Visit of company

We submit our forms and then get the permission of

working in the factory. Firstly they introduce us to all
the members and to all the stations and the work
performed at there...
They given the list of all the stations which we have to
visit and collect the information about all that. After the
visit of all the stations we meet the person Mr.
R.S.Khatri sir to know about the Safety procedure of the
company and some rules of the company. While in the
company helmet, nose mask, ear plug, safety shoes,
Goggles etc were compulsory to wear. Without
knowing the thing using that was not allowed...
This company makes the mild-steel pipes of 16 to 80
and more inches of outer diameter. The raw materials
of the company is brought from the other companies,
as per the requirement of the quality of the materials
which the owner wants in there pipe.

COIL INSPECTION AND

IDENTIFICATION
PLATE YARD

Here mild-steel plate or coil is kept which the supplier

supplies with the MTC (material testing certificate).
Then with the MTC material is again tested for the
enquiry of all alloys present in the supplied material, its
strength, amount of energy it can absorb, weather the
material is defected or chances of defect is more on
working etc.

After its certification the real work process of

straightening, forming, cutting, welding, inspection of
coil into the plates started. The quality
of the pipe totally depends on the material brought and
welding done on the pipe.
All the coils are inspected that all the coils of mild-steel
contains heat no., pipe no. , etc. Here scratch, cuts,
cracks, thickness, size etc. The defects which can be
seen through our naked eyes are visualized and then
either corrected if it can be, otherwise the plate is
rejected or it is used in the tab welding. Here cleaning
process of the dust is also done by the Air pressure.

ENTRY LINE
Since in this very compact machines are used and just
a time after, the coils have to pass through the different
forming machines so entry line is provided to these raw
materials for the transformation from coils to the
straight plates. In this firstly the de-coiler is placed then
strip joint, edge miller, edge prebending.

DECOILER
When the coil is brought it is firstly send for the
decoilling, where the pipe is opened and then
straightened, after that the slittering process takes

place, in this process the plate width is fix and the extra
part is cut.

PRE-BENDING
The pre-bending of the pipe is done in order to
straighten the pipe from the edges. A hydraulic press is
fixed which press the pipe from the middle which helps
in securing the pipe. The edge of the pipe is more
severe to the failure which effects the formation of the
pipe.

STRAIGHTENING PRESS
The front section of the plate is send to the rolling
machine which press the plate and straighten the
plate.
The straightness of the plate is very important for
the formation of the pipe, if plate is not straight
then in the spiral rolling of the pipe formation is
very difficult.
It requires more pressure force to convert it into
the pipe.
X=sin1 (w/pi*d)

SLITTER
It helps to maintain the size of the spiral pipe by cutting
through the edges of the pipe. It also straighten the
edges of the pipe

SHEARING

 In this the required length of the pipe is cut by the

shearing process. A huge bed is made after the
shearing machine on that marking of the different
length is done and when the plate reaches to the
required length the heavy load (2000-3000 psi) is
drop on the plate and the plate is cut. After cutting
the coils into the plate the marking is done heat
number, pipe number, customer Name etc.

JOINING PROCESS (WELDING)

AUTO METAL INERT GAS WELDING

AND ITS REPAIRING (MIG)

This welding is done continuously so it is also called

continuous TACK Welding. In this the welding wire is of
same grade as of pipe and of size .6 to 1.2 mm in
diameter. This is done only along the root phase of the
pipe. In this welding the inert gas is used to protect the
pipe from the oxide formation.
Grooves become very close to each other then MIG
welding occurs automatically as it is sets in the

machine. After this the visual inspection is done of the

welding if any defect is found in the welding then it is
corrected manually.
It is done to provide the support for the two main
welding (internal and outer), to fix completely both the
edges of the pipe and become stronger to beer the
pressure.
Current= 450-550 amp
Voltage= 25-35 volt
Selected speed (IPM) = 100-110
After the welding the visual inspection is done of the
welding, in this the defect like narrow bid, under cut,
bid bend, burn through, MIG UP, MIG DOWN etc defect
which can be seen through our naked eyes are checked
and then corrected them manually by the manual
machine.

PLASMA CUTTING
The pipe made here is very long till the end of the
plate so cutting of the pipe is done in the running
of the pipe. Here cutting of the pipe is done by the
plasma which cuts the pipe more accurately while
moving with the pipe.
All the things are automated only a person has to
start the process and end the process. Rest all
things is done by the computer.

TAB WELDING
This welding is done to give better flow to the ID and
OD welding. As from starting the welding is weak so a
TAB is welded to both sides (outer) so only TAB is weak
welded. The size of the TAB is about (900-1500 mm)
and in this TAB also V- groove is made manually by the
workers in the straight line of the pipe.

