SPIJ Detailed Flow

Production: General Layout

Upsetting

Heat Treatment Heat Tretment

tubing casing

Hold for tests

A
Ndt Line
(EMI, VI, Wmpi)

U.T. U.T.
(Dapco) (Olympus)

Hydrotest
(Yamasui/tubing/
premium)

Threading
Threading Threading Threading (Tubing)
(Premium 2) (Api) (Premium)

Api Dispatch

Dopeless
A Ndt Line Buck On
(Mpi x SEA) Buck On Buck On

Buck On Wms
Wms Wms rfid
rfid (Tubing)
(Api) (Premium) rfid

Coating & Swaging

Stenciling Stress reliese

Fi.Co.

Hold For test

Packing A Same line

SPIJ Detailed Flow 22/05/2014 Page: 1 of 21

SPIJ Detailed Flow
Production: Upsetting
The line processes one end at the time so the
process must be repeated for the second end.
wip
yard
For product Heavy Upset can be also a thrid
time process.

Line entry Bin

No operator to check the pipes;
Pipes split by heat

In case of cut along the process we may receive

pipes to upset again as part of the reparation
process, in this case there is the traceability.

Upsetting

At the end of the process of the Grinding

Workorder will be processed
Inspection
the cut pipes

Pipe

Rej

Cutoff
Good

Production reporting,
Defines sequence in the exit bed
Beveling
Quality report: online or at the
temporary bed?

Cut Pipe

Good
Line exit bed
Line exit bed

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yard

Plain End No HT

yes

Tubing prem. Stress

Stress relieve Prod. Other Next Process
Connection relieve

API Conncet EUE

Threading HT

NDT People per

Line / Position # Crews
Crew

Upsetting 4 1
Upsetting Operator 1 1
Grinding Operator 1 1
Upsetting Inspector 1 1
Beveling Operator 1 1

SPIJ Detailed Flow 22/05/2014 Page: 2 of 21

SPIJ Detailed Flow
Production: HT - Tubing

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yard

The operator identifies the heat of the pipes.

Ht 1
(Austening &
Quenching) Process control samples, not for MTC
Samples cut. Move to casing via crane.
There is no samples cutting in tubing area.

An operator reports the production

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yard

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yard

The operator identifies the pipe (the heat) and

writes with a marker the id that the pipe will
assume after the HT (in future also the Heat
Lot Id)

Ht 2 Heat Lot
(Tempering) Pipe Traceability

Straightening
Samples valid for MTC
Stenciling? Move to casing via crane.
There is no samples cutting in tubing area.
Samples cut.
After cutting the pipes came back to tubing exit
bed (changing our sequence)

An operator reports the production, pipe by

pipe building the correct sequence for SUCH.

Pay attention to the pipes that has been cut for

samples, returning to the exit bed they will be
out of sequence.

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yard

Hold for Lab.

Tests

Back to HT? No ok
People per
Line / Position # Crews
Crew
Yes
HT Tubing 3 0
Auxiliary 1 0
Next Process Straightening Operator 1 0
Exit Visual Inspector L1 1 0

SPIJ Detailed Flow 22/05/2014 Page: 3 of 21

SPIJ Detailed Flow
Production: HT - Casing - NoCr13

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yard

The operator identifies the pipe (the heat) and

writes with a marker the id that the pipe will
assume after the HT (in future also the Heat
Lot Id)

Heat Lot
Pipe Traceability Full HT
Only 1 step
Quenching
samples

Straightening
Stenciling?
From HT Tubing Samples reporting and labels
Samples cut.
(via cranes) printing (link to e-labo)
Tubing
Back to HT Tubing An operator reports the production, pipe by
(via cranes) pipe building the correct sequence for SUCH.

Pay attention to the pipes that has been cut for

samples, returning to the exit bed they will be
out of sequence.

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yard

Hold for Lab.

Tests

Back to HT? No ok

Yes

Next Process

People per
Line / Position # Crews
Crew

HT Casing 5 3
Auxiliary 1 3
Process Control Technician 2 4
Straightening Operator 1 3
Exit Visual Inspector L1 1 3

SPIJ Detailed Flow 22/05/2014 Page: 4 of 21

SPIJ Detailed Flow
Production: HT - Casing - Cr13

wip
yard

The operator identifies the heat of the pipes.

Ht 1
(Austening &
Quenching) Process control samples, not for MTC
Samples cut. Move to casing via crane.
There is no samples cutting in tubing area.

An operator reports the production

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yard

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yard

The operator identifies the pipe (the heat) and

writes with a marker the id that the pipe will
assume after the HT (in future also the Heat
Lot Id)

Heat Lot
Ht 2 Pipe Traceability
(Tempering)

Straightening
Stenciling?
Samples cut. Samples reporting and labels
printing (link to e-labo)

An operator reports the production, pipe by

pipe building the correct sequence for SUCH.

