Email : info@sainest.com

Precision Seamless Carbon Steel Tubes Manufactures

(Well Known Tube/Pipe Maker under the Indian Boiler Regulation 1950)

Quality assurance plan for Seamless Carbon Steel & Alloy Steel Straight Tubes/Pipes


SAINEST TUBES PRIVATE LIMITED (AN ISO 9001:2000 CERTIFIED COMPANY)
Sr. No Operation Characteristics Type/Method of Check Ref STD. Instrument used Testing arrived used Extend of check %
1. RAW MATERIAL
1.1 Seamless Mother Hollows
[A] Dimension Dimensional Measurement ( OD, THK ) As per Application STD. Micrometer OD & THK S.T.P.L As per Q.S.P
[B] Surface Visual Inspection - Visual S.T.P.L Random Checking
[C] Chemical Checking Chemical check analysis As per Std. & P.O. Req. Spectrometer At out side NABL approved Lab. 01 Sample from each heat lot.
[D] Mechanical Testing Tensile Testing (Yield st., U.T.S. & % EL.) As per approved STD. U.T.M machine S.T.P.L On Each lot basis as per QSP
[E] Color Coding - Color code chart - - -
2. IN PROCESS CONTROL
2.1 Intermediate 100% Prod. & Q.C Dept. Heat Treatment
[A] Temperature Temp.Monitoring As per Std. & PO Req. Automatic Temp.Controller S.T.P.L 100%
[B] Speed & Feed Qty AC Variable Drive Automatic Temp.Controller S.T.P.L Speed & feed checking for maintaining soaking time (Depends on OD & THK of the tube )
2.2 Intermediate Pickling % of HCL,% of Fe. Titration method - Chemical Testing Lab by Titration S.T.P.L Random Check
2.3 Coating Acidity of Phosphating both Fe% - - Lab. S.T.P.L Randomly Check from Each lot
2.4 Drawing
[A] Dimensions Dimensional Measurement ( OD, Thk, Length ) As per Std. & P.O Req. Micrometer OD, Thk & Measuring tape S.T.P.L Random Dimensions ( OD, Thk, Length ) As per Application Std. & PO Req.
[B] Surface Visual Inspection Visual S.T.P.L Random Checking
2.5 Soap Bath % of Fatly Acid - - Chemical Testing Lab. S.T.P.L Random Check
2.6 Heat Treatment
[A] Temperature Temp. Monitoring As per Appro. Std. & P.O Req. Automatic Temp. Controller S.T.P.L 100%
[B] Speed & Feed Depends on Tubes OD & Thk A.C. variable Drive S.T.P.L Speed & feed checking for maintaining socking time ( Depends on OD, THK, of the tube )
[C] Mechanical Testing Tensile Testing / Hardness Checking As per Appro. Std. & P.O Req. U.T.M. Machine / Rockwell superficial hardness tester & Rockwell hardness Tester S.T.P.L U.T.M. Machine / Rockwell superficial hardness tester
2.7 Pickling HCL % & Fe % - - Lab. S.T.P.L 100% on each lot
2.8 Straightening
[A] Dimensions Dimensional Measurement ( OD, Thk, Length ) As per Std. & P.O Req. Micrometer OD, Thk & Measuring tape S.T.P.L Random Dimensions ( OD, Thk, Length ).
[B] Surface Visual Inspection - - S.T.P.L Random Checking
2.9 End Cutting Length Checking Length check by measuring tape As per P.O Req Lab. S.T.P.L Random Checking
2.10 Hydro Testing Pressure Testing by keeping of pressure for minimum of 5 seconds. Hydrostatic test As per Std. & P.O Req. Hydrostatic test Bench S.T.P.L 100%
2.11 Eddy Current( If applicable) Surface & sub surface condition E.T Method(Non Destructive test) ASTM –A 450/ E-309 Off line eddy current testing machine S.T.P.L 100%
2.12 Mechanical Testing for Mechanical Properties
[A] Tensile U.T.S., Yield ST & % El As per Std. & P.O Req. U.T.M M/C S.T.P.L Random Tensile test carried out As per Std. applicable
[B] Hardness Testing Hardness testing As per Std. & P.O Req. Rockwell superficial, Rockwell Hardness Tester S.T.P.L Randomn Check as per applicable Std.
[C] Flaring, Flatting bend testing - As per Std. & P.O Req. - S.T.P.L Randomn Check as per applicable Std.
[D] Impact Testing - As per Std. & P.O Req. Impact Testing Machine Out side NABL approved Lab Randomn Check as per applicable Std.Req.
2.13 Ultrasonic Testing( If applicable) Sub surface condition Non Destructive testing by U.T. method ASTM –E 213& P.O Req Ultrasonic testing machine Outside 100%
2.14 Chemical Testing
Product analysis Chemical check analysis As per Std. & P.O Req. Spectrometer Outside NABL approve Lab. Random testing as per app. STD Req.
P.M.I machine Spectrometer S.T.P.L 100%
2.14 Final Cutting Length length measurement by measuring tape As per Std. & P.O Req. Measuring Tape S.T.P.L Random check as per application standard Req.
3. FINAL INSPECTION
3.1 Visual Dimensional
[A] Dimensions Dimensional Measurement (OD, Thk, Length ) As per app. Std. Micrometer OD, Thk & measuring tape S.T.P.L 100%
[B] Visual ( Surface ) Straightens,End cuts surface checking - - S.T.P.L 100%
3.2 Identification Product marking Stenciling & testing As per app. Std. Marking M/C,marking slates S.T.P.L 100%
4. PACKING
4.1 Packing Product delivery condition Visual - - S.T.P.L 100%
5. DOCUMENTATION
5.1 Final documents Compliance to quality system procedure, P.O. Req. & appli. TDC Req. Verification and Review As per quality system procedure & PO Req. (Material Test certi.) - S.T.P.L 100%