SMAW WELDING (spiral metal arc

welding)
INTERNAL DIAMETER WELDING (ID)
Firstly the welding is done from the internal side so that
the internal welding can cover the half portion of the
MIG welding and make the welding stronger from
inside. In this welding FLUX is used instead of the inert
gas. The work of the flux is also same as of the gas, to
control the formation of the oxides and to stop the
incoming of the FORIEGN metal, dust etc in the
welding.
All these things are set on the computer wire for
welding, the flow of flux, speed of pipe, current,
voltage, pressure etc. Then the welding of the pipe
started.
Current lead= 650-750 amp
Trail= 625-725 amp
Voltage lead= 25-35 volt
Trail= 35-45 volt

Selected speed (IPM) = 45-55.

This welding is done with the help of two wire of the
size 3.2 mm of the diameter from the TAB. A grinder
size disk is fixed in the middle which moves in the Vshape groove and a camera is focused in this groove so
that the disk is in the groove line and the welding done
is in the groove only. This groove is always seen in the
computer screen if any misalignment happened then it
is again set on the groove line.
OUTER DIAMETER WELDING (OD)

In this also two wires is attached and welding is done,

all things are set in the computer and the welding

starts from the TAB. All equipments are same as in the

ID welding except the amount of current, voltage,
speed etc. In this,
Current lead= 850-950 amp
Trail= 625-725 amp
Voltage lead= 30-40 volt
Trail= 35-45 volt
Selected speed (IPM) = 45-55
After completing the welding again its visual inspection
is done on both sides internal and outer. A man sits on
the scatting board with the light and chalk in the hand,
where ever he find the defect he mark it there after
that its correction is done by them internally.
In the OD also the defects are checked and then
corrected manually by the employees all the defects
are marked by the no., which they categorise in the
different groups.

INTERMEDIATE ULTRASONIC TEST (IUT)

Here only the welding area is checked. The different
defects like LOP (lack of penetration), LOF (lack of
fusion), UNDER FILL, CHAIN POROSITY, CLUSTER
POROSITY, INSIDE CRACKS, etc are known through this
machine. Where it indicates the defect there different
colour is sprayed by the machine itself it is
automatically sets in the computer. Then with the help

of the manual machine the defect is confirmed, is there

actually any defect or not!
If the defect is confirmed then the pipe is send for the
X-RAY to confirm the type of defect on which area the
defect is actually present. After that the report is shown
to the TPI (THIRD PARTY INSPECTION) with his
permission the repairing is done on the pipe.

X-RAY
Its films are imported from the other countries
BELGIUM, GERMANY etc. These films are kept in the
cold place temperature less than 22 degree Celsius
because if these films are kept at more temperature
then it might expose and melt, so the films cannot be
developed. The thickness of the film is .125 mm and
these films are of, both the side emulsion which means
for the radiation the film can be kept of any side. For
the correct radiation on the film the distance between
the film and the focus of the radiation machine must be
less, here it is around 700 mm. The focal spot size is
5.5 mm. The expose time of the film of D7 and D8 quite
fast, the D2 film is the slowest film to expose in the
radiation, it take 16 times than the D7 to expose in the
radiation. No person is allowed to be in the cabin of the
radiation because X-rays light are very dangerous for
the body; it can cause cancer to our body and some
other physical effect to our body.

END FACER

In this the ends of the pipe is tapered with the bevel

angle (30-45 degree) and with the Root face of 2.4 mm
or as per the requirement. When the two pipes end is
joined it again makes the V-Groove for the welding.

SQUARENESS TESTING
This test is done with the help of the pendulum. The
string is attached to the upper root face and for the
stillness of the pendulum in the bottom side the fluid is
kept; now the distance between the lower side of the
string from the lower end of the pipe is measured. For
complete square, the gap between the string and the
lower end of the pipe must be very less.

MAGNETIC PARTICLE INSPECTION (MPI)

This test is done on the bevel angle and the root phase
of the pipe. In this test a square board is set and in its
middle a circular iron metal is fitted on which the coils
of wire are rotated to produce the magnetic flux. The
iron particles made solution is sprayed on the edges of
the pipe then an opaque glass which is made one side
defected and this defect can only be seen in the U.V.
Rays after the reflection from the ends of the pipe. If
the defect is seen then the pipe is up to the mark
otherwise there is a chance of some defects. After this
with the help of the MAGNAFLUX the magnetic flux in
the pipe is checked. If the pointer is on the zero then
there is no defect in the pipe, if there is a change in the
flux then there is a defect present in the pipe which is
perpendicular to this device.

