|
Production Process |
|
Seamless Tube / Pipe
|
'U' Tube |
Welded Tube / Pipe |
|
|
|
|
| |
|
Grade |
|
AISI
|
UNS
|
NF
|
EN
|
BS
|
JIS
|
|
|
|
|
|
|
|
|
304
|
S30400
|
Z
6 CN 18.09
|
1.4301
|
304
S 15
|
SUS
304
|
|
304L
|
|
|
|
|
|
|
316
|
S31600
|
Z
6 CND 17.11
|
1.4401
|
316
S 16
|
SUS
316
|
|
316L
|
S31603
|
Z
2 CND 17.12
|
|
316
S 12
|
SUS
316L
|
|
316Ti
|
S31635
|
Z
2 CND 17.12
|
1.4571
|
320
S 17
|
----
|
|
321
|
S32100
|
Z
6 CNT 18.10
|
1.4541
|
321
S 12
|
SUS
321
|
|
347
|
S34700
|
Z
6 CNNb 18.10
|
1.4550
|
347
S 17
|
SUS
347
|
|
| |
|
Specifications |
| |
|
ASTM - Standards |
| A
213 / SA 213 |
Seamless
ferritic and austenitic alloy steel boiler, super heater and heat
Exchanger tubes |
| A
249 / SA 249 |
Welded
austenitic steel boiler, Super Heater, Heat Exchanger and Condenser
Tubes |
| A
268 / SA 268 |
Seamless
and welded ferritic and martensitic stainless steel tubing for
general service |
| A
269 /SA 269 |
Seamless
and welded austenitic stainless steel tubing for general service |
| A
312 / SA 312 |
Seamless
and welded austenitic stainless steel pipes |
| A
358 / SA 358 |
Welded
pipe for High temperature service |
| A
688 / SA 688 |
For
Welded feed water heater ‘U’ Tubes |
|
|
GOST |
| GOST
9940 |
Seamless
stainless steel tubes, hot finished |
| GOST
9941 |
Seamless
stainless steel tubes, cold and hot finished |
|
|
German Standards |
| DIN
17456 |
Seamless
circular austenitic stainless steel tubes for general service |
| DIN
17457 |
Welded
circular austenitic stainless steel tubes subject to special requirements |
| DIN
17458 |
Seamless
circular austenitic stainless steel tubes subject to special requirements |
| DIN
28180 |
Seamless
steel tubes for heat exchangers |
| SEW
400 |
Stainless
steels |
| AD
2000-W2 |
Materials
for pressure vessels - austenitic stainless steels |
| DIN
EN ISO 1127 |
Seamless
stainless steel tubes (Dimensions and weights) |
|
|
NF Standards |
| NF
A 49-117 |
Seamless
ferritic and austenitic stainless steel tubes for general service |
| NF
A 49-217 |
Seamless
ferritic, austenitic, and ferritic-austenitic stainless steel
tubes for heat exchangers |
|
|
BS
Standards |
| BS
3059 |
Steel
boiler and super heater tubes |
| BS
3605 |
Austenitic
stainless steel pipes and tubes for pressure purposes |
| BS
3606 |
Steel
tubes for heat exchangers |
|
|
JIS Standards
|
| JIS
G 3459 |
Stainless
steel pipes |
| JIS
G 3463 |
Stainless
steel boiler and heat exchanger tubes |
|
| |
|
Pipe Dimension |
|
|
| Size |
Wall Thickness & Weight
|
|
Nominal
Pipe Size
in inch |
Outside
Diameter |
Schedule 5s
|
Schedule 10s
|
Schedule 40s |
Schedule 80s
|
| In mm. |
W.T.
In mm. |
W.T.
kg/Mt. |
W.T.
In mm. |
W.T.
kg/Mt. |
W.T.
In mm. |
W.T.
kg/Mt. |
W.T.
