Quality Assurance Plan
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% |