QA/QC


Mechanical Testing Laboratory

Tejas Tubular Products has a fully equipped in-house mechanical testing laboratory which provides a wide range of capabilities to perform the mechanical testing required for tubular goods to meet client and API standards. The lab also supports the testing required for Tejas Tubular Products heat treat process verification. The lab is also used to perform sample testing of any outsourced material and metallurgical services that Tejas may use. Key mechanical testing performed by Tejas Tubular Products includes:

  • Precision sample preparation machine shops
  • Tensile testing
  • Impact testing
  • Chemical analysis
  • Hardness testing
  • Bend tests
  • Flattening tests
  • Metallographic sample analysis

 


Document Control and Mill Test Reports

Upon successful testing of samples, all information relevant to the product are summarized and entered into our in-house database system and a Material Test Certificate (MTR) is generated. The MTR is a quality assurance document that certifies the raw material meets the customer purchase order along with the appropriate ASTM/API specifications. An MTR is used to summarize the test results of all chemical and, physical properties and non-destructive examination (NDE) testing/inspection associated with the material heat and lot number in accordance with the specific customer PO. Depending on the type of material required, a test certificate reports the following:

  • Ultimate tensile strength
  • Yield strength
  • Elongation
  • Hardness (C scale and B scale) as applicable
  • Chemical composition (up to 15 elements are reported)
  • Charpy impact test
  • High collapse pressure test
  • Flattening test for ERW pipe
  • Weld bend test for oilfield drill pipe

Additional testing and information may include hydro-testing; another type of non-destructive testing, electromagnetic inspection, and ultrasonic testing for-weld line inspection.

Retention of Records

Tejas maintains work order files including inspection and testing results from each job. These records are maintained and reviewed before shipments are released to customer. All work order files including all inspection and testing data are preserved in our electronic document control system and archived for a minimum of five years.

Non-Destructive Testing (NDT)

NDT is any technique used to detect and evaluate defects in materials without causing damage to the material. NDT techniques used at Tejas include: electromagnetic inspection, also known as the eddy current technique; magnetic particle inspection, and ultra-sonic testing to detect defects in the materials.

  • Electromagnetic Inspection (EMI) Tejas has two NDT-5500 units capable of inspecting pipe OD from 1 2/3 to 5 1/2 in. OD. Tejas also has one NDT-6000 unit which is capable of inspecting pipe sizes from 2 3/8 to 13 3/8 in OD. Both of these units are capable of inspecting material with a wall thickness ranging from 0.100 to 0.450 in. The Tejas Tubular EMI units are capable of non-interrupted continuous inspection of the pipe body consisting of a four function inspection system which includes longitudinal, transverse; wall thickness; and component grade verification. All API products, including drill pipe, are 100% inspected.
  • Magnetic Particle Inspection Magnetic particle inspection is broken into two categories; dry magnetic particle inspection or wet magnetic particle inspection. The medium used for dry magnetic particle inspection is dry iron powder. Wet magnetic particle inspection uses a solution of fluorescent magnetic powder and a liquid carrier. Dry magnetic particle inspection uses a visible (or) white light and to look for defects. Wet magnetic particle inspection uses ultra-violet (UV) light to find defects.
    • Special End Area (SEA) Inspection SEA inspection is performed 18 in. from the ends of the pipe on all products to make sure that the ends are free from defects. The SEA inspections performed at Tejas employ either wet or dry magnetic particle inspection.
    • Full Length Magnetic Particle Inspection (FLMPI) FLMPI inspection is performed on pup joints and tubing joints and the entire tube body is inspected using dry magnetic particle inspection.
    • Coupling Inspection Every coupling manufactured is inspected to API requirements using wet magnetic particle inspection.
  • Ultra-Sonic Testing (UT) Tejas also employs UT techniques for checking the tubing wall to detect defects in the material and to find defects during the weld line inspection on electric resistance welded (ERW) material.


Statistical Data Analysis

Tejas Tubular Products has a centralized statistical process control (SPC) group within the QA department. Data from all areas of inspection and testing are analyzed using Tejas SPC software and the reports generated are analyzed and used in the Tejas decision making process. This action works as a decision support system and provides feedback necessary to evaluate suppliers and vendors. The reports and charts generated by the SPC are also used to deliver continuous improvement of our products, and enhance the effectiveness and efficiency of our manufacturing model.