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Ref.

No: ESCL-SOP-015

EGBA SPLIT-CLAMPS LIMITED

Rev. No: 00
Issue Date:12th Nov, 2012

Procedure for Production of


Egba Split-Sleeve Clamps

Page 1 of 11

PROCEDURE FOR PRODUCTION OF


EGBA SPLIT-SLEEVE CLAMPS

APPROVAL AND REVISION STATUS


Rev. No.
00

Issue Date

Revision

12/11/2012

Identification
First Issue

Prepared by

Reviewed

Approved by

Production
Manager

by
QHSE
Manager

Managing
Director

EGBA SPLIT-CLAMPS LIMITED

Ref. No: ESCL-SOP-015


Rev. No: 00

Procedure for Production of


Egba Split-Sleeve Clamps

Issue Date:12th Nov, 2012


Page 2 of 11

CHANGE (S)/AMENDMENT (S)


The change(s)/amendment(s) noted below have been made and approved by the
Managing Director for issue.
Change/Amendment No.

Date

Page

Description of Change/Amendment

EGBA SPLIT-CLAMPS LIMITED

Ref. No: ESCL-SOP-015

Procedure for Production of


Egba Split-Sleeve Clamps

Rev. No: 00
Issue Date:12th Nov, 2012
Page 3 of 11

1.0 PURPOSE
The purpose of this procedure is to outline the sequence, activities and responsibilities in
the production of Egba Split-Sleeve Clamps.
2.0 SCOPE
This procedure is applicable to the production of split-sleeve clamps by ESCL.
3.0

REFERENCES
NIS ISO 9001:2008, Quality Management Systems-Requirements
NIS ISO 9000:2005, Quality Management Systems-Fundamentals and Vocabulary
ESCL Quality Manual (ESCL-QM-001)
ESCL-QSP-004, Control of Nonconforming Product
ESCL-SOP-012, Procurement Control Procedure
ESCL-SOP-014, Materials/Store Control Procedure
ESCL-SOP-016, Work Instruction for Workshop Operators
ESCL-SOP-018, Inspection and Test Procedure for Egba Split-Sleeve Clamps
Form 125, Job Card
Form 126, Certificate of Conformance
Form 127, Client Feedback

4.0 TERMS AND DEFINITIONS


The following terms and definitions and the ones given in ESCL Quality Manual and
NIS ISO 9000:2005 apply.
4.1

ESCL: Egba Split-Clamps Limited

4.2

ISO: International Organization for Standardization

4.3

NIS: Nigerian Industrial Standard.

4.4

Egba: Local name for clamp

5.0

RESPONSIBILITIES AND AUTHORITY

5.1

Managing Director, Production Manager, QHSE Manager: Overall production/project


planning, execution and communication with the client in respective projects.

5.2

Production Manager: Responsibility for the allocation of jobs to the Workshop


personnel.

5.3

Machinists, Welders, Fitters, Painters: Responsible for ensuring that assigned jobs
are undertaken in accordance with associated specification or instructions.

5.4

QHSE Manager: Overall responsibility for QHSE issues in project processes.

EGBA SPLIT-CLAMPS LIMITED

Ref. No: ESCL-SOP-015

Procedure for Production of


Egba Split-Sleeve Clamps

Rev. No: 00
Issue Date:12th Nov, 2012

6.0

PROCEDURE

6.1

Fabrication Process

Page 4 of 11

a) The fabrication process starts from identifying the required pipe size and schedule in
line with the design specifications. As a policy our clamp materials are thicker than the
pipe under repairs.The pipe is then marked out following the clamp dimension;
b) The appropriate pipe class and size is cut to the specified overall length as in Table 1. A
5 mm machining allowance is provided;
c) The pipe is cut into equal halves, realigned and tack welded back before sending for
machining. This is to ensure roundness and dimensional accuracy of the internal bore
and features when opened;
d) The work piece is set concentric to the rotation axis ensuring an accurate alignment on
a Centre Lathe, Vertical Boring Machine or Face Lathe;
e) The face is cleared and squared;
f) The internal surface is then bored to the desired diameter as deep as the long rigid
boring bar can go;
g) The undercut is grooved to the desired width and depth to receive the seal;
h) The ends are chamfered to 300 and all sharp edges are relieved;
i) The work piece is now reversed end to end;
j) The work is now set concentric and square to the already machined diameter and face;
k) Work piece is now faced to final length plus or minus 0.5 mm.
l) Diameter is bored through if necessary;
m) Again, chamfer this second end to 30o;
n) The second undercut is positioned to achieve the specified distance between the two
end seals;
o) All sharp edges are de-burred and the halves are separated and cleaned up.
(See Machining and Welding Drawing of 18x14 and 18x24 Clamps below Fig. 1, Fig 2
and Fig 3).

