inspection and test plan for manufacturing pipe from plate

1. Quality Control Plan
(QC-FO-28)
QCP No.: 67-1401-15*1016
Quality Control Plan for Helical Submerged Arc Welded Pipes
Client : … Project Spec. : …
QCP No. : 67-1401-15*1016 Customer : ‫ﺷﺮﮐﺖ‬
‫ﺳﺎز‬ ‫ﭘﻨﺎه‬
‫ا‬
‫ﯾ‬
‫ﺮان‬
Pipe Size(mm) : 1016*15 (OD*Thk) Steel Grade : X60(API-5L 2018)
Date of Issue : 2023.02.15(1401.11.26) Ref. Standard : ASTM-A252(2010)
Scope:This quality control plan defines the process of manufacturing, inspection and repair of Spiral Submerged Arc Welded Pipes piles.
Abbreviations
I (Inspection): Manufacturer indicate any inspection point of the process to assure conformance of the given requirements.
W (Witness Point): client’s inspector to be informed 3 day before starting the task and may proceed with past the witness point, if the client's inspector is not available.
R (Review Document): It is surveillance of a document for the purpose of verifying that an activity conforms the established requirements.
H (Hold Point): Client’s Inspector to be informed 3 working day before starting the task and work shall not be done without witness of Client’s Inspector.
SW(Spot witness): Witness is non- mandatory;the Manufacture shall inform employer incpectorthe start of activity date.the imployer inspector will arrenge to random inspection at
least part of ongoing activity
KSE : Kowsar Sanat Espadana/PNS:Panahsaz IRAN(Client)/TPA:GL(Inspector)/NIOEC:(OWNER)
Note: According to our production scheduled plan, these pipes will be produced in Kowsar Sanat Espadana Factory.
Manufacturer’s QC Manager : Mehdi Ghorbani Client’s Inspector Client’s Consultant

2. Quality Control Plan
(QC-FO-28)
QCP No.: 67-1401-15*1016
1-Steel Coil Inspection and Testing
Document
Responsibility
Inspection Stage
Testing
Frequency
Measuring
Device
Reference
Standard
Acceptance Criteria
Task Name
Description
NIOEC
TPA/PNS
KSE
Mill Test
Certificate
Raw Material
Inspector
R
R
R
Each Coil
Review
API 5L(2018)
EN 10204(2004) Type 3.1
Certificate
Control
(1-1)
Material
inspection
Report
Raw Material
Inspector
R
W
I
Each Coil
Visual
ASTM A635(2004)
Section 13.1
1 Tag attached to each coil
Marking
(1-2)
Visual
Inspection
Report
Raw Material
Inspector
R
W
I
Each Coil
Visual
ASTM A700(1999)
4 Radial &
2 circumferential belt
Bundling
Report
Raw Material
Inspector
R
W
I
Each Coil
Visual
ASTM A635(2004)
Section 9
Coils shall be free of defect, oxide, scale
& oil
Surface
Inspection
Report
Raw Material
Inspector
R
W
I
Each Coil
Ultrasonic
Thickness meter
ASTM A635(1998)
Table A1.2
Min. : 14.7 mm
Max. : 15.3 mm
Thickness
(1-3)
Dimensional
Inspection
Report
Raw Material
Inspector
R
W
I
Each Coil
Steel Tape
Meter
DIN 1016(1986)
Section 5.7
Maximum 60 mm From One Side
Telescopic
Report
Raw Material
Inspector
R
W
I
2 Point of
Each Coil
Steel Tape
Meter
ASTM A635(2004)
Table A1.3
Min. : 1500 mm
Max. : 1538 mm
Width
Mill Test
Certificate
Manufacturer’
s Laboratory
R
R
R
Each Heat
…
API 5L(2018)
Table 4
Max: C:0.25% - Mn:1.4%
P:0.03% -S:0.03%- Nb+V+Ti:0.15%
Chemical
Analysis
(1-4)
Chemical
Properties
Only MTC
Manufacturer’
s Laboratory
R
R
R
Each Heat
…
API 5L(2018)
Table 6
YS: Min. 415 MPa
UTS:Min. 520 MPa
Tensile Test
(1-5)
Mechanical
Properties
…
…
…
…
…
…
…
…
Charpy
V-Notch
Manufacturer’s QC Manager : Mehdi Ghorbani Client’s Inspector Client’s Consultant