In mm. |
W.T.
kg/Mt. |
| 1/4 |
13.72 |
1.24 |
0.387 |
1.65 |
0.498 |
2.24 |
0.643 |
3.02 |
0.808 |
| 3/8 |
17.15 |
1.24 |
0.493 |
1.65 |
0.640 |
2.31 |
0.857 |
3.20 |
1.116 |
| 1/2 |
21.34 |
1.65 |
0.812 |
2.11 |
1.014 |
2.77 |
1.286 |
3.73 |
1.642 |
| 3/4 |
26.67 |
1.65 |
1.032 |
2.11 |
1.300 |
2.87 |
1.708 |
3.91 |
2.225 |
| 1 |
33.40 |
1.65 |
1.310 |
2.77 |
2.121 |
3.38 |
2.537 |
4.55 |
3.282 |
| 1 1/4 |
42.16 |
1.65 |
1.671 |
2.77 |
2.728 |
3.56 |
3.435 |
4.85 |
4.524 |
| 1 1/2 |
48.26 |
1.65 |
1.923 |
2.77 |
3.150 |
3.68 |
4.101 |
5.08 |
5.484 |
| 2 |
60.33 |
1.65 |
2.421 |
2.77 |
3.989 |
3.91 |
5.515 |
5.54 |
7.588 |
| 2 1/2 |
73.03 |
2.11 |
3.741 |
3.05 |
5.336 |
5.16 |
8.756 |
7.01 |
11.570 |
| 3 |
88.90 |
2.11 |
4.578 |
3.05 |
6.546 |
5.49 |
11.449 |
7.62 |
15.484 |
| 3 1/2 |
101.60 |
2.11 |
5.258 |
3.05 |
7.514 |
5.74 |
13.756 |
8.08 |
18.891 |
| 4 |
114.30 |
2.11 |
5.981 |
3.05 |
8.483 |
6.02 |
16.298 |
8.56 |
22.628 |
| 5 |
141.30 |
2.77 |
9.593 |
3.40 |
11.721 |
6.55 |
22.065 |
9.52 |
31.364 |
| 6 |
168.28 |
2.77 |
11.461 |
3.40 |
14.014 |
7.11 |
28.648 |
10.92 |
43.142 |
| 8 |
219.08 |
2.77 |
14.979 |
3.76 |
20.240 |
8.18 |
43.129 |
12.70 |
65.526 |
| 10 |
273.05 |
3.40 |
22.920 |
4.19 |
28.163 |
9.27 |
61.131 |
12.70 |
82.661 |
|
| |
|
Tube Dimensions |
| Wall thickness
in mm. |
0.5 |
0.6 |
0.7 |
0.8 |
1.0 |
1.2 |
1.6 |
2.0 |
2.6 |
3.0 |
3.2 |
3.6 |
| O.D.
in mm. |
Weight in kg/meter |
| 6.0 |
0.069 |
0.081 |
0.093 |
0.104 |
0.125 |
0.144 |
0.176 |
- |
- |
- |
- |
- |
| 9.52 |
0.112 |
0.134 |
0.154 |
0.174 |
0.213 |
0.249 |
0.317 |
- |
- |
- |
- |
- |
| 10.0 |
0.119 |
0.141 |
0.163 |
0.184 |
0.225 |
0.264 |
0.336 |
- |
- |
- |
- |
- |
| 12.7 |
0.153 |
0.182 |
0.210 |
0.238 |
0.293 |
0.345 |
0.444 |
- |
- |
- |
- |
- |
| 14.0 |
0.169 |
0.201 |
0.233 |
0.264 |
0.325 |
0.384 |
0.496 |
- |
- |
- |
- |
- |
| 15.87 |
0.192 |
0.229 |
0.266 |
0.301 |
0.372 |
0.440 |
0.571 |
0.694 |
- |
- |
- |
- |
| 19.0 |
0.231 |
0.276 |
0.320 |
0.364 |
0.450 |
0.534 |
0.696 |
0.850 |
1.066 |
1.200 |
1.264 |
- |
| 25.0 |
0.306 |
0.366 |
0.425 |
0.484 |
0.600 |
0.714 |
0.936 |
1.150 |
1.456 |
1.650 |
1.744 |
1.926 |
| 25.4 |
0.311 |
0.372 |
0.432 |
0.492 |
0.610 |
0.726 |
0.952 |
1.170 |
1.482 |
1.680 |
1.776 |
1.962 |
| 31.8 |
- |
- |
- |
- |
- |
0.918 |
1.208 |
1.490 |
1.898 |
2.160 |
2.288 |
2.538 |
| 38.0 |
- |
- |
- |
- |
- |
1.104 |
1.456 |
1.800 |
2.301 |
2.625 |
2.784 |
3.096 |
| 44.5 |
- |
- |
- |
- |
- |
1.299 |
1.716 |
2.125 |
2.724 |
3.113 |
3.304 |
3.681 |
| 50.8 |
- |
- |
- |
- |
- |
1.488 |
1.968 |
2.440 |
3,133 |
3.585 |
3.808 |
4.248 |
| 63.5 |
- |
- |
- |
- |
- |
- |
2.476 |
3.075 |
3.959 |
4.538 |
4,824 |
5.391 |
| 76.1 |
- |
- |
- |
- |
- |
- |
2.980 |
3.705 |
4.778 |
5.483 |
5.832 |
6.525 |
| 101.6 |
- |
- |
- |
- |
- |
- |
4.000 |
4.980 |
6.435 |
7.395 |
7,872 |
8.820 |
|
| |
|
'U' Tube |
|
'U' bending is done by
cold working process.
