Document No MPS-C.L.

P-01
Revision 1
Page Page 1 of 24
Date 1/9/10

Manufacturing Procedure Specification

MANUFACTURING PROCEDURE
Project: Contract No: CLB/C/SM/2500

SPECIFICATION
For Spiral Welded Marine Piles, Steel Grades including: Q345B
Client

Consultant Engineer

Contractor

Nanjing Grand Steel Piling No 181 Hunan Road, Nanjing

Manufacturer
Co.,Ltd. China
 Document No MPS-C.L.P-01
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Manufacturing Procedure Specification

Table of contents

NO’S OF
SECTION DESCRIPTION REVISION DATE
PAGE
1 Scope 1 1 1/9/10
Manufacturing Process & Quality
2 3 1 1/9/10
Control
Coil End Preparation and Sampling
3 1 1 1/9/10
for Tests
4 Cross Welding (Coil Ends Joint) 2 1 1/9/10

5 Strip Edge Preparation 1 1 1/9/10

6 Forming and Welding 2 1 1/9/10

Ultrasonic, Visual & Dimension
7 1 1 1/9/10
Inspections During Production
Plasma Dimension Cutting and Pile
8 1 1 1/9/10
Identification
Sampling of Test Piece
9 1 1 1/9/10
(Physical Test)
10 Welding Repair Procedure 1 1 1/9/10
Pile Shoe Manufacturing – Sub-
11 2 1 1/9/10
operation
12 Shoe to Pile Welding 3 1 1/9/10

13 Coating 1 1 1/9/10

14 Pile Marking 1 1 1/9/10

15 Final Product Inspection 2 1 1/9/10

16 Stock Yard 1 1 1/9/10

Section 1
 Document No MPS-C.L.P-01
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Manufacturing Procedure Specification

Scope:

This procedure specifies the control of manufacturing and inspection of structural steel
columns including raw material receiving, production, inspection, testing, welder and
welding operator qualification, production welding, repairs, marking and dispatch.
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Manufacturing Procedure Specification

Section 2

Manufacturing and Quality Control Procedure:

Process 1: Pile manufacturing

Incoming Raw Material Inspection

(Mill Certificates, Visual; Dimension;
Chemical; Lamellar test, Mechanical test)

Coil End Cutting; Sample Cutting for

Analysis

UNCOILING

LEVELLING

CROSS WELDING
(COIL ENDS WELDING)

STRIP EDGE TRIMMING

STRIP EDGE PREPARATION

(CLEANING & PRE-BENDING)

FORMING
(Spiral Process: Internal & External Welding)

ULTRASONIC & VISUAL ＆

DIMENSIONAL INSPECTION OF WELD
SEAM ON PILE BODY
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Manufacturing Procedure Specification

PLASMA FLAME CUTTING TO LENGTH

PILE IDENTIFICATION

SAMPLING OF WELD SEAM TEST

PIECE
(FOR MECHANICAL PROPERTIES)

END FACING & BEVELING

VISUAL AND DIMENSION INSPECTION

(WELDS AND PILE BODY)

REPAIR WELDING
(Finishing)

SHOE MANUFACTURING
SUB-OPERATION ROLLING & WELDING

JOINT SHOE TO PILE

PRODUCT FINAL INSPECTION

(DIMENSION; VISUAL; NDT TEST)
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Manufacturing Procedure Specification

COATING

MARKING

FINAL INSPECTION

STOCK YARD

成形
外焊
内焊
(螺旋过程)
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Manufacturing Procedure Specification

Section 3

Coil end Preparation and Sampling for Tests

1. During material receipt and prior to releasing coils for production, a visual and
dimensional inspection check will be conducted to ensure steel coils comply with
order requirements, namely;
a. Mill certificate verification of steel properties,
b. Mill certificates match with coil labels,
2. Visual check of the steel coils recording surface defects or imperfections such as
variations in thickness, flaws, cracks, laminations etc.
3. Coil ends are checked for kinks or bends and repaired by cutting back to remove
any portion which may affect consistent linear coil feed.
4. Measure steel coils by ultrasonic calibrator (or thickness micrometer) according to
material standard. Thickness of steel coils should not exceed +1.0 mm.
5. Measure the width of the steel coil to ensure width conforms to standards
recording the values on “Steel Materials Inspection Report(BP-17)”.

Note: Any materials which do not meet visual or dimensional tolerances are marked and
recorded before being rejected and quarantined.

