制造工艺与质量控制.doc

Manufacturing Inspection Test Plan制造工艺与质量控制Client : Job No. Clients approval （用户批准）Approved byPlease approve this document by Jiangsu Kailai Steel Tube Co.,Ltd.江苏开来钢管有限公司DateJan 18, 2010 (Rev.0) Approved byChecked byPrepared byManufacturing Inspection Test PlanNoProcess 工艺Equipment & Operation 设备与操作Material Identification 材料标记Quality Control Procedure 质量控帽程序Scheduled date for Customers witness Remark By FWPM1IngotSA210 GR.A1/SA210 GR.C & （fully killed steel ） -SA210 GR.A1/SA210 GR.C 管坯必须是镇静钢 Receiving -收料Identification on the raw material -确保管坯的标记准确Analysis of composition as per China National Standard-按照中国国家标准进行化学成分分析Two specimens of each Heat NO.-每个炉号取个试样“W”microstructure inspection ( Incl -foreign inclusions) as per China National Standard-按照中国国家标准进行低倍检验和非金属夹杂物检验Four specimens of each Heat NO.-每个炉号取个试样Visual and dimension inspection ，and grinding to remove the defect If necessary -,酸洗检查外表商,并根据需要修磨each Bar to be inspected -每支检查2Hot-Piercing-热穿孔Mandrel Shop -穿孔车间Putting traveling card on each Lot ( Heat No) -工艺流转卡标识内容完整Billet Cutting-断料As per work instruction -按照江苏开来钢管作业指导书“W”Control of Furnace temperature-炉温控制Checking and Recording temperature of Piercing-核对并记录穿孔温度piercing穿孔After hot swage ,Checking surface outside and inside condition and dimension热打头后，检查内外表面和尺寸Checking work No. and Heat No. Identification -检查工艺流转卡和炉号标识“W”3Mother tube Inspection -荒管检查Inspection and conditioning by grinder, if necessary -检查，根据需要修磨Putting traveling card process control card for cold-working mill on each lot -完整 的工艺流转卡到冷拔 Visual inspection surface quality-检查荒管的表面质量As per work instruction -按照江苏开来钢管作业指导“W” Recording of Inspection results.-记录检查的结果4Preparation for cold-drawn -冷拔准备Descaling and lubricating -酸洗,磷化和皂化Comparing number of tubes and traveling card-检查对比钢管与流转卡Inspection of surface defect of mother hollow, do the grinding if necessary.酸洗后进行毛管表面检查, 根据需要进行修磨.As per work instruction -按照江苏开来钢管作业指导“W”Control of concentration and temperature of solution and dipping time-酸洗与皂化控制5Cold-drawn-冷拔Cold drawing chain bench- 冷拔机Checking dimension of first three drawings of each lot-遂支检查每吊冷拔钢管的前三支的尺寸, 符合要求方可操作, 操作过程中每吊钢管尺寸再进行抽检.As per work instruction -按照江苏开来钢管作业指导“W”Comparing number of tubes and traveling card-检查对比钢管与流转卡Cold reducing outside diameter and wall thickness passing die and mandrel- 减径与控制钢管壁厚Visual checking of draw tube and drawing tools-外观检查冷拔的钢管和冷拔模具Cold Draw-冷拔6Heat Treatment热处理Controlled atmosphere conditinuous furnace.-可控气氛连续炉Comparing number of tubes and traveling card-检查对比钢管与流转卡Automatic control of furnace temperature-炉温自动控制As per work instruction -按照江苏开来钢管作业指导“W”Heat treatment as per order specification -按照订货钢管进行热处理Checking and recording temperature and feeding speed-检查和记录炉温，以及钢管进炉速度Final heat treatment : Tube SA210 GR.A1/SA210 GR.C shall be normalized. 钢管最终热处理：SA210 GR.A1/SA210 GR.C必须正火；7Testing-试验 Testing required in specification and purchase order-根据规范和定单试验Putting specimen control card on the test specimen-试样标记according to specification and purchase order-按照规范和定单要求As per ASME CODE -按照规范“W”8Straightening-钢管校直Roller type straightening machine-钢管校直机Comparing number of tubes and traveling card-检查对比钢管与流转卡Checking straightness-检查不直度, 按订单/标准进行控制.Each tube to be inspected, straighten if any - 逐支检查、矫直“W”9Eddy current inspection-涡流检测Eddy Current detector-涡流探伤机 Comparing number of tubes and traveling card-检查对比钢管与流转卡 Eddy current inspection-涡流检测As per ASTM E-309 (use through wall holes , The drilled hole diameter should be less than 0.8mm. Or by transverse notch )-按照ASTM E 309 (仅采用穿透孔缺陷,穿透孔直径小于0.8毫米或横向刻槽.“W” / “H” Recording of inspection results-涡流检测记录10Ultrasonic inspection-超声波检查 Ultrasonic detector -超声波探伤机Comparing number of tubes and traveling card-检查对比钢管与流转卡 According to specification-按照规范Use Longitudinal Notches on O.D. & I.D. at 5% notch depth only as per ASTM standard E213.-按照ASTM E 213-（人工缺陷仅采用纵向糟，在内壁（内直径）和外壁（外直径上）刻纵向槽，（其槽深应为指定最小壁厚的5%）“W” / “H” 11Cutting切管Cutting machine-切管机Comparing number of tubes and traveling card-检查对比钢管与流转卡 Checking of cut-length by steel tape at the beginning -卷尺检测钢管的长度As per product standard -按照产品标准。“W” Cutting to the specified length-切管12Final inspection-终检Inspection and conditioning by grinder, if necessary -检查，根据需要修磨Comparing number of tubes and traveling card-检查对比钢管与流转卡 Visual inspection-外观检查As per work instruction and the tube thickness will be checked in four places at each end of finished tube length。100% check and 5% of the result should be recorded -按照江苏开来钢管作业指导, 关于钢管壁厚检测， 每支钢管采用检定合格的游标卡尺对每个端部至少四个方向检测厚度. 100% 检查并作5%检测记录。“W” / “H” Dimensional checking-尺寸检验13Spectrum Analysis光谱检验Spectrum光谱检测机tubes and traveling card-检查对比钢管与流转卡Each number of tubes逐支光谱检查As per work instruction -按照江苏开来钢管作业指导“W”14Sparkle inspection火花检验Pneumatic grinding machinetubes and traveling card-检查对比钢管与流转卡Sparkles inspection controlled by two procedures (Tube ends inspection and packing inspection) 每支火花检验,且经两个工序重复把关 (先端部检验, 最后成品打包时检验)As per work instruction -按照江苏开来钢管作业指导“W”15Coating & Packing-油漆与包装Coating preservative to the outside surface -钢管外表面涂防锈清漆Comparing number of tubes and traveling card-检查对比钢管与流转卡according to specification and purchase order-按照规范和定单要求As per the requirement of PO and ASME CODE -按照规范和订单要求“W” / “H” Each tube ID end plugged by plastic caps-每支钢管两端必须用塑料管帽置入钢管内 Bundled with steel band-钢管采用钢带捆轧16Marking-标记 Paint stencil on eachbundel of tubes-每捆钢管标牌 Checking of marking items-检查标记内容Per the requirement of PO - 按照订单要求“W”17Document and Shipment-文件与发运 CMTR-质量证明书Packing list and weight memo-装箱单和重量记录单As per Purchase order and will also state on the CMTR: We here