'U' bending is done to
the required radius as per customer drawings.
The bend portion and six
inch leg is stress relieved by resistance heating.
Inert gas (Argon) is
passed through it at the required flow rate to avoid oxidation in ID.
The radius is checked
for its OD and wall thinning with the recommended specification.
The physical properties
and microstructure is checked at three different position.
Visual inspection for
waviness and cracks is done with Dye Penetrant Test.
Each tube is then hydro
tested at the recommended pressure to check for leakage.
Cotton ball test is done
to check the ID cleanliness of the tube.
Thereafter pickled,
dried, marked and packed.
All procedure is
strictly followed as per TEMA "C" and ASTM A-688.
|
|
| |
|
Bead removal Tube |
| Bead removal is done as
per the requirement of standard specifications.
Bead is cold worked and
brought in level with the base metal.
Bead rolling is made
in-line before heat treatment on tube mill.
Weld structure will
thereby recrystallise & homogenize faster in annealing process.
Which improves corrosion
resistance.
Which improves easy
expansion in tube sheets and orbital welding.
Which
improves easy flow and easier cleaning and less scale deposits. |
|
| |
|
품질관리 |
|
All products of Suraj
Stainless Ltd.' have to meet a very high standard, set by stringent quality
specifications and norms. All process parameters and conditions are developed
and constantly monitored throughout the entire manufacturing process.
A quality system to ISO
9001 : 2000 , AD 2000 – Merkblatt / WO , and PED – 97 /23/EC as outlined in
this manual has been developed and implemented to ensure that all the customer requirements
is satisfied. The quality system is applicable to all departments and all
activities undertaken by the company for manufacturing of Stainless Steel
Seamless/Welded Pipes, Tubes and ‘U’ Tubes.
The quality policy of Suraj
Stainless Ltd is very simple to perform work of the highest attainable quality
in accordance with applicable codes / standards / specification and customers
specification. Our products are subjected to various quality testing such as
Eddy Current test, Hydrostatic test, UTS, Hardness test, Air under water test,
Dimensional test, visual test etc.
Quality Control measures
include chemical analysis, measurement of mechanical and metallurgical properties
and close dimensional tolerances as per applicable codes / standards /
specification.
|
|
|
|
|
Quality Assurance Process |
|
Quality Assurance Process
|
|
Sr. No.
|
Process Operation
|
Quality Characteristics
|
Method of control
|
Test equipments
|
|
01. |
Raw
Material
(Strip,
Mother-Hollow) |
a) Dimension
b) Chemical Analysis
c) Control of Slit
Width within
Specified limits
d)
Surface |
Actual measurement as per
Std.
Analysis
of all elements as
per Std.
Testing as per various Std,
Actual
measurement of width,
thickness & recording,
Visual
Inspection. |
Vernier, Micrometer
Volumetric &
Gravimetric,
UIN 10-T Testing Machine
Brinnels/Rockwell
Tester |
|
02. |
Tube Mill |
a) Weld Test, Flare
Flange,
Flattering
Reverse bend &
Reverse Flattening
b) Inspection
of Weld,
Seam
c) Dimensions
d) Surface |
Testing as per Standard
specification
& recording the
results. One test for every
30 to 35 mtrs.
Visual
Inspection Weld zone
fusion of O.D.
Thickness & Length.
Check
roller surface profile
& finish. |
Universal testing
Machine UIN 10-T
Self
Fabricated Tube Mill
Microscope & Visual.