Mechanical and chemical properties

Inspection of mechanical properties and chemical composition of steel coils should be
conducted by the supply mill/manufacturer and a formal certificate of quality guarantee
issued to the fabricator and to the client, (Hold Point):
A. Chemical composition - % maximum
AS/NZS 3678-350 Inspection Frequency
Ingredients
Q345B
Carbon (C)
0.22
Silicon (Si)
0.55 Each Heat number
Manganese(Mn)
1.70
Phosphorus(P)
0.040
Sulphur (S)
0.030
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Manufacturing Procedure Specification

B. Mechanical Properties
Items Tensile Strength Yield Strength Elongation Inspection
(MPa - Min) (MPa – Min) (% - Min) Frequency
Permissible
450 350 20
value
Not less than Once per heat
AS/NZS 3678- 350 according AS/NZS 3678-
Standards
1996 to contract 1996
standards

Material traceability
Prior to coil straightening all conforming material data is recorded e.g. heat number, batch
number, etc. Pile series numbers are generated at the start of production and used
continuously throughout production - manufacturing, inspection and transportation for all
records and reports.
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Manufacturing Procedure Specification

Section 4

Cross Welding(Coil ends joint)

Procedure:

1. The outgoing coil is cut and left with welding groove using oxygen-acetylene flame
cutter.
2. The incoming coil after being flattened is cut and left with the welding groove using
oxygen-acetylene flame cutter. The welding groove is cleaned and finished by
grinding.
3. The edges of both coils are aligned with the root gap maintained between two
coils.
4. Welding method is submerged-arc welding using single-side techniques, with red
copper weld backing strip.
5. Set current, voltage and speed.
6. When pile rolls off the production line, carbon-arc-air-gouging is used on back
welding seam of the butt weld with manual SMAW.
7. Please see the detailed WPS according to the following table.
Pipe Diameter(mm) Wall Thickness(mm) WPS NO.
1400 25 PWPS-C.L.P-09
1500 25 PWPS-C.L.P-09
1700 25 PWPS-C.L.P-09
1000 20 PWPS-C.L.P-09
1000 22 PWPS-C.L.P-09
1000 16 PWPS-C.L.P-10
1100 20 PWPS-C.L.P-09
700 16 PWPS-C.L.P-10
610 12.7 PWPS-C.L.P-10
800 12.7 PWPS-C.L.P-10
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Manufacturing Procedure Specification

Section 5

Strip Edge Preparation

1. To ensure welding quality, clear impurities from coil and pre-open welding groove.
2. A two edge milling machine mills both sides of coil and produce X-type welding
groove.
3. Groove parameter table
Welding a
groove Type α b p H
H p 20mm
mm

Spiral b
welding V 60° 0~1 6-7 7±2
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Manufacturing Procedure Specification

Section 6

Forming and Welding

Forming
1. The forming process incorporates three set of the rollers. The flat coil is fed into
the forming Mill at an angle and as it passes through the rollers, a helical spiral is
formed and a forming seam for seam welding is created.
2. Spiral angle is determined by the diameter and the width of the trimmed steel
coil.
3. After forming and welding, inspect circumference and outside diameter of the
pipe verifying specification standards.
a. Wind the tape measure around the circumference of the pile keeping it
tight – read and record the measurement directly from the tape.

Note: Any variation from the nominal value must be fed back to the operator for
immediate adjustment.

Welding
1. As soon as the pile has been formed automatic submerged arc welding is
performed internally followed by external welding after one to two spirals interval.
8. Please see the detailed WPS according to the following table..
Pipe Diameter(mm) Wall Thickness(mm) WPS NO.
PWPS-C.L.P-02 or PWPS-
1400 25
C.L.P-08
1400 40 PWPS-C.L.P-06
PWPS-C.L.P-02 or PWPS-
1500 25
C.L.P-08
1500 40 PWPS-C.L.P-06
PWPS-C.L.P-02 or PWPS-
1700 25
C.L.P-08
1700 50 PWPS-C.L.P-06
PWPS-C.L.P-02 or PWPS-
1000 20
C.L.P-08
1000 40 PWPS-C.L.P-06
PWPS-C.L.P-02 or PWPS-
1000 22
C.L.P-08
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Manufacturing Procedure Specification

1000 40 PWPS-C.L.P-06
1000 16 PWPS-C.L.P-01
PWPS-C.L.P-02 or PWPS-
1100 20
C.L.P-08
700 16 PWPS-C.L.P-01
610 12.7 PWPS-C.L.P-01
800 12.7 PWPS-C.L.P-01

Note: External weld bead height must not exceed 3mm;

