Professional Documents
Culture Documents
MPS 3lpe
MPS 3lpe
7A,to 1'76
Signature Signature :
MPS-CP-18-19-032-01
3 0 A Date (I:NAN) Date (FN/AN)
Manufacturing Procedure Specification (MPS) — 3LPE Coating
WCL-LS-MPS-18-45-01 MANUFACTURING PROCEDURE SPECIFICATION ( LSAW PIPE
0 A
PLANT)
Returned by Specialist Does Collected by
Contractor
Mr
Signature with date
' , Format No. QA/F/021 Rev. 01
Plant Name & Location : External Coating Plant (Anjar Coating Plant), Gujarat, India
Wall
Sr. Item Pipe size OD Qty.
thickness (in i ,, t-a
G i de
No. No. (in mm) In Meters
mm)
1 B1 323.9 7.9 API 5L X70 PSL2 (ERW) 6,038
Pipe Size / Pipe Grade : 2 B2 323.9 9.5 API 5L X70 PSL2 (ERW) 6,038
3 Cl 219.1 7.9 API 5L X56 PSL2 (ERW) 6,300
6 D1 114.3 6.4 API 5L X42 PSL2 (ERW) 2,100
Total 90,492
Manufacturing Spec./ • MEC/S/05/21/014 Rev. 0 Edition 1 Dated Feb 2008 : Specification for 3-Layer
Technical Specification/ : Polyethylene Coating of Linepipes
Reference Documents • PJS No. : MEC/23QC/05/21/M/001/S012A PARTICULAR JOB SPECIFICATION
Revision Record
Rev. Approved by
Description Date Prepared by Reviewed by
No. Welspun Client / TPIA
,---;-:-.„
,
Co4, ,
..
I
"\4ott",
( ,-
1 . 4,1
;
Name of Section-OIL&G
MECON LIMITED/ c-P-i-1
Location-Delhi
Format No. QA/F/021 Rev. 01
WELSPUN CORP
W ELSPU N Document No. MPS/CP/18-19/032/01
Revision 00
Date 31.08.2018
Quality Assurance
Page Page 2 of 10
CONTENTS
•
Clause No. Description Page No.
1.0 Quality policy 03
2.0 Flow chart 04
3.0 Foreword 05
4.0 Coating application 05
5.0 Application and inspection procedure 05
5.1 Purpose 05
5.2 Glossary 05
5.3 References 05
5.4 Responsibility 05
6.0 Coating system requirements 06
6.1 Procedure qualification test 06
7.0 Sequence of operation for 3LPE coating 06
7.1 Bare pipe receiving 06
7.2 Bare pipe inspection at inlet 06
7.3 Preheating 06
7.4 Abrasive blasting 07
7.5 Preheating 07
7.6 Phosphoric acid treatment application 08
7.7 Chromate treatment application 08
8.0 Application station 08
8.1 Fusion bonded epoxy application 08
8.2 Adhesive application 08
8.3 Polyethylene application 08
8.4 Cooling zone 09
9.0 On line inspection station 09
9.1 End cleaning 09
9.2 Holiday test 09
10.0 Lab test 09
11.0 Final inspection 10
12.0 Yard handling and storage 10
Approved by
Prepared by Reviewed by
Client / TPIA
V V WELSPUN CORP
VVELSPU N Document No. MPS/CP/18-19/032/01
Revision 00
7 ' ,, r,i5 ,,,•.:, -.,
Date 31.08.2018
Quality Assurance
Page Page 3 of 10
Welspun Corp Ltd, Anjar, Gujarat, India aims to maintain its leadership position by
embedding the highest Standards of Quality Management System in each segment of
Welded Steel Pipes (SAWL, SAWH, HFW), Hot Pulled Induction Bends and application of
anticorrosion Coating on Pipes and Bends, by using a Process & risk based approach.
