THINGS
REQUIRED TO CHECK DURING INSPECTION OF TEST CERTIFICATES OF THE MATERIAL
As we
know inspection is main activity in fabrication and any other field so during
inspection large numbers of factors which is considered lets we discuss the
parameters to be checked during inspection of different grades of Plates, Pipes and
Flanges.
Checking
of mill test certificates:
Mill Test certificates or MTC’s (Material Test Certificates) is also
known as Mill Test Report (MIR) is the certificate of that particular product
like plates, pipes etc provided by manufacturer who certify the mechanical and
chemical properties and other additional technical specifications of the
respective items. Basically Material Test Certificates is the quality assurance
document. All items like Forging, Plates, Pipes MTC’s is provided by the manufacturer
with the product. So, we discuss about the things that required to check in MTC
or Mill Test Certificate during inspection.
When The vendor required
the material of plates, pipes, forge etc, The vendor provide TDC (Technical Data
Sheet) to manufacturer. The TDC is the document on the basis of that document
the material is order this data sheet consisting all necessary data required as
per client or the code requirement of the specification so manufacturer provided
the material on the basis of TDC.
Material
Test Certificate provides all necessary data about the product for example, If
we purchase plates from manufacturer, the manufacturer provides MTC’s of that respective
product and which is required to review
by inspection agency before processing for further process so following
parameters are present in MTC’s as,
- Manufacturer’s Name: First, the Manufacturer name is shown on MTC’S at Top with address of the plant. Manufacturer is one which making the material, some well-known manufacturer’s named as ESSAR STEEL, SAIL, METINVST, MAHARASHTRA SEAMLES, R.D. FORGE etc.
- Test Certificate Number : Test Certificate Number is one unique number for particular test certificate for transability of the certificate’s.
- Process Route: The Process Route of the material is the process through which material is making which consisting different stages, For example.
VD
(Vacuum Degassing)
CCM
(Continuous Casting Method)
RHF
(Rotary Hearth Furnace)
Plate
Rolling
Furnace
Normalizing. Etc
- NDT requirements: UT (Ultrasonic Testing) as per code requirements is required or not is checking while review if Test Certificate’s.
- P.O. Number: The P.O. Number is Purchase Order Number an unique assigned number against that P.O. Number material is supplied. The Purchase Order Number will be referenced throughout the transaction process by both vendor and manufacturer.
- Customer Name: On material Test Certificate the customer no is mentioned.
- Product Specification: Different grades of material required for fabrication for example For Plates: SA 516 Gr.60/70, SA 537 CL.1,IS 2062 E250
For Pipes: SA 333 Gr. 3/6, SA
106 GR. B Etc.
- Certification : Test Certificate also mentioned certification consisting as 2.1,2.2,3.1,3.2,3.1A/B/C Each have specific meaning.
So, the specification is
mentioned on Material Test Certificate as per the product specification of the
material.
- Heat No./Plate No./Batch No.: Every product like plates, pipes flanges the each product have heat no and plate no same to be mentioned on actual material .One heat number have no of plates.
For
Example: H-C98128 H-C98128
P-RG782125/1 P-RG782125/1
- Size,Qty and Weight of Product: Size with quantity and the weight is mentioned on Material Test Certificate’s so its required to check the given material with size which is mentioned in Test Certificate.
For Example For Plates, Size(mm) Weight (Mt.) Qty.
T
X W X L 7.238 5
30 X
2500 X 12000
- Mechanical Properties: This factor is most important while review of Material Test Certificates Mechanical Properties contain
1) Yield
Strength. (YS)
2) Ultimate
Tensile Strength. (UTS)
3) %
of Elongation. (%EL)
4) Impact
Testing (If required)
Other any additional testing’s
as per specification mentioned on respective material and grades in Material
Test Certificate’s.
- Chemical Analysis: Chemical Analysis obtained from a sample during the poring of material. Chemical Analysis is mentioned in percentages (% of element) . Two types of analysis as LA (Ladle Analysis) or Heat Analysis and PA (Product Analysis) consisting % of elements as C (Carbon), Mn (Manganese), S(Sulphur), P (Phosphorus), Si (Silicon), Cr(Chromium), Ni(Nickel), Cu(Copper), Ti(Titanium),V (Vanadium), Nb(Niobium), Mo(Molybdenum), Al(Aluminum), etc and Carbon Equivalent so the all % of elements as per respective code grade of specification acceptable or not is checked while review of Test Certificate.
The Carbon Equivalent (CE) is generally calculated by
formula,
CE =
C+Mn/6+(Cr+Mo+V)/5+9Ni+Cu)/15
Typical example of Sample of Test Certificate for
reference shown below,
Pic.01
Other data and testing’s like Grain Structure, Surface
conditions, Hardness testing, killed or semi-killed or other client tolerances
is mentioned as per requirements of the material.
The monogram
(Symbol) of manufacturer, Plate Number, Heat Number, Size, Specification, UT
Code is hard punched on the material and same to be mentioned in Material Test Certificate’s
so during inspection or identification of the material its Quality Inspectors
Duty to check all the given material’s Test Certificate’s Heat No Plate No, and
other data is matched or not.
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