Welding conditions and parameters

The welding process is direct current submerged arc welding (SAW). This process is
used for each weld pass. Refer to following table for specific parameters:

Equipment: Lincoln-America;
Power: DC 1500A

Welding Welding Materials Welding Welding

Techniques Current Voltage Speed
(Welding wire+
SAW (A) （V） mm/min Electrode
welding flux)

1 Inside H08Mn2 + SJ101 750±70 35±3 DCEP

2 Outside H08Mn2 + SJ101 850±80 35±3 DCEP

400-520
3 Inside H08Mn2 + SJ101 570±100 40±3 DCEP

4 Inside H08Mn2 + SJ101 550±50 42±3 DCEP

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Manufacturing Procedure Specification

Section 7

Ultrasonic, Visual & Dimension Inspection During Production

1. Full length of the weld seam and pile body is inspected visually and subject to
ultrasonic inspection as per ITP requirements while rotating. Refer to 4.3 of Pile
supply spec.
2. Any defects are marked for repair.
3. Inspect size of steel piles before cutting as per table below:

Item Tolerance
Circumference ±10.0 mm
Outside Diameter ±5.0 mm
Thickness ±1.0 mm
Length -0~+∞
Straightness 0.1% Length Max
Squareness <4.0 mm
Deviation from circ arc ±3.0 mm
Splice Alignment-Radial <10.0% of Thickness
Splice Alignment-Circumferential <3πmm
Weld Bead Height 3.mm Max and Cross Section<1:4
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Manufacturing Procedure Specification

Section 8

Plasma Dimension Cutting and Pile Identification

Plasma dimension cutting

1. The steel tubular pile are cut to the required length with plasma cutting
machine..

Measure the length to be cut according to order requirements and make marks.

2. Air plasma cutting can cut steel tubular pile without preheating process. With
plasma cutter correctly positioned, start air plasma cutting machine. Steel
structural column cutting will be performed by a circumferential cut.

Pipe Identification:

1. The following marks should be sprayed on internal surface. Refer to Tubular

Piles Schedule.

-- Serial number of steel tubular pile

-- Length of steel tubular pile
-- Marking numbers run through all procedures and reports before final inspection. And

there is no repeated marking number on steel tubular pile during final inspection.
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Manufacturing Procedure Specification

Section 9

Sampling of Test Piece (Physical test)

Physical testing:
Tensile strength of Tensile strength of
Item
tubes welding part
Grade of coil materials Q345B(AS/NZS 3678- Q345B(AS/NZS 3678-
350) 350)
Inspection frequency 1 piece/each group 1 piece/each group
(specification) (specification)

Tensile strength (Min) 450 450

Yield strength – Mpa (Min) 350
Elongation - % (Min) 20

Section 10
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Manufacturing Procedure Specification

Welding Repair Procedure
All welding personnel are qualified to the applicable process and relevant standard.
Welding process: Manual Shielded Metal Arc Welding (SMAW)
1. Defective areas are clearly marked and identified.
2. Defective area is arc-air-gouged and ground clean.
3. Repair area welded internally first followed by external weld.
4. Clean and remove spatter.
5. Grind back weld bead to correct profile.
6. Retest weld repair with UT probe.
7. Test local area with MPI to ensure material is free from imperfection.
8. Please see the detailed WPS according to the following table..
Pipe Diameter(mm) Wall Thickness(mm) WPS NO.
1400 25 PWPS-C.L.P-04
1400 40 PWPS-C.L.P-05
1500 25 PWPS-C.L.P-04
1500 40 PWPS-C.L.P-05
1700 25 PWPS-C.L.P-04
1700 50 PWPS-C.L.P-05
1000 20 PWPS-C.L.P-04
1000 40 PWPS-C.L.P-05
1000 22 PWPS-C.L.P-04
1000 40 PWPS-C.L.P-05
1000 16 PWPS-C.L.P-03
1100 20 PWPS-C.L.P-02
700 16 PWPS-C.L.P-03
610 12.7 PWPS-C.L.P-03
800 12.7 PWPS-C.L.P-03
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Manufacturing Procedure Specification

Section 11

Pile Shoe Manufacturing.

Pile shoe manufacture is an off-site operation within an NSPE group company all under
supervision by NSPE management and technical personnel. All welding personnel are
qualified to the applicable process and relevant standard, with approved welding
procedures and qualification records maintained by NSPE. All products are fully tested,
inspected and documented prior to delivery to NSPE mill.