FINAL ULTRASONIC TEST (FUT)

This test is done only on the welding bid. With the help
of 3 cameras and 16 probes (as per requirement the
cameras and the probes can be increase) the welding
area is accurately checked that it is not defected. The
defects like LOP, LOF, chain porosity, cluster porosity,
inclusion and lamination etc are checked. If these
defects are not found then it is passed to the other
station, if any defect is found then it is checked by the
manual machine if this also indicates then it is again
send for the X-Rays (Radiography), for the confirmation
of the defects.

X-RAYS (RADIOGRAPHY)
If there is no indication of the defect by the FUT then
only on the outer side of the pipe (900 mm) X-Ray is
done. If there is an indication of the defects on the pipe
then on that area also X-Ray is done just for the
confirmation. If the X-Rays indicates the any kind of
defect which is not in the criteria of acceptance then
the pipe is rejected.
Otherwise it is shown to the TPI with his approval the
pipe is continue to the finishing, and despatch.

DIFFERENT TYPES OF WELDING

DEFECTS -:
1.) Porosity- - ->|chain porosity
- - ->| cluster porosity

2.) LOP= lack of penetration

3) A.)KEY HOLE

3) LOF= lack of fusion

4) Burnt through

5) Undercut

6) HAZ= heat affected zone

7) Gas inclusion

8) Bid bend
9) Narrow bid
10) Deflection of arc

REMEDIES OF SOME DEFECTS

END MANUAL ULTRASONIC TEST (MUT)

As the ends of the pipe are not able to be tested by the

automatic UT, so it is done manually to know the defect
which can be present on the ends. It is done about
(200-400 mm) on the outer ends of the pipe, if any
defect is found then to remove that defect a circular
ring of the pipe is cut down. The rest portion of the pipe
is send for the approval and then despatch.

FINAL VISUAL INSPECTION

Here pipe is only visually checked for the any kind of
defects like dents, cracks etc. The thickness,
circumference, length, bid of the welding part both
internal and outer, under cut, narrow bid etc are again
checked. The length, circumference, thickness of the
pipe are written on the pipe and in the last the bevel
protector is attached on the pipe then it is despatch
from the company or send for the transportation to the
ports.

HYDRO TESTING

In this both outer side of the pipe is fixed in the

hydro testing machine then the rubber valve is
fixed on its outer part. After doing this the water is
passed in the pipe and the pressure of water is
created in the pipe after creating the pressure it is
kept on that pressure for 10 sec or as per demand
or requirement. If any leakage is in the pipe then
the pressure will automatically fall down and the
defect is recorded.
OPERATION:
After the expansion, take the pipe b/w the test
heads.
Start medium pressure and filling pumps.
Move ram forward forcing pipe over both tapered
rings until ram movement stops.
Fill the pipe with water until the air is escaping
from the pipe, then seal the pipe.

 Close vent valve and begin test cycle. Start power

pack and adjust the pressure accordingly.
When test pressure reaches, preset pressure hold
for specified period as per the process chart.
Observe the pressure drops in the pressure gauge
and the data recorder.
After specified period the pressure is released
automatically.
Back off ram until pipe is clear of taper rings.
Wait for water to stop flowing from the pipe and
kick pipe out of the tester.
Apply the status indicator.
The pipe that shows leakage\burst will be
segregated and a NCR is raised.

Its procedure is: The completed bend after welding the dished end
is placed on wooden saddles with weld seam on
the top.
Vent pipe for air removal is connected at the high
point on one dished end.
Bend is filled with water at ambient temperature.
Pressure is increased up to the specified pressure
by a water pump and then weighted accumulator is
used to adjust the pressure.
Applied pressure is held for specified period.

 Pressure is released with pressure release valve.

RECORDING Pressure shall be measured by a calibrated pressure

gauge and recorded in the hydro test report.

RESPONSIBILITY
The responsibility of the work done here is, of the
Supervisor and Operator for Operation and
Maintenance.
Since there is no option of repairing of the pipe after
the EXPANDER and HYDRO test. So the defected pipe is
rejected.

END FACER
In this the ends of the pipe is tapered with the bevel
angle (30-45 degree) and with the Root face of 2.4 mm
or as per the requirement. When the two pipes end is
joined it again makes the V-Groove for the welding.

END MANUAL ULTRASONIC TEST

(MUT)
As the ends of the pipe are not able to be tested by the
automatic UT, so it is done manually to know the defect
which can be present on the ends. It is done about
(200-400 mm) on the outer ends of the pipe, if any
defect is found then to remove that defect a circular
ring of the pipe is cut down. The rest portion of the pipe
is sending for the approval and then despatch.

