SOP-EQ-002
Rev 1 · Issued 2026-05-24 · Next review 2028-05-24
CouponMaster
Standards basis: OHSA s.25; O.Reg 851 s.24 (machine guarding), s.84 (point of operation), s.105 (PPE); CSA Z460-13 (Control of Hazardous Energy — pneumatic isolation); CSA Z432 (Machine Safeguarding); CSA W117.2 cl. 9 (mechanical hazards in welding-allied processes); CSA Z94.3 (eye/face protectors); CSA Z94.2 (hearing protection — sustained air motor noise).
Machine Specs
| Machine | Tri Tool BevelMASTER Model 208B / CouponMaster assembly |
|---|---|
| Application | Internal-mandrel pipe bevelling for weld prep (training coupons) |
| Drive | Air-powered (90–100 PSI supply required) |
| Bevel Angle | 37.5° (standard toolbit — confirm before each run) |
| Axial Feed Travel | 2.000" max |
| Min. Coupon Length | 3" (76 mm) — HARD MINIMUM. Discard anything shorter. |
| Optimal Coupon Length | 4" (102 mm) — dual-bevel, no reclamation required |
⚠ Danger
⚠ Never operate without confirming mandrel is fully engaged and jaw blocks are gripping the pipe ID. Partial engagement will cause the machine to spin out or damage the pipe.
PPE Required
Safety glasses — CSA Z94.3 (minimum). Face shield recommended.
Work gloves — do not wear loose-fitting gloves near rotating mandrel
Hearing protection — air motor generates sustained noise
Steel-toed boots — CSA Grade 1 minimum
FR clothing — chips and burrs are ejected during operation
Pre-Use Inspection
- Correct jaw block installed for pipe ID (see table above)
- Air supply connected — regulated to 90–100 PSI
- Air hose is clear of workspace and not a trip hazard
- Toolbit is sharp, undamaged, and set to 37.5° bevel angle
- Feed handle moves freely through full 2" travel
- Coupon length is 3" minimum — measure before loading
- Bench/stand is stable; coupon master is secured for operation
Reference
2. MANDREL SELECTION TABLE
Select jaw block set based on pipe NPS and schedule. Verify ID range falls within jaw block mounting range.
Note: Always verify mandrel fits snugly in pipe bore before engaging air supply. If jaw blocks don't grip at 3" insertion, coupon is too short — discard.
| NPS | Schedule | OD (in) | Wall (in) | ID (in) | Jaw Block |
|---|---|---|---|---|---|
| 2" | Sch 40 | 2.375 | 0.154 | 2.067 | Standard (06-0499) |
| 2" | Sch 80 (XH) | 2.375 | 0.218 | 1.939 | Standard (06-0499) |
| 2" | Sch 160 | 2.375 | 0.344 | 1.687 | Standard (06-0499) |
| 2" | XXS | 2.375 | 0.436 | 1.503 | 2" XX (06-0580) |
| 4" | Sch 40 | 4.500 | 0.237 | 4.026 | Extended (48-0475) |
| 4" | Sch 80 (XH) | 4.500 | 0.337 | 3.826 | Extended (48-0475) |
| 4" | Sch 160 | 4.500 | 0.531 | 3.438 | Extended (48-0475) |
| 6" | Sch 40 | 6.625 | 0.280 | 6.065 | Extended — verify fit |
| 6" | Sch 80 (XH) | 6.625 | 0.432 | 5.761 | Extended — verify fit |
| 8" | Sch 40 | 8.625 | 0.322 | 7.981 | Extended — verify fit |
4. OPERATING PROCEDURE → 4.1 Standard Dual-Bevel Coupon Workflow (4" Ring) (table content)
| NOTE ON LAND: If your WPS requires a 1/16" (1.6mm) land, set the toolbit stop accordingly BEFORE starting. This is a setup step — do not adjust mid-run. |
|---|
4. OPERATING PROCEDURE → 4.2 Reclamation (If Required) (table content)
| Starting Length | Max Reclamation Cycles |
|---|---|
| 4.00" | 4 cycles (discard at 3.00") |
| 3.50" | 3 cycles (discard at 3.00") |
| 3.25" | 2 cycles |
| 3.00" | DISCARD — do not process |
6. QUALITY CHECK — ACCEPT / REJECT CRITERIA
| Criterion | Accept / Reject |
|---|---|
| Bevel angle | 37.5° ± 2° — use bevel gauge to verify |
| Land (if required) | 1/16" ± 1/32" — measure with caliper |
| Surface finish | No chatter marks, tears, or heavy tool marks |
| Pipe end squareness | Cut end must be square before bevelling — reject crooked cuts |
| Coupon length | 3.00" minimum after bevelling |
Operation
4.1 Standard Dual-Bevel Coupon Workflow (4" Ring)
- CUT — Cut stock pipe to 4" length on bandsaw (6" and 8") or Evolution saw (4") per cutting SOP.