EGBA SPLIT-CLAMPS LIMITED

Ref. No: ESCL-SOP-015

Procedure for Production of


Egba Split-Sleeve Clamps

Rev. No: 00
Issue Date:12th Nov, 2012

Fig 1

Fig 2

Page 5 of 11

EGBA SPLIT-CLAMPS LIMITED

Ref. No: ESCL-SOP-015

Procedure for Production of


Egba Split-Sleeve Clamps

Rev. No: 00
Issue Date:12th Nov, 2012
Page 6 of 11

Fig 3
6.2

Milling and Cutting Works on Clamp Body


The machined pipe spool is split into two equal halves;

The width and depth of side seals are marked out at the two ends;
The seal positions are milled off/disc cut;
All sharp edges are cleaned up.
6.3

Cutting of Girder Rings and Side Strips


The girder rings are marked out on a mild steel plate of 1.5 mm thickness;
The top and side seal plates are marked out;
The end girder and end plates are now cut as marked out;
All sharp edges are cleaned;
See Drawing of Side Girder Strip below. Fig. 4.

EGBA SPLIT-CLAMPS LIMITED

Ref. No: ESCL-SOP-015

Procedure for Production of


Egba Split-Sleeve Clamps

Rev. No: 00
Issue Date:12th Nov, 2012
Page 7 of 11

Fig 4
6.4

Production of Arms
Special Notes
The material for the clamp arms is mild steel of rectangular cross section.
Clamps between the range of 16 to 24 are fabricated with rigid arms of not less
than 100mm x 100mm. Clamps of 14 overall length and below is fabricated with 3
nos. bolting holes for even stress distribution. Longer clamps of up to 18-24
overall lengths are equipped with 7 nos. bolting holes for same reason. The longer
the clamp, the more numbers of bolting holes for less stress on individual bolts. See
Technical Specification for Egba Split-Clamps.

The arms are cut and milled to specified thicknesses;


The ends are squared to specified length;
Bolt hole positions are marked out from a common datum face;
The arm piece is set up and clamped rigidly for drilling of holes;
The bolt hole drilling is performed gradually and at intervals to avoid drill
breakage and distorted holes;
All sharp corners are de-burred and cleaned.

(See Drawing of Arm. 18x14 Fig. 5).

EGBA SPLIT-CLAMPS LIMITED

Ref. No: ESCL-SOP-015

Procedure for Production of


Egba Split-Sleeve Clamps

Rev. No: 00
Issue Date:12th Nov, 2012
Page 8 of 11

Fig 5
6.5

Assembly

Welding is performed using approved welding procedure specification for


plate and pipe
by certified approved welders in accordance with ASME or AWS.DI.1.
Surface and edge to be welded have standard API mill bevel (smooth, free
from tear, gouge and other discontinuities), which might otherwise affect the
quality or strength of weld. Bevel and surrounding areas shall be clean, free
from moisture, oil, grease, scale, oxide, etc.
Electrodes with hydrogen covering E7018, E6010 are used except otherwise
recommended by the client.
The clamp body and arms are assembled and tack welded. Any misalignment
is corrected to obtain best fit before full welding take place. The steel girders
and eye bolt are welded appropriately.
6.6

General Inspection and Pressure Testing


Production girth welds are subjected to 100% visual inspection. Welds that
do not meet acceptance criteria are repaired in accordance with approved
specification. In addition, dye penetration test is carried out to ensure best
quality weld when required.
Quality control checks are carried out on the assembly before Pressure
Testing at random.
The piece to be pressure tested is clamped over a hole in the pressure
testing device (a pipe with a drilled hole on the surface, representing a
leakage, but has both ends closed).
The clamp size determines the size of testing piece to be used.