Vernier,
Micrometer &
Measure Tape. |
|
03. |
Cold
Drawing |
OD
WT
Surface finish
on
OD&ID
Length. |
Dimension
Measurement
Visual
Inspection |
Micrometer
Measurement
Tape |
|
04. |
Oxalate
Soap
Coating |
Bath analysis Temperature |
Bath Testing
Scratch
Test |
Volumetric
Analysis
Thermo-meter |
|
05. |
Solution
Annealing |
A) Temperature
b) Hardness
c)
Micrometer |
Automatic
Relay
Temp/Controller
Adjusted to present
level.
Measurement of Hardness
as per Std one
Test / Lot /
Heat |
Digital graphic
Temperature
Scanner
Recorder
Digital Temperature
Indicator and
control
metallurgical Microscope
Rockwell / Brinell.
Hardness
tester. |
|
06. |
Straightening |
Straightness
OD
Surface |
Adjust roller setting
measure
Visual |
Roller straightening m/c
Straightness
edge/keep
on table
Micrometer
Visual Observation |
| 07. |
Cutting |
Square cut
Length |
Right angle to
length
Visual |
Abrasive cut-of
m/c
MessureTape |
| 08. |
Deburring |
Burs removal
OD, ID
Edges |
Visual |
Pneumatic/
electrical
Deburring tool
Check with hand/visual |
| 09. |
Chemical
Treatment
a) Pickling
b)
Passivation |
Concentration
Concentration
Temperature |
One Test / Bath
Day
One Test / Bath Day
Temperature Control |
Hydraulic
Tester.
Volumetric Analysis
Thermometer. |
| 10. |
Hydraulic
Test |
Test
Pressure |
100% Inspection at
test
pressure specified as per
Standard. |
Hydraulic
Pressure
tester |
| 11. |
Eddy
Current
Test |
Surface /
Sub
Surface defects |
As per
Standard. |
Eddy Current
Test
Instrument |
| 12. |
Final
Inspection |
IGC
Test
Dimensions
Surface
Physical Testing
Grade Check
Prod.
Analysis |
As per
standard
100% inspection of
Dimensions as specified.
Visual inspection
for
surface defects.
Physical Testing as per
standard
specification.
(100% Inspection)
Chemical Analysis.. |
Beaker,
Condenser,
Chemicals, hot Plate,
Micrometer / Vernier
Universal
testing M/c.
UIN-40T Molly detector
& carbon sampling at
random
spectro / wet
method. |
| 13. |
Marking |
Marking as per
Std. |
Check for
proper
marking |
InkJet Machine/Electro
ETCH
Co-relation of Heat No.
Size, Grade, etc. With
Test
Certificate. |
| 14. |
Packing |
Seaworthy
packing
Box crate
Bundles
Fumigated. |
Check for packing,
quantity,
shipping mark, fumigation
certificate. |
Box, Crate,
Polythene,
Hessian. |
|
|
List of Testing Equipments |
| Universial testing machine |
| Capacity |
40 tons |
| Make |
F.I.E. |
| Facility |
i)
Computerised with printer
ii) Calibrated by third party |
| No. of Machines |
One |
|
| Hardenss Tester |
| Make |
Saroj |
| Facility |
Hardness tester with superficial facility to measure
hardness in HRC, HRB, 15T, 30T Scale
|
|
|
Polishing / Grinding
Machine
|
|
Single 200 mm diameter disc
polisher with variable speed facility for grinding &
polishing
|
|
|
Eddy Current Testing
|
| Make |
Technofour, Pune
|
| Facility |
Digital Flawmark Electronics Test
Systems
|
|
|
|
|
|
|
|
|
Chemical Testing
Laboratory
|
|
Facility to carry out day-to-day testing of
different solution used in packing
department.
|
|
|
|
| |
|
Certificates |
| ISO9001:2000ANSI/ISO/ASQ Q9001 |
|
AD2000Merkblatt W0 |
|
|
|
|
|
PED97/23/EC
|
|
Government Export House
|
|
Awards for Export Excellence
|
|
|
|
|
|
|
|
| |
|
Packing & Transportation Method |
|
As per client's
requirement, we adopt 3 different ways to pack our goods.
|
|
Wooden box packing
|
|
Crate packing
|
|
Bundle packing
|
|
|
|
|
|
|
|
| |
| Once the packaging is
done, we transport our goods by following three ways :
|
| Open Top Container |
| LCL Cargo |
| Flat Bed Container |
)
)
)
)
)
)
)
)