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SC5 Liaison Report to SC18SC5 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

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Steel-making

Pipe rolling

Heat treatment

Inspection and Testing

Threading

Marking

Buck-on

Straightening

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.

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Description:Steel is melted and cast (continuously, or in ingots).

Output:Steel billet

Key objectives: Adjust the amount of alloying elements to achieve chemical compositionRemove impuritiesAchieve 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 furnaceChemical analysis instrument*Ladle metallurgy capability to control sulfur, phosphorous, carbon, etcVacuum or inert atmosphere degassing of ladleContinuous billet or round castingInventory of scrap and/or ore

Steel-making

Pipe rolling

Heat treatment

Inspection and Testing

Threading

Marking

Buck-on

Straightening

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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 furnacePiercer – press or cross rollingPlug, mandrel, pilger, or Assel mill or push benchStands of mills for sizing: pipe mandrel, reducingInventory of rolls and mill tooling

Steel-making

Pipe rolling

Heat treatment

Inspection and Testing

Threading

Marking

Buck-on

Straightening

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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 sprayersTempering furnace*Cooling racks and/or beds

Steel-making

Pipe rolling

Heat treatment

Inspection and Testing

Threading

Marking

Buck-on

Straightening

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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

Steel-making

Pipe rolling

Heat treatment

Inspection and Testing

Threading

Marking

Buck-on

Straightening

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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 requirementsIdentify and remove small flawsReject tubulars with unacceptable flaws or defects

References in 5CT:Material requirements (7)Defects (8.13)Inspection and testing (10)

Expected facility equipment:Hydrostatic test stationScale* 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 inspectorsMaterial analyzer*; microscope (for grain size)Tensile* and Charpy impact* test equipmentHardness tester*Sulfide stress cracking test lab

Steel-making

Pipe rolling

Heat treatment

Inspection and Testing

Threading

Marking

Buck-on

Straightening

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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 assemblyProtect thread from handling damage

References in 5CT:Threads conform to Spec 5BCouplings (9)Thread protectors (12.2)

Expected facility equipment:Computer Numeric Controlled (CNC) lathesVariety of thread element gauges* (see 5B for elements)Ring gauge* (pins) or plug gauge* (couplings)Thread protectors and thread and/or storage compoundCleaning and plating tanks (couplings)

Steel-making

Pipe rolling

Heat treatment

Inspection and Testing

Threading

Marking

Buck-on

Straightening

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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 compoundHorizontal bucking unit with torque gauge*Thread protectors and storage compound

Steel-making

Pipe rolling

Heat treatment

Inspection and Testing

Threading

Marking

Buck-on

Straightening

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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 equipmentScale* and length measurement* equipmentMethod for applying paint bandsEquipment to apply external coating

Steel-making

Pipe rolling

Heat treatment

Inspection and Testing

Threading

Marking

Buck-on

Straightening

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Destructive tests:Chemical composition (10.3)Tensile (10.4)Hardness (10.6)Impact (10.7)Hardenability (10.9)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)

[For EW: Flattening (10.5) ]

Steel-making

Pipe rolling

Heat treatment

Inspection and Testing

Threading

Marking

Buck-on

Straightening

Non-destructive Inspection:

Visual (10.14)Wall thickness (10.15)Ultrasonic (10.15)Flux leakage (10.15)Eddy current (10.15)Magnetic particle (10.15)

List of specific inspections and tests referenced in API 5CT

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Steel-making

Pipe rolling

Heat treatment

Inspection and Testing

Threading

Marking

Buck-on

Straightening

Proposed hierarchy of API 5CT Grades:

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)

Slightly revised from teleconference list

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Steel-making

Pipe rolling

Heat treatment

Inspection and Testing

Threading

Marking

Buck-on

Straightening

Candidates for product sub-categories:

Seamless, heat-treated tubeERW tubeCouplingsThreading (more details of process?)AccessoriesTubingChrome products (steel-making challenge)

The typical process flow described in this package is most applicable for products next to the red bars.

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ANY QUESTIONS?Just ask Jim Powers