This article provides practical recommendations for improving the quality of pipe fittings based on an analysis of key production issues identified through statistical analysis and the 5M1E method. The recommendations focus on key stages, including design, procurement, and manufacturing, to improve the understanding of pipe fitting production among purchasers, manufacturers, and third-party stakeholders. The analysis highlights several issues in the current manufacturing processes of pipe fittings for oil and gas pipelines. Problems in the manufacturing of products that appear simple and low-cost can lead to significant challenges during installation, use, and maintenance. Early identification and effective resolution of quality risks require improvements across design, procurement, production, and quality control processes.
3.1 Design Team
Due to the wide variety of specifications and materials for station and valve room pipe fittings, the design team should include detailed datasheets for each type of pipe fitting in the engineering documentation. The design team must calculate and verify the parameters in the datasheet, particularly the wall thickness of tees. If selected by the manufacturer, the wall thickness of tees from different suppliers with the same pressure rating can vary significantly, introducing potential risks. Additionally, the design team must clearly define the pipe fitting standards in the technical documentation. For any ambiguous or missing sections in the product standards, such as test frequency, measurement, and inspection, quantitative criteria must be clearly defined, or guidance should be provided. This will help avoid discrepancies arising from the use of multiple similar yet conflicting standards in the technical documentation.
3.2 Purchaser
The purchaser should avoid combining steel, forged, and stainless steel pipe fittings in a single bidding process. During the bidding process, pipe fitting suppliers should be classified into categories, with separate selections for forged pipe fittings (e.g., flanges, blind plates), steel pipe fittings (e.g., tees, elbows, reducers, pipe caps), and stainless steel pipe fittings.
This approach ensures better quality control in the later stages. The supplier selection criteria should assess the factory’s production equipment capacity, permissible specifications, order volume, labor qualifications, personnel capabilities, and historical performance. Field visits should be conducted to verify that the selected suppliers' production capacity aligns with their bidding commitments. Only suppliers that successfully pass the evaluation should be contracted, minimizing the risk of uncertainty associated with selecting suppliers based solely on the bidding process. Additionally, the purchaser should develop a product supply and technical capability database, regularly assess each supplier’s capabilities, and maintain a clear understanding of the products and processes they can produce. The scope of outsourcing and external suppliers should be clearly defined, and the evaluation of outsourced manufacturers’ capabilities should be strengthened. Effective supplier management using accurate data can also prompt the factory to independently upgrade its production and inspection equipment, thereby enhancing its ability to meet customer needs.
3.3 Manufacturers
The manufacturing capabilities of a manufacturer are determined by the capacity of their equipment. The production of pipe fittings relies on high-quality molds. Mold dimensions determine the profile size of the pipe fittings, while mold specifications define the range of sizes that can be produced. The quantity and specifications of molds, along with press capacity, are critical to producing pipe fittings within specified dimensions. The stability of heat treatment and related equipment ensures the performance characteristics of products after processing. Manufacturers should optimize the accuracy, stability, and monitoring of such equipment to improve the quality and production efficiency of pipe fittings. When selecting raw materials, pipe fitting manufacturers should choose materials with good weldability, hardenability, and stable high-temperature heat processing properties, based on material selection and design expertise. Based on market availability and trial production, no more than three core materials should be selected for each steel grade or pipe fitting type to streamline process control.
Manufacturers should establish a raw material inventory based on their capabilities, sourcing traceable materials with quality standards from steel mills or reliable suppliers. Manufacturers must provide regular training for key staff in heat treatment, non-destructive testing, physical and chemical testing, and finished product inspection to improve technical expertise and process efficiency. Key personnel should be considered in performance appraisals, incentives, and workforce planning to reduce staff turnover among essential employees. Regarding testing and inspection capabilities, pipe fitting companies must develop non-destructive testing capabilities as a fundamental requirement for their growth. The automation and digitalization of testing are essential for keeping pace with industry advancements. Due to the variability in performance and potential defects in pipe fittings after hot processing, all dimensional parameters and non-destructive testing must be subject to 100% inspection. The manual measurement and recording process is outdated compared to modern industrial standards. Manufacturers should expedite the upgrade of equipment capabilities, implement automated testing and digital evaluation systems, reduce reliance on manual measurement, and improve both measurement efficiency and accuracy.
4. Conclusion
While pipe fittings for oil and gas pipelines may seem straightforward, their manufacturing and quality control processes are challenging. As critical components of specialized equipment, pipe fittings must meet stringent quality and safety standards, while also optimizing design efficiency and production cost-effectiveness. Through data analysis and the application of the 5MIE method, this paper identifies key issues in pipe fitting production, such as deficiencies in raw material selection and traceability, equipment configuration and capacity, the stability of hot processing, and the accuracy of testing methods and results. Addressing these issues requires collaboration and investment in design, procurement, and manufacturing. Improving material selection specifications, enhancing production equipment capabilities, strengthening automated production, and adopting modern testing methods are crucial to improving the reliability and quality of pipe fittings. These improvements will substantially improve the quality of pipe fittings for China’s oil and gas pipelines and set new industry standards.
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