- LOAD — Insert mandrel into pipe bore. Hand-tighten jaw blocks until snug. Pipe should not slide or wobble.
- ENGAGE AIR — Apply air trigger. Allow machine to reach operating speed before applying feed.
- BEVEL END 1 — Apply steady forward feed pressure on feed handle. Advance until bevel is complete (full 37.5° face cut, no flat remaining).
- RETRACT — Back off feed handle to starting position. Stop air trigger.
- FLIP — Remove pipe. Flip end-for-end. Re-insert mandrel into now-bevelled end (bore is intact — grip is not affected).
- BEVEL END 2 — Repeat steps 3–5.
4.2 Reclamation (If Required)
- INSPECT — Examine the incomplete or defective bevel: flat land remaining, chatter, gouge, or wrong angle.
- MEASURE — Confirm coupon length BEFORE re-cutting. Reclamation must leave a finished coupon ≥3" (76 mm).
- RE-LOAD — Insert mandrel into the intact bore; hand-tighten jaw blocks until snug (bore grip is unaffected by a bevel defect).
- RE-BEVEL — If flat land remains: advance feed to complete the 37.5° face. If gouged or chattered: face off the defective bevel, then re-bevel.
- RE-MEASURE — Confirm finished coupon is still ≥3". If now under 3": REJECT to scrap — do NOT re-run (short-coupon ejection hazard).
- STAGE — Place reclaimed coupon in the staging bin; flag reworked pieces for instructor QA spot-check.
Prohibitions
- Never operate without confirming mandrel is fully engaged and jaw blocks grip the pipe ID — partial engagement causes spin-out
- Never use a coupon shorter than 3″ (76 mm) — ejection hazard
- Never exceed 100 PSI supply pressure
Emergency Stop
Emergency Response
(1) Release air trigger immediately. (2) Close air supply valve at the regulator. (3) Wait for mandrel to come to a complete stop — do NOT remove pipe or mandrel before full stop. (4) Disconnect air supply at quick-connect. (5) If pipe ejection or coupon failure occurred: hold position, assess injuries, signal for help. Do not move the workpiece until the instructor inspects.
| Scenario | Immediate response | Notify |
|---|---|---|
| Pipe spin-out / ejection (mandrel partial engagement) | Release air trigger immediately; close air supply at regulator; do not approach until mandrel fully stopped | Instructor immediately |
| Glove, sleeve, or hair caught in rotating head | Release air trigger; close air supply at regulator/wall; do NOT attempt to free until rotation fully stopped | Instructor + 911 |
| Tool bit breaks during cut | Release trigger; close air; clear area; inspect for ejected fragments before approach | Instructor + first aid if struck |
| Air hose ruptures or whips | Close air supply at the WALL valve immediately; stay clear of whipping hose until fully depressurized | Instructor immediately |
| Short-coupon ejection (piece under 3") | Hold position; release trigger; close air; assess for injury; signal for help | Instructor + first aid |
| Chip laceration (sharp, hot chips) | Stop operation; control bleeding; cover wound; chips are hot — check for burn as well as cut | Instructor + first aid |
Power Isolation
Cord-and-Plug Control
Before servicing, cleaning, or accessory change — unplug the unit and maintain exclusive control of the plug. Per CSA Z460-20 cl. 4.3.5.
Post-Use
- Disconnect air supply at quick-connect before changing toolbits or jaw blocks.
- Remove and wipe down mandrel assembly.
- Brush chips clear of work area — do not blow with air.
- Inspect toolbit for wear — a dull bit produces chatter and poor bevel finish.
- Store jaw blocks in labelled tray matching mandrel kit.
- Tag machine OUT OF SERVICE if toolbit is worn, chipped, or bevel angle is suspect.
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On the next page you will confirm you have:
- Read this entire SOP
- Received instructor demonstration of the procedure
- Demonstrated competent operation to the trainer
- Understood the prohibitions and the emergency stop
- Had the opportunity to ask questions
If you are unsure about any step or any control on this machine, stop and ask the instructor before you sign off.
Sign off on the CouponMaster