Work Instruction. - Tensile Testing NEW

BHUSHAN STEEL LIMITED
KHOPOLI
IMS
CONTROL No. MSW/T- ISO 9001:2015 ISO 50001:2011 Issue No.: 04 Issue Date:
QA/07 ISO 14001:2015 OHSAS 18001:2007 Revision 01.04.2017
No.:00 Rev. Date: NIL
WORK INSTRUCTION: TESTING OF TENSILE STRENGTH, YIELD STRENGTH &
PERCENTAGE ELONGATION OF TUBES
A. DOCUMENT CONTROL :
Preparation, Revision, Distrib. & Control : ISO Coordinator - QA
Review : HOD - QA (Tube Div.)
Approval : Division Head – Tube Division
B. INTERFACING : ENGINEERS, OPERATORS & SUPERVISORS
C. DISTRIBUTION :
Master Copy Holder : Management Representative (M.R.)
Controlled Copy Holder : HOD - QA Tube Division, and Displayed at Quality lab.
D. Objective : Tensile, Yield stress & Elongation test.
E. Scope : This method covers the mechanical properties testing of tubes.
F. Responsibility : HOD - QA Tube Division
G. Procedure
Safety Precautions to be taken before start:
1. Ensure safety shoes, Cotton hand gloves & helmet.
2. Ensure safety while testing to avoid accident due to tube edge.
Now you are ready to start your work, Please follow below steps :
1. Reference : (Indian standards) - IS 1608:1995

2. Sampling Procedure: Min. one sample per mother coil.
3. Testing Procedure:
a) For round tube up to 76.20 mm OD use directly with both end flattened or with suitable plug.
b) For higher OD > 76.20 mm & boiler sizes cut sample strip from 250mm long tube.
Test to be carried out :

i) Dimensional checking:
 Measure the outer diameter (O.D.) of the tube samples by flat ended (both sides) micrometer (of
required range) of least count 0.01 mm & take the average.
 Measure the thickness of tube samples by ballpoint micrometer of range 0 mm to 25 mm having least
count of 0.01 mm and take the average.
 For OD of boiler sizes measure the average width at parallel portion with vernier (0.02mm least
count) & measure the thk. by ball point micrometer.
ii) Gauge length marking:
 Mark the gauge length of 50 mm or gauge length = 5.65√ (original cross-sectional area) mm, in case
of proportional test piece on the sample.
 Mark gauge length with marker / knife on tube sample from center of tubes on both ends except
flattened portion
Prepared By Reviewed By Approved By
ISO Coordinator Head of Department Division Head

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KHOPOLI
IMS
QA/07 ISO 14001:2015 OHSAS 18001:2007 Revision No.:00 01.04.2017
Rev. Date: NIL
iii) Gripping of Test Piece:

 Flattened the both ends of sample for gripping by using hydraulic press.
 The test pieces shall be held by suitable means such as wedges, screw holder etc.
 Every endeavor shall be made to ensure that test pieces are held in such a way that the force is applied
as axially as possible.
UTS = Max. load/Cross section area of tube (Kg/mm² or N/mm²)

YS = Yield load/ Cross section area of tube (Kg/mm² or N/mm²)
% El =% of (Change in length-Original length)/Original length
Operational instruction:
A – UTS 1 ( Near ERW section )
i) Universal testing machine:

 Clamp the sample on the machine. Fix in upper crosshead & adjust it in
lower crosshead. Don't grip in lower crosshead.
ii) UTES 60 - TS software:

 Click on "FILE" and then click on "NEW". A new window is open for
selection of "Project type".
 Click on required project type i.e. "Load Rate Control"and click on
"Done".
 Enter "Basic Data" i.e. Customer name, Lot no., Sample Size Details &
Company Name.
 Enter "Sample data" i.e. Gauge Length & select sample type and fill
respective dimensions.
 Enter "Cycle data" i.e. Rupture Peak (80%), Safe Load (600kN), Pre-load
(0.1%), Load Rate (50kN/min.) & Elongation Rate (20mm/min.). Click on
"Done".
 Close the Relive Valve and Supply Valve.
 Start the hydraulic & open Supply valve slightly to remove dead load of
machine. This can be seen on panel. At power ON the load display value
will be (-840) kgf approx. When you open Supply valve, it starts
decreasing & at one point the load display becomes stable & near to
zero. When the display gets stable, click on "Close Valve" on panel.
 Click on "Tare Load" & "Reset Displacement". Now click on "Cycle

