Quality Assurance
The Quality Assurance System at Kanak Pipe Industries Private Limited (KPIPL) covers all stages of production, right from the raw material selection and sorting, to re-drawing, and final annealing, till the final product is ready for dispatch. The elements of the quality assurance system correspond to requirements of national and international standards, as well as the customer’s own QA requirements, if any.
The Quality control department is independent of the manufacturing department. All tests are carried out by trained quality personnel, in compliance with the guidelines of the Quality Assurance System. Depending upon the intended application and technical delivery conditions or customer’s specifications, a variety of specific tests can be carried out to ensure that the highest quality standards are maintained.
The works have been equipped with reliable testing and measuring equipment for destructive, nondestructive, physical, and chemical tests under one roof. The Client’s Approved Representative (CAP) or any third-party inspection agency (TPIA), can witness the testing/inspection of finished products, of copper and copper alloys tubes, as per various Standard Specifications, such as ASTM, BS, DIN, JIS, IS and other relevant International Standards
SPECTROMETER:
KPIPL has a SPECTRO, Germany make Computerized Direct Reading Optical Spark Emission Spectrometer, for precise testing of the chemical composition of all copper and copper alloys, including checking of traces & low elements such as C, S, P, B & Nitrogen. It Can Measure Up To 31 Elements and gives the result of any sample within 45 seconds.
EDDY CURRENT TEST:
KPIPL has a Computerized Offline Techofour Flaw mark Dual Channel Eddy Current Test System, for Non Destructive Inspection to detect defects like Crack Pin Hole, Void, Inclusions, Concentrated Porosity, Mechanical Damage, Slivers, Opened up Skin Lamination and Deep Pitting on OD or ID of the tubes.
The inclusions and tube flaws are reliably detected and logged by the System. The 100% Inspection can be witnessed by any customers or any third party inspection agency (TPIA), from tube sizes ranging from 9MM in OD to 160MM OD, as per ASTM, BS, DIN, JIS, IS or other relevant International Standards.
HYDROSTATIC PRESSURE TEST:
KPIPL have a hydrostatic pressure testing machine for testing tubes in 9mm-160mm OD size range. All tubes and pipes are subjected to 100% hydro testing with calibrated pressure gauge to check the tube for any leakage under elevated hydraulic water pressure.
Hydrostatic Testing can be carried out at pressures up to 400 kg /cm sq, using high pressure Triple Plunger pumps and 100% Inspection Can Be witnessed by any customer or any third party inspection agency(TPIA) as per various Standard Specifications
UNIVERSAL TESTING MACHINE:
KPIPL have 400KN TESTWELL make, universal testing machine for destructive tests with computerized interface & Real time graph facility,
Destructive tests like Tensile Test, 0.2%Yield Stress proof Test, Flaring Test and Expansion Test, Reverse Bending Test, Flattening Test, are normally carried out at room temperature
Customer or any third party inspection agency (TPIA) can witness all mechanical test of finish product of copper and copper alloys tube with real time graph facility, as Per Various Standard Specifications
TENSILE TEST:
This test provides the mechanical test values of finish products. The tensile test specimen serves to determine the strength and ductility characteristics i.e. yield strength, tensile strength and elongation.
FLARING TEST AND EXPANSION TEST:
The flaring test establishes the forming behavior of tubes or pipes when expanded to a specific degree in conformity with the code requirements. The specimen to be tested is expanded in a press to the degree specified and defects which occur as result of this process are not permissible.
FLATTENING TEST:
Flattening test mainly serves to detect microscopic internal and external flaws. It involves compressing a tube section between two planes placed parallel to a predetermined distance. Incipient cracks and internal or external defects which occur as result of this process are not permissible.
REVERSE BENDING TEST:
Reverse Bend Test is ensures full ductility of the tubes, as well as tests the base metal strength by stretching the material to its physical endurance limit.
FLANGE TEST:
Flange test is carried out to check the material under deformation.
HARDNESS TEST:
KPIPL have FIE make Vickers hardness tester with 1to 50kgf test load to measure accurate hardness values of Tubes / Pipes. Samples from each lot are tested to ensure that the hardness of the tube is within permissible limits also as per ASTM, BS, DIN, JIS, IS or other relevant International Standards
MICROSTRUCTURE EXAMINATION:
KPIPL have a Vardhan make computerized inverted metallurgical multi range microscope, which has a built in CCD camera with analyser polarized attachment and image analyser software
This test involves grain structure examination at a magnification 75X tube after annealing process as per various Standard Specification like ASTM, BS, DIN, JIS, IS Or Other Relevant International Standards
VISUAL & DIMENSION INSPECTION:
All products at KPIPL are subjected to 100% visual inspection to detect any dents, surface defect or scratch on the surface of tubes. Dimensional inspection with calibrated measuring instrument ensures that product dimensions are within tolerance requirement as per various standard specification such as ASTM, BS, DIN, JIS, IS Or Other relevant International Standards
HYDROGEN EMBRITTLEMENT TEST:
KPIPL has Abrol’s make Hydrogen Embitterment Testing system to check the presence of Cupro Oxide which Is determined by bending thermally treated specimens into Flattened “U” Shape
CONDUCTIVITY MEASURING TEST:
KPIPL has a Techofour make Digital Conductivity Meter to measure Electrical Conductivity of Nonferrous Metals in the range of 10% To 102%I.A.C. as per International Annealed Copper Standard (IACS)
MERCUROUS NITRATE TEST & AMMONIA VAPOUR CRACKING TEST.
This in-house testing facility detects the presence of residual (internal) stress, which might result in failure of individual parts in storage or in service due to stresses and corrosion cracking.
MARKING:
Finished tubes/pipes are marked with Electric Etching/Electronic inkjet printing machine. Each tube/pipe is marked with “manufacture logo, Name, Size, Specification, Grade, Heat no”.
PACKING:
Tubes and pipes are wrapped with plastic/HDPE/Hessian cloth as per the customer’s requirements. Wooden box/wooden crate packing is also provided as per customer’s requirement.
