Ensuring Material Integrity with Advanced Base Metal Testing & Evaluation

Raw material inspection is a critical quality control process in the manufacturing of industrial pipe fittings, involving the inspection of chemical composition, material thickness, and dimensional accuracy to ensure that raw materials meet project specifications. This process ensures compliance with industry standards and is vital for traceability in high-performance piping systems.

All required tests are conducted in accordance with the Inspection and Test Procedure (ITP) and specific project requirements. Test samples must possess the same material grade and raw material furnace number as the fittings and must undergo the same heat treatment process. Chemical analysis testing is performed as per approved ITP. Tensile testing for seamless (SMLS) fittings complies with ASTM material standards, as detailed in the ITP. Additionally, Charpy-V impact testing requirements for piping materials are carried out according to ITP and ASTM standards.

3.1 & 3.2 Certification

The initially, Base material whenever comes to us and a Standard practice will follow including verification of Factory certificate we received.In second step as per our in house rule we collect random samples & send to our in house Lab for testing as per material standard & project requirements.

3.1

As a standard practice we do Chemical & Mechanical Tests. Mechanical Test includes Tensile, Charpy Impact, IGC etc. And follow the other instructions as per Inspection & Testing Plan.

3.2

It always begins as per Inspection and Testing Plan & MPS always been approved by the client.

CUTTING

Cutting pipe by manual operation or plasma cutting machine.in case of small qty, flame cutting by manual is accepted but layout specimen must be used for cutting elbow halves/ reducers. Stainless steel material must be used plasma cutting machine. After cutting, the heat number and serial number should be properly marked on pipes for traceability.

According to the technical requirements of the drawings, use flame welding or semi-automatic plasma to cut raw material plates, tubes, etc., and meet the requirements of the drawings

Cutting pipe fittings is a common task in pipefitting projects. The specific cutting method depends on the type of pipe fitting and the material being used. Here are some general guidelines for cutting different types of pipe fittings: Copper Pipe Fittings:

Copper Pipe Fittings:

• Copper pipe fittings can be cut using a tubing cutter or a hacksaw.
• For a tubing cutter, place the cutter on the fitting, align the cutting wheel with the mark, and rotate the cutter around the fitting, tightening the cutter after each rotation until the cut is complete.
• Alternatively, use a hacksaw to cut through the fitting along the marked line. Ensure the cut is clean and perpendicular to the fitting.
• After cutting, use a deburring tool or sandpaper to remove any sharp edges or burrs.

• Steel pipe fittings are typically cut using a reciprocating saw with a metal-cutting blade, a hacksaw, or a pipe cutter specifically designed for steel pipes.
• Measure and mark the desired length on the fitting.
• Use the chosen cutting tool to make the cut along the marked line. For reciprocating saws or hacksaws, apply steady pressure while cutting to maintain a straight line.
• After cutting, use a file or a grinder to remove any burrs or rough edges.

Always wear appropriate personal protective equipment, such as safety glasses and gloves, when cutting pipe fittings. Additionally, ensure that the pipe is securely held in place to prevent accidents or injuries during the cutting process.

Forming and Pressing

The material is formed by using a hydraulic press and a suitable tire mold. According to the control temperature, it is divided into cold forming and hot forming. Elbows are divided into mandrel pushing, Two half-shells, and bending. extruded tee, forged

LR Elbow Forming: Cool pushing process used seamless pipe. cool pushing elbows by mandrel:
Cut piece of T shape to be loaded into cold forming elbow die, lubricant to be applied. Close the die, push the cut pipe by hydraulic press from horizontal direction to force cut pipe slide onto cavity between die and mandrel to achieve one time forming with efficiency. Heat treatment to be followed to relieve stress.
SR Elbow Forming:
Hot pushing process used seamless pipe. Hot form elbow in seamless：
mandrel checked, cut pipe checked, induction voltage, output power checked, hydraulic system pressure checked before production and along the production. Preheating mandrel until satisfactory temperature then followed with pipe mandrel bending
Resizing/calibration by hydraulic die closing to be followed immediately after hot elbows are being formed.

To manufacture wrought fitting various methods are used;

• These methods are
  • Hot forming or Extrusion Method
  • Hydraulic Bulge method – Cold forming
  • UO or Single weld seam Method
  • Monaka or Double weld seam Method
  • Deep Drawing Method for caps
  • Flare Method for Stub ends