SC5 Liaison Report to SC18
SC5 Work Item 1065 – Audit Effectiveness
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Work Item 1065
• Charge has been completed
• A document package will be created for
submission to Monogram Program
Board/SC18
• Basic approach will be defined and example
shown
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Example:
OCTG Product Realization
Heat-treated seamless casing
3
Steel-making
Pipe rolling
Heat treatment
Straightening
Inspection and
Testing
This is a typical process flow. Subsequent slides
describe each of the basic steps and equipment that
will likely be used.
The steps are typically in this order, with some
exceptions (for example, some inspection is done
after threading; also, intermediate marking is used
for process traceability).
An asterisk next to the expected equipment implies
that calibration of the equipment is expected.
Threading
Buck-on
Marking
4
Steel-making
Pipe rolling
Heat treatment
Straightening
Inspection and
Testing
Threading
Buck-on
Marking
Description:
Steel is melted and cast (continuously, or in ingots).
Output:
Steel billet
Key objectives:
Adjust the amount of alloying elements to achieve
chemical composition
Remove impurities
Achieve billet or round structure
References in 5CT:
Fine-grain practice (6.1)
Chemical composition (7.1)
Heat analyses (10.3.1)
Expected facility equipment:
Electric-arc furnace or Basic oxygen furnace
Chemical analysis instrument*
Ladle metallurgy capability to control sulfur,
phosphorous, carbon, etc
Vacuum or inert atmosphere degassing of ladle
Continuous billet or round casting
Inventory of scrap and/or ore
5
Steel-making
Pipe rolling
Heat treatment
Straightening
Inspection and
Testing
Threading
Description:
Steel billet is reheated and formed into a seamless tube.
Output:
Plain-end tubular joint
Key objectives:
Create a uniform geometry
References in 5CT:
Size (8.3)
Mass (8.5)/wall thickness (8.4)
Length (8.6)
Expected facility equipment:
Rotary hearth or walking beam furnace
Piercer – press or cross rolling
Plug, mandrel, pilger, or Assel mill or push bench
Stands of mills for sizing: pipe mandrel, reducing
Inventory of rolls and mill tooling
Buck-on
Marking
6
Steel-making
Pipe rolling
Heat treatment
Straightening
Inspection and
Testing
Threading
Buck-on
Description:
Tubular joint is reheated and cooled.
Output:
Tubular joint with final grain structure
Key objectives:
Obtain strength, ductility, and corrosion resistance
References in 5CT:
Heat treatment (6.2)
Tensile properties (7.2)
Toughness (7.3)
Hardness (7.7)
Hardenability (martensite) (7.10)
Grain size (7.11)
Expected facility equipment:
Austenitizing furnace* (or normalizing furnace)
Quench tank or array or sprayers
Tempering furnace*
Cooling racks and/or beds
Marking
7
Steel-making
Pipe rolling
Heat treatment
Straightening
Inspection and
Testing
Description:
Tubular joint is bent.
Output:
Straight plain-end tubular joint
Key objectives:
Remove deviation from straight
References in 5CT:
Straightness (8.9)
Drift (8.10)
Expected facility equipment:
Rotary straightener (hot or cold) or gag press
Threading
Buck-on
Marking
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Steel-making
Pipe rolling
Heat treatment
Straightening
Inspection and
Testing
Threading
Buck-on
Marking
Description:
Tubular properties are measured.
Tubular is inspected for defects and flaws.
Output:
Assurance of quality of plain-end tubular joint
Key objectives:
Confirm that tubular properties meet requirements
Identify and remove small flaws
Reject tubulars with unacceptable flaws or defects
References in 5CT:
Material requirements (7)
Defects (8.13)
Inspection and testing (10)
Expected facility equipment:
Hydrostatic test station
Scale* for weighing joints (may be at marking stage)
Ultrasonic wall thickness and flaw transducer array*
Electromagnetic flux leakage*
Eddy current inspection unit*
Magnetic particle inspection (wet or fluorescent)
Qualified inspectors
Material analyzer*; microscope (for grain size)
Tensile* and Charpy impact* test equipment
Hardness tester*
Sulfide stress cracking test lab
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Steel-making
Pipe rolling
Heat treatment
Straightening
Inspection and
Testing
Threading
Buck-on
Marking
Description:
Tubes are externally threaded at each end.
Coupling material is cut into blanks and internally
threaded on each end.
Output:
Threaded tubular joint or coupling
Key objectives:
Create thread that facilitates assembly
Protect thread from handling damage
References in 5CT:
Threads conform to Spec 5B
Couplings (9)
Thread protectors (12.2)
Expected facility equipment:
Computer Numeric Controlled (CNC) lathes
Variety of thread element gauges* (see 5B for elements)
Ring gauge* (pins) or plug gauge* (couplings)
Thread protectors and thread and/or storage compound
Cleaning and plating tanks (couplings)
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Steel-making
Pipe rolling
Heat treatment
Straightening
Inspection and
Testing
Threading
Description:
A coupling is installed power tight on one end of the
tubular joint.
Output:
Tubular joint ready to run into a well
Key objectives:
Create thread that facilitates assembly
References in 5CT:
Threads conform to Spec 5B (1.5 excludes threads from
5CT)
Coupling make-up (8.14)
Expected facility equipment:
Thread compound
Horizontal bucking unit with torque gauge*
Thread protectors and storage compound
Buck-on
Marking
11
Steel-making
Pipe rolling
Heat treatment
Straightening
Inspection and
Testing
Threading
Description:
Tubular joints are marked along their length.
Output:
Marked tubular joint
Key objectives:
Label joints for identification, information, traceability
References in 5CT:
Marking (11)
Coating (12)
Expected facility equipment:
Stencil or stamp marking equipment
Scale* and length measurement* equipment
Method for applying paint bands
Equipment to apply external coating
Buck-on
Marking
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List of specific inspections and tests referenced in API 5CT
Steel-making
Pipe rolling
Heat treatment
Straightening
Inspection and
Testing
Threading
Non-destructive Inspection:
Destructive tests:
Visual (10.14)
Chemical composition (10.3)
Wall thickness (10.15)
Tensile (10.4)
Ultrasonic (10.15)
Hardness (10.6)
Flux leakage (10.15)
Impact (10.7)
Eddy current (10.15)
Hardenability (10.9)
Magnetic particle (10.15)
Sulfide stress cracking (10.10)
Non-destructive tests:
Hydrostatic (10.12.2)
Drift (10.13.5)
Measurements:
Diameter (10.13.2)
Mechanical wall thickness (10.13.4)
Length (10.13.6)
Weight (10.13.7)
Straightness (10.13.8)
Buck-on
[For EW: Flattening (10.5) ]
Marking
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Steel-making
Slightly revised from
teleconference list
Proposed hierarchy of API 5CT Grades:
Pipe rolling
Heat treatment
Straightening
Inspection and
Testing
Threading
Buck-on
The typical process flow described in this package is
most applicable for seamless pipe in the grades next
to the red bar.
Different acceptance standards typically apply for the
higher grades (not just strength, but also inspections)
Marking
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Steel-making
Pipe rolling
Heat treatment
Straightening
Candidates for product sub-categories:
Seamless, heat-treated tube
ERW tube
Couplings
Threading (more details of process?)
Accessories
Tubing
Chrome products (steel-making challenge)
Inspection and
Testing
Threading
The typical process flow described in this package is
most applicable for products next to the red bars.
Buck-on
Marking
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Just ask Jim Powers
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