The welding process for the shoe seam weld is automatic submerged arc metal welding
(SAW)

Shoe Joint Welding Procedure

Shoe joint preparation and welding is performed according to WPS-C.L.P-06

All weld seams are 100% UT tested on Pile to shoe longitudinally.

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Manufacturing Procedure Specification

Section 12

Shoe to Pile Welding

All welding personnel are qualified to the applicable process and relevant standard.
Welding process: Submerged arc metal welding (SAW)

Fabricate jig and clamps to provide correct alignment.

Ensure welding groove is clear of rust, grease, dirt, moisture over a 30 mm length.
Perform root weld after check is accepted.
Record details associated with daily welding
activities to maintain welding traceability. Pile

Splice Figure - Pile to Shoe.

Joint
Note 1

Shoe

ID

OD
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Manufacturing Procedure Specification

Note 1

GAP:0-2 ㎜

External

Pile 25㎜ 10㎜

Shoe 40㎜

Internal 60° a

b a:b=1:4

Welding and electrode parameters

Internal and external welding is conducted by direct-current welding. Refer to WPS-C.L.P-

07 for specific electrode parameters.
Please see the detailed WPS according to the following table.
Pipe Diameter(mm) Wall Thickness(mm) WPS NO.
1400 25/40 PWPS-C.L.P-07
1500 25/40 PWPS-C.L.P-07
1700 25/50 PWPS-C.L.P-07
1000 20/40 PWPS-C.L.P-07
1000 22/40 PWPS-C.L.P-07

Section 13

Coating
Please refer to the coating MPS (MPS NO.:MM-XS-A-1009) and ITP(ITP NO.: Appendix
 Document No MPS-C.L.P-01
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Manufacturing Procedure Specification

C) for details.

Section 14

Pile Marking
1. Marking color is yellow; priming paint is black, spray over template;
2. Piles are externally marked from toe level in 250mm increments.
3. The pipe depth markings must be circumferentially marked 10 meters from toe
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Manufacturing Procedure Specification

level in 250mm increments to the pipe head.

Piles are internally marked on top with marking details:

PILE BENT
PILE REF.
PILE Type
Dimension
NSPE
Made in China
Shipping marks are externally marked with following details:
Order No.
Destination: Port Hedland
Pile Ref No.
Specification of steel structural columns
NSPE
Made in China
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Manufacturing Procedure Specification

Section 15

PRODUCT FINAL INSPECTION (DIMENSION; VISUAL; NDT TEST)

Final inspection of steel structural columns

Item Table:

Executing
Standards
Inspecting items Checking methods Allowance
Or
Basis

Measure by winding
methods with standards:
Circumference ±10mm
strain tapeline vertical to
axis.
Outside
Steel tapeline ±5mm
diameter
Thickness
micrometer，clear
Thickness ±1 mm
incidental in measuring
area.
Length Steel tapeline，flare-out -0~+∞
Firmly fix two ends at
maximum bending area
by fishing cord or nylon
Straightness cord; measure distance ＜0.1%L
from lowest point to
fishing cord by straight
steel ruler.
Put steel structural
columns on adjusted
rolling shelf and measure
by square. Distance
between two ends and
Squareness
square is oblique cut.
Turn steel structural 900 h ＜ 4mm
columns 900 and
measure again, and
select the larger value.
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Manufacturing Procedure Specification

Executing
Standards
Inspecting items Checking methods Allowance
Or
Basis

Circular deviation
Deviation form
(Δr)=max. Or min. radius
circ arc Δr=±3mm
— nominal radius
Splice Measure by universal
Alignment- gauge or welding ＜10%Thickness
radial inspecting ruler

Splice Girth deviation equals

Alignment absolute vale of balance ＜3πmm
-Circumferential between actual girth and
standard girth.
Weld Bead
3.mm Max and Cross
Height Welding Inspection Ruler
Section<1:4

Non-destructive Spiral welding seams：10%UT

Ultrasonic Test
Inspection Splice welded seam：100%UT
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Manufacturing Procedure Specification

Section 16

Stock Yard
1. Finished goods stock yard should be firm, flat, ventilated with drainage.
2. Yard area should have basic foundation work with sufficient backfill layers to
ensure non-uniform subsidence is avoided.
3. Storage and material movement plans prepared according to shipping plan – first
pipes out on top tier or first stack.
4. Check lifting gear, hoists and hooks condition repairing / replacing as necessary.
5. Coated pipe movements to be minimised.
6. Bottom tier pipes to be adequately chocked to ensure no rolling of the pipe.
7. No higher than 3 tiers of pipe allowed.