Beruflich Dokumente
Kultur Dokumente
No: ESCL-SOP-015
Rev. No: 00
Issue Date:12th Nov, 2012
Page 1 of 11
Issue Date
Revision
12/11/2012
Identification
First Issue
Prepared by
Reviewed
Approved by
Production
Manager
by
QHSE
Manager
Managing
Director
Date
Page
Description of Change/Amendment
Rev. No: 00
Issue Date:12th Nov, 2012
Page 3 of 11
1.0 PURPOSE
The purpose of this procedure is to outline the sequence, activities and responsibilities in
the production of Egba Split-Sleeve Clamps.
2.0 SCOPE
This procedure is applicable to the production of split-sleeve clamps by ESCL.
3.0
REFERENCES
NIS ISO 9001:2008, Quality Management Systems-Requirements
NIS ISO 9000:2005, Quality Management Systems-Fundamentals and Vocabulary
ESCL Quality Manual (ESCL-QM-001)
ESCL-QSP-004, Control of Nonconforming Product
ESCL-SOP-012, Procurement Control Procedure
ESCL-SOP-014, Materials/Store Control Procedure
ESCL-SOP-016, Work Instruction for Workshop Operators
ESCL-SOP-018, Inspection and Test Procedure for Egba Split-Sleeve Clamps
Form 125, Job Card
Form 126, Certificate of Conformance
Form 127, Client Feedback
4.2
4.3
4.4
5.0
5.1
5.2
5.3
Machinists, Welders, Fitters, Painters: Responsible for ensuring that assigned jobs
are undertaken in accordance with associated specification or instructions.
5.4
Rev. No: 00
Issue Date:12th Nov, 2012
6.0
PROCEDURE
6.1
Fabrication Process
Page 4 of 11
a) The fabrication process starts from identifying the required pipe size and schedule in
line with the design specifications. As a policy our clamp materials are thicker than the
pipe under repairs.The pipe is then marked out following the clamp dimension;
b) The appropriate pipe class and size is cut to the specified overall length as in Table 1. A
5 mm machining allowance is provided;
c) The pipe is cut into equal halves, realigned and tack welded back before sending for
machining. This is to ensure roundness and dimensional accuracy of the internal bore
and features when opened;
d) The work piece is set concentric to the rotation axis ensuring an accurate alignment on
a Centre Lathe, Vertical Boring Machine or Face Lathe;
e) The face is cleared and squared;
f) The internal surface is then bored to the desired diameter as deep as the long rigid
boring bar can go;
g) The undercut is grooved to the desired width and depth to receive the seal;
h) The ends are chamfered to 300 and all sharp edges are relieved;
i) The work piece is now reversed end to end;
j) The work is now set concentric and square to the already machined diameter and face;
k) Work piece is now faced to final length plus or minus 0.5 mm.
l) Diameter is bored through if necessary;
m) Again, chamfer this second end to 30o;
n) The second undercut is positioned to achieve the specified distance between the two
end seals;
o) All sharp edges are de-burred and the halves are separated and cleaned up.
(See Machining and Welding Drawing of 18x14 and 18x24 Clamps below Fig. 1, Fig 2
and Fig 3).
Rev. No: 00
Issue Date:12th Nov, 2012
Fig 1
Fig 2
Page 5 of 11
Rev. No: 00
Issue Date:12th Nov, 2012
Page 6 of 11
Fig 3
6.2
The width and depth of side seals are marked out at the two ends;
The seal positions are milled off/disc cut;
All sharp edges are cleaned up.
6.3
Rev. No: 00
Issue Date:12th Nov, 2012
Page 7 of 11
Fig 4
6.4
Production of Arms
Special Notes
The material for the clamp arms is mild steel of rectangular cross section.
Clamps between the range of 16 to 24 are fabricated with rigid arms of not less
than 100mm x 100mm. Clamps of 14 overall length and below is fabricated with 3
nos. bolting holes for even stress distribution. Longer clamps of up to 18-24
overall lengths are equipped with 7 nos. bolting holes for same reason. The longer
the clamp, the more numbers of bolting holes for less stress on individual bolts. See
Technical Specification for Egba Split-Clamps.
Rev. No: 00
Issue Date:12th Nov, 2012
Page 8 of 11
Fig 5
6.5
Assembly
6.7
Rev. No: 00
Issue Date:12th Nov, 2012
Page 9 of 11
Corrosion Control
All surfaces to be coated are cleaned of all contaminants that may affect the
integrity of the coating system.
Prior to surface preparation, the work pieces is cleaned, using appropriate
solvent cleaning detergent as outlined in SSPC-Sp-1 or NACE equivalent.
Corrosion control include sand blasting (where necessary), power brushing,
application of primer, undercoat and finish coating using appropriate
industrial paint approved for the purpose.
6.8
Coating/Painting
Surface to be coated is clean, dust free and dry before application of any
coat of paint.
The primer is applied as soon as possible after cleaning to avoid rusting,
discoloration or contamination.
Coating is applied under the environmental conditions stipulated by coatings
manufacturers Data Sheet as specified by NACE standard.
Inorganic zinc coating is continuously stirred during
mechanical spray pot agitator or other approved means.
application
by
All coatings is allowed to dry for the minimum time recommended by the
paint manufacturers, before applying the succeeding coat.
Minimum layer thickness of 500um is obtained as recommended.
Coated work pieces are allowed to dry properly before further handling.
6.9
Fixing of Seals
High quality Elastomeric Gasket materials are used for End and Side seals.
For crude oil services to 1200C (2500F), NBR is used. For 1200C 1500C, HNBR
is used. For condensate services, FKM (VITON) is used.
The seal cut to size are held down firmly in the groove with the teeth of the
steel girder to prevent shift when under pressure.
6.10 Identification/Coding
All clamps are coded for easy identification and against piracy and faking.
The identification label or tag includes Product Name, Nominal Size, Serial
Rev. No: 00
Issue Date:12th Nov, 2012
Page 10 of 11
Inside Diameter
A
(Inches)
Inside Length
(Distance b/w
Seals)
B
(Inches)
Overall Length
C
(Inches)
Approx.
Weight
(Pounds)
51/4
81/2
42
71/8
51/4
62
91/8
51/4
10
125
10
111/4
51/2
101/2
147
12
131/4
51/2
101/2
230
14
14 /2
14
385
16
161/2
14
420
18
181/2
14
555
20
201/2
14
580
22
221/2
14
635
24
241/2
14
680
7.0
RECORDS
7.1
Work Order
7.2
7.3
7.4
Certificate of Conformance
7.5
7.6
7.7
Rev. No: 00
Issue Date:12th Nov, 2012
Page 11 of 11
PRODUCTION
PLANNING
(MEETING)
PROCUREMENT
JOB CARD
CUTTING
OPERATION
MACHINING
QC
OPERATION
MILLINGQC
PROCESS
CUTTING OF GIRDLE
QC SIDE
RINGS AND
STRIPS
ARMS PRODUCTION
QC
COATING/PAINTING
FIXING OF SEALS
QC
ASSEMBLE
QC
GENERAL
INSPECTION
QC
CODING
QC
CORROSION
QC
CONTROL
PRESSURE TESTING
QC TO
DELIVERY
CLIENT
QC