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IMS
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Start".
 Another dialogue box will appear asking for "Start" & "Modify
Parameters". For start the test grip the sample in lower crosshead and
click on "Start" or for any modification in parameters click on "Modify
Parameters".
 The loading application done by servo load control. When sample is
properly gripped between the jaws, the load start increasing. To view the
graph click on icon of graph.
 When the sample breaks, the machine stops automatically. Remove the
broken pieces of sample. Close the Supply valve and open Relive valve.
 A dialog box open for final gauge length. Enter the final G.L.(essential
for % elongation) and click “Done” icon. The software will give the final
Result.
 To obtain the test certificate click on "HOME" and find "Report" option
and click on it. A computer generated test certificate is display on
screen. To change the unit in certificate slide over your finger on unit
icon then click on "Refresh". You can take printout of this certificate.
B – UTS 2 ( Near CEW section)
i) UTNSRL serial software:

 In software select ‘Test type’ as “Extensometer Test” or “Tension Test”.
 Select ‘File” Menu & click “Create New” option.
 Enter file name, sample type, dimensions, gauge length, click “yield calculation” to yes, enter
personalize data and then press “save”.
 Clamp the sample on the machine. Fix in upper crosshead & adjust it in lower crosshead. Do not it in
lower crosshead.
 Close the left control valve (LCV) & Right control valve (RCV).
 Start the hydraulic & open RCV slightly to remove dead load of machine. This can be seen on
electronic panel. At power ON the load display value will be -8.100 approx. When you open RCV, it
starts decreasing & at one point the load display becomes stable & near to zero. When the display
gets stable, close the RCV.
 In software click ‘Start Test” menu.
 Enter following details. Preload %F.S. as 0.1 with extensometer test otherwise enter 0.2, Rupture %
peak as 50, safe load as less than or equal to 600, Yield determination as by offset method,
Extensometer remove warning value = 1/1.2/1.5 etc.
 Click “Data OK” then on line graph window will appear.
 With extensometer test, clamp the extensometer on sample. The extension value showing on display
should be less than 0.200mm.

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 Enter the graph scale Xmax value & Ymax value. Click “OK” button.
 On machine, lock the sample in lower crosshead.
 In software, click “Tare Load” button to make load display.
 Click “Start Test” button in software.
 Open RCV slightly to particular position, to start the test.
 When the load display value goes to 3-4 kN, release the lock from lower crosshead.
 With extensometer test, when the extensometer display reaches the entered value, the software gives
message “Remove Extensometer”. Then remove extensometer. If the load starts decreasing before
reaching to extensometer entered value, then click ”Stop extensometer test” button in software &
remove extensometer.
 When extensometer test stops, the standard test will continue up to rupture of sample.
 When the sample breaks, the machine stops automatically. Remove the broken pieces of sample.
Close the RCV and open LCV.
 In software enter the final G.L. & final dia. (essential for % elongation & %RA calculation ) and
click “close” button. The software will give message “Result Saved”.
 Then result window will appear. You will get two graphs, one is load vs extension & other is load vs
displacement. Selection is given in “Select graph option”. You can take print of both results.
H. Instruments/Apparatus Used: Universal testing machine, venire caliper, micrometer, hydraulic press.
“Software required: UTNSRL serial software”
I. EHS instructions:
1. Ensure proper housekeeping at work place to avoid accident.
2. Ensure that tested sample, used hand gloves, cotton & waste to be store in designated bin
(Hazardous/Non Hazardous) & shift to scrap yard / Store for proper disposal.
3. Ensure that tested tube sample should be kept in metal bin for proper disposal.
J. EnMS Instructions:
1. Please switch off equipment / lights / any accessory if not in use to avoid wastage of energy.
K. QMS Instructions:
1. Ensure that only calibrated instruments are used for inspection.
L. Implications of not following above instructions:

1. Injury to body parts, cut, wound or severe accident.
2. Mix up of hazardous and Non-hazardous waste and poor housekeeping.

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Rev. Date: NIL
3. Use of Un-calibrated instrument leads in customer rejection
M. Documentation:
Document Name Document Control No.
Final Inspection & Test report( ERW) As per master list of Document
Final Inspection & Test report( CEW) As per master list of Document
Final Inspection & Test report( CTL) As per master list of Document

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What safety precautions should be taken before starting the tensile strength test?

What safety precautions should be taken before starting the tensile strength test?

What are the steps involved in the tensile strength test?

What are the steps involved in the tensile strength test?

BHUSHAN STEEL LIMITED

1. Reference : (Indian standards) - IS 1608:1995

Test to be carried out :

Prepared By Reviewed By Approved By

ISO Coordinator Head of Department Division Head

iii) Gripping of Test Piece:

UTS = Max. load/Cross section area of tube (Kg/mm² or N/mm²)

i) Universal testing machine:

ii) UTES 60 - TS software:

ISO Coordinator Head of Department Division Head

B – UTS 2 ( Near CEW section)

i) UTNSRL serial software:

ISO Coordinator Head of Department Division Head

L. Implications of not following above instructions:

ISO Coordinator Head of Department Division Head

3. Use of Un-calibrated instrument leads in customer rejection

Prepared By Reviewed By Approved By

ISO Coordinator Head of Department Division Head

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