無縫鋼管檢驗試驗計劃

1、INSPECTIONANDTESTPLAN檢驗及試驗計劃CUSTOMER客戶：FORP.O.NO.訂單號：5100103644/UD63056536PRODUCT產品：ITEMNO.項目號DESCRIPTION描述LENGTH長度CONTRACTQTY(PCS)合同數量(支)0001112.75”*0.25inchASTMA53GR.BSEAMLESSLINEPIPE無縫管1000CM28ApplicableSpecifications適用規(guī)范ASTMA53-2012STANDARDSPECIFICATIONFORPIPESTELLBLACKANDHOT-DIPPED,ZINC-COATED,

2、WELDANDSEAMLESSValidity后效期:3年Durationofthecontract合同期：年Rev.NoReasonsOriginatedDate日期Checked審核Date日期Approved批準Date日期Draft0王利男2013.03.09r代鵬程邵明珠Draft1Draft2ItemNo.序號ProcessDescriptionorQ.C.Activity過程描述/質量控制措施Frequency頻率Verifying(Document)/Item確認(文件)/項Nonconformityhandling不符合項處理Inspection檢驗InHouse1方Clie

3、nt客戶Activity活動TPI第二力General總體Workingshiftreportshallberecordedateachitem.每一工序要有每班記錄一一一1Orderreview訂單審核Eachorder每一訂單Sales,Technical,QualityandPlanningDepartments,Reviewofcontract.銷售、技術、質量進行合同評審合同變更時應重新進行評審Negotiatewithcustomer與客戶商議H一一2Internalorderissuance內部計劃單發(fā)放Fileforeveryorder每一訂單歸檔Contractrequire

4、mentstransferredtointernalorder合同要求包含于內部計劃單Re-issuance重新發(fā)放H一一ItemNo.序號ProcessDescriptionorQ.C.Activity過程描述/質量控制措施Frequency頻率Verifying(Document)/Item確認(文件)/項Nonconformityhandling不符合項處理Inspection檢驗InHouseJ方Client客戶Activity活動TPI第二方3HeatAnalysis熔煉分析1/batch1/每爐鋼ProductanalysisadoptsChemicalSpectrometryan

5、alysis,whichisinaccordancewiththechemicalrequirements.Workoutthecarbonequivalentaccordingtoproductanalysisreport.化學光譜分析，熔煉成分符合化學成分要求。Changethematerial更換材料H一W4RawMaterial原材料1/batch每爐Rawmaterialsguaranteecertificate質保書Retesttomaterialqualified,復檢至合格，材質合格H一R5BilletInspectionandCutting管坯檢驗及下料Everyheat每爐

6、100%HeatNo.,materialNo.,Length(identificationStencilorstamp)materialcertificate,surfacequality爐號，鋼號，長度，表面質量Paperreport書面t己錄Repairorreject返修或判廢H一R6Heatingincircularfurnace環(huán)形爐加熱爐Accordingtoheatingschedule依照加熱制度執(zhí)行H一RItemNo.序號ProcessDescriptionorQ.C.Activity過程描述/質量控制措施Frequency頻率Verifying（Document）/Item

7、確認（文件）/項Nonconformityhandling不符合項處理Inspection檢驗InHouseJ方Client客戶Activity活動TPI第二方7Piercing,hotrolling穿孔，軋制8hourspershift每班8小時Surfacecheckingofthemandrel檢查芯棒的表面質量H一R8Slight-stretchreduction微張力減徑Accordingtositeconditions根據現場情況ODandWTchecking檢驗外徑及壁厚尺寸H一R9Samplingforpipebody管體取樣2perlotof200pcs2/批（200支）Ma

8、ketwospecimensforeachlotofsamplesandmarkfurnacebatchNo.onthem.(Sample,markandstampaccordingtoAPT5Lstandard.)每組試樣做成兩個試片并且在試樣上用記號筆標明具體爐批號(做標記及做鋼印，鋼印做批號的后兩位)Takenewsamples另取樣H一WItemNo.序號ProcessDescriptionorQ.C.Activity過程描述/質量控制措施Frequency頻率Verifying（Document）/Item確認（文件）/項Nonconformityhandling不符合項處理Insp