• We are committed to:
o Quality; complying with the requirements of applicable National &
International Standards / specification and continual improvement of the
effectiveness of Quality Management System.
o Understand and consistently satisfying the needs & expectations of our
Customers including applicable statuary and regulatory requirements.
o Have transparency to our Customers and their representatives towards
our Quality Systems, Processes and Practices.
o Perform things right the first time, every time.
o Promote the use of the Process and risk based approach.
o Provide communication for the implementation of effective Quality
Management and of conforming to the Quality Management System &
product requirements to all our employees.
o Up gradation of the Technology used in manufacturing, Inspection &
Testing facility through Innovation.
o Ensure that all levels of our management team are held accountable for
preventing problems, constantly seeking opportunities for continual
improvement, and effectively implementing this policy.
o Ensure that the integrity of Quality Management System is maintained
when changes to the Quality management system are planned &
implemented.
o Ensure the integration of the Quality Management System requirements
into the Organization's business process.
o Ensure that the resources needed for the Quality Management System are
available.
o Provide trainings for the development of our employees.
Approved by
Prepared by Reviewed by
Welspun Client / TPIA
---,..-----,
r.,-, . ,I,,),Co,to
/
,111, C.. ■ t---, q,
..
/
,.._ ,.,..........
- -..........----
Tarkesh Rathod Atul Mishra Dr. Smita Kumari
Manager-(QA/QC) AGM-QA/QC GM — (QA/QC)
Format No. QA/F/021 Rey. 01 • •
WELSPUN CORP
V1/ ELSPU N Document No. MPS/CP/18-19/032/01
Revision 00
Date 31.08.2018
Quality Assurance
Page Page 4 of 10
...
we rat
mar4 Sitailiiiii WM 1 ---* Clz:, .-->
ill
BARE =I
El..ow 0 Jr I.V.E.•=1C %
*.9,&471%* „Er,a'.E STATIC N
E _- .7., — 7.•
it tk AA r1
- -,
si
il
I ,
111111111111111111140
MIMES
'-.:,-' =Eli 5... ..: ' .- 7 F.*.C..1::
_.-_ -_-17-7 = N.FAE•Q
P-Thi
I
I uI.
fr- III ,:i“i
- ,,,,E._::, E. S. .3-,Erriv-eve : Ns. . . . . .
-”--._ - _---- : .:_• ,-..:=,....sk.a apw-lcsracir.4
•CrAnAr." .574"-:::: ,, E- - - SYS:1-e, i,,, L161,04 s4
ZONE
Approved by
Prepared by Reviewed by
Welspun Client / TP1A
,;,,tk coko - *-
'1
,..
WELSPUN CORP
VVELSPU N Document No. MPS/CP/18-19/032/01
Revision 00
Date 31.08.2018
Quality Assurance
Page Page 5 of 10
3.0 FOREWORD
Coating plant shall do the 3LPE coating as per Client specification.
Raw material used for 3LPE shall be complying with Client specification requirements.
Application Facilities
5.2 GLOSSARY
5.3 REFERENCES
5.4 RESPONSIBILITY
The Production Manager or his authorized person is responsible for carrying out the
coating process.
Approved by
Prepared by Reviewed by
Welspun Client / TPIA
CO,t0
.f •
.
IC,
i
(---
....------ 4
WELSPUN CORP
WELSF'U N Document No. MPS/CP/18-19/032/01
Revision 00
Date 31.08.2018
Quality Assurance
Page Page 6 of 10
Abrasive blasting is more effective on a dry and hot surface. Preheating of pipes before
abrasive blasting shall be carried out. Heating system is equipped with 2 gas fired oven, of
430000 kcal / h. It can heat up to 100 ton steel per hour and up to 100°C.
Preheating of pipe shall be done at least 65 — 85°C. Pipe Temperature, Relative Humidity,
dew point shall be measured by dew point meter and recorded by QC inspector.
Oxidation of cleaned pipe surface (in term of bluing and other apparent oxide formation is
not acceptable. Proper function of pipe temperature monitoring & recording shall be
shown during PQT stage and during regular production).
Appro ed by
Prepared by Reviewed by
Welspun Client / TPIA
WELSPUN CORP
VVELSPU N Document No. MPS/CP/18-19/032/01
Revision 00
Date 31.08.2018
Quality Assurance
Page Page 7 of 10
Two Abrasive blasting machines are placed one after another. Each machine consists of
two turbines with 50 hp motors.
Each machine is capable to clean up to Sa 2 1/2 (ISO 8501-1) cleanliness.
Each machine is equipped with dust vacuum suction, grit reclaim system, grit sieving &
spent particle removal.
After blasting, pipes are moved to blowout station where all dusts, shots & grits are blown
out from inside pipe surface.
