NO.

: WGSRL/LS/QC/WI/25
WELSPUN REV.NO.: 04
GUJARAT STAHL ROHREN LTD. DATE : 25.05.2006
WELSPUN BHARUCH
PAGE NO.: 1 of 5

QUALITY ASSURANCE & CONTROL DEPT.

(LONGITUDINAL SAW PIPE DIVISION)

WORK INSTRUCTION
FOR
FINAL VISUAL & DIMENSIONAL
INSPECTION

ISSUED BY :

ISSUED TO :

COPY NO :

PREPARED BY REVIEWED BY APPROVED BY

SHIFT-IN-CHARGE (QC) ASST. MANAGER (Q C) H O D (QC)

WORK INSTRUCTION NO.: WGSRL/LS/QC/WI/25

FOR REV.NO.: 04
 DATE : 25.05.2006

FINAL VISUAL & DIMENSIONAL PAGE NO.: 2 of 5

INSPECTION
1. PURPOSE :
The purpose of this work instruction is to establish and maintain documented procedure to ensure that the
final Visual and dimensional Inspection of saw pipe is carried out to meet the specified requirements.
2. SCOPE :
This work instruction is applicable for the final visual & dimensional inspection of pipes at Longitudinal
SAW Pipe Division, manufactured as per API 5L (Latest Edition) / customer specification.
3. RESPONSIBILITY :
Assistant Manager (QC) / Sr. Engineer / Sr. officer / Engineer / Officer will be responsible for
implementing this work instruction.
4. PERSONNEL REQUIREMENTS :
Personnel performing the visual and dimensional examination of the pipes shall be qualified in accordance
with the company’s qualifications criteria.
5. PHYSICAL REQUIREMENTS :
Personnel performing the final visual & dimensional inspection shall have annual vision test to assure
natural or corrected near distance acuity so that they are capable of reading standard Jaeger (J-1 letters)
test type charts for near vision. Equivalent near vision tests are acceptable and the record of eyes shall be
maintained.
6. INSPECTION REQUIREMENTS & METHOD:
 Each pipe shall be inspected under sufficient illumination of 100 foot-candles (1000 lux) and
magnifying lens may be used for detecting surface imperfection which is not clearly visible to the
naked eyes as per ASME SEC. V (ARTICLE 9).
 The weld and parent body of each pipe shall be inspected both from inside & outside for any
visual defects such as dents, off set, off seam weld, hard spot, bead height, cracks, sweats, leaks,
arc buns, laminations, slivers, under cuts, under fills etc.
 Each pipe shall be measured for end diameter; body diameter, thickness, bevel angle, root face,
straightness, out of roundness, square ness, length, weight, and the record of each pipe shall be
maintained in Dimensional & Visual Inspection Report (WGSRL/LS/QA/12). The bead height, off
set of plate edge shall also be checked for each pipe. The same shall be measured and recorded for
min. 3 pipes/shift.
 The instruments use to measured the dimensions shall be calibrated as per Work Instruction
(WGSRL/LS/QA/WI/27).
 It is ensured that each pipe has covered all the inspection stages before preparing a final
dimensional inspection report and generated on SAP (pipe tracking system).
 If any pipe does not cover any specific inspection / process stage, the same shall be sent for
reprocess / rework by filling a rectification memo and also the same shall be routed through re-
work process on SAP system.
 WORK INSTRUCTION NO.: WGSRL/LS/QC/WI/25
FOR REV.NO.: 04
FINAL VISUAL & DIMENSIONAL DATE : 25.05.2006
WELSPUN INSPECTION PAGE NO.: 3 of 5