Pay attention to the pipes that has been cut for

samples, returning to the exit bed they will be
out of sequence.

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yard

Hold for Lab.

Tests

Back to HT? No ok

People per
Yes Line / Position # Crews
Crew

HT Casing 5 3

Next Process Auxiliary 1 3

Process Control Technician 2 4
Straightening Operator 1 3
Exit Visual Inspector L1 1 3

SPIJ Detailed Flow 22/05/2014 Page: 5 of 21

SPIJ Detailed Flow
Production: NDT - EMI
NDT Inspection process, all the machines are in Upsetting or
Tubing prem.Connection Threading
line. Swaging

No automation, the graphs will be stored in the pc Cut Prod.

of the machine related with the sequence number
defined by the operator.
wip API Conncet EUE Upsetting HT NDT Again
yard

Quality report and reso

Line exit bed after reparation or scrap

Good
An operator reports the production
And the destination of the pipes and
build the sequence in the beds. Pipe Rejected Prove Up

Pay attention to the pipes after proveup

that may be out of sequence vv
Wet MPI The EMI operator will decide what pipe will
(both ends) enter in the line, if he wants to receive from
ProveUp he will stop the entry table

Visual Inspection He could process the proveup at the end of

a heat
EMI
(tuboscope)

Drifting

vv

Line entry Bin

An operator reports the production After verification
And the destination of the pipes and
build the sequence in the beds.
Pipes
Pay attention to the pipes after proveup identification
that may be out of sequence

Input Bin
Entry from yard
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yard
Entry: Threading Premium 2
Only for: MPI - SEA

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SPIJ Detailed Flow
Production: UT_Dapco

The operator can read the

number of pipe,

Dapco

Good Pipe

Rejected
Rejected:
- to repair: yellow band,
- to scrap: pink band Mixed pipes

Repaired pipes Line entry Bin

Line exit bed
Via cranes

wip wip
yard yard

People per
Line / Position # Crews
Crew

UT 2 3
Prove Up Technician 1 3
UT Technician L2 1 3

SPIJ Detailed Flow 22/05/2014 Page: 7 of 21

SPIJ Detailed Flow
Production: UT_Olympus

Tracking totally managed by AUTM. Autm PC manage

Should connect AUTM to Tandem the tracking

Rejected Pipe Good pipes

Olympus

Reparation bed:
- ctuoff,
- grinding,
- ...

After reparation
Autm PC to start
Autm PC manage the tracking
the tracking and
declaring defects wip
yard

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yard

SPIJ Detailed Flow 22/05/2014 Page: 8 of 21

SPIJ Detailed Flow
Production: Hydro -Yamasui

wip
yard

Pipes
identification

Hydro
Production reporting,
Defines sequence in the exit bed
Only defines Good and Rejected
Rejected Pipe

Good

Line exit bed

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yard

People per
Line / Position # Crews
Crew

Hydro 3 3
Auxiliary 2 3
Hydrotest Operator 1 3
SPIJ Detailed Flow 22/05/2014 Page: 9 of 21
SPIJ Detailed Flow
Production: Hydro - Tubing

Pipe

Phosph.1 Inspect.
Buck
Buck on
on
Prot. 2 Prot. 1

Phosph.1

Hydrotest
Hydrotest MPI
MPI

WMI operator will report Hydrotest Wms - bypass

Inspect.
Thread 2
Pipe
Inspect.
Good Thread 1

Rejected

Line entry Bin

After verification
Pipes
identification
Mixed pipes Input Bin
Entry from yard

Entry table Tubing

Exit table Tubing

wip
wip yard
yard

NB:
- pipes for Quingdao: only HT + NDT + Tubing WMS + Coating;
- Hydrotest is done only on Plain End pipes, so:
- if Hydrotest no threading;
- if threading, the Hydrotest is in bypass.

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SPIJ Detailed Flow
Production: Hydro - Premium

wip
yard

Entry table Premium

Input Bin
Entry from yard

Line entry Bin

After verification

Thread 1
Inspect.
Thread 2
Inspect.
MPI
MPI
Phosph.1
Phosph.2

Buck
Buck on
on
Inspect.

