无缝钢管检验试验计划

1、INSPECTIONANDTESTPLAN检验及试验计划CUSTOMER客户：FORP.O.NO.订单号：5100103644/UD63056536PRODUCT产品：ITEMNO.项目号DESCRIPTION描述LENGTH长度CONTRACTQTY(PCS)合同数量(支)0001112.75”*0.25inchASTMA53GR.BSEAMLESSLINEPIPE无缝管1000CM28ApplicableSpecifications适用规范ASTMA53-2012STANDARDSPECIFICATIONFORPIPESTELLBLACKANDHOT-DIPPED,ZINC-COATED,

2、WELDANDSEAMLESSValidity后效期:3年Durationofthecontract合同期：年Rev.NoReasonsOriginatedDate日期Checked审核Date日期Approved批准Date日期Draft0王利男2013.03.09r代鹏程邵明珠Draft1Draft2ItemNo.序号ProcessDescriptionorQ.C.Activity过程描述/质量控制措施Frequency频率Verifying(Document)/Item确认(文件)/项Nonconformityhandling不符合项处理Inspection检验InHouse1方Clie

3、nt客户Activity活动TPI第二力General总体Workingshiftreportshallberecordedateachitem.每一工序要有每班记录一一一1Orderreview订单审核Eachorder每一订单Sales,Technical,QualityandPlanningDepartments,Reviewofcontract.销售、技术、质量进行合同评审合同变更时应重新进行评审Negotiatewithcustomer与客户商议H一一2Internalorderissuance内部计划单发放Fileforeveryorder每一订单归档Contractrequire

4、mentstransferredtointernalorder合同要求包含于内部计划单Re-issuance重新发放H一一ItemNo.序号ProcessDescriptionorQ.C.Activity过程描述/质量控制措施Frequency频率Verifying(Document)/Item确认(文件)/项Nonconformityhandling不符合项处理Inspection检验InHouseJ方Client客户Activity活动TPI第二方3HeatAnalysis熔炼分析1/batch1/每炉钢ProductanalysisadoptsChemicalSpectrometryan

5、alysis,whichisinaccordancewiththechemicalrequirements.Workoutthecarbonequivalentaccordingtoproductanalysisreport.化学光谱分析，熔炼成分符合化学成分要求。Changethematerial更换材料H一W4RawMaterial原材料1/batch每炉Rawmaterialsguaranteecertificate质保书Retesttomaterialqualified,复检至合格，材质合格H一R5BilletInspectionandCutting管坯检验及下料Everyheat每炉

6、100%HeatNo.,materialNo.,Length(identificationStencilorstamp)materialcertificate,surfacequality炉号，钢号，长度，表面质量Paperreport书面t己录Repairorreject返修或判废H一R6Heatingincircularfurnace环形炉加热炉Accordingtoheatingschedule依照加热制度执行H一RItemNo.序号ProcessDescriptionorQ.C.Activity过程描述/质量控制措施Frequency频率Verifying（Document）/Item

7、确认（文件）/项Nonconformityhandling不符合项处理Inspection检验InHouseJ方Client客户Activity活动TPI第二方7Piercing,hotrolling穿孔，轧制8hourspershift每班8小时Surfacecheckingofthemandrel检查芯棒的表面质量H一R8Slight-stretchreduction微张力减径Accordingtositeconditions根据现场情况ODandWTchecking检验外径及壁厚尺寸H一R9Samplingforpipebody管体取样2perlotof200pcs2/批（200支）Ma

8、ketwospecimensforeachlotofsamplesandmarkfurnacebatchNo.onthem.(Sample,markandstampaccordingtoAPT5Lstandard.)每组试样做成两个试片并且在试样上用记号笔标明具体炉批号(做标记及做钢印，钢印做批号的后两位)Takenewsamples另取样H一WItemNo.序号ProcessDescriptionorQ.C.Activity过程描述/质量控制措施Frequency频率Verifying（Document）/Item确认（文件）/项Nonconformityhandling不符合项处理Insp