3. Quality Control Plan
(QC-FO-28)
QCP No.: 67-1401-15*1016
2-Welding Material Inspection and Testing
Document
Responsibility
Inspection Stage
Testing
Frequency
Measuring
Device
Reference
Standard
Acceptance Criteria
Task Name
Description
NIOEC
TPA/PNS
KSE
Report
Raw Material
Inspector
SW
W
I
Each Pack
Visual
AWS-A5.1(2001)
Section 23 , 24
Shall be suitably packaged
and marked
Marking & Packaging
(2-1)
Shielded Metal
Arc Welding
Electrodes
Report
Raw Material
Inspector
SW
W
I
3 Electrode
of Each Lot
Caliper &
Visual
AWS-A5.1(2001)
Table 12 , Sec 20
Shall be free of defects
Diameter ,Length &
Covering
Mill Test
Certificate
Raw Material
Inspector
R
R
R
Each Lot
Review
AWS-A5.01 &
AWS-A5.1(2001)
EN 10204(2005) Type 3.1
Certificate Control
Mill Test
Certificate
Manufacturer’
s Laboratory
R
R
R
Each Lot
…
AWS-A5.1(2001)
Table 7
Max.: V:0.08%-Si:0.75%
Ni:0.3%-Cr:0.2% -Mo:0.3% -
Mn:1.6%
Weld Metal Analysis
Mill Test
Certificate
Manufacturer’
s Laboratory
R
R
R
Each Lot
…
AWS-A5.1(2001)
Table 3
Average Min.
27 J at -29 °C
Impact Test
Mill Test
Certificate
Manufacturer’
s Laboratory
R
R
R
Each Lot
…
AWS-A5.1(2001)
Table 2
YS: Min 399
UTS: Min 482 MPa
E%: Min: 22%
Tension Test
Report
Raw Material
Inspector
SW
W
I
Each Reel
Visual
AWS-A5.18(2001)
Section 21 , 22
Shall be suitably packaged
and marked
Marking & Packaging
(2-2)
Gas Metal Arc
Welding Wires
Report
Raw Material
Inspector
SW
W
I
Each Reel
Caliper &
Visual
AWS-A5.18(2001)
Section 16 , 17.4
Suitable coating
Diameter & Copper Coating
Mill Test
Certificate
Raw Material
Inspector
R
R
R
Each Lot
Review
AWS-A5.01 &
AWS-A5.18(2001)
EN 10204(2005) Type 3.1
Certificate Control
Mill Test
Certificate
Manufacturer’
s Laboratory
R
R
R
Each Lot
…
AWS-A5.18(2001)
Table 1
C:0.06-0.15%
Si:0.8-1.15%
Mn:1.4-1.85%
Wire Analysis
Manufacturer’s QC Manager : Mehdi Ghorbani Client’s Inspector Client’s Consultant

4. Quality Control Plan
(QC-FO-28)
QCP No.: 67-1401-15*1016
2-Welding Material Inspection and Testing
Document
Responsibility
Inspection Stage
Testing
Frequency
Measuring
Device
Reference
Standard
Acceptance Criteria
Task Name
Description
NIOEC
TPA/PNS
KSE
Report
Raw Material
Inspector
SW
SW
I
Each Reel
Visual
AWS-A5.17(2001)
Section 16.7 , 17.4
Shall be suitably marked
Marking
(2-3)
Submerged Arc
Welding Wire &
Flux
Report
Raw Material
Inspector
SW
SW
I
Each Reel
Visual
AWS-A5.17(2001)
Section 16.6 , 17.3
Suitable Package
Packaging
Report
Raw Material
Inspector
SW
SW
I
Each Reel
Caliper
AWS-A5.17(2001)
Table 8M
Specified: ±0.06 mm
Wire
Diameter
Report
Raw Material
Inspector
SW
SW
I
Each Reel
Visual
AWS-A5.17(2001)
Section 16.2.4
Suitable Coating
Wire Copper
Coating
Mill Test
Certificate
Raw Material
Inspector
R
R
R
Each Lot
Review
AWS-A5.01 & AWS-
A5.17(2001)
EN 10204(2005) Type 3.1
Certificate
Control
Mill Test
Certificate
Manufacturer’s
Laboratory
R
R
R
Each Lot
…
AWS-A5.17(2001)
Table 1
C:0.06-0.15%
Si: Max 0.1%
Mn:0.8-1.25%
Wire
Analysis
Report
Raw Material
Inspector
SW
W
I
Each Lot
Sieve Shaker
DIN 760(1996)
Section 5
According to order & supplier
certificate
Flux Particle
Size
Mill Test
Certificate
Manufacturer’s
Laboratory
R
R
R
Each Lot
…
AWS-A5.17(2001)
Table 5M
YS: Min 400
UTS: 480-660 MPa
E%: Min: 22%
Weld Metal
Tension Test
Mill Test
Certificate
Manufacturer’s
Laboratory
R
R
R
Each Lot
…
AWS-A5.17(2001)
Table 6M
Average Min.
27 J at -40 °C
Weld Metal
Impact Test
Manufacturer’s QC Manager : Mehdi Ghorbani Client’s Inspector Client’s Consultant

