In today’s high tech world tubular products comply with requirements, ensuring their use for the purpose specified and minimizing risks of staff and equipment damage, downtimes and environmental pollution.
To the effect of stable fulfillment of contractual obligations to the customers of is applied multilayered system of products and processes quality control, which is an integral part of quality management system, and consists of the following elements:
→ Planning of tubular products quality
→ Incoming control of billets
→ Operational control
→ Acceptance control
→ Products certification
Planning of tubular products quality
At the stages of request analysis and order acceptance products quality planning is carried out with ERP system through the process charts and so-called quality assurance plans. This system allows to determine at initial stage the sequence of technological operations, equipment and personnel required for production, and control required to comply with standards and specifications.
Incoming control of billets
In order to use only high-quality billets and meet the requirements of both internal and external customers, all incoming billets pass incoming inspection carried out by competent experts of QCD, including:
→ 100% control of documentation (quality certificates, marking and approval mark compliance)
→ 100% visual inspection of each billet and roughness control
→ 100% inspection of geometrical parameters
→ 100% positive material testing of each billet (PMI)
→ Detailed chemical analysis of each melt
→ 100% control of radioactive contamination
Mechanical and technological tests, tests for intergranular and pitting corrosion resistance are carried out according to requirements of proper regulatory documents.
Established procedure for nonconforming products management at this stage allows to minimize the risks of billets re-supply, not satisfying the requirements of procurement specifications.
Operational control is carried out directly by executors of production operations to be confident that the finished products will meet the specified requirements.
In the basis of operational control lies motivation system of “3 NO”, formed on the following principles:
1) Do not receive nonconforming products
2) Do not produce nonconforming products
3) Do not hand over nonconforming products
Results of the main production steps functioning are analyzed applying statistical methods to manage the production process efficiently.
All finished products undergo acceptance control to confirm meeting of all requirements of the customer.
Acceptance or finish control is carried out by QCD, which is administratively independent from production services. QCD also certifies that results of laboratory tests comply with requirements of normative documentation.
Equipment using for control, measurements and monitoring is regularly calibrated.
Scope of control is determined by customer requirements specified in order through the standards, specifications and additional requirements, along with internal normative documentation.
Scope of acceptance control includes:
→ 100% visual inspection;
→ 100% inspection of geometrical parameters;
→ 100% positive material testing (PMI).
At the same time as agreed with the customer additionally could be carried out:
1. Non-destructive testing:
→ Ultrasonic Test (UT);
→ Penetration test (PT);
→ Eddy-current test (ET);
2. Laboratory testing, as follows:
→ Control of finished tubes chemical composition;
→ Mechanical test;
→ Technological test;
→ Corrosion resistance test (intergranular, pitting, stressed, etc);
→ Metallographic test, etc.
3.Hydrostatic test (HT);
Non-destructive testing of products is carried out on the high tech equipment of well-known leaders MAC, GE, Foerster, allowing to perform full range of fault detection and control of geometric parameters on the entire length of the tube (wall, diameter, eccentricity). Staff performing nondestructive testing, trained and certified at level 1, 2 and 3.
In the company is widely used practice of certification by independent certification and inspection companies, as well as directly by the customers.
As a result of successful completion of all types of control and tests is issued quality certificate for tubular products certifying products conformity.