Pipe

Hydrotest
Hydrotest

Prot. 2 Prot. 1

Wms

Rej. Pipe Wms will report also Hydro

Good

Buck on Machine

Exit Premium

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yard

SPIJ Detailed Flow 22/05/2014 Page: 11 of 21

SPIJ Detailed Flow
Production: Threading Area

wip wip wip

yard yard wip wip
yard yard yard

Exit table Cut Off Entry table API Entry table Premium Entry table Dopeless Exit table Tubing Range 3

Thread 1
Inspect. Rejected
Thread 1 Thread 2 Robot A
Cut off Inspect.
Inspect.
Thread 2 MPI
Inspect. MPI Pipe
Robot B
Phosph.1 Phosph.1
Phosph.2
Phosph.2 Phosph.1 Inspect.
Buck on Buck on Buck on
Inspect. Robot C
Inspect.
Prot. 2 Prot. 1
Rej. Api To
Cutoff Pipe rejected Pipe Phosph.1
online Hydrotest
Good Pipes
Hydrotest
Buck on MPI
Wms
Wms MPI
Prot. 2 Prot. 1 Inspect.
Tally Wms Rej. Small Tally
Pipe List Pipe
Rej. Premium: orders Good Pipe List Inspect.
- threading, to cutoff API via crane
- Phosphate direct to phosphate, Tally Thread 2
- buck on: direct to buck on Pipe List Rejected big orders,
Rejected dopeless Inspect.
Good Rejected Thread 1
Rej. Good pipes

Rej.

Good

Exit Dopeless Exit table Tubing Entry table Tubing

Waiting
Exit API wip
Exit Premium customer yard
wip wip
approval yard
wip wip yard
yard Rej. Wms API yard

SPIJ Detailed Flow 22/05/2014 Page: 12 of 21

SPIJ Detailed Flow
Production: Threading Tubing

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yard

To API WMS Good pipes

Exit table Tubing Range 3
Or to Premium WMS Range 3

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yard
In case of rejected pipes, the
operatord doesnt know on
Entry table Hydrotest Rejected which machine the pipe will be
cut: may be: Heat tretment or
reclamation

Pipe Production reporting,

Defines sequence in the exit bed
Also Quality report in case of
Phosph.1 Inspect. yellow band

Rejected area Buck on

Prot. 2 Prot. 1

Phosph.1
Rejected Pipe

Hydrotest
Hydrotest MPI
In case of rejection,:
Good - paint yellow band,
If the pipes will go to dopeless, we have to MPI
- stencil defect code,
add virtual Coupling: len and weight
on the pipe
Is it still necessary?
Can be done in dopeless buck on?
Wms
Inspect.
Will report also Hydrotest
Tally Thread 2
Good Pipe List
Inspect.
Thread 1
report
Dopeless: defects for
yes Dopeless Thread & report defects for
HOW? Mpi Thread & Mpi

no Rejected Line entry Bin

After verification
Pipes
identification
Mixed pipes Input Bin
Entry from yard

Entry table Tubing

Exit table Tubing

wip
wip yard
yard

NB:
- pipes for Quingdao: only HT + NDT + Tubing WMS + Coating;
- Hydrotest is done only on Plain End pipes, so:
- if Hydrotest no threading;
- if threading, the Hydrotest is in bypass.

SPIJ Detailed Flow 22/05/2014 Page: 13 of 21

SPIJ Detailed Flow
Production: Dopeless

wip
yard

Entry table Dopeless

Input Bin
Entry from yard

Line entry Bin

After verification

Robot A

Robot B

pipes coming from Tubing are already

added with theoretical coupling. Robot C
The process is always after the WMS, so the
theoretical Weight is already added in WMS
Buck on
Inspect.

Rej. Small
orders Pipe

Rejected big orders,

Rejected dopeless
Good pipes

Exit Dopeless

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yard

People per
Line / Position # Crews
Crew

Dopeless Coupling 5 2
Auxiliary 2 2
Blasting Operator 1 2
Automatic Dopeless Painting Operator 2 2

SPIJ Detailed Flow 22/05/2014 Page: 14 of 21

SPIJ Detailed Flow
Production: Threading Premium

wip
yard

Entry table Premium

Input Bin
Entry from yard

Line entry Bin

After verification
report defects for
Thread & Mpi
report defects for
Thread 1 Thread & Mpi
Inspect.
Thread 2
Inspect.
MPI
MPI
Phosph.1
Phosph.2

Buck on
Inspect.
Production reporting,
rejected Pipe Defines sequence in the exit bed
Also Quality report in case of yellow
band
Rej. Premium for: Hydrotest
Hydrotest
- threading: to cutoff API, via crane Pipes rejected will pass through
- Phosphate: direct to phosphate, Prot. 2 Prot. 1 WMS (in bypass) we can ask the
- buck on: direct to buck on operator to mark the yellow band
Wms and in WMS declare the defect
To declare the destination of the
pipes, shared between both rejected Tally
Prils Rej. Pipe List WMS will declare also Hydro