5. Quality Control Plan
(QC-FO-28)
QCP No.: 67-1401-15*1016
3-Pipe Production Process
Document
Responsibility
Inspection Stage
Frequency
Reference Standard
Acceptance Criteria
Task Name
Description
NIOEC
TPA/PNS
KSE
Report
Production
Department
SW
W
I
Each Pipe
AWWA-C200(2017)
…
Coil Longitudinal
Edge Trimming
(3-1)
Coil Preparation
Report
Production
Department
SW
W
I
Each Pipe
AWWA-C200(2017)
…
Pipe Forming
(3-2)
Pipe Production
Report
Production
Department
SW
W
I
Each Pipe
AWWA-C200(2017)
…
Pipe Cutting
Report
Production
Department
SW
W
I
Each Skelp End Weld
AWWA-C200(2017)
…
Skelp End Weld
Report
Production
Department
SW
W
I
Defected Pipes
ASME Section IX(2019)
…
SMAW & GMAW
(3-3)
Repair Welding
Report
Production
Department
SW
W
I
Each Pipe
ASME Section IX(2019)
…
Inside & Outside
(3-4)
Spiral Weld Seam
(SAW)
Report
Production
Department
SW
W
I
Each Skelp End Weld
ASME Section IX(2019)
…
Inside & Outside
Outside
(3-5)
Skelp End Weld
Manufacturer’s QC Manager : Mehdi Ghorbani Client’s Inspector Client’s Consultant

6. Quality Control Plan
(QC-FO-28)
QCP No.: 67-1401-15*1016
4-Products Destructive Tests
Document
Responsibility
Inspection Stage
Testing Frequency
Measuring
Device
Reference
Standard
Acceptance Criteria
Task Name
Description
NIOEC
TPA/PNS
KSE
Report
First set of
mecanical
propertice in
3th party
labratory
SW
W
I
One tension test shall be
made on one length or
fraction thereof of each
size, or one piece of skelp
representing
each lot of 200 lengths or
fraction thereof of each
size
SANTAM
600 KN
ASTM-A252(2010)
Section 16.1
UTS: Min. 520 MPa
Transverse Weld
Tensile Test
(4-1)
Mechanical
Properties
Manufacturer’s QC Manager : Mehdi Ghorbani Client’s Inspector Client’s Consultant

7. Quality Control Plan
(QC-FO-28)
QCP No.: 67-1401-15*1016
5-Products Non Destructive Inspection & Testing
Document
Responsibility
Inspection Stage
Testing Frequency
Measuring
Device
Reference
Standard
Acceptance Criteria
Task Name
Description
NIOEC
TPA/
PNS
KSE
Report
Level II VT
Man
SW
W
I
1- Whole of inside &
outside pipe body &
weld seam of each pipe
2-After repair
Cambridge &
V-Wack Gage
ASTM-A252(2010)
Section 14.1
The finished pipe piles shall
be reasonably straight and
shall not contain
imperfections in such
number or of such
character as to render the
pipe unsuitable for pipe piles.
VT Defect
(5-1)
Visual Inspection
Report
Hydro test
operator
R
W
I
Only pipes Have T-Joint
(Min 20% of all pipes)
Hydro tester
AWWA-C200(2017)
Section 5.2.1
Any leak at pressure:
P=15 (Bar)
Holding Time : (30 Sec)
Hydrostatic
Test
(5-2)
Hydrostatic Test
Report
Level II UT
Man
SW
W
I
3 Time per shift
Ultrasonic Flaw
Detector
ASME Section V
Article 5 (2019)
Echo height from 3 mm hole
set on 80% CRT & Threshold
on 50% of CRT
Calibration
(5-3)
Online Ultrasonic
Test
Report
Level II UT
Man
SW
W
I
100% of weld seam
each pipe
Ultrasonic Flaw
Detector
ASME Section VIII
Division 1(2019)
Threshold set on 50% of CRT
Test
Report
Level II UT
Man
SW
W
I
3 Time per shift
Ultrasonic Flaw
Detector
ASME Section V
Article 5 (2019)
…
Calibration
(5-4)
Manual Ultrasonic
Test Report
Level II UT
Man
SW
H
I
1-UT online indication
2-Skelp end weld
3-After repair
Ultrasonic Flaw
Detector
ASME Section VIII
Division 1(2019)
Appendix 12
Paragraph 12-3
1- Crack , LOF , LOP shall be
rejected.
2-any response that exceed
reference level and length
greater 6 mm shall be
consider as defect.
Test
Manufacturer’s QC Manager : Mehdi Ghorbani Client’s Inspector Client’s Consultant