Pipes received at blasting inspection rack are checked for below mentioned parameters in
accordance with ITP.
• Cleanliness : Sa 2 1/2 (ISO 8501-1)
• Roughness : 50 — 70 p.m
• Degree of dust : Rating — 2 or Class — 2 maximum(ISO 8502-3)
• Salt contamination : 2 pg/cm 2 maximum
Surface roughness shall be checked each pipe by stylus method. The surface being coated
shall not be exposed for a length of time that can result in flash rust and under no
circumstance shall the time be more than 4 h.
All the measuring instruments are calibrated and verified in accordance with approved ITP.
Any pipe, which is not meeting the ITP requirement will be marked as "NTC" and sent for
rectification/re-blasting.
After inspection of bare pipe, coupling may be attached on one end of pipe for smooth
coating. The coupling will be slightly heated to make up for the heat loss at the time of
induction heating due to additional thickness of the coupling.
Optionally masking tape shall be applied at both ends for required coating cut back length.
7.5 PREHEATING
Preheating of pipes at 45°-75°C before phosphoric acid application shall be carried out.
Heating system is equipped with two gas-fired oven of 430000 kcal / hr each. It can heat
up to 100-ton steel per hour and up to 100°C.
Approved by
Prepared by Reviewed by
Welspun Client / TPIA
—
.._
7 7
----' 1 /
The phosphoric acid treatment is done after blasting and thereafter rinsed with high
pressure de-mineralized water. The acid application cabinet is equipped with four nozzles
of 1.5 M 3/Hr. capacity. Phosphoric Acid treatment shall be done as per raw material
manufacturer's recommendation.
To enhance the bond strength between the substrate and fusion bonded epoxy layer,
chromate layer is applied using rubber wiper. The pipe temperature before chromate
application shall be 40°-80°C. Chromate application shall be done as per Raw material
manufacturer's recommendation.
Pipes are heated by one induction coils of 2000kw and 600-1500 Hz capacity. Pipe surface
temp is recorded using temperature gauge with roller type probe. The temperature shall
be minimum 190°C or as per epoxy manufacturer's recommendation.
Application of epoxy primer is carried out using 10 electrostatic guns max of capacity 1000
kg/hr (no of guns may vary on thickness requirement).
The system is also equipped with fluidized bed with venture pumps, surplus powder
suction & recycling plant.
The system is equipped with lifting platform. It is provided with vacuum feeding unit and a
hopper neck with heating control unit.
Adhesive Extruder capacity of 150 Kg/Hr.
Adhesive film temperature is measured using digital infrared thermometer.
Approved by
Prepared by Reviewed by
Welspun Client / TPIA
In the cooling zone coated pipe shall be subsequently quenched & cooled in water for a
period which shall sufficiently lower the temp of pipe coating to permit handling &
inspection. This zone is 32 M Long, provided with water distribution system, hydraulic
power units & motors.
Chiller capacity 12 m 3/hr., 75 tr
Cooling water circulation rate 300m 3/hr
Here the thickness of the applied coating is measured by digital thickness gauge.
Inspection checks shall be in accordance with approved ITP.
If any imperfection appears on coating such as coating damage, the pipe is then sent to the
repair bed for rectification.
Brushing machines equipped with 2 electric motors of capacity 60 hp. with adjustable
brush to create bevel to PE.
Brushes to remove coating up to steel and form taper end.
After brushing cutback ends shall be abrading by emery paper, emery disc or mop wheels
for clean the steel surface. Cutback length shall be in accordance with approved ITP.
Each pipe is passed through the holiday ring to check for any discontinuity in coating.
The holiday detector is low pulse D.C. full circle electronic detector with audible & precise
voltage control.
If any holiday observed it is marked and repaired in accordance with approved repair
procedure.
After holiday color codification is given in accordance with approved ITP.
Lab tests on raw materials and coating shall be conducted in accordance with approved
ITP.
Approved by
Prepared by Reviewed by
Welspun Client / TPIA
----
• ' -
col i -----.)
) L. — sir 1 1. - •
WELSPUN CORP
VV ELSF'U N Document No. MPS/CP/18-19/032/W.
Revision 00
Date 31.08.2018
Quality Assurance
Page Page 10 of 10
Approved by
Prepared by Reviewed by
WeIspun Client / TPIA
k .i-Ceo;?<;\\
c..