Waiting customer approval

After customer Good

approval
Rejected pipe
Buck on machine hydrotest

Exit Premium

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yard

SPIJ Detailed Flow 22/05/2014 Page: 15 of 21

SPIJ Detailed Flow
Production: Threading Api

From Thread tubing

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yard

Entry table API

Input Bin
Entry from yard

Line entry Bin

report After verification
defects
for Thread report
defects for
Thread
Thread 1
Inspect.
Thread 2
Inspect.
Phosph.1 In case of rejection,:
Tu Cutoff Api Phosph.2 - paint yellow band,
- stencil defect code,
Buck on on the pipe
Inspect.
Rej. Api To
Cutoff Pipe
online

Protector Box Production reporting,

Defines sequence in the exit bed
Also Quality report in case of
yellow band

Wms

In case of rejection, operator

Tally knows where to send the pipes.
List Are there any rules we have to
check?
Rej. Pipe
Rej.

Good

Exit API

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yard

People per
Line / Position # Crews
Crew

Thr API 8 1
Auxiliary 0 1
API Threading Operator 0 1
Threading API Inspector 0 1
Auxiliary 0 1
Auxiliary 0 1
Make up API Operator 0 1
Phosphatizing Operator 8 1
Auxiliary 0 1
Auxiliary 0 1
WMS Operator 0 1
Auxiliary 0 1

SPIJ Detailed Flow 22/05/2014 Page: 16 of 21

SPIJ Detailed Flow
Production: CutOff Api

wip
yard

Exit table Cut Off

Pipes mixed
between API and
Premium

To report the cut

Cut off

Pipes mixed
between API and
Premium

Entry from premium Entry from Api

via cranes online

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yard

SPIJ Detailed Flow 22/05/2014 Page: 17 of 21

SPIJ Detailed Flow
Production: Threading Premium 2

wip
yard

Input Bin
Entry from yard

Line entry Bin

After verification
First End

Thr-end-1
Inspection

Thr-end-1
Inspection
Temporary Rack: wip Production reporting,
Prove up Pril yard Rejected Pipe Defines sequence in the exit bed
Cut pipes Also Quality report

Good

Line exit bed

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yard

Input Bin
Entry from yard

Line entry Bin

After verification
Second End

Thr-end-2
Inspection

Thr-end-2
Inspection
Temporary Rack: wip Production reporting,
Prove up Pril yard Rejected Pipe Defines sequence in the exit bed
Cut pipes Also Quality report

Good

Line exit bed

wip
To API Dispath
yard

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SPIJ Detailed Flow
Production: Swaging - Stress Relieve
Option 1: Option 2:

Two machines working different orders. Two machines working in line

wip wip wip

yard yard yard

To report the To report the

production production

Stress Rel. 1 Stress Rel. 1

Swaging 1 Swaging 1

Stress Rel. 2 Stress Rel. 2

Swaging 2 Swaging 2

To report the
production

wip wip wip

yard yard yard

SPIJ Detailed Flow 22/05/2014 Page: 19 of 21

SPIJ Detailed Flow
Coupling shop

wip
yard Left.
Over

Coup.
HT pipe
heat id mt

Long pipes
941867 1,00 12,00
NTD

Cutting
UT
(Dapco)
pipe
cutting heat id mt
01 02 03 941867 1,01 0,70
941867 1,02 0,70
Cut pipes
941867 1,03 0,70
Turning 941867 1,04 0,70
01 02 03 941867 1,05 0,70
941867 1,06 0,70
941867 1,07 0,70
Die 941867 1,08 0,70
Stamping
941867 1,09 0,70
941867 1,10 0,70
Threading premium Threading API totale Length 7,00
Leftover 5,00
01 02 03 04 01
Only one mother pipe per pallet
Max 60 Couplings x Pallet
Leftover

05 06 07 08 02 Only one mother pipe per

pallet or UC

MPI pipe
heat id mt
Pipe Rejected 941867 1,00 5,00

CR13 pril Work order

A7100 1 cutting machine Ax01 P 7012367 1
Plating Next operation
Phosphat A7102 Turning P

Dopeless Mother Heat id Mt kg

pipe 945782 27 12,27 3.589 P
Yes
Dopeless yes Couplings API 5L steel Grade B, diam w.t. len (mt)
coupling
123,45 6,5 0,7
Blasting

New finish pipe

Dopeless
(couplings)
coupling
No No len (mt) LeftOver
Id Box / Pallet
1 0,7 5,27 457864
Painting & 2 0,7
stenciling 3 0,7
4 0,7
5 0,7
Coup. 6 0,7
yard 7 0,7
8 0,7
9 0,7
10 0,7
- To Customer (Sale)
- To Buck on

SPIJ Detailed Flow 22/05/2014 Page: 20 of 21