FINAL VISUAL INSPECTION

Here pipe is only visually checked for the any kind
of defects like dents, cracks etc. The thickness,
circumference, length, bid of the welding part both
internal and outer, under cut, narrow bid etc are
again checked. The length, circumference,
thickness of the pipe are written on the pipe and in
the last the bevel protector is attached on the pipe
then it is despatch from the company or send for

the transportation through the ports to the real

owner.
The company also gives the guarantee of the
welding of the pipe. If anything happens to the
welding in the given year then it is the
responsibility of the company and the company
have to replace the entire pipe with the new one
with the compensation.

QUALITY ASSURANCE
The products manufactured in this company are of
very good quality. This company assures the buyer
that the product he buys from this company is
manufactured with the details the buyer provided
and the product will with stand in their conditions.
The buyer can surely continue his work without any
problems in the product which he buys.

QUALITY CONTROL
The third party inspection (TPI) is appointed by the
buyer so that he is assured that the manufacturing
of the product is continued under the guidelines
which they provided. He is given the full power of
stopping the manufacturing process, and without
his sign the finish Goods are not accepted.

QUALITY SYSTEM
This ensures that by following which standards the
product is manufactured. This whole system
depends on the 4 major parts: Plan
Do
Check
Act

NACE TESTING & METALLOGRAPHY

For the safety procedure gas mask and oxygen cylinders

are used.

 In this lab different solutions are made by dissolving in the

water.
PH of the solution is test by the help of the PH-meter. On
this lab two types of test are performed: SSCC (Sulphide stress corrosion cavity) test.
HIC (Hydrogen induce cracking) test.

Four points bend test: The metal strip of size 16-20cm in length and 5-8 cm in
width is cut from the pipe.
Then the whole set-up is placed in the steel cylinder in
which it is highly pressurized by passing in it H 2S gas.
This test is performed for 92 hrs or as per demand of the
customers.
This test proves the quality of the material and its chance
of survival to that place, it also tells the strength of the
materials.

HIC test Hydrogen induced cracking test

This test is performed for 92hrs or 3months or as per the
demand of the customers.
In this test H2S gas passed through all the different vessels
containing different solutions.
H2S gas is highly poisonous and reactive gases present in
the sour water or in the ocean, which reacts quickly with
metals.
The metal strip is corroded, if the corrosion present on the
metal surface is in accurate amount as per the demand of

the customer then the material is passed from this test

and gets certified. Now the material can be taken in the
process of production.

MECHANICAL MAINTENANCE
For hydraulic In this any problem regarding the
hydraulic pressure is solved. In this the main
problem occurs in the direction of the fluid flow and
chock out occurs and to control or solve this
problem pilot pump is also fitted so that High
pressure is created to the pump and fluid pressure
could not be reversed and its viscosity is
maintained so that high force can be created to the
piston for the movements and very high force is
also created for forming purpose and its piston is
checked for the different force and dies are
maintained in its original shape and position.
Different parts are also checked by the employees,
if any part is found to be damaged then its
dimension and shape is send to the workshop for
manufacturing it after that damaged part is
replaced.
Pneumatic In this air pressure is created. Firstly
the Air is suck from the atmosphere then it is send
to the low power turbine then this air is passed
through the inter-cooler and then move to the high
pressure turbine and compressor then its
temperature and pressure is checked and safety
valve is used to control the pressure and this

pressure is stored in the tank. This stored Air is

again distributed to the different-different stations
and used for the different work of force and pipe
transferring.
Before starting the machine its every part is first
checked from nuts to the bolts, its wings, working
tools and its working parts etc.

RESULT AND DISCUSSIONS: The whole process in the complete formation of the
pipe starts from the shearing operation, after that
forming operations takes place after its visual
inspection, the welding operation is done on the
plate. After that the quality of the welding is
checked by the help of the different testings
performed on that.
After passing all the tests and inspections and the
clearance from the Third party inspection who is

appointed from the customer side the final product

i.e. pipe is supplied to the customer.

Conclusion: For the complete formation of the product, the raw

material have to pass all the tests then through the
entire machines from cutting to the forming then
welding then inspections by both machines and
men. Finally the finished product is transported to
the customer for whatever purpose of their
requirement they can use it. The product
guarantee is taken by the company according to
conditions which it would have to face there. Then
the final product is supplied to the customer.
Manufacturing science 1--- Er. K.M.MOID

 Manufacturing technology 2--- Er. R.K.Rajput

Material science--- Mr. O.P.Khanna
Welding Technology--- Mr. O.P.Khanna
Production Technology--- Mr. R.S.KURMI, K.M.GUPTA ...