Pressure is applied at intervals until it is built up to 1.5 times the maximum


working pressure, held and observed for twenty four (24hrs).

6.7

EGBA SPLIT-CLAMPS LIMITED

Ref. No: ESCL-SOP-015

Procedure for Production of


Egba Split-Sleeve Clamps

Rev. No: 00
Issue Date:12th Nov, 2012
Page 9 of 11

Corrosion Control
All surfaces to be coated are cleaned of all contaminants that may affect the
integrity of the coating system.
Prior to surface preparation, the work pieces is cleaned, using appropriate
solvent cleaning detergent as outlined in SSPC-Sp-1 or NACE equivalent.
Corrosion control include sand blasting (where necessary), power brushing,
application of primer, undercoat and finish coating using appropriate
industrial paint approved for the purpose.

6.8

Coating/Painting
Surface to be coated is clean, dust free and dry before application of any
coat of paint.
The primer is applied as soon as possible after cleaning to avoid rusting,
discoloration or contamination.
Coating is applied under the environmental conditions stipulated by coatings
manufacturers Data Sheet as specified by NACE standard.
Inorganic zinc coating is continuously stirred during
mechanical spray pot agitator or other approved means.

application

by

All coatings is allowed to dry for the minimum time recommended by the
paint manufacturers, before applying the succeeding coat.
Minimum layer thickness of 500um is obtained as recommended.
Coated work pieces are allowed to dry properly before further handling.
6.9

Fixing of Seals
High quality Elastomeric Gasket materials are used for End and Side seals.
For crude oil services to 1200C (2500F), NBR is used. For 1200C 1500C, HNBR
is used. For condensate services, FKM (VITON) is used.
The seal cut to size are held down firmly in the groove with the teeth of the
steel girder to prevent shift when under pressure.

6.10 Identification/Coding
All clamps are coded for easy identification and against piracy and faking.
The identification label or tag includes Product Name, Nominal Size, Serial

Number, Seal Material, Maximum Operating Pressure, and Operating


Temperature.

EGBA SPLIT-CLAMPS LIMITED

Ref. No: ESCL-SOP-015

Procedure for Production of


Egba Split-Sleeve Clamps

Rev. No: 00
Issue Date:12th Nov, 2012
Page 10 of 11

Table 1: Standard Dimensions and Approximate Weight for Short Egba


Split- Sleeve Clamps
API
Pipe
Size

Inside Diameter
A
(Inches)

Inside Length
(Distance b/w
Seals)
B
(Inches)

Overall Length
C
(Inches)

Approx.
Weight
(Pounds)

51/4

81/2

42

71/8

51/4

62

91/8

51/4

10

125

10

111/4

51/2

101/2

147

12

131/4

51/2

101/2

230

14

14 /2

14

385

16

161/2

14

420

18

181/2

14

555

20

201/2

14

580

22

221/2

14

635

24

241/2

14

680

7.0

RECORDS

7.1

Work Order

7.2

Work Execution Plan/Job Card.

7.3

Service Delivery Reports

7.4

Certificate of Conformance

7.5

Client Feedback Record

7.6

Project Change/Deviation Record

7.7

Project HSE Records

EGBA SPLIT-CLAMPS LIMITED

Ref. No: ESCL-SOP-015

Procedure for Production of


Egba Split-Sleeve Clamps

Rev. No: 00
Issue Date:12th Nov, 2012
Page 11 of 11

Appendix: Clamps Production Flow Chart


CLIENT ORDER

PRODUCTION
PLANNING
(MEETING)
PROCUREMENT
JOB CARD

CUTTING
OPERATION

MACHINING
QC
OPERATION

MILLINGQC
PROCESS

CUTTING OF GIRDLE
QC SIDE
RINGS AND
STRIPS

ARMS PRODUCTION
QC

COATING/PAINTING

FIXING OF SEALS
QC

ASSEMBLE
QC
GENERAL
INSPECTION

QC

CODING
QC

CORROSION
QC
CONTROL
PRESSURE TESTING

QC TO
DELIVERY
CLIENT

QC