Sterling Tubes

VARIOUS QUALITY TESTS

DIMENSION CHECK

To ensure dimensional accuracy of OD, ID, Thickness, Length, Ovality, etc.

Surface Check

To ensure that finished tubes are free from scale, pit marks rupture I.D. & O.D scores, roll marks, dent, etc.

Chemical Test

To test chemical constituents & quality parameters of raw materials & finished products.

MECHANICAL TESTS

Hardness Test

It is carried out by Rockwell I Twin Hardness Testers.(HRC, BHN Scale)

Tensile Test

It is carried out by Electronic Digital, Universal Testing Machine with Graphical Presentation.

Flaring Test

To check the ductility of material.End of tubes should be flared successfully without developing cracks.

Flange Test

This test is conducted to check the strength by subjecting to extreme compression stress. The photo besides shows a test piece subject to Flange Test as per standard.

Flattening Test

This test is conducted to check the strength by subjecting to extreme compression stress. Flattening test is to test the ultimate Steel deformation ability of seamless steel pipes under the given conditions and crush deformation without crack defects. The principle is to apply the length of the seamless steel pipe to the specified length of the end of the sample or seamless steel pipes

Bend Test

At its most basic level a bend test is performed on a testing machine by placing a specimen on two support anvils and bending it through applied force on 1 or 2 loading anvils in order to measure its properties. Pipes are bent as per specification at 90 C. without developing cracks.

Non Destructive Test

Hydro Test (Uo To 1500 Bar):-

Hydro testing, more formally called hydrostatic testing, is a type of test that is performed on pressure vessels to check for leaks. Hydro testing involves completely filling up a pressure vessel with water and then pressurizing it. Once pressurized, leaks can be detected.100% Hydrosatic testing is carried by precision machine on all tubes.

Eddy Current Test :-

Eddy current testing is a non-destructive testing (NDT) inspection method used for a variety of purposes, including for flaw detection, material and coating thickness measurements, material identification and establishing the heat treatment condition of certain material& it is to detect subsurface inhomogeneities from inside & outside of tubes.

Utrasinic Test :-

Ultrasonic testing (UT) is a non-destructive test method that utilizes sound waves to detect cracks and defects in parts and materials. It can also be used to determine a material's thickness, such as measuring the wall thickness of a pipe.For detection OD subsurface flaws & imperfection.

Chrome Plating Layer / Thickness & Hardness Test :-

"Measuring Hard Chrome Plating Thickness"

Good Magnetic Thickness Testers Are Non Destructive And Excellent For Checking Hard Chrome On Steel.
A Relatively Cheap Hand Held Magnetic Instrument Normally Measures No Better Than A Tenth, Plus Or Minus A Tenth
Induction Hardening Is A Type Of Surface Hardening In Which A Metal Part Is Induction-Heated And Then Quenched. The Quenched Metal Undergoes A Martensitic Transformation, Increasing The Hardness And Brittleness Of The Part. In Induction Hardening Frequency Is High.

Quality Assurance Plan

Sr. No	Operation	Characteristics	Type/Method of Check	Ref STD.	Instrument used	Extend of check %
1.1	Seamless Mother Hollows
		[A] Dimension	Dimensional Measurement ( OD, THK )	As per Application STD.	Micrometer OD & THK	As per Q.S.P
		[B] Surface	Visual Inspection	–	Visual	Random Checking
		[C] Chemical Checking	Chemical check analysis	As per Std. & P.O. Req.	Spectrometer	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	On Each lot basis as per QSP
		[E] Color Coding	–	Color code chart	–	–
2.1	Intermediate 100% Prod. & Q.C Dept. Heat Treatment
		[A] Temperature	Temp.Monitoring	As per Std. & PO Req.	Automatic Temp.Controller	100%
		[B] Speed & Feed Qty		AC Variable Drive	Automatic Temp.Controller	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	Random Check
2.3	Coating	Acidity of Phosphating both Fe%	–	–	Lab.	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	Random Dimensions ( OD, Thk, Length ) As per Application Std. & PO Req.
		[B] Surface	Visual Inspection		Visual	Random Checking
2.5	Soap Bath	% of Fatly Acid	–	–	Chemical Testing Lab.	Random Check
2.6	Heat Treatment
		[A] Temperature	Temp. Monitoring	As per Appro. Std. & P.O Req.	Automatic Temp. Controller	100%
		[B] Speed & Feed		Depends on Tubes OD & Thk	A.C. variable Drive	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	U.T.M. Machine / Rockwell superficial hardness tester
2.7	Pickling	HCL % & Fe %	–	–	Lab.	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	Random Dimensions ( OD, Thk, Length ).
		[B] Surface	Visual Inspection	–	–	Random Checking
2.9	End Cutting	Length Checking	Length check by measuring tape	As per P.O Req	Lab.	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	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	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	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	Randomn Check as per applicable Std.
		[C] Flaring, Flatting bend testing	–	As per Std. & P.O Req.	–	Randomn Check as per applicable Std.
		[D] Impact Testing	–	As per Std. & P.O Req.	Impact Testing Machine	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	100%
2.14	Chemical Testing
		Product analysis	Chemical check analysis	As per Std. & P.O Req.	Spectrometer	Random testing as per app. STD Req.
		P.M.I machine	Chemical check analysis	As per Std. & P.O Req.	Spectrometer	100%
2.14	Final Cutting	Length	length measurement by measuring tape	As per Std. & P.O Req.	Measuring Tape	Random check as per application standard Req.
3.1	Visual Dimensional
		[A] Dimensions	Dimensional Measurement (OD, Thk, Length )	As per app. Std.	Micrometer OD, Thk & measuring tape	100%
		[B] Visual ( Surface )	Straightens,End cuts surface checking	–	–	100%
3.2	Identification	Product marking	Stenciling & testing	As per app. Std.	Marking M/C,marking slates	100%
4.1	Packing	Product delivery condition	Visual	–	–	100%
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.)	–	100%

Quality