9、ection檢驗InHouse1方Client客戶Activity活動TPI第二方10ChemicalAnalysis產品化學分析2/heat2/爐ProductanalysisadoptsChemicalSpectrometryanalysis,whichisinaccordancewiththechemicalrequirements.產品分析采用化學光譜分析法；必須符合化學成分表的要求；Re-test,reject重測，判廢H一W+RChemicalRequirement化學成分要求（Weight重量）Grade鋼級ChemicalAnalysis化學成分CSiMnPSCrMoVBmin

10、max0.301.200.050.0450.400.150.08BCuNiminmax0.400.40注：Cu+Ni+Cr+Mo+V1.00%ItemNo.序號ProcessDescriptionorQ.C.Activity過程描述/質量控制措施Frequency頻率Verifying(Document)/Item確認(文件)/項Nonconformityhandling不符合項處理Inspection檢驗InHouse1方Client客戶Activity活動TPI第二方11MechanicalTesting機械性能測試Tensile(拉伸)flatteningtest壓扁試驗2/Lot每批取

11、兩個試樣進行試驗1/batch每批取一個試樣Tensiletestisshowedasfollows:板狀試樣Stripsample伸測試見卜表Re-test,re-heattreatment加倍重測；或判廢H一W+R屈服(Rt0.5)>240抗拉強度Rm>415伸長率AE>30壓扁要求：至H距離/=(!+l/D)式中H二壓板間距，irU注4);單位長度變形量(與鋼種級別相應的常數，A級為0.09出級為0.07)：£=規(guī)定壁厚，in.(mm);D二規(guī)定外徑in.(mm)0ItemNo.序號ProcessDescriptionorQ.C.Activity過程描述/質量

12、控制措施Frequency頻率Verifying(Document)/Item確認(文件)/項Nonconformityhandling不符合項處理Inspection檢驗InHouse1方Client客戶Activity活動TPI第二方12NonDestructiveInspectionforpipebody(MFLL4)尺寸檢驗和外觀檢查100%Beginningeveryshift每班的開始WTofallpipeendsmeasuredbymicrometer,allpipebodiesbymanualultrasonic.所有的管子兩端測壁厚用千分尺，管體中間用手動超聲測厚。Finis

13、hedpipeODWTlength、surfacequality、Straightness,polishingthedefectedpipe成品管外徑、壁厚、長度、孟面質量、彎曲度郎查，修磨有缺陷部位。VisualandDimensionalInspection肉眼和尺寸檢查：1.ODtolerance外徑公差：(1%D)2 .WTtolerance壁厚公差：(+12.5%t,-12.5%t)TheWTatanypointofthepipeshallbemorethan87.5%ofnominalwallthickness.在任何部位管子的壁厚都不得低于標稱壁厚的87.5%。WTonpipes

14、endsismeasuredwithmicrometer.WallthicknessmeasuringonpipebodyisperformedbymanualUTforWTcovering3ringsorsectionallalongthepipebodywth6readingsateachsection.菅端壁厚用T分尺測重,管體用竽提超聲測厚儀棚量。3 .Pipebodybenddegree管體彎曲度：0.20%ofthepipelength管長的0.20%Measuredwithataughtline用張緊的線進行測量Pipeendbenddegree管端彎曲度:Shouldnotbe

15、morethan3.0mmin1.2m在1.2m內不人丁3.0mmMeasuredwithastraightbar用直尺測量。Remanence剩磁<30GsRejectorrepairwhenpossible,RemainingWTmeasurement如果可以的話就進行修磨，測量剩余壁厚，修磨/、合格判廢。HCRW+RItemNo.序號ProcessDescriptionorQ.C.Activity過程描述/質量控制措施Frequency頻率Verifying(Document)/Item確認(文件)/項Nonconformityhandling不符合項處理Inspection檢驗I

16、nHouse1方Client客戶Activity活動TPI第二方13Outandinsidesurfaceinspection鋼管內外表面檢查Everypiece逐支Noburrintheend,管端應無毛刺；Checkingsurfaceandinnersideofeachpipe,nocracks,infoldings,evagination,rollingscars,linesetc.TheWTofthedefectivepipesshouldbemorethan-12.5%ofnorminalthicknessafterrepaired.應逐根檢查鋼管內外表面；鋼管內外表面不得有裂紋、

17、內折、外折、軋疤、青線等缺陷；有缺陷經修磨后剩余壁厚/、得小于公稱壁厚的-12.5%;H一WItemNo.序號ProcessDescriptionorQ.C.Activity過程描述/質量控制措施Frequency頻率Verifying(Document)/Item確認(文件)/項Nonconformityhandling不符合項處理Inspection檢驗InHouseJ方Client客戶Activity活動TPI第二方14HydrostaticTest水壓測試100%CHydrostatictestpressureisshowedasfollow水壓試驗壓力按下表所?。篢estinghol