8. Quality Control Plan
(QC-FO-28)
QCP No.: 67-1401-15*1016
6-Products Final Inspection
Document
Responsibility
Inspection Stage
Testing
Frequency
Measuring
Device
Reference
Standard
Acceptance Criteria
Task Name
Description
NIOEC
TPA/PNS
KSE
Report
Final Inspector
SW
W
I
A & B End of Each
Pipe
Circumference
Meter
ASTM-A252(2010)
Section 12.2
Min.: 3160 mm
Max.: 3224 mm
Circumference
of Pipe End
(6-1)
Visual & Dimensional
Inspection
Report
Final Inspector
SW
W
I
Each Pipe
Ultrasonic
Thickness meter
ASTM-A252(2010)
Section 12.3
Min.: 13.125 mm
Thickness of
Pipe Body
Report
Final Inspector
SW
W
I
Each Pipe
Steel Tape
Meter
ASTM-A252(2010)
Section 13.1
Specified: 12000 ±25.4 mm
Single random lengths:4.88
to 7.62 mm, incl
Double random lengths:
over 7.62 m with minimum
average 10.67 m
Length
Report
Final Inspector
SW
W
I
A & B End of Each
Pipe
Steel Tape
Meter
API-5L(2018)
Table 10
Max.: 2% Outside Diameter
Out of
Roundness
Manufacturer’s QC Manager : Mehdi Ghorbani Client’s Inspector Client’s Consultant

9. Quality Control Plan
(QC-FO-28)
QCP No.: 67-1401-15*1016
6-Products Final Inspection
Document
Responsibility
Inspection Stage
Testing
Frequency
Measuring
Device
Reference
Standard
Acceptance Criteria
Task Name
Description
NIOEC
TPA/PNS
KSE
Report
Final
Inspector
SW
W
I
Each Pipe
Cambridge &
V-Wack Gage
API -5L(2018)
Max.: 4.5 mm
Height of Weld
Reinforcement
(6-2)
Visual &
Dimensional
Inspection
Report
Final
Inspector
SW
W
I
A & B End of
Each Pipe
Cambridge &
Caliper
ASTM-
A252(2010)
Section 15.1
Angle:30°+5°
Bevel Angle &
…
Final
Inspector
SW
W
I
Each Pipe
Visual
ASTM-
A252(2010)
Section 22.1
Each length of pipe pile shall be legibly
marked by stenciling, stamping, or rolling
to show manufacturer brand,the outside
diameter, nominal wall thickness
Marking
…
Final
Inspector
SW
W
I
Each Pipe
Visual
AWWA-
C200(2017)
Sec 6.2
Pipe shall be loaded & handled with
proper equipment and in a manner to
prevent damage.
Handling &
Loading
Manufacturer’s QC Manager : Mehdi Ghorbani Client’s Inspector Client’s Consultant

10. Quality Control Plan
(QC-FO-28)
QCP No.: 67-1401-15*1016
7-Documents & Records
Document
Responsibility
Inspection Stage
Task Name
Description
NIOEC
TPA/PNS
KSE
-
Pipe History
System
R
H
I
1. Visual Inspection Report
2. Hydrostatic test procedure
3. UT online & Manual UT test procedure
4. Final Inspection Report
5. NDT Personnel Qualification
6. Welder Qualification
7. Equipment & Instrument Calibration Certificates
8. Raw Material Certificates
9. Destructive Test Report
10. Hydrostatic Test Report
11. Pipe Specification
12. MPS
13. WPS
14. PQR
15. QCP
(7-1)
Final Book
Manufacturer’s QC Manager : Mehdi Ghorbani Client’s Inspector Client’s Consultant