QA&QC Activities for Manufacturing Procedure For the butt weld fitting -Based on DNV.GL Report

Transcription

1 QA&QC Activities for Manufacturing Procedure For the butt weld fitting -Based on DNV.GL Report (Pipeline Fittings Quality Assurance Technical Paper, PP179886) 1 As of Jun 28, 2017

2 Quality Policy 2 Transparency 透明性 -All manufacturing process shall be clearly transparent Quality Culture 品質文化 (*) -TK shall build his own quality culture Quality TK Corp Traceability 追跡性 -All manufacturing process shall be traceable Jump TK (*) Quality culture building campaign co-work with JGC, Japanese EPC Investment 投資 -Continuous investment can ensure continuous quality improvement Training 敎育訓鍊 -All TK members shall be regularly & properly trained & educated

3 Case Summary 3 National Energy Board Amended Safety Advisory NEB SA A2 TK Corporation Fittings Case In September 2012, a fitting manufactured by TK Corporation (TK) was deformed during a hydrostatic test conducted by a pipeline operator at a pump station on a provincially regulated pipeline. As a result, further testing was conducted on additional TK manufactured fittings which resulted in the pipeline operator being unable to identify which fittings potentially did not meet specifications. An engineering assessment was conducted to determine the criteria for replacing over 400 of the fittings. The pipeline operator that discovered the issue advised other pipeline operators and instituted revisions to internal engineering standards as well as quality assurance procedures. In addition, manufacturers and distributors were provided with improved guidance on the operator s requirements for materials. The Board has been informed by TK that once it learned of the hydrostatic test failure, it conducted an investigation into the manufacturing process of its high strength welded fittings and, based upon its findings, it made improvements to its equipment, starting materials and quality assurance programs. TK also confirmed to the Board that it is committed to protecting public safety.

4 4 1. Traceability (para 5.4 Manufacturing Traceability) Current industry standards do not require traceability of raw materials such as slabs, plates and welding consumables (Para5.8 Inspection and Testing Enhancements) Mandate traceability to clearly track each fitting from raw material to finished goods. Activities for Traceability in TK Corporation To enhance traceability, TK has maintained below activities 1) Raw material Receiving Inspection TK s Receiving Inspection Manager gives HCN (Heat Code Number) to each raw material in addition to Raw material s Heat Number. HCN will be put on each size (O.D & Wall thickness respectively) per each Raw material s Heat Number. 2) In-process from Cutting (1) Color coding (2) Identification Marking with low stress die stamp Material Symbol+ Raw Material Heat No. + Traveler Card No. (Bar code No.) (3) Highlight with paint or paint marker (4) Bar code label and Work Instruction (traveler card) (5) Consecutive marking has been done to L6, L650, P9, P11, X65 and others since September of 2012

5 5 Big Color coding notice boards are posted in many places(size : 1.2m x 1.8m).

6 6 No Process Picture Identification Method Cutting raw material 3 4 Identification Marking Rolling Fit up & Welding Before forming TK gives clear identification marking (low stress die stamp) from cutting process of raw material 1 Identification Marking with low stress die stamp Material Symbol+ Raw Material Heat No. + Traveler Card No. (Bar code No.) 2 Highlight with paint or paint marker 3 Color coding 4 Bar code label or work instruction(traveler card) 5 Consecutive marking has been done to L6, L650, P9, P11, X65 and others since September of 2012 Note) 1) Bar code label shall be attached on each single piece of fitting. 2) In case of L6 or higher grade CS or AS, additional consecutive marking is required as L6, L650, P11, P9, X65 and others. 3) Other markings: RT No, Welder ID, MT Operator ID, AV(Alloy Verification)

7 7 Job No. Item Material Dimension Customer name Delivery Current progress Weight & Quantity Project title Color coding NDE Remaining days Barcode Barcode number / date of issue

8 8 2. Materials Verification (para 5.6 of Technical Paper, Para 5.8) -Quality safeguards within industry standards are insufficient to identify all potential issues, and the use of sample coupons and/or testing of starting material may not accurately represent the properties of finished products. -Conduct destructive tests of finished components to verify the accuracy of coupon tests. To ensure accurately represent the properties of finished products, TK conducts additional test on WPHY material by using not only attached specimen, but also sacrificial fitting and prolongation part test since * The results are reported to Top management every week. Specimen Test (CSA ) CSA Test specimens for mechanical tests shall be representative of finished fitting. Sacrificial fitting Test (Additional) For seamless pipes, TK put sacrifice fittings per each HCN for mechanical test. Prolongation Part Test (Additional) For welded pipe for hot forming elbow, elliptical forming elbow, elliptical forming tee, TK take prolongation part per each HCN for mechanical test.

