.,

1. Set the Fixture in the Lathe machine.

2. Set the Product in to the fixture properly clamped.

3. Give minor cut initially as per the machining drawing to the product.

4. Maintain the required dimensions as per the machining drawing.

5. Maintain the finish cut absolutely smooth and without any deep tool
marks.

6. Remove extra burs which are formed inside or outside during machining.

7. Before unloading the product from the fixture, check the dimensions
accuracy as per standard, and if found satisfactory then continue the
same to the balance quantity.

8. If dimension is not meeting the required then do the necessary re

machining, to get the correct dimension.

PREPARED BY REVIEWED BY APPROVED BY

 QUALITY SYSTEM PROCEDURE Doc. No. : SPFPL-WI-01
Rev No. : 00
WORK INSTRUCTIONS Date : 01.01.2013
Page : 4 of 5

HEAT TREATMENT PROCESS

SCOPE: This work instruction is related to Heat treatment process of BW &

SW Pipe Fittings like Elbow , Tee, Reducer, Cap , & Flanges etc.,

1. Set fittings in to the furnace according to the size of the furnace.

2. Check the calibration status of the Recorder and Thermocouples before

firing the furnace.

3. Fire the burners by allowing proper flow of oil by opening the furnace
door.

4. Maintain constant firing for at least 30 mins and when the temperature
reaches 300 deg. C, then close the doors.

5. Maintain constant temperature by checking the digital recorder and

maintain 125 – 130 deg per Hr.

6. When the temperature reaches to the required level, then soak the
material 30 mins., minimum or material thick ness 25.4mm / Hr.

7. Upon completion of soaking, take out the material by proper handling and
allow them cooled at room temperature for normalising.

8. If the material grade is alloy steel, without opening the doors, allow the
material to cool in the furnace, and if material is Stainless steel allow the
material solution annealed.

PREPARED BY REVIEWED BY APPROVED BY

 QUALITY SYSTEM PROCEDURE Doc. No. : SPFPL-WI-01
Rev No. : 00
WORK INSTRUCTIONS Date : 01.01.2013
Page : 5 of 5

MECHANICAL TESTING

SCOPE: This work instruction is related to Tensile and Hardness testing of BW

& SW Pipe Fittings like Elbow, Tee, Reducer, Cap, & Flanges etc., after heat
treatment.

TENSILE TESTING:

1. Machine the tensile sample as per ASTM A 370.

2. Mark the Guage length and note the dimensions in to the report along
with Control no. Fix the sample in to the Universal Testing Machine

3. Apply load to the sample by operating the Hydraulic load lever

constantly.

4. When at certain load the sample will broke and note the reading.

5. Calculate the YS, UTS and % of elongation with the help of sample
dimensions.

6. Co-relate the final values are as per the standard and record the same in
the report.

HARDNESS TESTING:

1. Check the calibration of the machine before testing on the sample.

2. Put the testing stick on the buffed surface of the sample and press.

3. Check the reading on the digital indicator and record. Always test for
three indentations and record the average value. Co-relate the final
values as per standard.

PREPARED BY REVIEWED BY APPROVED BY