18、dtime:Morethan10seconds,withoutleakage。壓力保持時間/、小于5秒，無滲漏。Re-test,reject,Investigationofthereason重測，判廢H一W+RGrade鋼級OD外徑Testingholdtime保壓時間Seconds秒HydrostaticStandardPressure試驗標準壓力MPaB323.85>55.7ItemNo.序號ProcessDescriptionorQ.C.Activity過程描述/質量控制措施Frequency頻率Verifying(Document)/Item確認(文件)/項Nonconformi

19、tyhandling不符合項處理Inspection檢驗InHouseJ方Client客戶Activity活動TPI第二方15PipeendsEveryBeveledangle:30-35D管端坡口角度：30-35度；H一W+Rprocessandinspection管端加工及檢測piece每支rootface1.60t8nlm坡口鈍邊：1.6=0.8mm；squareness<1.6W端切斜：<1.6mm；pipeendItemNo.序號ProcessDescriptionorQ.C.Activity過程描述/質量控制措施Frequency頻率Verifying(Document

20、)/Item確認(文件)/項Nonconformityhandling不符合項處理Inspection檢驗InHouse1方Client客戶Activity活動TPI第二方16MeasurementofLengthandweight長度和重量的測量100%Measurethelengthaccordingtobuyer'srequirement戶需要測量鋼管長度:生產內部控制Control:1212.05m。Calculationofactuallinearmass.Verificationofdeviationofactuallinearmassversustheoreticalli

21、nearmassiswithinAPItolerance.計算理論重量，質量公差為：米重的±0%范圍內。Otherwiseagreed.除非協(xié)議另有規(guī)定外Re-measure,reject.重新測量Re-measureorre-weightpreviouspipesuntillastacceptablecalibration.重新測量或重新稱重直到前一次合格校樣H一W17Coating,PipebodyMarking噴漆，管體噴標100%Coating:Ascustomerrequest.標識內容：Ascustomerrequest.Recoat重新噴漆Re-mark重新噴標H一WI

22、temNo.序號ProcessDescriptionorQ.C.Activity過程描述/質量控制措施Frequency頻率Verifying(Document)/Item確認(文件)/項Nonconformityhandling不符合項處理Inspection檢驗InHouse1方Client客戶Activity活動TPI第二方18MillCertificate工廠出具質保書Consistencyofinspectionandtestreports匯總檢驗試驗報告等開具產品質保書；blockingofgoodsforshipping禁止發(fā)運H一W+R+CR19Handlingandshipp

23、ing搬運和船運100%PresenceofdamageProtectioninrailcars確認是否后損傷車廂的保護措施Bundle:Looseloading.包裝：散裝Useloadingbeltforloadings,avoiddamagebyhooks.Hookscanbeusedtoloadingpipes,butbothendprotectorsmustbeused.用吊裝帶搬運管子，如果用吊鉤則兩頭需帶保護器。Truckscanbeusedintransporting,butgrassshouldbeputunderpipes.用汽車運輸管子時，應在管子和汽車之間放置緩沖物Pl

24、acebattenbetweenthetruckbodyandpipes.在車廂與管子之間放置木條Rejection,Unloadandre-loadwithadequateprotection判廢，卸貨重新在有保護措施的情況下裝運H一一ItemNo.序號ProcessDescriptionorQ.C.Activity過程描述/質量控制措施Frequency頻率Verifying(Document)/Item確認(文件)/項Nonconformityhandling不符合項處理Inspection檢驗InHouseJ方Client客戶Activity活動TPI第二方20理化檢驗試驗設備Phys

25、icalTestingandtestequipment確保檢驗試驗設備檢定有效，持有有效檢定合格證；包括：光譜分析儀、萬能力學性能試驗機等檢驗設備。Toensuretheeffectivenessofinspectionandtest.Validtestcertificateneeded.Suchequipmentsinclude:spectrumanalyzer,universalmechanicaltestingmachine,impacttestingmachine,lowtemperaturechamber,pulltheslotmachine,projector,metallurgicalmicroscopeH一R21靜水壓試驗機壓力傳感器、水壓力表Hydrostaticpressuretestingmachinepressuresensors