Shop Inspections of

Alloy Pipes

G Kannappan
Raghavendra Shenoy
16.05.2017
Knowledge City, Vadodara

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Contents

➢ Raw Material Inspection

➢ In-Process Inspection

➢ Final Inspection

➢ Non-Conformities

➢ Manufacturer Audit

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Testing Requirements
➢ Requirements are in:

➢ Material Specification (ASME Sec II)

➢ Supplementary Tests

➢ Customer Requirements

➢ Ordering Information: Write in PO

➢ Tests at Shop & Field: Mention in agreed QAP & FQAP resp.,

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 Raw Material Inspection

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Raw Material Identification

Billets identification

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Raw Material Identification

Stamping

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Raw Material Testing

Etching Macro-Structure

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Raw Material Testing

All the heat numbers chemical composition

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Raw Material Testing

Micro Testing for the forged billets

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Pipe – Heat Treatment

Pipes’ heat treatment records & charts (Normalizing &

Tempering) reviewed as per applicability of code / TDC
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 Finished Pipes Inspection

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Finished Pipe - Identification

Identification made at the billet stage is maintained

till the testing is finished
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Finished Pipe – Identification/Marking

All the pipes marked with following information:

P.O No., Manufacturer Name, Specification, Dimension (OD X Thick X Length),
Heat No., Year - Month, Inspector Seal, SAP Material Code, NDE
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Finished Pipe – Color Coding

SA 106 B Pipe with Red - Longitudinal

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Finished Pipe – Color Coding

P22 Pipe with Red & Blue - Longitudinal

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Finished Pipe – Color Coding

P91 Pipe with Brown & Red - Longitudinal

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Finished Pipe – Color Coding

All IBR pipes with red color at the ends

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Finished Pipe – Visual & Dimensional

OD Measurement
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Finished Pipe – Visual & Dimensional

Thickness Measurement
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Finished Pipe – Visual & Dimensional

Thickness Measurement
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Finished Pipe – Visual & Dimensional

Straightness Measurement
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Finished Pipe – Mechanical Testing

Transverse Tensile Test Specimen with identification

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Finished Pipe – Mechanical Testing

Measurement for
elongation
Tensile Test under progress
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Finished Pipe – Flattening Test

Flattening test sample with identification

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Finished Pipe – Bending Test

Bending Test sample after Bending

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Finished Pipe – Flaring Test

No observance of Cracks after flaring

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Finished Pipe – Hardness Test

Sample tested for its hardness

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Finished Pipe – Chemical Test

Heat wise Chemical analysis witnessed on the

samples collected from Pipe (product)
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Finished Pipe – Microstructure Test:

P91 Micro Structure test with 500x

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Finished Pipe – Non-Destructive Test

Where the nondestructive electric test is

performed, the lengths shall be marked
Online UT under with the letters “NDE.”

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Finished Pipe – Positive Material Identification

PMI Testing
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Finished Pipe – Hydro Test

Hydro Test Bench

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Finished Pipe – NDE/Hydro Test Marking

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Finished Pipe – Painting

All the pipes were painted with rust

preventive coating outside
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Finished Pipe

Vapor Corrosion Inhibitors (VCI) packets

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Finished Pipe – Packing

Placing of Endcap

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Non-Conformities Raised against Vendor

Some of the pipes already in production without raw

material inspection by L&T
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Non-Conformities Raised against Vendor

Pipe Inside Surface observed with uneven surface and a

depth up to 2 mm in some cases
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Non-Conformities Raised against Vendor

Surface observed with uneven grinding (Scratches like)

at some of the places on the below mentioned pipes
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Non-Conformities Raised against Vendor

Hardness not within the limits for the Grade 91.

Requirement 180 to 250 BHN
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Non-Conformities Raised against Vendor

With a step of up to 3 mm on Deep notch like with a

the outer surface depth more than 1 mm

140 MT of pipes (21 pipes) with a dimension of ID810x53; SA 335

P91 found with surface imperfections which are not acceptable.
All the pipes need to be reworked with grinding.
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Non-Conformities Raised against Vendor

Requirement: As per TDC (8900-BN05-02; Rev:00), Eddy Current Test (ET)

shall be carried out as per E309 with drill hole of 0.8 mm as well as
longitudinal or transverse notch (15% of thickness) on outside.

Actual: Vendor carried out ET only with different drilled hole sizes as per
A106.
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Inspection Findings

➢ Pipes found to be out of OD tolerance

➢ Pipes found to be out of tolerance with respect to
Straightness as per TDC requirement
➢ Pipes found heat number marking mistakes.

➢ Remedy:
➢ Mfg shall improve internal QC inspection to
reduce the unacceptable pipes with respect to
dimensions and marking

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 Manufacturer Audit

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