 All the dimensional inspection records shall be entered in the SAP R/3 system by the respective
inspectors in each shift.
 Any imperfection in parent body as mentioned above having a depth greater than 12.5% (or as
specified in other specs. and process chart) of the specified wall thickness, measured from the
surface of the pipe shall be considered defect and shall be disposed as :-
o The defective area shall be ground. The grinding shall blend the ground area with the
contour of the pipe and removal of defect shall be verified by visual inspection. After this,
the thickness shall be checked. If thickness is with in acceptance limit, the pipe shall be
accepted. If not, then the pipe shall be cut off provided after cut off, the pipe length is with
in specified limits.
o The pipe shall be rejected.
The thickness of ground portion shall be recorded. For cosmetic grinding, recording is not required
 The cut off pipe shall be identified with a Yellow color band on pipe OD at cut off end. For
Rejected pipe, a product NCR shall be raised by the concerned QC personnel and 2 yellow bands
on both ends shall be put and the pipe shall be kept separately. The final disposition of the pipe
shall be decided by QA dept.
 The rejected pipe shall be identified with RED colour band from both ends circumferentially and
the records of rejected pipe shall be maintained.
 All accepted pipes shall be marked with API Monogram (or as reqd. by other specs.) and required
marking by stenciling as per the Approved process chart (WGSRL/PLNG/LS/06) and QAP
(WGSRL/LS/QA/26).
 After final acceptance of the pipes, each pipe is allotted with an Unique Acceptance Serial Number
(ASL) generated by the SAP system.
 The marking of the pipes shall be checked by the Sr. Engineer / Engineer (QC) before sending
these pipes to the yard, for any errors. Again the marking shall be cross verified by yard QC
Engineer / Officer as per the approved Process Chart.
 Any pipe not meeting the specified requirements, then the monogram shall be deleted after
authorization from HOD ( QC )
7. FOR RE-WORKED PIPES:
Following points shall be strictly followed for re-worked pipes (like cut off, sample, etc,) Each
pipe shall be checked for:
 Debris, oil inside the pipe.
 Colour code as per the re-work.
 Re-stenciling & thk. colour code at the pipe ends.
 Flush grinding of ID/OD weld seam at the pipe ends.
 Review of all NDT reports, weld repair reports, if any.
Ensuring all the above points, a separate Visual & Dimensional inspection report shall be
prepared & in the presence of Shift-in-charge, same shall be offered to TPI.
 FIN
WELSPUN

8. ACCEPTANCE CRITERIA:
The acceptance criteria shall be as per approved process chart (WGSRL/PLNG/LS/06)/ QAP (WGSRL/
9. INSTRUMENTS USED FOR THE DIMENSIONAL MEASUREMENT:
As per attached TABLE - A
10. RECORD :
Dimensional & visual inspection report (WGSRL/LS/QA/12)
11. RERERENCE :

Chapter 4.1 of DPM-LS / QA & C.

TABLE - A

SR. INSTRUMENT FREQUENCY OF

ACTIVITY
NO. TO BE USED INSPECTION
01
End Diameter ( Both End ) Pie tape Each Pipe
02
Body Diameter Pie tape Each Pipe
03 Thickness ( Both End & at Ultrasonic
Each Pipe
Body ) Thickness Gauge.
04
Bevel Angle Bevel Protector Each Pipe
05
Root Face Root Face Gauge Each Pipe
Straightness Piano Wire / String
06 Each Pipe
07 ‘C’ Gauge or Steel
Out of Roundness Each Pipe
tape (3mtrs.)
Square ness Plumb
08 Each Pipe
Measuring Steel
09 Length Each Pipe
Tape (15 mtrs.)
10 Online weighing
Weight Each Pipe
M/c.
11 Weld Bead Height (Outside & Bead Height
Three pipes per shift
Inside ) Gauge
12
Offset of Plate Edges Off-set Gauge Three pipes per shift
 WELSPUN
FLOW CHART
MPI / Xray

Accepted Re-Work Reject

Reprocess Cut off Re-bevel Red Band

Rebevel MPI NCR

Re-Exp. Re Hydro Re-FUT Re-Xray Re-MPI

MUT Yard
Re Hydro Re-FUT If required
Re-Xray
X-Ray
Re-FUT Re-Xray

MPI
Re-Xray Re-MPI

Re-MPI

Final Inspection

Marking

Yard