9、ection检验InHouse1方Client客户Activity活动TPI第二方10ChemicalAnalysis产品化学分析2/heat2/炉ProductanalysisadoptsChemicalSpectrometryanalysis,whichisinaccordancewiththechemicalrequirements.产品分析采用化学光谱分析法；必须符合化学成分表的要求；Re-test,reject重测，判废H一W+RChemicalRequirement化学成分要求（Weight重量）Grade钢级ChemicalAnalysis化学成分CSiMnPSCrMoVBmin

10、max0.301.200.050.0450.400.150.08BCuNiminmax0.400.40注：Cu+Ni+Cr+Mo+V1.00%ItemNo.序号ProcessDescriptionorQ.C.Activity过程描述/质量控制措施Frequency频率Verifying(Document)/Item确认(文件)/项Nonconformityhandling不符合项处理Inspection检验InHouse1方Client客户Activity活动TPI第二方11MechanicalTesting机械性能测试Tensile(拉伸)flatteningtest压扁试验2/Lot每批取

11、两个试样进行试验1/batch每批取一个试样Tensiletestisshowedasfollows:板状试样Stripsample伸测试见卜表Re-test,re-heattreatment加倍重测；或判废H一W+R屈服(Rt0.5)>240抗拉强度Rm>415伸长率AE>30压扁要求：至H距离/=(!+l/D)式中H二压板间距，irU注4);单位长度变形量(与钢种级别相应的常数，A级为0.09出级为0.07)：£=规定壁厚，in.(mm);D二规定外径in.(mm)0ItemNo.序号ProcessDescriptionorQ.C.Activity过程描述/质量

12、控制措施Frequency频率Verifying(Document)/Item确认(文件)/项Nonconformityhandling不符合项处理Inspection检验InHouse1方Client客户Activity活动TPI第二方12NonDestructiveInspectionforpipebody(MFLL4)尺寸检验和外观检查100%Beginningeveryshift每班的开始WTofallpipeendsmeasuredbymicrometer,allpipebodiesbymanualultrasonic.所有的管子两端测壁厚用千分尺，管体中间用手动超声测厚。Finis

13、hedpipeODWTlength、surfacequality、Straightness,polishingthedefectedpipe成品管外径、壁厚、长度、孟面质量、弯曲度郎查，修磨有缺陷部位。VisualandDimensionalInspection肉眼和尺寸检查：1.ODtolerance外径公差：(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标称壁厚的87.5%。WTonpipes

14、endsismeasuredwithmicrometer.WallthicknessmeasuringonpipebodyisperformedbymanualUTforWTcovering3ringsorsectionallalongthepipebodywth6readingsateachsection.菅端壁厚用T分尺测重,管体用竽提超声测厚仪棚量。3 .Pipebodybenddegree管体弯曲度：0.20%ofthepipelength管长的0.20%Measuredwithataughtline用张紧的线进行测量Pipeendbenddegree管端弯曲度:Shouldnotbe

15、morethan3.0mmin1.2m在1.2m内不人丁3.0mmMeasuredwithastraightbar用直尺测量。Remanence剩磁<30GsRejectorrepairwhenpossible,RemainingWTmeasurement如果可以的话就进行修磨，测量剩余壁厚，修磨/、合格判废。HCRW+RItemNo.序号ProcessDescriptionorQ.C.Activity过程描述/质量控制措施Frequency频率Verifying(Document)/Item确认(文件)/项Nonconformityhandling不符合项处理Inspection检验I

16、nHouse1方Client客户Activity活动TPI第二方13Outandinsidesurfaceinspection钢管内外表面检查Everypiece逐支Noburrintheend,管端应无毛刺；Checkingsurfaceandinnersideofeachpipe,nocracks,infoldings,evagination,rollingscars,linesetc.TheWTofthedefectivepipesshouldbemorethan-12.5%ofnorminalthicknessafterrepaired.应逐根检查钢管内外表面；钢管内外表面不得有裂纹、

17、内折、外折、轧疤、青线等缺陷；有缺陷经修磨后剩余壁厚/、得小于公称壁厚的-12.5%;H一WItemNo.序号ProcessDescriptionorQ.C.Activity过程描述/质量控制措施Frequency频率Verifying(Document)/Item确认(文件)/项Nonconformityhandling不符合项处理Inspection检验InHouseJ方Client客户Activity活动TPI第二方14HydrostaticTest水压测试100%CHydrostatictestpressureisshowedasfollow水压试验压力按下表所小：Testinghol

