STANDARD OPERATING

PROCEDURE
( COILS / TUBES )

Prepared By: Checked By Approved By:

Sandeep S. Bhandari M. K. Jadhav A. S. Kulkarni

SOP / BnHQAC / 01, Rev. 0 Page 1 of 4

 SOP:- STANDARD OPERATING PROCEDURE
COILS [ECO. / SH / INBED], LOOSE, SUPPORT TUBES
For Tolerance, refer control sheet no.
Getting Drawing:-
Ensure that approved drawing is received and if any backside is there then it shall be pasted on
backside of drawing. The drawing shall be provided by planner to shop QC / Shop.

Review of ITP (Inspection & Test Plan):-

Shop QC shall review the latest revision of ITP to ensure which stages are to be offered to TPI / IBR /
IA & if any special requirement mentioned.

Tools Requirement:-

Scale, Thin rope, Chalk, Measuring Tape, Ultrasonic thickness meter, Permanent Marker, Vernier
caliper
Layout Marking & Inspection:-
Ensure that platform used for layout marking is in water level condition. Production to carry out layout
& shall get it check from Shop QC. Flatness of Plate shall be within 1mm / meter.

Shop QC shall ensure all parameters of layout marking such as Orientation, All dimensions [Length,
Width, Tan. Point to Tan. Point distance, diagonal, Bend Radius, Bend Degree, Pitch, No. of bends,
Support distance, Sleeve distance, End markings] & Identification Blr No. & Component

Sample / First Production Bend (Max. bend degree):-

After Clearance of previous stage by Shop QC, Production shall prepare the sample production bend
with 1800 or max. degree (as applicable) and shall offered to Shop QC for inspection.

Shop QC shall ensure that proper material as mentioned in drawing is used [Size, Specification] & is
cleared by inspecting authority as applicable.
Shop QC shall inspect the sample bend for Dimensions of Bends on layout [Bend Radius, bend
Degree, Pitch], Ovality, Thinning, Flow area, Kink, Flatness as per template, wrinkles & any surface
defects, die marks.

Shop QC shall fill sample bend inspection report & shall offer to inspecting authority, as applicable

After clearance by Shop QC, Production shall start the production of coil & shall offer for inspection
to Shop QC.
Bending of Tubes:-
Production shall start the bending of tubes with the same parameters of machine as used for sample
bend & production shall check first 10 bends for dimensionlly & visually.
Shop QC shall ensure the ovality, thinning, ball pass for on continuing production runs at least one
bend of every hundred bends along with Visual insepction of surface & shall maintain the records for
the same on each bending station.

SOP / BnHQAC / 01, Rev. 0 Page 2 of 4

 If Ovality & thinning founds unacceptable then bending shall be stop & setting of the machine to be
changed & sample bend shall be prepared again & 100% inspection shall be carried out for deviated
lot of bends.
If pinching is resulting from die forming which is not acceptable then blend grind uniformly to
surrounding metal & thickness check to ensure that minimum wall thickness is maintained as per
drawing or torus formula.
Inspection of coils after bending & Setup of butt joints:-

Shop QC shall ensure that proper material is used as per drawing & color coding is done, if required.

Shop QC shall ensure the matching of coils on layout & it shall be within acceptable limit as
mentioned.

Shop QC shall ensure the Identification marking of coils [ BLR No., Coil No., Item description]

Shop QC shall ensure that joint & 1" area adjacent to butt joint is cleaned on both sides.

Shop QC shall ensure the Orientation, Setup dimensions [Groove angle, Root Gap, Root Face] as per
drawing on layout.

Shop QC shall ensure the alignment of coils & shall be within acceptable limit

Shop QC shall ensure the orientation, dimensional parameters for Structural attachments on layout as
per drawing.
Shop QC shall ensure that edge preparation at ends is carried out as per drg. & dimensions are
matching on layout.
After Clearance from Shop QC, production shall start the welding of butt joints & structural
attachments.
Shop QC & production shall ensure that proper preheating of joint & its adjacent 1" area is carried out
before welding & interpass temperature is maintained, if applicable.
Welding of Butt joints & Structural attachments:-
Shop QC shall carry out visual inspection [Weld profile, appearance, Weld reinforcement] of all butt
joints & shall check that all coils are identified with welder No.

Shop QC shall ensure flow area by ball test.

For Stud welding & other requirements, Refer SOP no.

After clearance of Visual insepction & Ball test, Production shall offer the coils for applicable NDT to
NDE cell.
Post Forming / Bending Heat Treatment:-
If R/D ratio < 1.25, then Stress relieving shall be caried out for cold bends as per heat treatment cycle
given by welding cell.
Final Inspection:-

Shop QC shall ensure that required NDT is completed & is cleared.

SOP / BnHQAC / 01, Rev. 0 Page 3 of 4

 Shop QC shall ensure the inspection of coils [Overall dimensions, Edge preparation, End
Identification, Coil No., Item description]

Shop QC shall ensure that scope of drawing & BOM is complete

Shop QC shall ensure the edge preparation of the coils by stacking of all the coils in bunch lying with
support on all sides so as to verify that none of the coil is short or excess in length.

After completion of inspection, coils shall be offered for painting.

Painting Inspection:-

Shop QC shall ensure the proper cleaning of coils before painting form O/s.

Shop QC shall ensure the edge preparation of the coils by stacking of all the coils in bunch lying with
support on all sides so as to verify that none of the coil is short or excess in length.

Shop QC shall ensure that proper shade of paint, approved brand of paint, Batch no. of paint

Shop QC shall ensure visually that no Rundowns, Peel - offs, cracks are present & complete coverage
of coils.

Shop QC shall check the DFT of paint.

Shop QC shall ensure the cleaning of coils from inside before capping & ball test to be carried out.

Shop QC shall ensure that all tubes ends are properly capped.

Shop QC shall ensure that color coding is carried out as per the material & idnetified chart, if
applicable.

Shop QC shall ensure the stenciling [BLR No., Drg. No., Mark No.,Part No., Coil No.]

Hard Stamp of IBR

SOP / BnHQAC / 01, Rev. 0 Page 4 of 4