9 9 TK s standard practice to enhance accuracy of coupon test ITEM Manufacturing Method TYPE SIZE Representative Additional Test Coupon 4" and below I,T I,(T) (Sacrificial) SML'S Hot forming 5" and above I,T I,T (Sacrificial) ELBOW TEE REDUCER WELDED ALL I,T I.T (Prolongation) Cold forming SML'S ALL I,T I,T (Sacrificial) Elliptical forming 4" and below I,T I,(T) (Sacrificial) 5" and above I,T I,T (Sacrificial) WELDED ALL I,T I.T (Prolongation) 2-SEAM WELDED ALL I,T - (Specimen attached) Cold forming Elliptical forming SML'S SML'S WPHY (NOTE 1,2,3,4,5,6) 4" and below I,T I,(T) (Sacrificial) 5" and above I,T I,T (Sacrificial) WELDED ALL I,T - (Specimen attached) SML'S 14" and below I,T I,T (Sacrificial) 16" and above I,T I,T (Sacrificial) WELDED ALL I,T I,T (Prolongation) SML'S 12" and below I,T I,(T) (Sacrificial) 14" and above I,T I,T (Sacrificial) WELDED ALL I,T - (Specimen attached) * NOTE 1. C : CHEMICAL ANALYSIS, I : IMPACT TEST, T : TENSILE TEST 2. Tensile/Yield and Hardness test shall be included. 3. Heat treatment of a specimen for receiving inspection shall be carried out according to TK heat treatment specification. 4. All tests shall be carried out after heat treatment. 5. WPHY "I,(T)" : When taking IMPACT specimen, Tensile strength test shall be carried out if a specimen for tensile test can be taken. 6. The hardness test shall be carried out for WPHY, WPL3 and AISI4130 that the quenching is applied.

10 10 3. Heat treatment Control (para and others of Technical Paper) To ensure the soundness of products that heat treatment is applied, the below activities have -The stacking of fittings in the furnace, and use of certain steel support racks effectively increased the overall thickness and mass of the material to be heated and been hence implemented the hold time in from the furnace A separate issue identified involved the adequacy of quenching following normalization. In this case the temperature of the quenching medium was not monitored and maintained to assure rapid cooling of the products. 1) Prohibit stacking to prevent any of non-uniformity during heating, holding and cooling. 2) Training Program / Periodic training program for heat treatment operators: once a month 3) TK modified heat treatment procedure. Transfer time to quenching bath is specified as 60 seconds. 4) Monitoring system / Monitoring supervisor is checking the status of heat treatment twice a day, and keep the records. The results shall be reported to the top management every day. 5) Self Inspection / Self-inspection procedure was strengthen, and the foreman shall report his results of quality control (Self-Inspection Report) as daily basis to the top management, myself. 6) Hardware investment To prevent rush works, TK is increasing the quantity of furnace TK had 5 heat treatment furnaces ; A) New Normalizing +Quenching furnace (15 tons) was built at May B) Another new 5 tons Normalizing gas-furnace was built until May 30, 2013 C) Quenching bath control and Monitoring devices were installed. 7) Other existing 15 tons & 7 tons furnaces were upgraded at Sep 30, 2014in

11 11 4. Heat treatment Control (para and others of Technical Paper) -The stacking of fittings in the furnace, and use of certain steel support racks effectively increased the overall thickness and mass of the material to be heated and hence the hold time in the furnace. -A separate issue identified involved the adequacy of quenching following normalization. In this case the temperature of the quenching medium was not monitored and maintained to assure rapid cooling of the products. Notice Board on Heat treatment To inform and share what customer requirements are and what kinds of procedures are applied, Work Instruction and Procedures reflecting customer requirements are displayed on the Notice Board whi ch is located very next of furnaces. Alarm system to inform that heat treatment is completed Procedures and Work Instructions According to these Work Instruction and Procedures, heat treatment is being carried out.

12 12 Measuring and Monitoring The cooling water temperature(max. 50deg.C), transfer time to Quenching bath(max. 60 Second), water quality are Monitored (Display Panel, Check sheet) and maintained from Agitating water in the quenching bath to prevent bubbling on product surface

13 Daily check sheet For Heat treatment 13 Check point 1. Calibration was done? 2. Effective dates 3. Latest version of applicable procedure 4.Special requirement from TM-IPC-012 applicable? 5. Recorder 6. Holding time 7. Cooling method 8. TK difference >1 per each lot 9. Gap between products 10. House keeping 11. Un-necessary thing? 12. Correct Work Instruction? 13. Comply with Hold time? 14. Waiting area control

14 Daily check sheet For Heat treatment 14 Check point 15. Mixture of material 16. Waiting fittings for 3 days? 17. Waiting specimen for 3 days? 18. Rack material control Quenching 19. Hardness check 20. Hardness tester condition 21. Quenching 22. Ferrite No. for all products 23. Recording F NO. on the heat treatment chart 24. Water Cooling within 60 seconds 25. Cooling water temperature 26. Chloride concentration check

15 EXPERIENCE LIST with improved system 15 TK has supplied High Yield Strength Fittings to the global customers without any quality issues Year Material Grade Size Q'ty (pieces) Customer 2013 WPHY grades 1 ~ 64 7,992 BP and Other 38 customers 2014 WPHY grades 1 ~56 22,182 ARAMCO and other 50 customers 2015 WPHY grades 1/2 ~ 56 15,368 TOTAL and other 46 customers 2016 WPHY grades 1/2 ~ 60 13,817 ARAMCO and other 46 customers 2017 WPHY grades 1 ~ ADMA-OPCO and other 30 customers TOTAL 60,153 pieces

16 16 Head Office Export & Import Subsidiary DaeShin Co., Ltd. TK Fitting USA INC , Noksan Saneop Daero, Gangseo-gu, Busan, Korea Tel : Fax : tkbend@tkbend.co.kr 801, Jwadongsunhwan-ro 80, Haeundae-gu, Busan, Korea Tel : ~8 Fax : ~5 tkworld@tkbend.co.kr Katy Freeway Suite #220, Houston, TX 77094, USA Tel : Fax : yjk@tkbend.co.kr