制造工艺与质量控制(精)

1、Manufacturing Inspection Test Plan制造工艺与质量控制Client : Job No. Clients approval （用户批准）Approved byPlease approve this document by Jiangsu Kailai Steel Tube Co.,Ltd.江苏开来钢管有限公司DateJan 18, 2010 (Rev.0) Approved byChecked byPrepared byManufacturing Inspection Test PlanNoProcess 工艺Equipment & Operation 设备与操作Material Identification 材料标记Quality Control Procedure 质量控帽程序Scheduled date for Customers witness Remark By FWPM1IngotSA210 GR.A1/SA210 GR.C & （fully killed steel ） -SA210 GR.A1/SA210 GR.C 管坯必须是镇静钢 Rec

2、eiving -收料Identification on the raw material -确保管坯的标记准确Analysis of composition as per China National Standard-按照中国国家标准进行化学成分分析Two specimens of each Heat NO.-每个炉号取个试样“W”microstructure inspection ( Incl -foreign inclusions) as per China National Standard-按照中国国家标准进行低倍检验和非金属夹杂物检验Four specimens of each Heat NO.-每个炉号取个试样Visual and dimension inspection ，and grinding to remove the defect If necessary -,酸洗检查外表商,并根据需要修磨each Bar to be inspected -每支检查2Hot-Piercing-热穿孔Mandrel Shop -穿孔车间Putting traveling card

3、 on each Lot ( Heat No) -工艺流转卡标识内容完整Billet Cutting-断料As per work instruction -按照江苏开来钢管作业指导书“W”Control of Furnace temperature-炉温控制Checking and Recording temperature of Piercing-核对并记录穿孔温度piercing穿孔After hot swage ,Checking surface outside and inside condition and dimension热打头后，检查内外表面和尺寸Checking work No. and Heat No. Identification -检查工艺流转卡和炉号标识“W”3Mother tube Inspection -荒管检查Inspection and conditioning by grinder, if necessary -检查，根据需要修磨Putting traveling card process control card for cold-working

4、mill on each lot -完整 的工艺流转卡到冷拔 Visual inspection surface quality-检查荒管的表面质量As per work instruction -按照江苏开来钢管作业指导“W” Recording of Inspection results.-记录检查的结果4Preparation for cold-drawn -冷拔准备Descaling and lubricating -酸洗,磷化和皂化Comparing number of tubes and traveling card-检查对比钢管与流转卡Inspection of surface defect of mother hollow, do the grinding if necessary.酸洗后进行毛管表面检查, 根据需要进行修磨.As per work instruction -按照江苏开来钢管作业指导“W”Control of concentration and temperature of solution and dipping time-酸洗与皂化控制5Cold-d

5、rawn-冷拔Cold drawing chain bench- 冷拔机Checking dimension of first three drawings of each lot-遂支检查每吊冷拔钢管的前三支的尺寸, 符合要求方可操作, 操作过程中每吊钢管尺寸再进行抽检.As per work instruction -按照江苏开来钢管作业指导“W”Comparing number of tubes and traveling card-检查对比钢管与流转卡Cold reducing outside diameter and wall thickness passing die and mandrel- 减径与控制钢管壁厚Visual checking of draw tube and drawing tools-外观检查冷拔的钢管和冷拔模具Cold Draw-冷拔6Heat Treatment热处理Controlled atmosphere conditinuous furnace.-可控气氛连续炉Comparing number of tubes and traveling ca

6、rd-检查对比钢管与流转卡Automatic control of furnace temperature-炉温自动控制As per work instruction -按照江苏开来钢管作业指导“W”Heat treatment as per order specification -按照订货钢管进行热处理Checking and recording temperature and feeding speed-检查和记录炉温，以及钢管进炉速度Final heat treatment : Tube SA210 GR.A1/SA210 GR.C shall be normalized. 钢管最终热处理：SA210 GR.A1/SA210 GR.C必须正火；7Testing-试验 Testing required in specification and purchase order-根据规范和定单试验Putting specimen control card on the test specimen-试样标记according to specification and purchase o

7、rder-按照规范和定单要求As per ASME CODE -按照规范“W”8Straightening-钢管校直Roller type straightening machine-钢管校直机Comparing number of tubes and traveling card-检查对比钢管与流转卡Checking straightness-检查不直度, 按订单/标准进行控制.Each tube to be inspected, straighten if any - 逐支检查、矫直“W”9Eddy current inspection-涡流检测Eddy Current detector-涡流探伤机 Comparing number of tubes and traveling card-检查对比钢管与流转卡 Eddy current inspection-涡流检测As per ASTM E-309 (use through wall holes , The drilled hole diameter should be less than 0.8mm. Or by transve

8、rse notch )-按照ASTM E 309 (仅采用穿透孔缺陷,穿透孔直径小于0.8毫米或横向刻槽.“W” / “H” Recording of inspection results-涡流检测记录10Ultrasonic inspection-超声波检查 Ultrasonic detector -超声波探伤机Comparing number of tubes and traveling card-检查对比钢管与流转卡 According to specification-按照规范Use Longitudinal Notches on O.D. & I.D. at 5% notch depth only as per ASTM standard E213.-按照ASTM E 213-（人工缺陷仅采用纵向糟，在内壁（内直径）和外壁（外直径上）刻纵向槽，（其槽深应为指定最小壁厚的5%）“W” / “H” 11Cutting切管Cutting machine-切管机Comparing number of tubes and traveling card-检查对比钢管与流转卡 Checking of cut-length by steel tape at the beginning -卷尺检测钢管的长度As per product standard -按照产品标准。“W” Cutting to the specified length-切管12Final inspection-终检Inspection and conditioning by grinder, if necessary -检查，根据需要修磨Comparing number of tubes and traveling card-检查对比钢管与流转卡 Visual inspection-外观检查As per work instruction and the tube thickness will be checked in four places at each end of finished tube length。100% check and 5% of the result should be recorded -按照江苏开来钢管

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