18、dtime:Morethan10seconds,withoutleakage。压力保持时间/、小于5秒，无渗漏。Re-test,reject,Investigationofthereason重测，判废H一W+RGrade钢级OD外径Testingholdtime保压时间Seconds秒HydrostaticStandardPressure试验标准压力MPaB323.85>55.7ItemNo.序号ProcessDescriptionorQ.C.Activity过程描述/质量控制措施Frequency频率Verifying(Document)/Item确认(文件)/项Nonconformi

19、tyhandling不符合项处理Inspection检验InHouseJ方Client客户Activity活动TPI第二方15PipeendsEveryBeveledangle:30-35D管端坡口角度：30-35度；H一W+Rprocessandinspection管端加工及检测piece每支rootface1.60t8nlm坡口钝边：1.6=0.8mm；squareness<1.6W端切斜：<1.6mm；pipeendItemNo.序号ProcessDescriptionorQ.C.Activity过程描述/质量控制措施Frequency频率Verifying(Document

20、)/Item确认(文件)/项Nonconformityhandling不符合项处理Inspection检验InHouse1方Client客户Activity活动TPI第二方16MeasurementofLengthandweight长度和重量的测量100%Measurethelengthaccordingtobuyer'srequirement户需要测量钢管长度:生产内部控制Control:1212.05m。Calculationofactuallinearmass.Verificationofdeviationofactuallinearmassversustheoreticalli

21、nearmassiswithinAPItolerance.计算理论重量，质量公差为：米重的±0%范围内。Otherwiseagreed.除非协议另有规定外Re-measure,reject.重新测量Re-measureorre-weightpreviouspipesuntillastacceptablecalibration.重新测量或重新称重直到前一次合格校样H一W17Coating,PipebodyMarking喷漆，管体喷标100%Coating:Ascustomerrequest.标识内容：Ascustomerrequest.Recoat重新喷漆Re-mark重新喷标H一WI

22、temNo.序号ProcessDescriptionorQ.C.Activity过程描述/质量控制措施Frequency频率Verifying(Document)/Item确认(文件)/项Nonconformityhandling不符合项处理Inspection检验InHouse1方Client客户Activity活动TPI第二方18MillCertificate工厂出具质保书Consistencyofinspectionandtestreports汇总检验试验报告等开具产品质保书；blockingofgoodsforshipping禁止发运H一W+R+CR19Handlingandshipp

23、ing搬运和船运100%PresenceofdamageProtectioninrailcars确认是否后损伤车厢的保护措施Bundle:Looseloading.包装：散装Useloadingbeltforloadings,avoiddamagebyhooks.Hookscanbeusedtoloadingpipes,butbothendprotectorsmustbeused.用吊装带搬运管子，如果用吊钩则两头需带保护器。Truckscanbeusedintransporting,butgrassshouldbeputunderpipes.用汽车运输管子时，应在管子和汽车之间放置缓冲物Pl

24、acebattenbetweenthetruckbodyandpipes.在车厢与管子之间放置木条Rejection,Unloadandre-loadwithadequateprotection判废，卸货重新在有保护措施的情况下装运H一一ItemNo.序号ProcessDescriptionorQ.C.Activity过程描述/质量控制措施Frequency频率Verifying(Document)/Item确认(文件)/项Nonconformityhandling不符合项处理Inspection检验InHouseJ方Client客户Activity活动TPI第二方20理化检验试验设备Phys

25、icalTestingandtestequipment确保检验试验设备检定有效，持有有效检定合格证；包括：光谱分析仪、万能力学性能试验机等检验设备。Toensuretheeffectivenessofinspectionandtest.Validtestcertificateneeded.Suchequipmentsinclude:spectrumanalyzer,universalmechanicaltestingmachine,impacttestingmachine,lowtemperaturechamber,pulltheslotmachine,projector,metallurgicalmicroscopeH一R21静水压试验机压力传感器、水压力表Hydrostaticpressuretestingmachinepressuresensors